schneider iiee 2013

It’s now time to save the world with…

ALTIVAR Variable Speed Drives

Altivar 12 Altivar 212 Altivar 312 Altivar 61 Altivar 71

Charles Nierves

Drive Champion

Make the most of your Energy

Efficient Motor Control With

Power Drives Systems

2Schneider Electric IIEE2013Summary

Efficient Motor Control With Power Drives SystemsSummary

> Energy consumers

> What is a Power Drive System ?

> EE by Motor optimization

> EE by EE by Gear optimization

> EE by Speed control of pumps and fans

> EE by Speed control - other opportunities

> Conclusion


> Energy consumers



> EE by Gear optimization



> Conclusion

Efficient Motor Control With Power Drives Systems Summary

4Schneider Electric IIEE2013

Energy consumersMain Energy Consumers

Buildings + Industry are big energy consumers!

28%Transportation

31%Industry

& Infrastructure

21%Residential

18%Buildings

>2%Data centres &

networks


Energy consumersMotor consumption in the world.

85% of drive systems are

Pump, Fan, Compressor

● in Building, Motors consume

36% of electricity *

● in Indu&Infr, Motors consume

69% of electricity *

* SAVE Programme of the European Union


Energy consumersGlobal Motor Costs

Energy bill = Motor cost x 100

Energy

97%

Investment : 1%

Installation

& Maintenance : 2%

Global costs during Motor Life (average 15 years)

• Where goes your money ?

Big Motor:1 Month Energy Bill = Motor Cost

Beyond the investment, the key point is to secure an efficient motor control



> Energy consumers






> Conclusion


What is a PDS ?

Driven

Machine

Process

ControlVariable

Speed

Drive

Motor Gear

PDS

PDS = Power Drive Systems


Compressor Example

Motor Control

Star/delta starting

Induction Motor

Gear

Pulley/belt

Driven machine

compressor

Process

AIR pressure

regulation


Hoist Example

Motor

Planetary

Gear

Driven machine

Vertical Hoist

Speed control

By VSD

Process

Hoisting vertical

movement



> Energy consumers




> EE by Speed control of pumps and

fans

> EE by Speed control - other

opportunities

> Conclusion


Driven

MachineGear

EE by Motor optimization

Process

VSD*

PDS

* Variable Speed Drive

Motor

2 main factors for energy savings :

Technology

Sizing


Motors optimization Motor Efficiency

● Electrical motor efficiency (η) is the ratio between the mechanical shaft output power and

the electrical input power

● Internal losses (electrical, mechanical, magnetic, …)

0,80 0,87 0,93

Pmeca= Pelec * η Cosφ3IUPe T.ωPm

● For a similar motor power range the motors have not all the same efficiency


Motors optimization IEC classification

New motor classification from

IEC 60034-30 (21/10/2008)For low voltage motors up to 375kW

Classe IEC 60034 Previous (EU) NEMA (US) *

Premium efficiency IE3 Premium

High efficiency IE2 EFF1 Energy Efficient

EPAct **

Standard efficiency IE1 EFF2 Pre-EPAact

Below - EFF3 Pre-EPAact

* Closest NEMA catégory there are slight differences, ** Energy Policy Act (1992)


Motors optimization IEC classification


Motors optimization Technology

● We are not motor manufacturer but ….

Starting January 1,

2015

Only IE3 can be

connected direct on-

line

IE2 will only be

accepted when managed

by speed drives


Motors optimization Motor Sizing

● There are many good (and bad) reasons for oversizing

● Safety margin (cheapest way to ensure that there is no chance of the motor being overloaded)

● Forecast of installation life extension or production increase

● Need of very high transient power or torque …

● But as energy costs rise, and oversizing can rapidly becomes a wasteful and

expensive answer to this design issue

● Significantly over sizing a motor :

● Increases the capital cost

● Decreases the functional motor efficiency

● Can increase the motor’s operating speed (and so the energy consumption)


Motors optimization Near future

● Up to now 90% of the motor are induction motors (they are robust, low cost, reliable)

● But Synchronous motors (with permanent magnets) will be used more and

more …

● They are more efficient than asynchronous motors (induction)● No need of magnetising current for creating the rotor flux

● Low speed and high torque design allow to suppress gearboxes

● The cost is still higher than asynchronous motors but as the quantities are

growing, the price should be less and less …

● We start to see some applications in pumps …


Motors optimization

● Synchronous motors have to be

managed by frequency converters

● ATV71-61 (up to 800kW)

● Synchronous motor control open loop

● ATV32 (up to 15kW)

● Synchronous motor control open loop



> Energy consumers




> Speed Control


> Conclusion


Driven

Machine

EE by Gear optimization

Process

VSD*

PDS


Motor

2 main factors for energy savings :

Technology

Maintenance

Gear


Why a gear ?

● Why a gear ?

● Adapt Speed, Torque, Inertia

● Standard motors have generally a high

rated speed compared to machines

needs

● Low speed/high torque motors are

expensive

● Inertia of the load have to be close to

the motor inertia to avoid oscillation

during fast accelerations

● Change movement direction/angle …


EE by Gear optimizationGear fundamentals

Motor

GearBox

Ratio = k

Efficiency =

Machine

angular speed

T torque

P power

(1) motor shaft

(2) machine shaft

● 2 = 1/k Speed reducer

● T2 = T1.k. Torque amplifier

● P2 = P1. Power transmitter

● J1=J2/k² Inertia adaptor

Power

(1) (2)


EE by Gear optimization Efficiency

● Gear efficiency (η) is the ratio between the mechanical shaft output power and mechanical

shaft input power.

● Losses are due to mechanical frictions

● They can be speed dependent

● Higher the gear ratio, the higher the losses

Worm

0.50 to 0.80Pulley belt

0.90 to 0.95Planetary

0.85 – 0.90

● For a similar ratio, function of the technology, gears do not have the same efficiency


EE by Gear optimization Maintenance

● Gear efficiency decreases with aging

● Pulley-belt system have to be well set and controlled

(tension and alignment)

● Gear needs oil or grease

● Careful sizing is needed (not to overload the pinions)


EE by Gear optimization Opportunities

We are not gear manufacturer but ….

● ATS Soft Starter and ATV Speed Drives allows :

● Smooth start and stop -> avoid belt slip

+● Torque limitation -> protect pinion gears teeth

= Increase the life time of mechanical transmission and preserve efficiency

tAcc

ramp

Slow

down

ramp

Stop

ramp

Rated

speed

Low

speed

Spee

d

Time


EE by Gear optimization Gearless systems

● Removing the gearbox is a way to simplify mechanical systems, save space

and allow for energy savings.

● But It needs specific motors high torque and low speed (multi-poles)

● However it occurs more and more

● Example for lift motors and extruders


EE by Gear optimization Gearless systems

Conventional motor + gear

Low cost but …

● Poor efficiency

● Mechanical stress

● Oil in the gear box

Gearless systems

● Fewer mechanical parts

● Less space required

● Energy savings

● Noise reduction

● Need a speed drive to be controlled


EE by Gear optimization Opportunity

● Gear less motors have to be managed by

frequency converters

● ATV71Lift (up to 75kW)

● For lift Asynchronous and Synchronous

motors open loop and close loop

● ATV71 (up to 800kW)

● Synchronous motor open loop



> Energy consumers






> Conclusion


Driven

MachinePDS

Motor

Main factors for energy savings :

Speed control

Process regulation

Start/stop management

Gear

Process

VSD

EE by Speed control of pumps and fans


EE by Speed control of pumps and fansElectricity Consumption

For the processes and the building utilities :

● 65 % of energy is used for the fluid applications

In a typical building :

● 50% of all energy is used is for HVAC operations.

● Electricity consumption growth for air conditioning was around 55% in the last 10 years.

Compression

30 %

Pumping

20 %Ventilation

15 %

Process

35 %


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0% 20% 40% 60% 80% 100%

Flow

Power

Speed

Pumps and fansPower consumption

Power=K . Speed3


How to waste energy ?Flow regulation with a valve


This solution is bit like …

…regulate the speed of your car

by keeping one foot on the accelerator

the other on the brake.

Brake

still one of the most commoncontrol methods

….. with a considerable waste of energy

EE by Speed control of pumps and fansEnergy Wastes


How to save energy ?Speed control


EE by Speed control Potential energy savings with pumps

Depends on the design

and duty cycle.

With Speed control :

20% to 50%

savings

Power

Valve

Speed Control

Flow


EE by Speed control Potential energy savings with fans

Depends on the design

and duty cycle,

With Speed control :

20% to 70%

savings

Speed Control

Power

Flow

Output valve

Input valve

DEMO

Training Canada\EE\EE ventlation anim flash\Schneider_v4.exe


EE by Speed control Energy saving motor control law

● Altivar integrates specific motor control laws which allow optimization of energy consumption

● Quadratic law (U/f = kN²)

● Command law dedicated to centrifugal pumps and fans

● Energy Saving law (NoLD)

● This law integrates a flux vector control that adjusts the magnetizing current as a function of torque.

Function of the load :

Up to 5%

savings more


EE by Speed control PID Regulator – Sleep Wake up

● Altivar integrates functions to run the motor only when needed

● PID Regulator

● Function used to regulate a process (i.e. pressure in water circuit)

● Sleep / Wake Up Function

● Function which sleeps the application when there no demand

Sleep /

Wake UpPID Motor

Sensor

Reference

Output

Frequency

Feed

ba

ck


● In addition to Energy Savings, using a Variable speed drive has

many other advantages :

● Less mechanical stress on motor and system (water hammer,

cavitations, ...)

● Less mechanical devices – Less Maintenance

● Reduce pumps or fan noise

● Flexibility

● Can be controlled with BMS, field bus, …

EE by Speed control Other Benefits ...


what Schneider Electric can

offer to you ?

a wide range of

products

solutions

services


To optimize your installationa complete range from 0.25 HP to 2400HP

from Compact to Engineered Drives

EE by Speed control Altivar Ranges

ATV12ATV312

ATV212

ATV32

ATV71-ATV61

Drive system


EE by Speed control of pumps and fansATV212

HVAC applications for Buildings

ATV 212 up to 75kW

• low Harmonics

• PID Regulation

• no need for line Inductance

• reduced Losses

• easy integration in BMS (Building Mgt System)

• energy Saving Motor Control laws


EE by Speed control of pumps and fansATV61

Pumps & Fans in Industry and Infrastructure

ATV 61 up to 800HP

Common features

● PID regulation

● connectivity with all Field Buses

● easy Settings

● guaranteed Performance & simulation Tools

● energy Saving Motor Control laws

Specific applications

● Ventilation : mastered Harmonics & enhanced Safety

● Pumping : Multi Pumps management


EE by Speed control of pumps and fansEngineered Drives

Drives systems ready to use

ATV 61/71 Plus up to 2400kW

• High degree of protection

• Compactness

• Mastered harmonics

• Flexible offer


EE by Speed control of pumps and fansECO2 calculation of energy savings

● ECO2

● Show the potential energy savings in a few

clicks

● Select the ATV

● Provides a report :

● The consumption with and without the ATV

● The potential savings

● The payback

● Based on the application and it’s duty cycle

ECO2


Without

VSD

With

VSDSaving

Average Power / motor 104 kW 40 kW

62%CO² rate per year 459 t 175,5 t

Total annual Cost 34,9 k£ 13,3 k£

Payback period 10 months

EE by Speed control of pumps and fansExample : Tarmac (UK) : Extract Fan

● SE Commitment to reduce CO² levels

● Project & Services actions

● Audit to confirm the key point: extract fan

● Monitoring to analyze consumption

● Speed Drive installed

● Confirmation of final Saving

● Tarmac Benefits :


Period April - February 2007- 2008

Without

VSD

2008 - 2009

With

VSDSaving

Electric

Consumption277 MWh 106 MWh 61,7%

EE by Speed control of pumps and fansExample : Schneider Electric Grenoble (F) : Primary Pumps on Heating

● Services actions

● Installation of Variable Speed Drives on primary

pumps of the installation of heating

● Two Altivar 61 15 kW installed on the 2 primary

pumps which provide the heating of buildings

T1, T2 and T7 on Grenoble plant

● Project in collaboration with Dalkia

● Schneider Benefits :



> Energy consumers






> Conclusion


The main target(first priority)

The next step

(second priority)

EE by Speed control - other opportunitiesWhat about other loads


Modulation

All or NothingVar. Speed drive

EE by Speed control - other opportunitiesScrew Compressors

Different ways to regulate the pressure with a compressor :

● All or nothing

● Valve at the aspiration side, the valve is closed or open according to

the pressure demand

● Modulation with valves

● If the demand decrease an auxiliary valve opens progressively and

send back the air to the input.

● Speed variation

● Regulation with a variable speed drive

● Speed control benefits

● Savings up to 20%

● No current peaks

● Reduced mechanical stress

● Precise pressure regulation


Centrifuge Compressor

Variable torque kN²

EE by Speed control - other opportunitiesCompressors with potential

Screw Compressor

Near constant torque

Scroll Compressor

Near constant torque


EE by Speed control - other opportunitiesDC Bus connection

With Sharing of DC bus

MotorWinder

Unwinder

Generator

+-

Example of winder/unwinder

MotorWinder

Unwinder

Generator

Without Sharing of DC bus


● Bus DC connection :

● Example :

Process machine with

Winder/Unwinder




Example of multiple hoisting or elevators

+-


● ATV71 option : the Network Braking Unit

● The power is regenerated onto the network

when the drive system is working as a

generator

● May replace braking resistors in system with

long generating cycle or high braking power :

hoisting, high inertia machines …

● For such applications, it's a good compromise

volume / efficiency / cost

● And the energy saving allows a quick

paying back (less than 3 years)

EE by Speed control - other opportunitiesRegenerative units

Drive

NBU

Generator modeMotor mode


EE by Speed control - other opportunitiesActive Front End (AFE)

Feedback energy

Reduce energy costs

Increase power quality

Harmonic mitigation

… is an option to Altivar ATV61 and ATV71 range


EE by Speed control - other opportunitiesActive Front End (AFE)

● Hoisting

● Downhill conveyors

● High inertia and high

dynamic applications

● Test stands

● Winches

Regenerative operation

● Weak main supply

● Utilization of full transformer power

● Generator supply

● Compliance to IEEE 519 THD

● Power factor correction

Harmonic mitigation


Example of a Crane

EE by Speed control - other opportunitiesRegenerative units

Hoist1

250kw

Hoist2

250kw

NBU

or

AFE

Boom

250kw

NBU

or

AFE

Gantry1

160kw

Gantry2

90kw

Hoist3

250kw

Hoist4

250kw

NBU

or

AFE

Main Power

Supply

4x345kw 1x90kw1x200kw



> Energy consumers






> Conclusions


Driven

Machine

Energy Saving in PDSPotential of Energy saving

Process PDS

VSD* Motor Gear

Sizing

Technology

5 – 10%

Technology

maintenance

5 – 10%

Speed control

Process regulation

Start/stop

management

20 – 70%(Process + VDS)



How to optimize Power Drive System ?

● … But first of all think variable speed drive

Its about 5% to 10% of saving …

it can be 20% to 70% of saving

● You can improve the couple Motor + Gear …

Conclusions


Conclusions

It is natural for

Bulbs

What has changed …..

● Consumption ÷5

● Life duration x5

Traditional

generation

New

generation

Speed Drives

……. what could change !

● Consumption, up to - 70%● Less Mechanical stress & less

Vibration Noise

… do the same for

Motors !Electromechanical

Speed Drive usage must become obvious !


uestions and Answers

Efficient Motor Control With Power Drives

Systems


Thanksfor your attention

Motion & Drives training

Make the most of your energy !

schneider iiee 2013

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