How to select}Contents "The process determines the choice of drive system ‘Throttle control or speed cont a question of energy savings yw control methods, Throttle control Speed control Other methods The effect of the oper consumption of energy Simplified method Jeon the ‘Two main types of speed-controlled drive systems, Investment caleulations Selection of speed controlled drive system =a technical - economical optimization ive systems on which the comparison is based 30INTRODUCTION ‘The selection ofa drive system for a particular application is be: coming inereasingly complicated. Developments in power and control tlectronies are rapid and result in the availability of an increasing numberof drive stem types.all with thelr petcuar advantages ‘and limitations. ‘Tobe able to offer clients the best solution, taking into consideration the requirements of the application concerned and environmental, factors, we are devoting considerable resources to the study of diffe rent applications and the development of recommendations for the selection of drive systems. Pumps are one of the most usual drive system applications and have naturally been the object of our parti ular interest, We do not have the same knowledge of pumps as pump manufacturers but our unsurpassed knowledge of drive systems is our speciality in this connection. We believe that your knowledge of pump technology and the use of pumps in different processes and our know ledge of drive systems, in combination, can give the user an optimum ‘tal solution ‘This guide to the selection of drive systems for pumps isour contribution to improved process prepared to add to this, our unrivalled capabilities as suppliers of Grive systems. September 1986 ‘ASEA DRIVES4 THE PROCESS DETERMIN} ‘THE SELECTION OF DRIVE, SYSTEM remains common however fra process low tobe nga valve the pump operating at o alaveomparedeocess estos [Contoiea oe Spe pam | ale “ASE ASA |ASBA ASA ASEA6 THROTTLE CONTROL OR SPEED CONTROL - A QUESTION OF ENERGY SAVINGS Flow control methods “Thove ara two main methods epulating a Now, by Imoens of thrtle valve inthe piping or by chang Thespeed of the pas. ‘Throttle control Th Curved shows the system ‘The system curveconest {hebead and the ow fattot be changed furve by changing intoductlon fa egulating valve makes possibe tjustable letea, We have now a ower aw at Use fpr na the presure rutletonses consist ofthe distance DE Point = elsed valve C= Tally open valve B= party open Distance DAP trol® Speed control Asenongy cots increase, greater interest isshown proces industries nthe contra of Mow Epa of the pump How a pump func tbc fthe spe pmol method on th enon shown in ig 3 “Theeneray consumed ind pimp varies with Use efiieney of the drive system Mhitndomonstrate its advantages over valve contol, nerdy consumption with an idal formed, Most elosetothe ‘With peed control we are not restricted as with throtilecontral andthe pump speed cant changed “Simply ffthetlw isto diagram shows how draci eaiuirement decreases with ie speed, Other methods ‘There are ther methods of controlling proces ow tha te two described the most important being ‘eo and. conteant speed pump Forexampe i iscommon for Fig.2 ControLaffow with sped controled pump Point D = duty point wi = duty point wi P= duty point wi speed nj and flow Qi speedy and iow Q2 Speed and Flow QS The ditance H-G is the achieved energy saving with speed contra atthe sped ay compared with throttle conta ‘The effect of the operating eyele on the consumption of energy. cf thetlow during the year 2 Time ig 4 Example ofan operation cycle curve fora pump. To make a orret al of the onenay fonsumpion the operation eyele curve must be Avid up nt wget. og, 2s pr | er | ea | | ah data Lara] any [a Time Fig Segmented operation curve isnow possible Py Pfr each For eachseament,Q pump withthe above Operation yee curve is equal fo the sim ofthe energy ‘hnsumpton foreach individual segment, At Stoo Power consumption & = Jevangas te very dificult obtain knowledge im oyle of te ae ‘ferent, typical operation evele curves forcentefugal pumps “The ingram i wed inthe allowing manner ‘© Determine thediageam wit the operation cyclo pplication concerned ‘© Thecorreet point onthe horizontal axis ean bo “itained on the bars the power tions, S000 hours perjear For shorter periods the ‘Svings ee proportionally Tes.ENERG! ial ENERGY Pee ee (nd 1200) EFFEKT Power (kW)h ENERGI | ENERGY Ear (MWh) 1201 | tg e0% 800 } Ts ot eae @ }—— EFFeKT wercl “39 so ~COSCSSCS*«é CP NERGY nis : @00|—~ - san | 000 —_|— 3000; _ — ° Z EAT a rT 00} — $EE eae Zr Ay $$} —JEFFEKT "300, 10‘TWO MAIN TYPES OF SPEED- CONTROLLED DRIVE SYSTEMS ‘The background to these diagrams is explained below: f= working speed of pump Py = power input to coupling PE? = fowerourputet coupling Fig? Hydraulic or eddy-current coupling Fig. 7 Shows thatthe speed ofthe motor st the Coupling ing a te spor tongue input to the ‘utput. Asse power tthe product ofthe torque and the speed, Figs Pampdriven by speed Figd, Pump diven by constant speed motor via! snadjastae cou raul lonses are eliioncy ofthe lahe magnetization and ex taken ints considera ‘Shupling becomes The power requirement for different drive systems is ‘obtained by dividing the power requirement of the total efitency of the dive system The types af drive tallow Power requirement for eletromechanieal hydraulic coupling al drive@ ‘Theditference in power equirement{ AP that tecomes the difference betwen the have a Curve A = Throttle control Curve = Speed control with hydrauliseday current coupling Curve = Spee control with purely eleeteial deive Distance Py = Difference in power consumption etweenthrote control and speed al with pure clectrieal drive Distance AP) = Distance P= Difference in power cons tion shu purely elec dive seteENERGI ENERGY PE ee (wh) 300}- Ln { } JEFFEKT 3m 400 60 800 000=«*1200=SK00S Power (tw)woe LT ENERGY ea ine inn 300 I + 200 — 2 oss | ARE ° za | | fh | | JerreKt 30 100 150, 200 250 300 Powertkw) ENERGY : hw rae ‘0 = _ =P Hg-50% 1000, Y— 5% ._ = (As 1 600 | 00 7 + m0 1 JEFFEKT a a a erENERGI { | ENERGY ‘ = (iw) EFFEKT Powerlk\) Un | 1 IEF FEKT a a a i a” INVESTMENT CALCULATIONS, Pay-off method 1 present valve methad 1 povolf method Net present value method Q Wis method relatesthe lationship lavestmentenannual energy saving (3) death a fine agra bw Nepramtulae= A-f—t 1 Snvestment oat An equation simpler to where f= amet present wale read fo Alara belowSELECTION OF SPEED- CONTROLLED DRIVE SYSTEM - A TECHNICAL - ECONOMIC OPTIMIZATION This con beillastrated with an example. A comparison lrtwcen twodrine systems nay chow thatthe higher Mfcieney ofane system can he evaluated 10,0008, Fequirements ofeach topurchase pice in relation ta operational cost, End eae ofservice are some othe fac third and las step, the pu fered. Many factors are Felaton diagram use ranch standards and practices whieh further lea general comparison compari i. = ctrangencludesthe mst fequenty ised drive por vied in three ‘The deve systems not stage can sw be comparedin a some ‘be quanliiedin money and will then, together wth thepurchase price instep 3, determine the selection20 0-30 kW etvetcseinase” | vans rommter ioe interior cenvarange Be ray encod Spec vesion 7 |sandava Brushless operat. | Yes ves = Start torque yes Yes yes ves | 00% tient |ioon ven Son [ico vw sow [ion yom sow [icon 75H Som Serer eds Se" foe as s @ is 70 sa Ee a Ce Ce poner tor ta io fps ta fos / I" 4 y Va in i ‘amy [Normal Minimal erfect on power supply Msintenance inspection 2-avimesye spec. competence | ERCaTGa) ectranical spare part Expensive pare [Expensive spare The figures given for maintenance are re i figures obtained from Customers it industry with extremely hig mands on availability Rule of thumb 9) Cost for brush set, assume 9 SEKIa 0-30kW comments: shattpower 5 0 5 2» % 30 ® General recommendation G The frequency controlled cage induction motor is often the best bacause the motoris very robust and requi to introduce speed co intenance. Frequency co! in an existing constant speed system Exception 1d then a DC motor system can be ch native when the H the environm: network is weal2 30-200 kW carenon Frequency convolled [De wivesysiom fnducionmotor = “age induc |(TYAAK) eddycurrent counting control range [9.100% + 100% 5-100 iS.) ]9°200% (0-100) ff0-200%) (52100) Fotailyencloed [standard Spec. varaon. 0 Standard Brushless operat_| You ve Ta0% 7% sou [vow 75% sow [i0o% 75% Sow [i00% 75% Som lex aoc: fas, az 70 ap m0 ss day sas ES CS | lose 5 lr te / es / a a a Eiiecton power |vormalardighty [Normal Minimal anil supply rower Drimewye Jr 2-imeaye Fiver replacement 5 Spec. competence | EecToTIGT Mechanical Spare paris Espensivespare | Eparsvespare [Expensive coupling | ‘The figures given for maintenance are realistic Figures obtained from customers iv industry with extremely high demands on avallobiity ule of thumb Price for airair cooler 20.000 SEK For capitalization of losses use SEX 10.000 Cost of reactive nower compensation wit Cost for rush set, assume 7 SERIA. Cost for rus et, assume 9 SERA,23 30- 200 kW felatve price a5 contnac ’ 7 30 7 7 as 7 . . commutstormtor 20 TYRAK os Shattpower 50 100 150 200 250 kw # General recommendation: {drives in the above power range. The motor is robust and can be suppl protection forms to suit the environment. Maintenance costs are minimal because the motor is brushless. H speed control of an existing pump motor is required thus a frequency convertor can be applied to the existing motor as this is usually a cage motor. Exception: I the environment s suitable, and the cheapest capital cost is equited then a OC motor system can be chosen. The commutator motor is only a realistic alternative when the network is weak24 control range fo-100% «7-10, 10-100 ’ ferushless operat. [ves yes ves, 10086 7556 5056 75m So% [100% 75% 50% [100% 75% 50% | —s., |L— —-| ae tin “Bia Teta The figures given for maintenance are realistic figures obtained from CUstomers in industry with extremely high demands on availability Rule of thumb 1) Price for aitlair cooler 50.000 Sex 2} Price for ait/ait cooler 60 000-75 000 SEK 3) Forcapitalization use 10.000 SECxW. 4) Costof reactive power compensation with filter 200 SEKIKVAr 5) Cost for brush set, assume 7 SEKIA2s 200-600 kW Relative price : 7 svn # sdaycorencoupting or comments Piawi © snatt power 200 00 600 t General recommendation ‘The best technical solution for a drive system for pumps in the above output range is cage motors with frequency control. The price for this system is higher than for a comparitive OC motor system but this soften counteracted by the ‘technical advantages as well asthe lower maintenance costs. Brushless motors with IP54 protection form are some of the advantages Exception: __ Where the lowest capital costs required then the DC motor system isthe best choice26 600-2000 kW [careRon Die are sytem crv. Frequency convoted synchronous motor iereasrn) Induction motor » fey current or ya eanvorrange fo 00 "0-100 ra Br [oo erences spacial voion) | tndars ain siesronec he he | nig Transf. needed '? Yes, ves ves res Tei sod [oR anda | HOT Radard ee "00% 00% 75% 50% sz 92 90 os 333 ‘oom 75% S0% [100% 75% 50% sor ae ozo wr se [oso 100% 75% 50% jess as ssa Power factor Fall foxa x ce cl Effect on power suey rinones doe paoisenance: inspection snraplacement replacerent 1 competence Electronicala Aelative price 600-2000 kW + KASKAD . Eddy curent and hrydtaulrccoushing (ote: powers above ‘ooo the be motors © 1000p) shattpower 0 500 1000 1500 2000 General recommendation The KASKAD system isthe best solution for normal pump drivesin this output range with ‘a speed control range of 60-100 %. This system has a high efficiency as well asthe lowest capital costs, Maintenance costs are also low. Exception For operation in bad environments (dirty, explosive ete) or where a large speed control range is needed then FREQSYN is the best alternative,28 > 2000 kw Jearenon ]ocanvesystm | siprecneryarve Frequency consoles [Inductonmotor + aan) ickseaoy yrconaus mater” | hydrate motor seas conwatrange 190% fois ——‘ronvoo 00 Ba |o-2005%) fica tion | mentee eee | igh Frans neeced.” |ver(mororoni [ver ver = eaciorwe [es ver ‘oom 75% so [ion 75% sow [roan 75m som [roo 75% Som a oso |as gs ve 6s as si 5a 52 [56553 |5e os oo os TZ, leo oa 4 Z =o “iin [ee on power Normal Minimal feed omer fc 2uimesye 12 meu sec competence Fedvonical Teeronical chal aa The figures gyen for maintenange are realistic gures obtained from customers industry with extremely high demands on avaflabiity. lula of thumb Tor ollimmersed transformer SEK 160 000.250,000 - (2000-6000 kvA) ‘ation of losses, use 10.000 SEK KW. fe power compensation with filter 100 SEK/RVAr set, assume 7 SEK/A h set, assume 4SEK/A29 Aelative pice > 2000 kW KASKAD x0 e o w 7 0 3 speed range 300°500 min aw shaftpower 2 a 5 8 10 ® ‘ge speed control range is needed then FREQSY! > 10 mW then FREQSYN is the only technical saoeEy Dic. drives with thyristor convertors the BO ier, alsode pusly improving and new generations are mute ‘ten intraduced. De motors are designed with ew ‘The most importante mieropracesoes fe ‘anced diagnostics, rivesand tye 6 most common variable speed ees of long tradition and te characteristics Noather seu ontoled drivecan lone replace this TYRAK can equiremeata Power rang 1-1DKW tphase here Contrl range Regeneration: Dynamic or egenerative nance of ot brakingcam be provided bearings ete, Convertor bridge:2 A.c. drives with induction motors and frequency convertor. CONTRACKS 0-6 CONTRACS DnkW CONTRACL —AnSttO KW Supply voltages: CONTRAC XS und = 600 ¥ CONTRACL. Bea Contrarange: —9:100°%.0, (o-1oorts a inom rated power} Power factor: Approx 0.96 within the ‘comiol range sped und ar ix pulse diode rectifier gives ow harmonic content inthe mot Ieused for euoning th ny direction34 Ac. drive system with slip motor and recovery frequency + (alip recovery dive). Systems. The sped: do sar now by aconvertoreaseade “The ASEA KASKAD system bymeansof the new wer regenerated davelopedby ASEA. ormitsthe sytem to perfor Peconneston afters Powerrange: 500-8000 KW Control range: 50-100% A startean be performed witha rheostatiestartor which ean Also be used up tothe rated speed Braking Harmonies: Sixpulse but duced in relation to fhe contral ange. Certain speed ‘org Power factor: Liceney: Very high Applications: Large pumpsand fans Comment:‘Other systems for slip contrt avail market Subsynehronous speed control with slip ‘The system he several designations, or example, drive system with lipring ition motor and The inadequate contol ofthe rotor power demonetrated bythe conventional solution wheo, for ina tendency Which s transformed heat, In prineiple this36 A.c.drive system with synchronous motor and frequency convertor Dynamic andor eegenerative bral 5 breve pulse depending on inecontal range isto be asin over “Tie system operates with requcneies fmapecd of machines ior Other systemson the market Ccycloconvertor systems Cyeloconvertors and apnchronous motoraare wed froferentilly forapientions mth arge torques cod {bw speeda, The maximum output frequency othe ves ately VSolthemainaitequency Jong periods. This irl mae vemolsaage©a8Scicn tien od ne oss and winder) Arar fee mane bee| ‘vantage a that start torque up 6 times the rt ne ; {enue canbe abtalned.38 eetro-mechanieal drive system 10.94% and tho losses caused bythe ar resistance of i coupling which givet.a system eicieney af 81 Inthe lowest pac stb iid 75% 80% of thevated sped ey current coupling rom L KW up t approxIoobtained. The efficiency is normally approsiemately 90% but the efcleney ofthe driving machine must. leo be considered Common tbat types is that the speed thus becomes dependent on the lading te Hydraulic coupling -aulie couplings of which there are several types, trancmitthe necessary torque by means of vane ofthe speed Sx which mean tht the effciney with rated date fe 94.965 4a total of 85-88% for relatively large drive e@40 Uncontrolled electrical drive systems oa. motors Sind proeeive These are used together with mechanical haiteven more for direct drive a i The tart eau. ‘equipment or are included Drive system with induction motor Squirrel cage motors ae often the logical selection in lew power ranges The moto simple and robust and lstease the art equipment consis of wesarter ora conaetorfae group eal Alivet on Ifthe supply system estrong, even large squreeleage trotorscanbe started Por applications with ited tart torque requirement, the Toad onthe thaineatstartcan be rededty wing special start Inathodse g reactor or tanaformer start tncertaln ‘ices, # ViD start can be used Squirrel eage motors [re available in the power range D220 000 wi nneetion voltages upto 13 BKV, Slipring asynchronous motorsare used when the Mreak or thestart heavy. The tae Stren through th rotor winding is here Sind high ar tora red with Tow start Srrent The most usual power range for equipment with slipring asynchronous motors is between 200 and 2000 WW: ASEA however ‘mats with powors down to 15 KW at 15 t Drive system with synchronous machine EW and oe rang oft reaetn or transformer entisexcesivewithadiroct