Welcome To National Seminar On Energy Conservation in Compressed Air Systems

Welcome to National Seminar on
Energy Conservation in
Compressed air systems
17 – 18 Dec 2004 Hyderabad
1
CII – National seminar on EnCon in Compressed air systems
Compressor Controls
Most industrial processes require a varying amount of air
The changes in air demand can be due to:
•Extent of plant utilization
-Time of the day or the day of the week
-Degree of maturity of the process
•Large consumers of air with intermittent demands (Forging
hammers,Presses,etc)
•Mass dependent processes such as air separation
•Or simply because the air demand is over-estimated
The compressor therefore requires a control system to regulate the air

generation of the compressor in direct relation to the demand
2
1
VARIABLE SPEED
CONTROL
3
Application
Why VSD??
l/s Typical air demand pattern Monday
Tuesday
Wednesday
250 Thursday
Friday
Saturday
200
Sunday
150
100
50
hour
4
2
Basic Control Philosophy
FREQUENCY
CONVERTER
ELEKTRONIKON MK IV
SET POINT
PRESSURE
SENSOR
AIR NET
AIR DELIVERY
SCREW ELEMENT VSD MAIN MOTOR
The system targets a constant delivery pressure (set point)

5
VSD Control
The Control Principle:
Once the VSD is started, the pressure sensor readout is
continuously compared with the programmed ‘SETPOINT’
pressure (P load and P unload don’t exist anymore).
If the net pressure is higher, the speed is decreased
If the net pressure is lower, the speed is increased
The usable compressor speed is limited by a Maximum and
Minimum. This is called the speed range
6
3
VSD Frequency Converter
Building blocks
Rectifier DC – link Inverter
Converts AC to DC ‘Cleans’ rectifier output Converts DC back to

Variable Frequency AC
7
VSD Alternatives
Integrated VSD Free-standing competition
8
4
Integrated vs stand-alone VSDs
Integrated VSD (Atlas Copco) Stand alone VSD (Competition)

• Mechanical build-up ensures no • Speed windows exist
speed windows
• Inverter duty motors • Standard motors
• Protection against bearing • No protection against bearing
currents currents
• Electro-magnetic compliance • No electromagnetic compliance
• Harmonic control • No harmonic control
9 9
Design Aspects Of VSD Equipment
Speed windows or speed locks
Inverter duty motors
Bearing currents
Efficiency aspects
Electromagnetic emissions and Harmonic distortions
10
5
Mechanical Adaptations
Old design
POINTS PRONE TO INDIVIDUAL VIBRATION
11
What Are Speed Windows ?

Vibration peaks at component resonance
0,9
0,8
0,7
Vibration levels
0,6
0,5
0,4
0,3
0,2
1000-
0,1
1200
rpm
0
1st Qtr 2nd Qtr 3rd Qtr 4th Qtr
min max
speed
Speed windows are speed ranges which are avoided in VSDs to
prevent resonating frequencies. This wastes a great deal of energy
ATLAS COPCO VSDS RUN WITHOUT SPEED WINDOWS
12
6
Complete mechanical re-design
THE NEW ZR VSD FF
Consolidation of masses and therefore no speed windows
13
Feature
Heavier integrated mass - good vibro-acoustic characteristics
Benefits
• Lesser pipes and bends – low pressure drops-energy savings
• Less vibrations at all speeds (VSD without speed windows)
• Lower noise levels
• Higher lifetimes
14
7
Prevention of resonating frequencies and speed windows
Internal channels in castings to

substitute piping
Centralization of masses
15
Capacity Range
EXAMPLE – 90 KW VSD
90 KW VARIABLE SPEED DRIVE
100 120 140 160 180 200 220 240 260

FAD (l/s)
78 L/S 260 L/S
16
8
Benefits of window free operation
To summarize, the benefits of no speed windows are :
• Large energy savings
• Constant pressure
• Better fit to the application
17
Other Solution??
Several loose masses and external piping

Number of speed locks – loss of energy
They use fixed speed motors on their VSDs
18
9
Bearing currents
Efficiency aspects
19
Fixed Speed Motor As Variable Speed
COOLING
FAN
Fan air flow is proportional to speed 2

Thus at 90% speed there is only 81% flow
Motor overheats - loses torque and efficiency

plus reduced winding life
20
10
Inverter duty motors have a

bigger fan flow to prevent
overheating at lower
speeds
Good cooling means good efficiency at all speeds,

sufficient torque, big speed range, long winding life
and good energy savings
21
Combined Efficiency
With inverter duty motors and drive matching, efficiency is stable
600 120
Peak combined efficiency
at 80% speed
500 100
Power kW / % combined efficiency
400 90
Capacity - FAD cfm
FAD cfm
Shaft input kW
300 80
Power input kW
Combined efficiency
200 70
Competitor fixed speed motors and unmatched combination

100 60
0 0
3450 3325 3125 2810 2000 1500 1250 No load
Speed rpm
22
11
Torque in fixed speed motors as VSD
T/TL %
100
90
80
Torque – Fixed speed
70 motor as VSD - cold
60
Torque – Fixed speed
50 motor as VSD - hot
40
Compressor torque
30
20
30%
10
0 0 10 20 30 40 50 60 70 80
Hz
motor over heats and the torque drops – limited speed

range – small energy savings
23
Torque in Inverter Duty Motors
T / TL %
Atlas Copco VSD with DTC
100
90
80
70
60
50
40
30
20 Compressor torque
10
0
Hz
0 10 20 30 40 50 60 70 80 90 100 110 120
Sufficient torque even at low speed – large speed

range – big energy savings
24
12
Bearing currents
Efficiency aspects
25
Bearing Currents Induced In VSD
Currents are induced in motors when used with inverter drives

If not dealt with, the currents will flow through the motor bearings and
create their pitting and pre mature failure
26
13
Vagabond currents In VSD
‘Vagabond’ currents, if not controlled, will flow from the motor shaft to the
compressor shaft causing bearing pitting also at the compressor
Motor Coupling Compressor
All our VSDs have flex couplings with rubber buffers to arrest the
flow of current to the compressors side
27

High frequency current pulses generated by high speed switching, causing
migration of metal from the rolling elements and races in to the lubricant
This leads to EDM craters and causes premature bearing

failure if no inbuilt protection is provided
28
14
In-built features to prevent bearing current damage in all Atlas Copco VSDs
Motor side bearings
• Insulated motor bearings
• Brushes to carry away the currents
Compressor side bearings
• No metal contact between motor side and compressor side couplings
Other measures
•HF straps or armour around the cables to carry away induced currents on the
motor frames and as an anti emission measure
Atlas Copco adopts all the necessary measures to prevent damage due to
bearing currents
How do competitors take care of this with retrofitting – They Don’t!!
29
Electrical Adaptations
Inverter duty motors offer protection against bearing currents
Armored cables to lead away

frame currents and contain
emissions
Bearing shields
Insulated couplings to prevent vagabond currents
30
15
Protection against bearing currents
Rated frequency 100 Hz
Large frame and cooling fan
Inverter duty motors ensure:

Good cooling at lower speeds
High efficiency
Adequate torque
31
Bearing currents
Efficiency aspects
32
16
New generation ABB convertor
High efficiency and compact
Complete compliance to EMC
directive 8/C9/EEC
Large cooling fan
ABB Motor
Model M2AA 250 SMB 4
Specially built for variable speeds
Large cooling fan for good air flow at low speeds
Optimised with the convertor
33
Bearing currents
Efficiency aspects
34
17
EMC
Electro Magnetic Compatibility
It is defined as the “compatibility of electronic equipment with the
electromagnetic environment, in which they are working”
There are two parts of EMC:
-The equipment should be so designed that it does not interfere with the
working of other equipment.This constitutes control
-The equipment should not be disturbed by electromagnetic emissions by
other equipment. This is called immunity
VSD equipment, if uncontrolled, emits electromagnetic waves which will
interfere with instrumentation signals and other equipment. If unprotected it is
also susceptible to external electromagnetic waves.
“experience shows that the cost of electronic equipment increases by 30% if
control and immunity measures are applied”
What can be done?
35
Inverter Scheme
Rectifier DC link Inverter
IGBT Harmonic
G distortions
36
18
EMC And Harmonics Control
Safety
device
RFI
+ line reactors and capacitors

Harmonic
distortions
VSD without proper filters Atlas Copco VSD

Can damage plant efficiency Safe for plant efficiency
37
Electro Magnetic Compatibility
EMC has two aspect
- Emission : the equipment may not disturb other equipment
- Immunity : the equipment must be immune for emission from other equipment
Directive 89/336/EEC of the EC defines levels of emission and
immunity:very stringent
In order to comply with this directive actions need to be taken
RFI filter in GA/Z VSD ensures compliance with directive
American standards - FCC can be met without filtration!!!
38
19
Electro magnetic shielding
RFI filters
Capacitor banks
Line reactors
39
Warnings With A Competitor
40
20
Other Adaptations
EXAMPLE – OVERSIZED OIL PUMP
Air
Water
Oil
Over sized oil pump
41
Innovative Design
Completely integrated VSD solution
No speed windows
ABB Motor and drive are completely matched for highest
efficiency
Inverter duty motors for high efficiency and sufficient torque
Compliance to EMC directive 8/C9/EEC
Limited harmonic distortions
It’s a winner !!!
42
21

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Welcome to National Seminar on

17 – 18 Dec 2004 Hyderabad

•Or simply because the air demand is over-estimated

The compressor therefore requires a control system to regulate the air

SCREW ELEMENT VSD MAIN MOTOR

The system targets a constant delivery pressure (set point)

Rectifier DC – link Inverter

Converts AC to DC ‘Cleans’ rectifier output Converts DC back to

Integrated VSD Free-standing competition

Integrated VSD (Atlas Copco) Stand alone VSD (Competition)

Design Aspects Of VSD Equipment

Speed windows or speed locks

Inverter duty motors

Electromagnetic emissions and Harmonic distortions

POINTS PRONE TO INDIVIDUAL VIBRATION

What Are Speed Windows ?

THE NEW ZR VSD FF

Consolidation of masses and therefore no speed windows

Internal channels in castings to

90 KW VARIABLE SPEED DRIVE

100 120 140 160 180 200 220 240 260

78 L/S 260 L/S

To summarize, the benefits of no speed windows are :

• Large energy savings

• Better fit to the application

Several loose masses and external piping

Speed windows or speed locks

Inverter duty motors

Electromagnetic emissions and Harmonic distortions

Fixed Speed Motor As Variable Speed

Fan air flow is proportional to speed 2

Motor overheats - loses torque and efficiency

Inverter duty motors have a

Good cooling means good efficiency at all speeds,

Competitor fixed speed motors and unmatched combination

motor over heats and the torque drops – limited speed

Torque in Inverter Duty Motors

Sufficient torque even at low speed – large speed

Speed windows or speed locks

Inverter duty motors

Electromagnetic emissions and Harmonic distortions

Bearing Currents Induced In VSD

Currents are induced in motors when used with inverter drives

Motor Coupling Compressor

Bearing Currents Induced In VSD

This leads to EDM craters and causes premature bearing

Motor side bearings

• Insulated motor bearings

• Brushes to carry away the currents

Compressor side bearings

• No metal contact between motor side and compressor side couplings

How do competitors take care of this with retrofitting – They Don’t!!

Armored cables to lead away

Insulated couplings to prevent vagabond currents

Rated frequency 100 Hz

Large frame and cooling fan

Inverter duty motors ensure:

Design Aspects Of VSD Equipment

Speed windows or speed locks

Inverter duty motors

Electromagnetic emissions and Harmonic distortions

Design Aspects Of VSD Equipment