ELECTRICAL DRIVES

Electrical Drives
The general meaning of a Drive is the system, which is driven by some energy. The source of energy may be any thing like wind, water, oil, steam, solar or electricity etc.

When the source of energy is electricity, the drive is called Electric Drive.

Utilization of electricity for driving the mechanical system employs the use of Electric Motors, which gives an output in terms of Mechanical Energy.

Many industrial applications requiring rotating electric drives are normally capable of speed control and often require an equipment to attain a versatile and smooth speed control and make the motor to operate at a desired specific speed torque characteristic. These drives are characterized by the nature of speed torque characteristic such as constant torque drives and constant power drives. These are sometimes characterized by the type of motor used in the drive i.e. dc and ac drives making use of dc and ac motors respectively.

Advantages of electric drives

Type of Drives
The various types of electric drives used in industries may be divided into three types:
1. Individual motor drive; 2. Group drive; 3. Multi-motor drive.

Individual motor drive

In individual drive, a single electric motor is used to drive one individual machine.

The machines can be placed in any desired position and can be moved very easily.
The machines can be built as an integral part of the complete system, which results in a good appearance, cleanliness and safety.

For the purposes where constancy of speed and flexibility of control is required, such as in paper mills and textile industry, individual drive is essential.

Group Drive
By group drive is meant a drive in which a single electric motor drives a line shaft by means of which an entire group of working machines may be operated.
It is also sometimes called the line shaft drive. The line shaft is fitted with multistepped pulleys and belts that connect these pulleys and the shafts of the driven machines serve to vary their speed.

This drive is economical in consideration of the first cost of the motors and control gear. A single motor of large capacity costs less than the total cost of a number of small motors of the same total capacity The efficiency and power factor of a large group drive motor will be higher, provided it is operated fairly 10% overload when being driven by group drive.

This form of drive has become obsolete now-a-days because of its following draw-backs and objectionable features, and the modern trend is to employ individual and multi-motor drives: 1.In group drive, speed control of individual machine is very cumbersome
using stepped pulleys, belts etc.

2.Owing to use of line shafting pulleys and belts group drive does not give
good appearance and is also less safe to operate.

3.In group drive since machines have to be installed to suit the layout of the
line shafting, as such flexibility of layout of the various machines is lost. Also it is not possible to install any machine at a desired place.

4.The possibility of installation of additional machines in an existing

industry is limited.

5.If, at any time, all operations are not required, the main motor will work
at low capacity and, therefore, operation efficiency will be low.

Multi-motor Drive
It consists of several individual drives each of which serves to operate one of many working members or mechanisms in some production unit.

Such drive is essential in complicated metal-cutting machine tools, paper making machines, rolling mills, and similar types of machinery. The use of multi-motor drive is continuously expanding in modern industry as their advantages outweigh the increase in capital cost as compared to the group drives.

FACTORS AFFECTING DRIVE SELECTION

Various Types of Driven Equipments

1. Pump; 2. Fan; 3. Compressors; 4. Conveyers; 5. Mill;

6. Crusher;
7. Crane; 8. Hoist; 9. Traction;

Amongst motor used in any modern plant and industry, the maximum number of motors used is 3-phase Induction motor because of their cheapness, robust construction and satisfactory performance. Their maintenance in service is also easier as compared to other types of electrical motors.
The Torque speed characteristic, inertia and duty cycle of load will mainly determine the electrical characteristic and rating requirements of the driving motor.

The proper selection of motor rating and design will result in a minimum motor cost for a specified motor life expectancy, torque-speed characteristic, inertia and duty cycle of load.

The selection of under size motor for low motor cost however may result in overloads and a consequent reduction in motor life.

Factors Affecting Motor Selection

Mechanical power output required
The most likely starting point for motor selection is the output required from it to drive the system. This information must be found from a consideration of the other elements in the system Load Load is defined as the torque required to drive the system, including the driven machine. This may be constant or may vary with speed. Thus a relationship between torque and speed, called a characteristic of the system, should be established. The nominal torque required by the system at normal running speed will be a function of the work done by the driven machine. It is usual to estimate the percentage overload which might be applied as a result of system malfunction before the motor reaches its stalling point

 If the torque varies with time then the maximum range should be found. If it varies with speed thenthe relationship between the two is needed.

The Duty of the system involves the number of hours per day it is in use and the proportion of time the system is working at full load. Motors are rated according to the time they can maintain their full load without its temperature exceeding the maximum permitted by the insulation class. Continuous rating means it can work continuously and has a built in overload margin. Intermittent rating for a given time means that working is restricted to that time and a minimum time must be allowed for cooling between loaded periods. I t follows that for a given motor the 'continuous' rating has the lowest value

 AC motors starting a system having high inertia usually demand a high starting current. The inertia of the system

and the frequency of starting should be determined.

Acceleration of the system will depend on the difference between the torque required to drive the system at a given speed and the torque provided by the motor at that speed.

Direction of Rotation
Most systems are designed to rotate in a specific direction so it is necessary to determine which direction

Speed
For systems which are required to be driven at varying speed the speed range must be supplied as well

Electrical Supply

A case study for 750KW, 6.6KV, 6 Pole Squirrel cage Induction motor which is optimally design for the specification as given below: Starting torque 90% Starting current - 600% Maximum torque - 230% Temperature rise - 70 0 C
Out of various design, two close designs were selected with the following parameters as shown in Table

Description S. N 1 2 Frame size

1st Design

2nd Design

1LA7 636-6

1LA7 710-6 54.5

Temperature rise (oC) 69.1

3
4 5 6 7 8

Starting current
Starting torque

6.027
1.037

6.12
0.894 95.95 0.864 8.0 Lakhs 31.66 kW

Efficiency at 100% 93.33 load Power factor at 100% 0.827 load Cost of machine Total loss 6.0 Lakhs 53.6 kW

Observations
1. From the above table, it can be seen that the efficiency and power factor of Frame 1LA7 710-6 is more than the frame 1LA7 636-6. 2. The saving in power loss by using 1LA7 710-6 motor is ( 53.6 31.66) kW = 21.94 kW. If the motors are running continuously, then the number of unit saved is 24x 21.94 = 526.56 kWh per day per motor or 192194 kWh per year per motor. 3. Taking the unit charge as Rs 4 per unit; the total saving is Rs 192194 x 4 = Rs 768776. 4. Let us take 15% interest and depreciation. The extra expenditure per year on the cost is 2x0.15 Lakh = Rs 30000. The pay back period is 30000 x12/768776 months = 0.468. It is less than 15 days only. It may be noted that the working hours were taken 24 hours which is not realistic. Let us take 8 hrs per day. The amount saved per year is Rs 768776x8/24 = 256259/-. Therefore payback period is 0.468x3 = 1.4 months. 5. If, there are 1x105 ( 1 Lakhs) motors operating every day, we can save power 21.94 x 1x105 kW = 2194 MW.

Variable Speed Drives

Q-H characteristics of pump
600 500

400 H 300 200 Hr1 Hr2

100 0 0 1 2 3 4 5 6 Discharge(Q) in m3/sec

In pumps and fans using constant speed motor with conventional control, variation in flow is achieved by means of throttling valve or damper as shown in Fig. The Power consumed P Q H/ (m xp) Where Q = Delivery of pump in m3/sec H = pressure head (m) m = motor efficiency p = pump efficiency s = m p

Let Q1 = 4; H1 = 200 Q2 = 3.6; H2 = 240 Let us assume that there is no change in system efficiency. Then P1 Q1 H1 4 x 200 = = = 0.9259 P2 Q2 H2 3.6 x 240

Therefore P2 = 1.08 P1

Pressure (H) in mm of water

Q-H Curve with variable speed motor

600
Pressure (H) in mm of water

500 400 H1 300 200 100 0 0 1 2 3 4 5 6 Discharge(Q) in m3/sec H2 Hr

Fig.: Pump curve at different speed with constant resistive curve for lower quantity Q1 = 4; H1 = 200 Q2 = 3.6; H2 = 160 P1 4 x 200 = = 1.39 P2 3.6 x 160 Therefore, P2 = 0.72 P1

It means, the power required by variable speed motor is only 72%. It is also possible to keep the system efficiency same as original one. Even if the system efficiency is down by 1%, the power required by pump system will be 72x85/84 = 72.85%. It can be seen that there is an advantage of having the variable speed motor. We can also see that in case of still lower delivery, the power reduction in percentage will be more because of lower head.

Energy conservation by Adjustable speed control

1. DC Motor DC motor with variable speed by rheostatic control in field and armature would give speed control. Some losses also occur in the resistance. DC motor with Thyristor converter is widely used for efficient and precise speed control in steel mills, Cement Plant, paper and textile mills. With fully controlled bridge, regenerative braking can be achieved. 2. Induction Motor In case of squirrel cage motor multispeed winding may help the operation at different speed while speed change can be achieved with the help of addition of rotor resistance. Energy conservation in Slip ring Induction Motor with Slip recovering is one of best method. In conventional SRIM, introducing resistance in the rotor circuit varies motors speed. Since power is absorbed by rotor resistance, efficiency of the motor drops as the speed decreases. The power otherwise wasted in rotor resistance can be fed back to the system by using a static converter, which converts the slip frequency power to DC and then converting in to three phase which would be fed to main supply for controlling the speed. This is fed back to the line with a line-commutated inverter. The variable voltage and variable frequency is also adopted for variable speed in Induction motor.

3. Synchronous motor The speed change is achieved by application of Variable frequency variable voltage. Fans a case study To have similarity of measurements, two 210 MW units at Vijaywada Thermal power station of Andhra Pradesh State Electricity Board were selected for carrying out site measurements and subsequent energy consumption comparisons. Unit 3 & 4 are 210 units and having tower type boilers supplied by the same source. Fixed speed induction motors drive unit 3 ID fans. The fan is coupled to induction motor through a hydraulic coupling so that the fan speed could be varied by scoop tube control. Unit 4 ID fans are driven by Variable Frequency Drive. The fan is coupled to the motor through a flexible coupling. A synchronous motor fed from Load Commutated Inverter (LCI) was used as a variable Frequency drive. The study conclusively proves that introduction of Variable Frequency Drive system for flow control application has a definite advantage in terms of substantial energy savings as shown in Table.

Variable Frequency Drive has got the following advantages in addition to power savings: (1) Increase in life of equipment due to soft start(2)Unlimited number of starts (3) Assimilation of plant automation system for higher productivity.

Unit 3
Type of motor Motor frame Rating Kw Sq. cage Ind. Motor 1LA7 902 1600

Unit 4
Synchronous Motor Brushless 1DQ3735 1368

Voltage
Frequency Method of speed variation

6.6KV
50 Hz Hydraulic coupling

1.2 Kv
Up to 47.33 Hz VVVF 1845 Kw 474 Kw 2527 MwHr

Power consumption for the same load 2319 Kw factor (207 MW) Power saving due to VFD at 207 Mw Energy saving for Generation time of 5333 Hr per year

Total Energy saving in Rs per year

Rs 81.62 (taking 1000/- per MWhr)

Rs

Taking the cost of Control Rs 3 to 4 Crores, Payback period can be of the order of 4-5 years only.

Energy conservation by Improving the power factor in case of Induction motor

For improving the power factor, there should be reduction in reactive power. For, inductive load, leading reactive power is required and for capacitive load, lagging reactive power is required. I1 = current before pf improvement; I2 = current after pf improvement; 1 = pf angle before pf improment; 2 = pf angle after pf improvement. P = Power consumed = V I1Cos 1= V I2Cos 2 Ic

2 1 I2
I1

The important disadvantages of low power factor are: Higher currents require larger size cable, switchgears, transformer and alternators etc. Thus the capital cost of the equipment is increased. This is, uneconomical from the supplier's point of view. 2. Higher currents give rise to higher copper losses in the system and therefore, the efficiency of the system is reduced. Also, the cost of energy loss (that is running cost) in the system increased. 3. Higher currents produce larger voltage drop in cables and other apparatus. This results in poor voltage regulation.
1.

Optimization of Power factor correction when Power is same If x is the annual cost per KVA of maximum demand then annual saving in the KVA demand charges = x ( S1 S2) = x P(Sec 1 Sec 2) If y is the annual cost per KVAr of the power factor correction equipment then annual cost of the power factor correction equipment. CPF = y Qc = y P ( Tan1 Tan 2) The total annual saving , Cs = CD - CPF = x P(Sec 1 Sec 2) - y P ( Tan1 Tan 2)
Condition for optimization is

Sin 2 = y/x

Optimization of Power factor correction when KVA demand is same

For the same kVA, the power can be conserved or productivity can be increased. Let us assumed that z is the annual cost per KW of the installation, then the annual saving due to increased power out would be = z S ( Cos 2 Cos 1) Let y is the annual cost per KVAr of the pf correction equipment then the annual cost of the power factor correction equipment is given by CPF = y Qc = y S (Sin 1 Sin 2) The net saving would be Cs = z S ( Cos 2 Cos 1) y S ( Sin 1 Sin 2)

For maximum annual saving

Tan 2 = y/Z

Power Factor Improvement Using Synchronous Condensers

When the KVAR requirement is small, it can be met through static capacitors. However when requirements exceed 10,000 KVAR, it is generally more economical to use the synchronous condensers. A synchronous condenser is essentially an over excited synchronous motor. Generally, it does not supply any active mechanical power. The excitation of the machine is varied to provide the necessary amount of the leading KVAR.
Advantages 1. By the use of synchronous condenser a finer control is possible than by the use of static capacitors. 2. A synchronous condenser can be overloaded for short periods but a static capacitor cannot be overloaded. 3. A momentary drop in voltage causes the synchronous condenser to supply greater KVAR to the system whereas in the case of static capacitor, the KVAR supplied is reduced. 4. The inertia of the synchronous condenser improves the system stability and reduces the effect of sudden changes in load.