automation 4 me TYPES OF LOAD 1

automation 4 me CONSTANT TORQUE LOAD : PERCENT SPEED NOTE:- A CONSTANT TORQUE LOAD IS NOT NECESSARILY 100% LOAD TORQUE PERCENT TORQUE AND HORSEPOWER TYPES OF LOAD 80 2

automation 4 me ConveyorsCompressorsRoot Blowers Positive Displacement Pumps TYPES OF LOAD CONSTANT TORQUE LOAD : 3

automation 4 me VARIABLE TORQUE LOAD : TYPES OF LOAD SPEED IN % TORQUE & POWER IN % TORQUE POWER 4

automation 4 me VARIABLE TORQUE LOAD ( Torque Varies as Square of Speed) TYPES OF LOAD Centrifugal PumpsCentrifugal Fans 5

automation 4 me TORQUE PERCENT SPEED TORQUE HORSE POWER PERCENT TORQUE AND HORSEPOWER CONSTANT HORSEPOWER LOAD : TYPES OF LOAD 6

automation 4 me CONSTANT HORSEPOWER LOAD : TYPES OF LOAD Lathe Grinders Winders Coilers 7

automation 4 me ENERGY SAVING APPLICATIONS 8

automation 4 me Key Applications Areas – The Energy Guzzlers Fans –AHU –Ventilation / Fresh Air –Exhaust –Cooling Tower Fans –ID / FD Fans Pumps –Process Water –Pressure booster pumps Compressors –Reciprocating, Screw, Centrifugal Energy Savings 9

automation 4 me Air flow control of fan Outlet side damper Inlet side damper FAN APPLICATION 10

automation 4 me Comparison of motor power for fan drive system Airflow or motor speed (%) Shaft or power consumption Energy saving Inverter control Shaft power for speed control Damper control 11

automation 4 me Flow Control-Affinity Laws Flow  Speed Pressure / Head  Speed 2 Power  Speed 3 Benefits of Flow Control… 12

automation 4 me Fundamentals- Traditional Flow control is achieved by riding the pump or the fan curve… Throttle 13

automation 4 me Flow control is achieved by riding the System Curve… Fundamentals- Evolution 14

automation 4 me PRESSURE VOLUME THROTTLE CONTROL B A O F E D CSPEED CONTROL ENERGY SAVING = SHADED REGION = AREA (OEAD) - AREA (OFCD ) PRINCIPLE - ENERGY SAVING BY SPEED CONTROL OF PUMPS 15

automation 4 me The energy saving effect to the pump type Flow rate Q (P.U.) Head H (P.U.) Axial pump As shown in the figure, the sharper the pump characteristic is i.e., the bigger the comparative speed is, the bigger the 1st energy saving effect becomes Energy-saving effect mixed flow pump Centrifugal pump System resistance 16

automation 4 me PRINCIPLE - ENERGY SAVING BY SPEED CONTROL As Per Affinity Laws Flow (%)HP (%) Required Required

automation 4 me Compressor 18

automation 4 me Compressed air is a major part of many Company`s production costs. For many companies the electrical cost will account for nearly 75% of the total operating cost of a compressed air system over a five years period. 19

automation 4 me Compressors Operates in a load/ unload cycle. Time Load 100% 20

automation 4 me Conventional compressor system work between two set pressures, resulting in pressure generated being higher than the pressure required in the system. TIME PRESSURE POWER 110PSI 90PSI MINIMUM SYSTEM PRESSURE REQUIRED 20 PSI 100% FULL LOAD POWER DURING LOAD CYCLE 20-30% OF FULL LOAD POWER DURING UNLOAD CYCLE LOAD UNLOAD TIME 100PSI Compressor – Load/Unload Control 21

automation 4 me  Energy consumption as high as 20-30% of full load power during unload period.  Pressure in the system is much more than the minimum system pressure required, resulting in extra power consumption and wear and tear of the mechanical system.  20PSI extra pressure in the system, results in 10% extra power consumption.  DOL or star/delta starting sequence on a motor creates a power surge in electrical system. Disadvantages of Traditional Compressor: 22

automation 4 me Typical Schematic AC MOTOR AIR COMPRESSOR AIRRECEIVERAIRRECEIVER VARIABLE SPEED AC DRIVE 4-20 mA/ 0-10V PRESSURE FEEDBACK SIGNAL 3 Ph./ 415V Supply To Plant PRESSURE TRANSMITTER 23

automation 4 me  Variable pressure setting possible.  Accurate pressure control.  No unload cycle, thus reducing power consumption typically by 20 to 30% of full load power.  Soft start with inverter control, power to the motor is increased progressively, avoiding peak power demand in the electrical system. Advantages with Inverter Control: 24