Variable Speed Drive Compressors. Anil Dave Atlas Copco Compressor Sales-Pune 4 th September 2010 Compressed Air Energy Conservation, CII Chennai

Transcription

1 Variable Speed Drive Compressors Anil Dave Atlas Copco Compressor Sales-Pune 4 th September 2010 Compressed Air Energy Conservation, CII Chennai

2 AGENDA What is VSD. Why is VSD required. How VSD works. Benefits of VSD. Who & When should opt for VSD compressor. References Leadership in Energy and Environmental Design (LEED Certification) 2 4th Sept 2010

3 VSD ADVANCED TECHNOLGY TO REDUCE ENERGY CONSUMPTION 3 4th Sept 2010

4 What is VSD Compressor VSD or Variable Speed Drive Compressor is a compressor which varies the capacity (FAD) based on the Air Demand pattern and consumes power proportional to Air Demand. thereby saving energy which would have gone waste in case of Fixed speed compressor. 4 4th Sept 2010

5 5 4th Sept 2010 Why VSD is required?

6 Why VSD is required? Because, not all applications demand continuous full load. Because a plant may have intermittent Compressed Air Applications. Because Air demand pattern vary within a Day (e.g.lunch time, Air demand is negligible) Because plants have 1 or 2 days off, so negligible air demand. Because different production shifts do not consume same amount of Air (e.g. night shift production may need less Compressed Air then day shift.) Finally, because we pay for Power. 6 4th Sept 2010

7 Cost Allocation Investment cost consists of: Purchase price Installation cost Investment cost depends on: Proper selection of compressor Capacity (FAD) Pressure Operating Pattern Energy cost is determined by: Annual operating time Load/unload utlisation Unit energy cost. 7 4th Sept 2010

8 Energy savings Facts & Figures The cost of compressed air it s not free 70% of industrial electrical consumption is for electric motors compressed air consumes 10 to 20 % of industrial electrical capacity this accounts for over 55 million tons of CO 2 emissions per year Electricity comprises more the 70% of the total life cycle cost of a compressor 8 4th Sept 2010

9 VSD Variable Speed Drive Energy savings Facts & Figures energy > 70% maintenance 10% investment 20% 9 4th Sept 2010

10 VSD Variable Speed Drive Energy savings the Potential With VSD energy savings of 35% or more can be realized over traditional compressor regulation 10 4th Sept 2010

11 VSD Variable Speed Drive Energy savings, Where do they come from? Key factor: fluctuation in air demand Defines operation & power consumption Air consumption in a compressed air system is proportional to the amount of equipment in use depends on the hour of the day or the day of the week Slide 6 of th Sept 2010

12 l/s VSD Variable Speed Drive WHY VSD? Match compressed air supply to exact demand Typical air demand pattern Monday Tuesday Wednesday Thursday Friday Saturday Sunday hour with minimum energy spendings. 12 4th Sept 2010

13 13 4th Sept 2010 VSD Variable Speed Drive 120 WHY VSD? FEW TEST RESULTS Air Demand Profile n Air Demand Profile n 1 80 Sunday Monday 60 Tuesday Wednesday Thursday Friday Saturday Sunday Monday Tuesday Wednesday Thursday Friday Saturday 20 0 Air Demand Profile n :15 1:30 2:45 4:00 5:15 6:30 7:45 9:00 10:15 11:30 12:45 14:00 15:15 16:30 17:45 19:00 20:15 21:30 22:45 0:00 Capacity in l/s 0:15 1:30 2:45 4:00 5:15 6:30 7:45 9:00 10:15 11:30 12:45 14:00 15:15 16:30 17:45 19:00 20:15 21:30 22:45 0:00 0:15 1:30 2:45 4:00 5:15 6:30 7:45 9:00 10:15 11:30 12:45 14:00 15:15 16:30 17:45 19:00 20:15 21:30 22:45 0:00 Capacity in l/s Capacity in l/s Time Time Average load determines the compressor s power consumption Time Sunday Monday Tuesday Wednesday Thursday Friday Saturday Peak load determines the compressor selection 88% 12%

14 Why VSD The Conclusion For Variations in demand VSD is ultimate Energy Saver 14 4th Sept 2010

15 How VSD works - Basic control Philosophy ELEKTRONIKON MK V FREQUENCY CONVERTER SET POINT AIR NET AIR DELIVERY PRESSURE SENSOR SCREW ELEMENT VSD MAIN MOTOR The system targets a constant delivery pressure (setpoint) 15 4th Sept 2010

16 16 4th Sept 2010 How VSD works - Animation

17 17 4th Sept 2010 Fixed Speed vs VSD compressor

18 VSD Benefits POWER V/S CAPACITY COMPARISON SUCTION MODULATION CONTROL & VSD CONTROL BENEFIT 1 : POWER CONSUMED = DEMAND REQUIRED Modulating Control Variable Speed Control 18 4th Sept 2010

19 VSD Variable Speed Drive BENEFIT 2 Soft start and stop operation no starting current peaks soft starting and stopping at a controlled acceleration and deceleration time no penalties for starting current peaks unlimited restarting meaning complete elimination of unload energy consumption % Full Load Current Starting Current Comparison Star Delta DOL Soft Starter VSD less stresses on electrical and mechanical components seconds 19 4th Sept 2010

20 VSD Variable Speed Drive BENEFIT 3 : Precise pressure control stableprocess constant pressure control 7 psig Customer Process Pressure Pressure - standard load-unload -7 psig or more! Pressure - centrifugal - 4 psig Pressure - VSD psig BENEFITS No pressure over-shoots Less energy cost lower working pressure Higher process stability 20 4th Sept 2010

21 VSD Variable Speed Drive BENEFIT -4 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. 21 4th Sept 2010

22 CONCLUSIONS VSD Variable Speed Drive VSD compressors are designed for maximum reliability 100 % designed and tested for Electro-Magnetic Compatibility EMC certificate of EU the most stringent standard Line reactor and RFI filter included All motors are designed for VSD and are protected against bearing currents Integrated controls for compressor + converter Converter is protected against overload by Elektronikon Start/stop and pressure control by the converter and the Elektronikon are fine-tuned during design The compressor is mechanically adapted for the complete speed range No speed windows for vibrations Changes to oil circuit for the right oil pressure/temperature 22 4th Sept 2010

23 VSD Variable Speed Drive BENEFITS Energy savings Low starting currents No peak torques Constant pressures Low average rpms High power factors at all loads Electronic gearing Large turn down ( Can be used for min max flow rates ) Integrated design 23 4th Sept 2010

24 VSD Variable Speed Drive ATLAS COPCO VSD Atlas Copco is market leader in VSD screw compressors, Supplied first VSD screw compressor in 1994, Sixteen years experience in VSD screw compressors Atlas Copco manufacture integrated VSD screw compressors in various capacities in lubricated and oil free range Today, 25 out of 100 screw compressors sold are VSD and expected to be 40 % in next three years 24 4th Sept 2010

25 Who and When should opt for VSD Compressor Plants having varying demand of Air (per day / per week basis) Plants having multiple Piston compressor installations. Plants having very old compressor installations, thereby consuming more energy. Ideally one should opt for VSD compressor while setting up a new plant. (1 compressor out of the bank can be VSD) When power cost is very high. In any case, its never too late to save Energy. 25 4th Sept 2010

26 How Atlas Copco can help you MBoxLite: By studying your plant Air consumption pattern with a very good Tool called MBoxLite. It measures the Air demand pattern and suggests possible saving. VSD Calculator program : Payback period can be arrived at by entering basic data provided by plant user. 26 4th Sept 2010

27 References -Two Random cases S No Company at which implemented 1 Rational Business Corporation, Bahal Garh Chowk,Sonepat Energy Saving achieved Around 10 kwh/hour, Earlier customer was using competiton screw air compressor. Investment (Rs Lakhs) Additional Investement for VSD Rs. 3,00,000/- Approx Payback Period Contact details of the company (Months) 12 months Mr. Ashok Kumar Gupta, Joint Managing Director, ashok@desmat.com, MERINO PANEL PRODUCTS LTD, 44KM STONE, DELHI- ROHTAK ROAD, VILLAGE ROHAD, BAHADHURGARH- HARYANA Around 12 kwh/hour, Earlier customer was using reciprocating air compressors. Additional Investement for VSD Rs. 2,50,000/- 8 Months Mr. B C Dua, Technical GM, merinorohad@merinoindia. com, , 27 4th Sept 2010

28 28 4th Sept 2010 Partial List of customers benefited with VSD

29 LEED Certificate for VSD 29 4th Sept 2010

30 Reach us Toll Free Number : th Sept 2010

31 31 4th Sept 2010 Committed to sustainable productivity.

32 32 4th Sept 2010