Danfoss Power Electronics One Company · Danfoss Power Electronics Low cost of ownership using VLTs in Air compressors One Company focused on ... HP Annual Energy cost in $ Annual

| Confidential/Property of Danfoss Power Electronics| Thursday, 09 September 2010 | 1Presenting Power Electronics

Danfoss Power Electronics

Low cost of ownership using VLTs in Air compressors

One Companyfocused onClimate & Energy

| C onfidential/Property of Danfoss Drives A/S | Thursday, 09 September 2010 | 2

Today‘s discussions

qCost of Compressed Air

qWhy VFD in Air compressors?

qWhat is VFD & its functions?

qVFDs role in Low cost of ownership of compressors


Energy consumptions & CO2 Emissions

Electricity

Gas/Oil

Water

Raw Mat.

Production

Emission

Waste

36% of carbon dioxide (CO2) emissions

•Electricity is 1/3rd contributor to the CO2 emissions…

•Compressor is the back bone of Indian industry & one of the large segment

•Industry focus shifting towards-Energy Efficiency, process etc.,

•However…. Investment decision & Low cost of ownership needs more focus !


•Compressed air is 8 times the cost of electricity

•Scope for Energy saving – However less focus on Cost of ownership.

•Focus is often on lowest “first cost”

Some known facts…


Air compressor Annual Energy Cost

HP

Annual Energy cost in $

Annual Energy cost in INR

Annual Energy cost in INR

50 37,500 1,800,000 18Lacs100 75,000 3,600,000 36 Lacs150 112,500 5,400,000 54 Lacs200 150,000 7,200,000 72 Lacs250 187,500 9,000,000 90 Lacs300 225,000 10,800,000 108 Lacs


n Air compressors-( Screw) are Normal constant torque loads

n Energy saving of 10-25% in a screw compressors with typical Load-Unload cycle.

n In recip. compressors the Energy saving will be ~10%

VFD energy saving possibility


Many options to start Motors- but see the Starting current!

How VFD can be better…

Smooth start & Stop-ensuring minimum

stress on mechanical components-

Minimize maintenance cost


Fixed AC Input

(3ph,415v/50hz)

Variable AC Output

( 0-415v,0-x Hz)

What is AC Drive( VFD)? Soft starter?

Fixed AC Input

(3ph,415v,50hz)

Variable AC Output


Conventional With VFD

How VFD controls the Air compressors?


Drive is a Drive- Save energy…

What is Low cost of Ownership?


Drive is a Drive- Save energy…What is Low cost of Ownership?

nRole of Design/technology of Drive

ØEfficiency/Heat loss, ØHarmonics filter, ØEMC ComplianceØWorking at 50 Deg. & Harsh environment like India

nDrive sizing

ØVFD to be sized based on Motor FLC ( not on kw)ØSF to be considered while selecting the VFD ratingØIf VFD selection is based on kw, there could be an impact on life of VFD and cost of ownership


Drive is a Drive- Save energy…What is Low cost of Ownership?

n Cost of service/ spares/ life timen Service and spares availability

Ø Availability of service within warranty period/outside warranty period

Ø VFD manufacturers back up to End customers Ø Design life of VFDØ Spares availability and spares cost incase the VFD model

become obsolete

nUse of relevant features of drives for efficient operationnIntegrations/interface with compressors

ØImportant to understand the compressor operations, configure VFD to deliver optimized performanceØOptimal fine tuning of PID is essentialØSpeed windows, minimal speed optimization etc., to be tunedØConfigure VFD display as compressor monitor tool- Set pressure, Line pressure, Energy consumed in Kwh, Hours of operations, Temperature ( all the display in single screen simultaneously)


Drive construction-configurations


Choose the right productfor harsh environment

The drive should performfor decades…


Protection class IP 55 / IP 66

n Can be installed directly at site without need of additional panel.

n All cast aluminium parts are powder coated with a strong epoxy coating.

n The corrosion resistance are tested with detergents commonly used in the industry.

IP66


No need of large panels to house the drive with separate SFU & wires….

The modular technology platform

n Easy component accessibility from the frontn Side by side mountingn Simple replacement of modular sub-assemblies

n Shared features and user interface

Cost saving( for 110kw)Panel :~Rs.15000/-Space :~ 1sq.mtrAccessories :~ Rs.6000/-


Environment


Need to address Indian aggressive environment

Special coated PCBs as standard

•To increase the lifetime the PCB’s can be conformal coated according to IEC61721-3-3.

•There are several levels of conformal coating described in the IEC norm.

•Most of the drives offered are without any coating and some time it is offered as 3C2 Coating.

9,03,01,00,50,1mg/m3Nitrogen Oxides

0,30,10,10,050,01mg/m3Ozone

35103,01,00,3mg/m3Ammonia

2,00,10,030,010,003mg/m3Hydrogen Fluoride

5,01,00,50,10,01mg/m3Hydrogen Chloride

1,00,30,30,10,01mg/m3Chlorine

103,00,50,10,01mg/m3Hydrogen Sulphide

105,01,00,30,1mg/m3Sulphur dioxide

Salt mistSalt mistNomg/m3Sea salt

Max

value

Mean

value

Max

value

Mean

value

3C33C23C1

ClassUnitEnvironment Parameter in aggressive environment•No premature

failure of Drives due to the harsh environment.


Harmonic performance


Multiples, mainly the 5th & 7th harmonics of the fundamental sine wave (50Hz),caused bythe switching current flow through theVFD’s input rectifiers, causes interference inthe incoming power.

Fundamental -sine wave

Summation of all harmonic

frequencies

Harmonic Distortion

n Harmonic Current Distortion increases the RMS current and can result in overheating of the supply transformer and cables.

n Harmonic Voltage Distortion can interfere with other equipment attached to the same line.

n Total Harmonic Distortion (THD) at the point of common coupling is discussed in IEEE 5-19.

Both DC reactors and AC reactors give similar reduction in harmonics but AC reactor has 3% voltage dropVoltage – harmonic filter solutions

HARMONIC CURRENT ANALYSIS------------------------------------------------Fund. Current 36.22 ATHD 42.51%RMS current 39.47 A

5’th Harmonic 12.91 A7’th Harmonic 7.03 A11’th Harmonic 3.06 A13’th Harmonic 2.10 A------------------------------------------------



DC reactors





AC reactors

ac-coilsInverter Inverter

dc-coils

Most times, AC line chokes are not supplied


Harmonic performance

n DC-coils are built-in standard

n Reduced installation cost

n Smaller transformer and cables

n VLT® complies with IEC 61000, generating less than 44% THiD (Below 40%)

Actual comparison on Harmonics control-Both drives have harmonic filters- Result?

x make= THDI 45.15% (full load)x make = THDI 76.34% (50% load)

Tested with EMC test software V2.32b / PAS15000 by Spi tzenberger + Spies GmbH & Co. KG, Schmidstr 32-34, D-94234 Viechtach, 14.06.2006

DC 2 4 6 8 10 12 14 16 18

I/A

0

0.5

1

1.5

2

2.5

3

3.5HARMONIC ANALYSIS: Test FAIL in Timewindow 1 of 469

Y make = THDI 43.33% (full load)Y make = THDI 70.92% (50% load)

Power F

actor=

0.91

Power Facto

r=0.9

1


EMC/ RFI performance


Best built-in EMC performance

n 3 levels filtering available, complies IEC 61800-3

n Screened Cable length up to 150m and 300m unscreened

n Flexibility to meet different requirements

n Eliminates interference with other installed equipment


Energy efficiency


Energy optimization

nAutomatic Energy Optimization (AEO)

n Better system efficiency

n Additional energy savings 3-5%

n Optimised o/p wrt Load

Lowest cost of ownership

Graph Lowest cost of ownership

Voltage

Speed

Annual cost difference on heatloss

Example: Drive at the size of 30kW

Difference = 504W (46%)

Working :24 hours x 360days Energy cost :Rs.5/kWh

Annual cost of excess Heat loss :Rs.21,772/-

Plus the extra costs for cooling……..

You could save Rs.21,000

for 30kw drive/yr

•Reputed make VFD Heat Loss = 1074W

•Make-2 Heat Loss = 570W


Example:Drive at the size of 75kW

Reputed make2 -75kw VFD Heat Loss = 1974W Danfoss VLT Automation Drive FC302 75kw Heat Loss = 1384W

Difference = 590W (~30%)In terms of cost/ yearWorking :24 hours x 360days Energy cost :Rs.5/kWh Annual cost of excess Heat loss :Rs.25,488/-

Plus the extra costs for cooling……..

You could save Rs.25488/-

for 75kw drive/yr

Annual cost difference on heatloss

Heat loss difference in 315kw drive cost you 1.15L/year

VFD make- XX• Heat loss: 8,650 W• + 44 % more heat loss

or 2,659 W

VFD make- YY• Heat loss: 5,991

WCosts……..• Energy costs: 1,000 W • Rs.5/-• Operational hours: 24hrs/365 days• ~Rs.100,000 per year

Additional Costs……..• Air Conditioning requirement for control room.

§ Every kW of losses requires another 0.5 kW of energy to remove the heat

You could save Rs.100,000 +

Rs.15,000per drive/yr

Heat dissipation- Drain your money indirectly

Hea

t lo

ss in W

atts

3 x 400V

Different make VFD kw

0

2000

4000

6000

8000

10000

Loss in watts

37 45 55 75 90 110 132 160 200 250 315 355

KW

HEAT LOSS COMPARISIONDanfoss ABB

61,714 74,022 91,761 110,595 117,822 38,325 28,689 7,402 47,216 40,208 24,046 Annual loss /rating in Rs


No AC requirement and lowest cooling cost

Save-85%


Save: 15.3lacs AC energy bill + 3.6lacs of AC unit cost

80% heat is taken out of Panel Room

Example:No.of drives :10 noTotal Kw : 6300kwHeat loss : 126kwHeat taken out of Panel Room : 107kwHeatloss in Panel Room : 19kw

Cost saving :AC cost saving :Floor space saving:


Motor friendly


Effective motor protection

nElectronic overload protection to ensure Motor protection

nThermistor input for Motor over heat protection

nMotor pre-heat for winter season start up

nIncreased motor life


Some Motor friendly VFDs can work reliable with any standard motor

•The operation of the control and regulation section produces a very clean waveform going to the motor.

•The more sinusoidal the wave form going to the motor the easier it is on the motor and the less heat resulting in longer motor life.

Unique Motor friendly algorithm


User friendly display to saves add on meter cost


Energy monitoring•Built-in energy measurement tool

• Helps user to track record of the energy

• Identifies energy improvement possibilities

• Maintenance & operation instructions support through LCP

•2 Stage password to protect sensitive data


Real time clock- Built in Intelligence


Real Time Clock for compressor maintenance by VFD

n20 actions can be triggered

n Eliminates need for external timers

n Increased flexibility

n Ideal for retrofit applications

nHelps planned system maintenance

Clock example

| Confidential/Property of Danfoss Power Electronics| Thursday, 09 September 2010 | 43Presenting Danfoss Power Electronics

•Established in 1998 as 100% subsidiary

•Indian operation focus in

üManufacturing,üProject Engineering,üMarketing,üSales & MarketingüTraining

•10 sales & service offices across India

•25 sales/service network to support customers

•Dedicated sales network focusing on

üIndustry –Mining, Chemical etc.,üTextile üF&B, üHVAC, üWater

Danfoss India


Solutions Ready:VLT® Drives Electronic motor control

n A frequency converter controls electric motors so they only run at the speed necessary to obtain the desired effect

n Electronic motor control can typically save half the energy in pump and fan applications

n Today, only 8% of all electric motors globally are frequency controlled

n Products

n Frequency converters

n Soft starters

n Accessories

26milliontons is the annual CO2reduction

made by the 2.4 million Danfoss frequency converters installed worldwide


Production in Europe, USA and China

Denmark

Graasten

Germany

Schleswig

USA

Loves Park, IL

Milwaukee, WI

China

Haiyan, Zhejiang Province


Solution example:Danfoss Turbocor compressors

n Danfoss Turbocor is the first high-efficiency, oil-free, variable speed, centrifugal compressor that can provide extremely high energy savings for HVAC systems

n It can reduce up to 35%-50% the energy consumption of a commercial HVAC system

n Today, less than 1% of buildings globally have HVAC systems with high-efficiency, oil-free, variable speed compressors!

400,000Cars removed from the road

is the CO2 equivalent emission savings of the current installedbase of Danfoss Turbocorcompressors worldwide

Thank you

PL.Palanisamy

National Business Segment Manager-Textile & Air compressors

Danfoss VLT Drives.

Danfoss Industries P.ltd,

296, Rajiv Gandhi Salai

Sholinganallur,

Chennai- 600 119

PH: +91 44 66501555 / Cell: +91 98403 58632.

E-mail: [email protected]

visit: www.danfoss.com

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Danfoss Power Electronics One Company · Danfoss Power Electronics Low cost of ownership using VLTs in Air compressors One Company focused on ... HP Annual Energy cost in $ Annual