MAGNADRI.WMV - - PowerPoint PPT Presentation

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MAGNADRI.WMV - - PowerPoint PPT Presentation

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SLIDE 1
  • 9/14/2016

1

MAGNADRI.WMV

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SLIDE 2
  • AVJ Engineering Consultants was established in the

year 2009 after I worked for 36 years and is based at:

Flat No.1, Plot No.21, Mahabali Housing Society,

9/14/2016 2

Mahabali Housing Society, Karve Nagar, Pune – 411052 Telefax: 912025460104 Mobile: 919923413733 Mail ID: vinod@avjengineering.com Website: www.avjengineering.com

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SLIDE 3
  • Presentation

Presentation on Reduction

  • n Reduction in

in Auxiliary Power Consumption Auxiliary Power Consumption and and Reduction in Reduction in O&M Cost Through O&M Cost Through

9/14/2016 3

MagnaDrive Magnetic Couplings and Adjustable Speed Drives (ASD) “The Next Industrial Revolution” By Vinod Malhotra

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SLIDE 4
  • MagnaDrive, Seattle USA

Flownetix, UK Electromagnetic & Ultrasonic Flow Meters

  • AVJ is Distributor & Marketing Associates for:

9/14/2016 4

Meters Jyoti Limited, Baroda – Pumps, Motors & Switch Gears Essential Power Transmission for Gear Box.

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SLIDE 5
  • Magnadrive Couplings and ASD

Magnadrive Couplings and ASD

Jyoti Pumps Jyoti Pumps

9/14/2016 5

Flownetix Ultrasonic Smart Flownetix Ultrasonic Smart Water Meters Water Meters

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SLIDE 6
  • MagnaDrive’s Value Proposition

“MagnaDrive’s revolutionary disconnected

MagnaDrive Benefits MagnaDrive is the Only GREEN Technology Which Offers Dual Benefits - Saves Energy & Reduces O&M Cost also

9/14/2016

torque-transfer technology reduces your total cost of ownership by lowering maintenance and operating costs, increasing process availability, and improving system reliability.”

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SLIDE 7
  • Founded in 1999
  • Technology of the Year by Industry Week

for 2001

  • 20 Domestic Patents and More than 200

International Patents

About MagnaDrive

9/14/2016 7

International Patents

  • Installed on Over 35,000 Systems and in

India 61 Systems.

  • Recently Awarded $2.7 million Contract by

U.S. Navy

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SLIDE 8
  • About MagnaDrive
  • 2004 Inc. 500

Fastest Growing Private Companies

9/14/2016

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SLIDE 9
  • About MagnaDrive
  • 2004 Inc. 500

Fastest Growing Private Companies

9/14/2016

  • 2004 Deloitte 500

Fastest Growing Technology Companies

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SLIDE 10
  • About MagnaDrive
  • Inc. 500

Fastest Growing Private Companies

9/14/2016

  • Deloitte 500

Fastest Growing Technology Companies

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SLIDE 11
  • MagnaDrive Produces Magnetic Adjustable Speed Drives and

Couplings that eliminate the physical link between the motor and load and instead uses a Magnetic field to transmit torque across an air gap. It’s a simple but effective mechanical technology that is GREEN gives following advantages

– Reduces energy consumption – Reduces motor stress at start-up

9/14/2016 11

– Reduces motor stress at start-up – Cushions shock loads and eliminates motor seizure – FGC Demo.wmv – Tolerates misalignment and thermal expansion – Extends equipment life and reduces maintenance requirements through reduced vibration and cavitations

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SLIDE 12
  • Principle of Operation

Magnet & Copper Penny Demo.wmv

9/14/2016 12

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SLIDE 13
  • MagnaDrive Benefits

A Mechanical, A Mechanical,

Imagine

Operates While Misaligned Controls Load Speed Cushioned Start Cushions Shock Loads

13

A Mechanical, Non-Electronic Device A Mechanical, Non-Electronic Device

Easy to Install Easily Understood Eliminates Motor Seizure Extends Equipment Life Reduces Vibration Compact

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SLIDE 14
  • Pumps

Application Types

Target Market

9/14/2016 14

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SLIDE 15
  • Pumps
  • Fans

Application Types

Target Market

9/14/2016 15

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SLIDE 16
  • Pumps
  • Fans
  • Blowers

Application Types

Target Market

9/14/2016 16

  • Blowers
slide-17
SLIDE 17
  • Pumps
  • Fans
  • Blowers

Application Types

Target Market

9/14/2016 17

  • Blowers
  • Centrifuges
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SLIDE 18
  • Pumps
  • Fans
  • Blowers

Application Types

Target Market

9/14/2016 18

  • Blowers
  • Centrifuges
  • Bulk Handling
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SLIDE 19
  • MagnaDrive is not only a Drive but a “Total Solution”

to Achieve Lower Total Cost of Ownership

A B S O L MagnaDrive is Solution MagnaDrive “THE” Solution Module

9/14/2016 19

MagnaDrive Energy Zero Vibration Works in Misalignment No Throttling Lower O&M cost No Motor Seizure L U T E S A V I N G S Lower Motor Ratings LOWER COST OF OWNERSHIP R E S U L T Lower Starting Current

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SLIDE 20
  • Couplings

Product Lines

9/14/2016 20

  • Couplings
  • Adjustable Speed Drives (ASDs)
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SLIDE 21
  • Coupling Range and Models
  • Constant and Variable Torque
  • 2 to 2500 KW Applications
  • Four Models:

Magnetic Couplings

9/14/2016 21

  • Four Models:

– First Generation Coupling (FGC) – Delay (MGD) – Torque Limiting (MGTL) – Vortex

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SLIDE 22
  • FGC - First Generation

Coupling

  • MGD – Magnaguard Delay

Couplings:

FGC MGD

Permanent Magnet Couplings

9/14/2016

  • MGD – Magnaguard Delay
  • MGTL- MagnaDrive Torque

Limiting

  • VORTEX

MGTL

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SLIDE 23
  • Product Overview -

Couplings

FGC Product Line

  • 2 to 2500 KW @1500
  • Variable and Constant

Torque applications

  • Can deliver higher starting

torques

9/14/2016

torques

  • Cushioned start desired
  • Shafts: standard or

special sizes

  • Dist. Between Shaft ends

(DBSE): within or beyond standard range

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SLIDE 24
  • FGC Coupling

CONDUCTOR STEEL COPPER CONDUCTOR COPPER CONDUCTOR CONDUCTOR STEEL MAGNETS AIR GAP SPACER SHRINK DISC SHRINK DISC

9/14/2016

LOAD HUB MOTOR HUB ALUMINUM MAGNET ROTOR AIR CLEARANCE (GAP)

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SLIDE 25
  • Range 16 to 625 KW
  • Air Gap Increases from 1/8 to

3/16 inch During Start Up

MGD Product Line

Product Overview - Couplings

9/14/2016

3/16 inch During Start Up

  • Gap Change Reduces Torque

Transfer About 50% for Cushioned Smooth Start

  • MGD Also Has Partial

Disconnect Feature Built In

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SLIDE 26
  • CONDUCTOR STEEL

COPPER CONDUCTOR COPPER CONDUCTOR CONDUCTOR STEEL ALUMINUM MAGNET ROTORS MAGNETS AIR GAP SPACER SHRINK DISC SHRINK DISC

Product Overview - MGD

9/14/2016

LOAD HUB MOTOR HUB AIR CLEARANCE (GAP)

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SLIDE 27
  • All the Features of the MGD, Plus

MGTL has Complete Disconnect Feature Built In

  • Complete Disconnection Results

when High Torque Repelling

MGTL Product Line

Product Overview – Couplings

9/14/2016

when High Torque Repelling Magnetic Force Occurs Due to Additional Slip

  • Repelling Force Completely

Uncouples Motor from Load for Complete Protection

  • Self Resetting when Motor is

Turned Off

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SLIDE 28
  • Coupling Benefits - MGTL

CONDUCTOR STEEL COPPER CONDUCTOR COPPER CONDUCTOR CONDUCTOR STEEL ALUMINUM MAGNET ROTORS MAGNETS AIR GAP SPACER SHRINK DISC SHRINK DISC

9/14/2016

LOAD HUB MOTOR HUB AIR CLEARANCE (GAP)

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SLIDE 29
  • Offers Low Maintenance
  • Simple Installation
  • Efficient Torque Transfer
  • Permits Shock Loadings

(Load is Cushioned & Slips)

Coupling Benefits:

FGC & MGE MGD

Product Overview - Couplings

9/14/2016

(Load is Cushioned & Slips)

  • Greater Misalignment

Tolerance

  • Ideal for Applications Subject

to:

– Vibration – Periodic Load Seizure – Pulsating Loads – Thermal Expansion – Higher Starting Inertia/Torque

MGTL

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SLIDE 30
  • Type of Loads
  • Centrifugal Loads
  • Centrifugal loads are rotating loads, such as centrifugal pumps, fans, and
  • mixers. They closely follow the affinity laws, which dictate how flow,

horsepower, and torque change as speed changes:

  • New Flow

= Original Flow × Δ Speed

  • New Torque = Original Torque × Δ Speed2

9/14/2016 30

  • New HP = Original HP × Δ Speed3
  • In other words, flow varies proportionally with change in speed (Δ Speed,

expressed as a percentage of the original speed), torque varies with the square

  • f the change in speed, and horsepower varies with the cube of the change in

speed.

  • It is important to understand that torque is demanded by the load. Attach a 2-

hp motor to a 2-hp load, then attach a 10,000-hp motor to the same load and both motors will generate 2-hp (ignoring losses).

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SLIDE 31
  • (HP1 / HP2) = (Flow1 / Flow2)3

Technology Technology

Affinity (or “Fan”) Laws

Proportion of Max Flow Flow Reduction Power Consumed Power Saved (Flow1/Flow2) (1-Flow1/Flow2) (HP1/HP2) (1-HP1/HP2) 99% 1% 97% 3% 98% 2% 94% 6%

  • Torque Transmitted

& Flow Are Reduced By Increasing the ASD Air Gap

  • A 1% Reduction in

9/14/2016 31

98% 2% 94% 6% 97% 3% 91% 9% 96% 4% 88% 12% 95% 5% 86% 14% 90% 10% 73% 27% 85% 15% 61% 39% 80% 20% 51% 49% 70% 30% 34% 66% 60% 40% 22% 78% 50% 50% 13% 88% 40% 60% 6% 94%

Speed and Flow Yields a 3% Energy Savings

  • A 10% Reduction in

Speed and Flow Yields a 27% Energy Savings

  • A 50% Reduction in

Speed and Flow Yields a 88% Energy Savings

Energy Savings May be Greater Due to Reduced Vibration and Misalignment Tolerance of MagnaDrive Air Gap

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SLIDE 32
  • Why pump should not be operated at full Valve Opening?

Pump Curve: Pump curve for 150 KW ECW pump.pdf

9/14/2016 32

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SLIDE 33
  • Non-Centrifugal Loads
  • Other loads, such as screw compressors, positive displacement pumps,

positive displacement blowers, paper roll machines, conveyor belts, punch presses, and rock crushers, do not follow the affinity laws.

  • Flow varies proportionally with speed.
  • Torque and horsepower may decrease, remain constant or increase—it

depends on the application.

  • Speed changes for non-centrifugal loads do not generate the same large

energy saving as with centrifugal loads, but changes in speed may be desirable for process control reasons. In other words, you may want to control the speed

9/14/2016 33

for process control reasons. In other words, you may want to control the speed

  • f the process, even though you are not saving any energy.
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SLIDE 34
  • Rigid Couplings

Rigid Couplings

Rigid Chain Gear Disc

Fixed Speed – Mechanical Couplings Fixed Speed – Mechanical Couplings

9/14/2016 34

Flexible / Elastomeric Couplings Flexible / Elastomeric Couplings

Flexible Shaft Rubber (Tire) Jaw Pin

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SLIDE 35
  • Misalignment
  • All couplings are subject to:

Fixed Speed – Mechanical Couplings Fixed Speed – Mechanical Couplings

9/14/2016 35 Parallel / Offset Misalignment Axial Misalignment

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SLIDE 36
  • MagnaDrive has a unique design:

Permanent Magnet Rotor Permanent Magnet Rotor Copper Conductor Rotor Copper Conductor Rotor Fixed Speed – Mechanical Couplings Fixed Speed – Mechanical Couplings

9/14/2016 36

Motor Shaft Load Shaft

Air Gap Air Gap

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SLIDE 37
  • Motor Shaft

Load Shaft

Fixed Speed – Mechanical Couplings Fixed Speed – Mechanical Couplings

9/14/2016 37

MagnaDrive can operate with Angular Misalignment MagnaDrive can operate with Angular Misalignment

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SLIDE 38
  • Motor Shaft

Motor Shaft Load Shaft Motor Shaft Load Shaft

Fixed Speed – Mechanical Couplings Fixed Speed – Mechanical Couplings

9/14/2016 38

MagnaDrive can operate with Parallel Misalignment MagnaDrive can operate with Parallel Misalignment MagnaDrive can operate with Axial Misalignment MagnaDrive can operate with Axial Misalignment MagnaDrive can operate with Angular Misalignment MagnaDrive can operate with Angular Misalignment

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SLIDE 39
  • Lower

Inrush at Startup

Cushioned Start

Coupling Technology

Reduced starting power requirement Reduced starting power requirement

9/14/2016 39

  • Lowers

Peak Demand

  • Immediate

Restarts

Energy Savings as a result Energy Savings as a result

  • f removing system
  • f removing system

inefficiencies inefficiencies

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SLIDE 40
  • Motor Characteristics

– Up to 5000 HP Motors @ 1500 RPM – Up to 3000 HP Motors @ 3000 RPM

  • Vibration Isolation
  • MagnaDrive Corp - Pump - No Vibration - Lorain,

OH, USA.wmv

Couplings

9/14/2016 40

OH, USA.wmv

  • Alignment Problems
  • ..\Misalignment Demo.wmv
  • Need for Cushion Start
  • Thermal Expansion Issues
  • Shaft Seizure Issues
  • Mechanical Seals are Present
  • Need to Protect Critical Equipment
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SLIDE 41
  • Rigid & Flexible Couplings

Rigid & Flexible Couplings MagnaDrive (MGE/FGC/MGD/MGTL) MagnaDrive (MGE/FGC/MGD/MGTL)

All mechanical couplings are somehow

physically connected causing:

Misalignment Vibration transfer Premature equipment failure Energy waste due to misalignment

The disconnected nature of the MagnaDrive

connection (air gap) provides:

Misalignment allowance up to 3 degrees No vibration transfer Longer equipment life (bearings, seals, etc.) Energy savings due to motor/load disconnection

Installation, operation, & maintenance issues: Installation, operation, & maintenance issues:

Fixed Speed – Mechanical Couplings Fixed Speed – Mechanical Couplings

9/14/2016 41

Installation, operation, & maintenance issues:

Time and money spent on laser alignment Time and money spent maintaining equipment Production downtime costs No overload torque protection Some types require grease/oil “Hard” start causes extra stress on equipment and energy spikes No speed adjustability

Installation, operation, & maintenance issues:

Virtually no time and money spent on alignment Less time and money spent maintaining equip. Lower production downtime costs Overload protection MagnaDrive is a GREEN technology “Cushioned” and delayed start increases equipment life and provides lower peak demand and inrush (additional energy savings) MagnaDrive couplings can be fine tuned to save energy

Increased cost

  • f ownership

Lower cost

  • f ownership
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SLIDE 42
  • Fluid Couplings
  • Applications:
  • Bulk Material Systems Conveyors:

9/14/2016 42

  • Bulk Material Systems Conveyors:
  • Coal Handling
  • Ash Handling
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SLIDE 43
  • Fixed Speed –

Fluid / Hydraulic Couplings Fixed Speed – Fluid / Hydraulic Couplings

9/14/2016 43

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SLIDE 44
  • Fluid Coupling Issues - Oil

Fluid Coupling Issues - Oil Fixed Speed – Fluid / Hydraulic Couplings Fixed Speed – Fluid / Hydraulic Couplings

9/14/2016 44

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SLIDE 45
  • Fluid Coupling Issues – High Maintenance

Fluid Coupling Issues – High Maintenance

"Replacement parts for fluid couplings are notoriously

  • expensive. However, we had no choice but to keep

paying out as the Dryer-Pulveriser Mill is such a key element within the refinery process. Unfortunately we were in a lose-lose situation, when the application faltered it not only cost us money to fix it, it was also costing us money for the duration it was off-line.“

Fixed Speed – Fluid / Hydraulic Couplings Fixed Speed – Fluid / Hydraulic Couplings

9/14/2016 45

costing us money for the duration it was off-line.“ "The coupling requires inspection every 12 weeks with frequent oil top ups, the oil used within a fluid coupling is highly volatile. The coupling incorporates a fusible drain plug which is designed to discharge oil if the operating temperature is too high. This feature was causing a considerable health and safety risk to operators, we had experienced several fires in the past caused by hot oil blowing the fusible plug and consequently igniting.”

http://www.hub-4.com/news/696/wbb-minerals-grind-down-maintenance-costs-using-siemens-soft-starters

Source:

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SLIDE 46
  • Fluid Coupling Issues - Hazardous

Fluid Coupling Issues - Hazardous Fixed Speed – Fluid / Hydraulic Couplings Fixed Speed – Fluid / Hydraulic Couplings

9/14/2016 46

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SLIDE 47
  • Fixed Speed –

Fluid / Hydraulic Couplings Fixed Speed – Fluid / Hydraulic Couplings Fluid Coupling Issues - Hazardous Fluid Coupling Issues - Hazardous

9/14/2016 47

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SLIDE 48
  • 2002 Fatality Accident with a

major brand Fluid Coupling at Lone Star Quarry & Mill

Fixed Speed – Fluid / Hydraulic Couplings Fixed Speed – Fluid / Hydraulic Couplings Fluid Coupling Issues - Hazardous Fluid Coupling Issues - Hazardous

9/14/2016 48

http://www.msha.gov/fatals/2002/ftl02m17.htm

at Lone Star Quarry & Mill Lone Star Industries, Inc. Cape Girardeau, MO For Official Accident Report Go To:

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SLIDE 49
  • “Curbing the killer Conveyors”

“Recently a steel worker was injured when an inclined conveyor ran backwards, out of control, and the fluid coupling in the drive train exploded like a bomb, spreading shrapnel and hot hydraulic oil

  • everywhere. It should never have happened”.

Fixed Speed – Fluid / Hydraulic Couplings Fixed Speed – Fluid / Hydraulic Couplings Fluid Coupling Issues - Hazardous Fluid Coupling Issues - Hazardous

9/14/2016 49

“The fluid coupling is sized to soft-start the conveyor and protect the motor/drive package from overloads. It is made from aluminum and is intended to run, in this case, at 1,500 to 1,800rpm. If it is run at speeds

  • f up to 6,000rpm then the aluminum casing will be put under massive

centrifugal loads sufficient to make the whole thing explode like a bomb”. “Then, when the drive train fails and the conveyor back-drives, the fluid coupling becomes a bomb just waiting to explode”.

http://www.renold.com/Company/News/Curbing_the_killer_conveyors.asp

Source:

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SLIDE 50
  • “An undermanager and a deputy on a backshift

were attempting to change the oil in a leaking fluid

  • coupling. The men were inexperienced in this task

Fixed Speed – Fluid / Hydraulic Couplings Fixed Speed – Fluid / Hydraulic Couplings Fluid Coupling Issues - Hazardous Fluid Coupling Issues - Hazardous

9/14/2016 50

which resulted in the deputy receiving oil burns to his face”.

http://www.cfmeu.com.au/storage/documents/Apr00CC.pdf

Source:

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SLIDE 51
  • Performance of Magnetic Couplings in Bulk Material Handling Systems:

MAGNADRIVE - BWE - ThyssenKrupp, Australia.wmv MAGNADRIVE - CONVEYOR - 1400 Ton Per Hour Conveyor in Australia.wmv MAGNADRIVE+-+CONVEYOR+-+Australia+-+SWCC+-+Thiess.wmv

9/14/2016 51

Apprehensions: Weather Magnetic Couplings will work in dusty environment? +Chile.wmv Dust Flying MAGNADRIVE - Tura - TURKEY (1).wmv

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SLIDE 52
  • Comparative Study between VFD and Magnadrive on Energy Savings in

Conveyor:

MAG Drive kilo Watt

30 35 Power consumption for Magnetic Drive 5 10 15 20 25 30 1 5 9 1317 21 2529 3337 41 4549 5357 61 60 Minute Interval kW MAG Drive kilo Watt

Power Consumption per hour - 1600.16 kWh Average Power per hour - 26.23 kW

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SLIDE 53
  • VSD Drive kilo Watt

40 50 60

Power consumption for Variable Speed Drive

10 20 30 40 1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 60 Minute Interval kW VSD Drive kilo Watt

Power Consumption per hour - 1933.08 kWh Average Power per hour - 31.68 kW

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SLIDE 54
  • Magnadrive/VSD Power Consumption Comparison Graph

MAG/VSD Comparison Graph

40 50 60 10 20 30 40 1 5 9 1317 21 2529 3337 41 4549 5357 61 60 Minute Interval kW MAG Drive kilo Watt VSD Drive kilo Watt

Energy Savings in conveyor Mooikraal Drive Recordings.xls

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SLIDE 55
  • Fluid Couplings

Fluid Couplings

Fluid Couplings are not totally disconnected

and are subject to:

Misalignment and vibration transfer Premature equipment failure (gear boxes, bearings, seals, etc.) Energy waste due to misalignment and additional fluid friction losses inside the coupling

The disconnected nature of the connection

(air gap) provides:

No misalignment and vibration issues Longer equipment life (bearings, seals, gear boxes, etc.) Energy savings due to the motor/load

  • disconnection. Because MagnaDrive operates

with a cushion of air, a 3-5% savings in power can be attained in relation to the same work done by a Fluid Coupling

Installation, operation, & maintenance issues:

Time and money spent on laser alignment

Fixed Speed – Fluid / Hydraulic Couplings Fixed Speed – Fluid / Hydraulic Couplings

MagnaDrive (FGC/MGD/MGTL) MagnaDrive (FGC/MGD/MGTL)

9/14/2016 55 Fluid Coupling Time and money spent on laser alignment Fluid Couplings are difficult to install and maintain Time and money spent maintaining equipment Most Fluid Couplings can not operate in both directions of rotation Fluid Couplings are filled with oil which is a hazard for the environment and people The Fluid Coupling overtorque protection is provided by a fusible plug which melts and sprays

  • il all around. When the plug fails to melt, the

Fluid Coupling literately becomes a time bomb

Installation, operation, & maintenance issues:

Virtually no time and money spent on alignment MagnaDrive Couplings have no oil, are lighter, and easier to install Less time and money spent maintaining equip. MagnaDrive Couplings transmit the same torque in either direction of rotation MagnaDrive is a GREEN technology and does not use any oil MagnaDrive Couplings basically slip if there is an overtorque condition, and certain models (MGTL) also offer a complete disconnect feature

Increased cost

  • f ownership

Lower cost

  • f ownership
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SLIDE 56
  • Adjustable Speed Drive

(ASD)

9/14/2016 56

(ASD)

slide-57
SLIDE 57
  • Variable Speed –

Valve / Damper Systems Variable Speed – Valve / Damper Systems

9/14/2016 57

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SLIDE 58
  • Variable Speed –

VFDs (Variable Frequency Drives) Variable Speed – VFDs (Variable Frequency Drives)

9/14/2016 58

slide-59
SLIDE 59
  • Variable Speed –

VFDs (Variable Frequency Drives) Variable Speed – VFDs (Variable Frequency Drives) Principle of Operation Principle of Operation

9/14/2016 59

slide-60
SLIDE 60
  • Variable Speed – VFDs (Variable

Frequency Drives)

Variable Speed – VFDs (Variable

Frequency Drives)

VFD Issues – Installation Complexity and Space Requirement VFD Issues – Installation Complexity and Space Requirement

9/14/2016 60

Building to house VFDs Building to house VFDs MagnaDrive minimal space requirement and simple installation MagnaDrive minimal space requirement and simple installation

slide-61
SLIDE 61
  • Product Lines
  • Variable Gap – For Adjustable Speed
  • Air-Cooled:

– Sizes 20 to 500 Hp @ 1500 RPM – Horizontal & Vertical Applications

  • Water-Cooled

Adjustable Speed Drives

9/14/2016 61

  • Water-Cooled

– 500 through 4,500 Hp @ 1500 RPM – Horizontal & Vertical Applications

slide-62
SLIDE 62
  • Variable Speed Control for Energy Savings
  • Low System Maintenance
  • Accepts Greater Misalignment
  • Eliminates Vibration Transfer Between

ASD Benefits

9/14/2016 62

  • Eliminates Vibration Transfer Between

Motor and Load

  • Unloaded Startup, Controlled Ramp-Up
  • Permits Shock Loading
  • Increased Seal & Bearing Life
  • Eliminates Electronic Harmonics
  • Unaffected By Power Quality Issues
  • Lightning Strikes
slide-63
SLIDE 63
  • Adjustable Speed Drive (ASD)
  • For Speed Control and Energy

Savings – ASD Energy Savings Demo.wmv

9/14/2016 63

– ASD energy savings New.wmv

slide-64
SLIDE 64
  • VFDs

VFDs MagnaDrive ASDs MagnaDrive ASDs

Variable Speed – VFDs (Variable Frequency Drives) Variable Speed – VFDs (Variable Frequency Drives)

Special issues and installation requirements:

Require inverter duty motors Are susceptible to dirty power Require environment control (temp, dust, hum.) Complexity of equipment and installation Are expensive in medium/high voltage Rapid obsolesce (6-7 years)/throw away Motors control space requirement

Operation & maintenance issues:

Harmonics

MagnaDrive ASDs:

Operates with any kind of motor Is not affected by dirty power Is not affected by temperature, dust, humidity and other factors in the operating environment Are simple to install and maintain Have a life span of 20 – 25 years, depending on

  • perating conditions

Operation & maintenance issues:

No issues with harmonics No issues with bearing fluting 9/14/2016 64

The disconnected nature of the connection

(air gap) provides:

No misalignment and vibration issues Less time and money spent aligning and maintaining equipment Longer equipment life Cushioned start No load start Energy savings due to motor / load disconnection Overload protection

Increased cost

  • f ownership

Lower cost

  • f ownership

Equipment connected with VFDs still has a

physical connection between the motor and load shaft causing:

Misalignment and vibration transfer Premature equipment failure Energy waste due to misalignment No overload protection Harmonics Bearing Fluting No rapid restart capability No issues with bearing fluting Rapid restart capability

slide-65
SLIDE 65
  • Case Study for Hindalco Muri for ID Fan and PA Fan

ID FAN Curve.pdf PA Fan Curve -- markup.pdf ASD Sizing for 26.5-28.5 for PA Fan for Hindalco Ranachi.xlsx

  • 9/14/2016

65

ASD sizing for WC-1000 for ID fan for Hindalco Ranchi.xlsx

slide-66
SLIDE 66
  • Magnadrive Capability

Magnadrive has supplied 6 Nos. ASDs WH – 4000 for 3037 HP / 980 RPM ID Fan To China Power Plant. MagnaDrive WH-4000 in China.pdf

9/14/2016 66

slide-67
SLIDE 67
  • List Of Customers

List of Indian Customers as on 6th June 2016.xlsx

slide-68
SLIDE 68
  • Pictures of Magnadrive Couplings at

NALCO Damanjodi

  • Installation of Magnadrive Couplings at

NALCO Damanjodi.pdf NALCO Damanjodi.pdf

  • Magnadrive Coupling Operating
  • DSCN0276.AVI

9/14/2016 68

slide-69
SLIDE 69
  • Installation of Magnadrive Couplings in

NTPC Plants.

  • Magnadrive Coupling Pictures in NTPC

Plants.pdf Plants.pdf

  • Performance of Magnadrive Couplings in

NTPC.pdf

9/14/2016 69

slide-70
SLIDE 70
  • NTPC Kayamkulam: 132 KW / 1500 rpm

DMCW Pump installation on 10.07.2014 Performance Results: Performance Results.pdf

  • 9/14/2016

70

Before Installation of Magnadrive Coupling Power consumption was 135.61 KW and After Installation of Magnadrive Coupling power consumption reduced to 113.54 Savings of 22.07 KW.

slide-71
SLIDE 71
  • NTPC Auraiya

Performance Data of Clarified Pump Coupled with Magnadrive Coupling: – Pump Model: CPRG-80-40 – Flow: 60M3/Hr. – Head: 45 Meters

  • – Rating in KW:

18.5 KW – Speed in RPM: 1470 Before Magnadrive: 421.5 Volts, 24.6 Amps, 0.79 PF, 4 Kg/Cm2 Head, 14.1 KW After Magnadrive: 416 Volts, 22.2 Amps, 0.77 PF, 4 Kg/Cm2 Head, 12.4 KW

Power Saving: 12.06%

71

slide-72
SLIDE 72
  • NTPC Tanda:

Magnadrive Coupling Model: FGC 18.5S. Conveyor: 2B Motor Rating: 110 KW

  • Motor Rating: 110 KW

Speed: 1450 RPM No Load Current with Fluid Coupling: 57 Amps No Load Current with Magnadrive Coupling: 52 Amps

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SLIDE 73
  • Vandana Global Ltd, Raipur

Application: ACW Pump Rating: 30 KW Energy Savings: 19.36%

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Energy Savings: 19.36% Coupling Model: FGC 10.5S Performance of FGC 10.5S at Vandana Global.pdf

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SLIDE 74
  • Quantified Business Results

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Plant Head Mr. Nandi Inaugurating Magnadrive Magnetic Coupling Model FGC 18.5S on Conveyor No. 6A At Dahanu Thermal Power Station

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SLIDE 75
  • Quantified Business Results

Client: Dahanu Thermal Power Station Application: Conveyor Motor Rating: 110 KW Speed of Motor: 1485 RPM Area: Coal Handling Plant Original Drive: Fluid Coupling Power Consumed With Fluid Coupling: 39.5 KW Power Consumed with

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Magnadrive Magnetic Coupling Model FGC 18.5S At Dahanu Thermal Power Station Power Consumed with Magnadrive : 37.36 KW Energy Savings: 2.14KWH Energy Savings / Yr: 18747 KWH

Energy Saving / Yr. in Rs.: 93732.00

Other Benefits Reduction in Vibration Level Zero Maintenance Increased MTBF Performance report of FGC 18.5S on 110 KW Conveyor at Dahanu Thermal Power.pdf

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SLIDE 76
  • Quantified Business Results

Client: Delhi Jal Board Project: Rithal ETP Application: Pump Liquid: Water Motor Power: 280 KW Voltage: 3.3 KV Speed of Pump: 1466 RPM Quantities: 8 Nos. Performance Parameters:

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Performance Parameters: Full Load Current: 63 Amps Magnadrive Coupling: FGC 21.0S Current Drawn with Magnadrive Coupling: 46 Amps Energy Savings: 78 KWH Energy Saving in Rs. 40.80L / Yr. Magnadrive Magnetic Coupling Model FGC 21.0S

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SLIDE 77
  • Client:

SAIL Project: BSP Application: Pump Liquid: Hot Benzyl Flow: 40m3/Hr Motor Power: 45 KW Voltage: 415 Volts Speed of Pump: 2980 RPM Quantities: 4 Nos.

Quantified Business Results

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Quantities: 4 Nos. Performance Parameters: Current before Magnadrive: 53 Amps Magnadrive Coupling: MGE - 11 Current Drawn with Magnadrive Coupling: 43 Amps Energy Saving in Rs. 201480 / Yr. Reduction in CO2 Emission: 1 Ton / Day from 4 Couplings. Magnadrive Coupling Model MGE-11 At Coke Oven Bhilai Steel Plant Performance Certificate for MGE-11 from BSP Coke Oven.pdf E:\VKM OWN\BSP\Coke Oven\Minutes of the Meeting.pdf

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SLIDE 78
  • Client:

SAIL Project: BSP WMD Application: Pump Liquid: Water Motor Power: 110 KW Voltage: 415 Volts Speed of Pump: 1480 RPM Quantities: 6 Nos. Performance Parameters: Current before

Quantified Business Results

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Current before Magnadrive: 163 Amps Magnadrive Coupling: FGC – 16.5 Current Drawn with Magnadrive Coupling: 134 Amps Energy Savings: 17 KWH Energy Saving in Rs. 438000 / Yr. Performance_certificate_from_WMD.pdf

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SLIDE 79
  • Client:

Tata Motors Pune Project: ETP Application: Pump Liquid: Effluent Motor Power: 15 KW Voltage: 415 Volts Speed of Pump: 1480 RPM Quantities: 1 Nos. Performance Parameters: Power before

Quantified Business Results

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Power before Magnadrive: 9.77 KW Magnadrive Coupling: MGE-11 Power Consumed with Magnadrive Coupling: 6.91 KWH Energy Savings: 2.9 KWH Energy Saving in %. 25% Performance Report for MGE 11 from Tata Motors.pdf

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SLIDE 80
  • Client:

Tata Steel Tata Nagar Location: Power House - 4 Application: Pump Liquid: Effluent Motor Power: 75 KW Voltage: 415 Volts Speed of Pump: 1480 RPM Quantities: 1 Nos. Performance Parameters: Power before

Quantified Business Results

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Power before Magnadrive: 50.6 KW Magnadrive Coupling: FGC 16.5S Power Consumed with Magnadrive Coupling: 44.27 KWH Energy Savings: 6.3 KWH Energy Saving in %. 12.45% Magnadrive Magnetic Coupling Model FGC 16.5S at Tata Steel PERFORMANCE REPORT FOR FGC 16.5S for pump by AVJ.pdf

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SLIDE 81
  • Quantified Business Results

Client: Tata Steel Tata Nagar Location: Coal Plant Application: Conveyor No. 4A Motor Power: 75 KW Voltage: 415 Volts Speed of Pump: 1480 RPM Quantities: 1 Nos. Performance Parameters: Power Consumption Before Magnadrive: 54.1 KW

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Magnadrive: 54.1 KW Magnadrive Coupling: FGC 16.5S Power Consumed with Magnadrive Coupling: 50.1 KW Energy Savings: 4.0 KWH Energy Saving in %. 8% Continue FGC 16.5S on Conveyor No. 4A At Tata Steel Ltd.

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SLIDE 82
  • Quantified Business Results

Study Report by Tata Steel Ltd for 75 KW Conveyor Study Report of MAGNA Drive r1 for conveyor of Tata Steel.pdf

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SLIDE 83
  • Quantified Business Results

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Magnadrive Magnetic Adjustable Speed Drive Model ASD 26.5 for 190 KW ID Fan at Jindal Steel & Power Ltd. Raigarh Performance parameters for ASD 26.5 from JSPL.pdf

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SLIDE 84
  • Quantified Business Results

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Magnadrive Magnetic Adjustable Speed Drive Model ASD 26.5 for 190 KW 6.6 KV ID Fan at Jindal Steel & Power Ltd. Raigarh Energy Savings around 73 KWH

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SLIDE 85
  • The starting current reduced by:

27% Power Reduction by: 2.25 KW Quantified Business Result for MGE 07 at Infosys Hyderabad.pdf

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% Energy savings: 26% Pay Back period: KWH saved: 2.25 Hrs of operation: 18 Hrs / Year: 6570 Cost of Power in Rs.: 6 Per Year Energy savings: 2.25X6570X6 = Rs. 88695 Per Month Saving in Rs.: 88695 / 12 = Rs. 7392 Cost of MGE 07:

  • Rs. 70478.00

Pay Back Period: 9.5 Months.

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SLIDE 86
  • Competitive Analysis

MagnaDrive ASD MagnaDrive Coupling VFD Eddy Current Mechanical Devices Fluid and Belt Drives MagnaDrive ASD MagnaDrive Coupling VFD Eddy Current Mechanical Devices Fluid and Belt Drives

Operation Mechanical Benefits Variable Speed

X X X

s Non-contact Power Transfer

X X

s s Process Control

X X X

s s Reduce Vibration

X X

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Process Control

X X X

s s Reduce Vibration

X X

Energy Efficiency

X X

s s Reduce Wear

X X

s Overload/Failure Protection s

X

s Misalignment Tolerance

X X

Constant Load s

X

s

X X

Reduce Power In-Rush

X X X X

s Hi/Medium Voltage (High HP)

X X

s

X

s Soft Start/Stop

X X X X

s Increase Bearing, Seal, Eqpt Life

X X

Cost Benefits Electrical/Electronics Issues Ease of Installation

X X

s Complex to Install/Support

X

Troubleshooting Ease

X X X

s Extensive Infrastructure

X

Lower Maintenace Costs

X X

s Sensitive to Power Quality

X

Maintained In-house

X X X

s Harmonic Distortion

X

Longer Service Life

X X X

s Frequent Parts Replacement

X

Reliability/Reduce Downtime

X X

s Parts Obsolescence

X

Lower Total Cost (1-50HP)

X

Lower Total Cost (50HP+)

X

X = Very Characteristic s = Somewhat Characteristic

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SLIDE 87
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