Pu Pump mp Kn Knowledge Wo Workshop: Eddy ddy Curr Curren ent - - PowerPoint PPT Presentation
Pu Pump mp Kn Knowledge Wo Workshop: Eddy ddy Curr Curren ent Technol chnology gy Theor Theory of of Oper Operation Pe Performance Anal Analysis Applic licatio ion Consid ideratio ions Presen esented by by: Gar Gary Pa Patterson Pu
Presen esented by by: Gar Gary Pa Patterson Pu Pump, Fa Fan & Compr Compressor ssor Technic chnical Sales Sales Di Director ctor DSI DSI/Dynama Dynamati tic
full voltage and frequency
horsepower and speed
Soft Start or Full Voltage
for Vertical Units
full voltage and frequency
horsepower and speed
Soft Start or Full Voltage Drum Member Coupled to Motor Shaft
Separate Shaft Magnetic Flux Induces Torque in Air Gap
Salient Pole Electro‐Magnetic Output Rotor
Coils: Alternating N‐S polarity Slip rings and carbon brushes
Pilot Bearing Grease Lubricated Main Thrust Bearing Grease or Oil Lube Antifriction or Kingsbury Type
Bearing Configurations
Horizontal Coupled units will have
support Drum Member
Tachometer‐Generator
Speed Feedback
DC Excitation Controller
Open‐Chassis for Retrofit
Separate Panel
1 phase AC Power input
tachometer inputs
and remotely
conversion for DC excitation
Published Empirical Data
.
200.0 250.0 300.0 350.0 400.0 450.0 500.0 550.0 600.0 60.00% 70.00% 80.00% 90.00% 100.00% KW Usage % Speed
VFD Eddy Current
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Percent Speed ECD eff'y Pump load Slip loss
Note that maximum slip loss is at 33% slip, at which it is only 16.2% of the load input.
Let’s begin by examining the effect
fan and pump loads. In this “ideal affinity law” instance, the load is reduced in proportion to the cube
reduction is usually the reason for choosing variable speed in the first
applied to this reduced load, the LOSSES in the eddy current drive are as shown.
Slip Loss
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Percent Speed ECD eff'y Pump load ECD loss
In fact, most pumps don’t behave exactly according to the ideal affinity curve. Many systems have static head or the process requires a minimum flow that limit the speed reduction of the
where there is static head in the system as shown here, the pump
speed. At this point, the discharge valve can be opened, and the pump will operate only between the zero flow point and maximum flow, usually at “full speed”.
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% ECD eff'y Pump load ECD loss
Evaluation is inconsequential at speeds below the zero flow point, so let’s only consider the performance from 80% to 100% speed. The next slide shows this same data with the horizontal axis expanded from 0 to 100% flow…
Percent Flow 0% 100%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0% 25% 50% 75% 100% ECD eff'y Pump load ECD loss 0% 25% 50% 75% 100% 80% 85% 90% 95% 100%
% Speed % Flow
Here’s the same data, displayed
which is renamed “Percent Flow”. Between zero and full flow, the percent flow is approximately proportional to speed. By expanding the axis, we get a closer look at the comparative losses. Remember that the power company bills for Kilowatt- hours, not “efficiency”.
System Data Flow % Time Name HI Webinar Example
10% 0%
Type Pump
Choose from drop down list
20% 0%
Flow Control Throttle
Choose from drop down list
30% 0%
Life Cycle Analysis
30
years [Default is 40]
40% 0% 50% 5%
Motor Data Driven Load Data
60% 15% HP 500 BHP 475
Default is 95% of HP
70% 30% RPM 900
885 80% 30% FL Efficiency 94.2%
62
% [Default is 75%]
90% 15% Volts 4160 100% 5%
Flow, not RPM!
100%
Total must =100
Hours of Operation Incentive Drive Selection
ECD Hours per Day 12
Utility Rebate Drive Cost
150,000 $ Days per Week 7
One Time Install Cost
20,000 $ Weeks per Yr. 52
Annual Rebates
‐ $ ‐ $ ‐ $
Net Cost
170,000 $ ‐ $ ‐ $
Cost
170,000 $ ‐ $ ‐ $
Summary of Energy Results
Choose Type
kWhr/yr Energy $/yr
ECD 1,345,935 107,675 $ Valve Control 1,560,031 124,802 $ Annual Saving 214,096 17,128 $
Throttled Valve
Duty Cycle Drive and Installation Data
Presumed to be same for all methods 0% 5% 10% 15% 20% 25% 30% 35% 10 20 30 40 50 60 70 80 90 100 Percent Flow
Analysis 30 years Pump Life Cycle Costs: A guide to LCC Analysis for Pumping Systems, published 2001 by Hydraulic Institute and Europump
Motor, Pump costs are presumed to be the same, and thus not compared in these calculations Analysis presumes a pre‐existing valve‐based flow control systemInitial Capital Costs Lifetime
Lifetime LifetimeLifetime Including purchase price, aux. services Equipment Purchase 150,000 $
‐ $ ‐ $
50,000 $
Enter cost data if newInstallation, commissioning, training Installation Costs 20,000 $
‐ $ ‐ $
10,000 $
system is to be comparedBrick/mortar mods to accommodate eqpt Construction Costs ‐ $ ‐ $ Calculated as 10% of above costs Engineering 17,000 $
‐ $ ‐ $
6,000 $ Initial inventory of spares Spare Parts ‐ $
‐ $ ‐ $
‐ $ End of life disposal (15% of Initial Cost) Decommission Cost 22,500 $
‐ $ ‐ $
7,500 $ Total Initial Cost 209,500 $
‐ $ ‐ $
73,500 $ Annual Costs Per yr. Yrs Lifetime Per yr Yrs Lifetime Per yr. Yrs Lifetime Per yr. Yrs Lifetime From System Info results x years of serviceEnergy Costs 107,675 $ 30 3,230,245 $ 124,802 $ 30 3,744,074 $ Labor for normal operation & supervision Operating Costs 1,500 $ 30 45,000 $ 1,500 $ 30 45,000 $ Routine and predicted maintenance Mainenance 2,500 $ 30 75,000 $ 1,200 $ 30 36,000 $ Total Annual Costs 111,675 $ 3,350,245 $ 127,502 $ 3,825,074 $ Recurring Costs (not annual) Per event Events Lifetime Per e Event Lifetime Per ev Events Lifetime Per event Event Lifetime Loss of production Down Time Cost ‐ $ ‐ $ ‐ $ ‐ $ Contamination from pumped liquid Environmental Cost ‐ $ ‐ $ ‐ $ ‐ $ Repairs in excess of routine maintenance Repair Cost 10,000 $ 3 30,000 $ 15,000 $ 4 60,000 $ Cost to replace failed, obsolete eqpt Eqpt Replacement 235,000 $ ‐ $ 50,000 $ 1 50,000 $ Total Life Cycle Costs 3,589,745 $ ‐ $ ‐ $ 4,008,574 $ ROI/Payback Calcs
Eddy Current Drive
Total Initial Cost (investment) 136,000 $ Initial Annual Savings (Energy, Operating, Maintenance) 15,828 $ Initial Simple payback (years) 8.6 Initial Simple Return on Investment 11.64% Life Cycle Cost Savings $418,830 Annual Return on Investment over Life Cycle (dollars) $13,961 Annual Return on Investment over Life Cycle (percent) 10.27%
Eddy Current Drive
Choose typeThrottled Valve
electro‐magnetic drive unit is easily cooled with ambient air.
motor.
to absorb and dissipate the heat load.
motor).
Cool Air In Warm Air Out
voltage & frequency.
the load power is involved.
1% of the pump load.
system is virtually zero.
assured without the need for analysis nor mitigation .
bearings to mitigate shaft currents.
.
Exciter Stator Exciter Rotor Rectifier Assembly AC Excitation Single phase
1000 HP Electronic Footprint Comparison
8 ft-7 in H 42 in H
Considerations
Cable Length Up to 500 feet (transmitting only DC voltage) before requiring increase in wire size External Cooling
.
Ambient air in most pumping applications Harmonic Mitigation Input Isolation Transformer: Up to 6KVA, 575VAC Input Line Reactor: None Required Output Harmonic Filters: None Required Installation Cabling No specialty cable requirements, only national electrical code standards apply. System Grounding No specialty grounding requirements, only national electrical code standards apply.
for Pump And Fan Drive Systems
Considerations
Motor Requirements Standard Class F insulated, Design B motors. Specific flange and shaft details are preferred for some vertical installations. Brand Flexibility Non‐exclusive Eddy Current systems are compatible with all motor manufacturers. Bearing Protection None required Due to absence of shaft currents, no shaft grounding or insulated bearings needed. Hydraulic thrust, if any, is absorbed by the lower ECD bearing, not the motor. Anti‐ReverseRatchet Available Option
for Pump And Fan Drive Systems (cont.)
carried by an optional thrust bearing in the lower end of the electromagnetic drive.)
Rotary Lobe) Pumps
Municipal or Industrial Water & Wastewater
Steam Plants (Power Generation or Central Heating/Cooling)