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 Pump, Fa Fan & Compr Compressor ssor Technic chnical Sales Sales Di Director ctor DSI DSI/Dynama Dynamati tic

● Constant Speed Motor, full voltage and frequency ● Sized for maximum pump horsepower and speed ● Motor Starter: Soft Start or Full Voltage ● Rigid Cast or Fabricated Frame ● NEMA P ‐ Base Flange ● Optional High Ring Base for Vertical Units

● Constant Speed Motor, full voltage and frequency ● Sized for maximum pump horsepower and speed ● Motor Starter: Soft Start or Full Voltage Drum Member Coupled to Motor Shaft

Salient Pole Electro ‐ Magnetic Output Rotor Separate Shaft Coils: Alternating N ‐ S polarity Slip rings and carbon brushes Magnetic Flux Induces Torque in Air Gap

Bearing Configurations Horizontal Coupled units will have outboard input ‐ end bearing to support Drum Member Pilot Bearing Grease Lubricated Main Thrust Bearing Grease or Oil Lube Antifriction or Kingsbury Type

Speed Feedback ● AC Tachometer ● DC Tachometer ● Proximity Pulse Pickup Tachometer ‐ Generator

DC Excitation Controller ● Power Consumption Approx. 1% ● Can be Enclosed or Furnished Open ‐ Chassis for Retrofit ● Power from Motor Circuit or Separate Panel ● Remote Operation from Manual or Automated Source Signal 1 phase AC Power input

DC DC Ex Excit citer ‐ Co Controlle ller wi with digit digital co cont ntrol pla platform rm ● Compact size ● Magnetic pulse pickup and AC or DC tachometer inputs ● Better than 0.5% speed regulation ● Keypad monitoring of two selectable variables ● Remote monitoring for any variables ● 4 programmable Run Presets accessible locally and remotely ● Digital logic circuit with rugged SCR power conversion for DC excitation ● PLC and SCADA compatible ● Ethernet IP communication link

Efficiency Comparison Published Empirical Data 600.0 550.0 500.0 KW Usage 450.0 400.0 350.0 300.0 250.0 VFD Eddy Current 200.0 60.00% 70.00% 80.00% 90.00% 100.00% % Speed .

Pump(and fan) Affinity Rule 100% Let’s begin by examining the effect 90% ECD eff'y of reduced speed on centrifugal 80% fan and pump loads. In this “ideal Pump load affinity law” instance, the load is Slip loss 70% reduced in proportion to the cube of the speed reduction. This load 60% reduction is usually the reason for choosing variable speed in the first 50% place. When this efficiency is applied to this reduced load, the 40% LOSSES in the eddy current drive 30% are as shown. 20% 10% Note that maximum slip loss is Slip Loss at 33% slip, at which it is only 0% 16.2% of the load input. 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Percent Speed

Efficiency at Practical Speed 100% 90% In fact, most pumps don’t behave ECD eff'y 80% exactly according to the ideal affinity curve. Many systems Pump load 70% have static head or the process requires a minimum flow that limit 60% ECD loss the speed reduction of the pump. If we look at an example 50% where there is static head in the 40% system as shown here, the pump only achieves flow at 80% pump 30% speed. 20% At this point, the discharge valve can be opened, and the pump 10% will operate only between the 0% zero flow point and maximum 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% flow, usually at “full speed”. Percent Speed

Efficiency at Practical Speed 100% 90% Evaluation is inconsequential at ECD eff'y 80% speeds below the zero flow point, so let’s only consider the Pump load 70% performance from 80% to 100% speed. ECD loss 60% 50% 40% The next slide shows this same 30% data with the horizontal axis expanded from 0 to 100% 20% flow… 10% 0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Percent Flow 0% 100%

Efficiency vs. Losses 100% 90% Here’s the same data, displayed on an expanded horizontal axis, 80% which is renamed “Percent Flow”. 70% Between zero and full flow, the 60% percent flow is approximately proportional to speed. By 50% ECD eff'y expanding the axis, we get a 40% closer look at the comparative Pump load losses. 30% ECD loss 20% Remember that the power 10% company bills for Kilowatt- hours , not “efficiency”. 0% % Flow 0% 25% 50% 75% 100% 0% 25% 50% 75% 100% 80% 85% 90% 95% 100% % Speed

Project Input Data Sheet

Duty Cycle and Energy Comparison Duty Cycle 35% System Data Flow % Time Name HI Webinar Example 10% 0% 30% Type Pump 20% 0% Choose from drop down list 25% Flow Control Throttle 30% 0% Choose from drop down list 30 40% 0% 20% Life Cycle Analysis years [Default is 40] 50% 5% Percent Flow 15% 60% 15% Motor Data Driven Load Data HP 500 BHP 475 70% 30% 10% Default is 95% of HP RPM 900 Max. RPM 885 80% 30% 5% FL Efficiency 94.2% Min. speed 62 90% 15% % [Default is 75%] Volts 4160 100% 5% 0% 10 20 30 40 50 60 70 80 90 100 100% Flow, not RPM! Presumed to be same for all methods Total must =100 Drive and Installation Data Hours of Operation Incentive ECD Hours per Day 12 Drive Selection Utility Rebate $ 150,000 Days per Week 7 Drive Cost One Time $ 20,000 Weeks per Yr. 52 Install Cost Annual $ ‐ $ ‐ $ ‐ Rebates $ 170,000 $ ‐ $ ‐ Net Cost  Cost $ 170,000 $ ‐ $ ‐ Summary of Energy Results Throttled Valve 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

Lifetime Ownership Cost & ROI & Payback Pump Life Cycle Costs: A guide to LCC Analysis for Pumping Systems, published 2001 by Hydraulic Institute and Europump Analysis 30 years 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 system Throttled Valve Eddy Current Drive Choose type Initial Capital Costs Lifetime Lifetime Lifetime Lifetime Including purchase price, aux. services Equipment Purchase $ 150,000 $ 50,000 $ ‐ $ ‐ Enter cost data if new Installation, commissioning, training Installation Costs $ 20,000 $ 10,000 $ ‐ $ ‐ system is to be compared Brick/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 service Energy 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 $ ‐ 0 $ ‐ $ ‐ 0 $ ‐ Contamination from pumped liquid Environmental Cost $ ‐ 0 $ ‐ $ ‐ 0 $ ‐ 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 0 $ ‐ $ 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%

Gr Graphic aphic Comparison Comparison

Ambient Air Cooling • Like the motors that drive them, the variable speed electro ‐ magnetic drive unit is easily cooled with ambient air. • Losses are approximately the same as those for the motor. • Typical locations provide an adequate volume of air to absorb and dissipate the heat load. • No air conditioning required to maintain safe operating temperature. • Standard design is for 40 o C ambient (same as for Warm Air Out motor). • Higher ambient designs available. Cool Air In

IEEE 519 ‐ 1992“Recommended Practice” • Motor runs across line at full voltage & frequency. • No electronic conversion of the load power is involved. • The exciter ‐ controller operates at approximately 1% of the pump load. • Harmonic distortion for the system is virtually zero. • IEEE ‐ 519 compliance is assured without the need for analysis nor mitigation .

No Negative Effect on Motors ● No induced harmonic voltage distortion ● No high frequency induced rotor and stator heating, shortening standard motor life ● Can use standard motors or safely retrofit existing motors without fear of damage or shortened life. ● No common ‐ mode voltage to threaten neutral insulation.