Application of VFD in
Power Plants
.........AN OVERVIEW
by
Amit Kulshreshtha
AGM(PE-Mech.)
Why to Use VFD
1.
2.
3.
4.
5.
6.
Energy savings on most pump and fan
applications.
Better process control and regulation.
Speeding up or slowing down a machine or
process.
Inherent power-factor correction
Protection from high in-rush currents
Safe Acceleration and braking
Electric & Power Basics
All VFDs must:
Run a machine or process at a
desired speed.
Produce adequate torque to
handle the load.
Use power efficiently to produce
the necessary torque at a given
speed.
Electric & Power Basics
The typical waveform consists of the
frequency portion (time based) of
the wave and the amplitude portion
(the magnitude). This wave is
actually in sine-wave form,
commonly referred to as the
fundamental.
Electric & Power Basics
Sinusoidal Waveform With Frequency
& Amplitude Components
AC-Induction-Motor Theory
AC Induction Motor Theory
AC Induction Motor Squirrel Cage Design
AC Induction Motor Theory
Three-phase
motor operation.
AC Induction Motor Theory
How a motor shaft rotates?
Torque is produced as the induction motor
generates flux in its rotating field.
As shaft torque load increases, the slip
increases and more flux lines cut the rotor
windings, which in turn increases rotor
current, which increases the rotor
magnetic field and consequently the rotor
torque.
AC Induction Motor Theory
Typical speed
versus torque
curve for a
NEMA design B
motor.
% Synchronous Speed
AC Induction Motor Issues
Starting Induction Motors
The starting current is very high, between 3 to 8
times the full load current. Depending on the size
of the motor, this can result in voltage sags in
the power system.
The full torque is applied instantly at starting and
the mechanical shock can eventually damage the
drive system, particularly with materials handling
equipment, such as conveyors.
In spite of the high starting current, for some
applications the starting torque may be relatively
low, only 1.0 to 2.5 times full load torque.
AC Induction Motor Theory
The speed of the rotating electric field
within the induction motor.
Synchronous Speed =
120 x frequency
No. of motor poles
AC Induction Motor Theory
1.
2.
3.
AC motor speed change can be
accomplished in three ways:
Change the number of poles in the motor; this
means separate windings
Change the slip characteristics of the motor;
this is done with varying resistors, such as is
done with a wound-rotor motor or by varying
the stator voltage; or
Change the frequency of the power supplied to
the motor. This can be achieved by VFD .
VFD Basics
The main objective of the VFD is to vary the speed
of the motor while providing the closest
approximation to a sine wave for current (while
pulsing DC voltage to the motor).
Components of VFD System
1. Operator Interface
2. Variable Frequency Controller
3. AC Motor
VFD Controller
The variable frequency drive controller
is a solid state power electronics
conversion system consisting of three
distinct sub-systems
1. A rectifier bridge converter
2. A direct current (DC) link and
3. An inverter
Rectifier bridge converter
All VFDs need a power section that converts AC
power into DC power.
This is called the Rectifier bridge.
The Rectifier is commonly a three-phase, fullwave-diode bridge.
Direct current (DC) link
The DC link may consist of a capacitor/inductor
which smoothes out the converter's DC output
ripple and provides a stiff input to the inverter. If
not, this distortion will show up in the output to
the motor.
Inverter
The inverter section is made up of modules that consist of a
transistor and diode in combination with each other which
inverts the DC energy back to AC.
The power semi-conductors in the inverter section act as
switches, switches of the DC bus, and therefore, are
pulsing the motor with some voltage.
By switching the invertertransistor devices on and off
many times per half cycle, a
pseudo - sinusoidal current
waveform is approximated.
VFD Types
Voltage-source inverter (VSI) drive
The DC output of the diode-bridge converter stores energy in
the capacitor bus to supply stiff voltage input to the inverter.
The vast majority of drives are VSI type with PWM voltage
output.
Current-source inverter (CSI) drive
The DC output of the SCR-bridge converter stores energy in
series-reactor connection to supply stiff current input to the
inverter. CSI drives can be operated with either PWM or sixstep waveform output.
20
VFD Types Cont..
Six-step inverter drive
The DC output of the SCR-bridge converter is smoothed via
capacitor bus and series-reactor connection to supply via
Darlington Pair or IGBT inverter quasi-sinusoidal, six-step
voltage or current input to an induction motor.
Load commutated inverter (LCI) drive
The DC output of the SCR-bridge converter stores energy via
DC link inductor circuit to supply stiff quasi-sinusoidal six-step
current output of a second SCR-bridge's inverter and an overexcited synchronous machine.
Cycloconverter or matrix converter (MC)
Cyclo converters and MCs are AC-AC converters that have no
intermediate DC link for energy storage.
Doubly fed slip recovery system
A doubly fed slip recovery system feeds rectified slip power to
a smoothing reactor to supply power to the AC supply network
via an inverter, the speed of the motor being controlled by 21
adjusting the DC current.
Pulse Width Modulation
Pulse-width modulation (PWM), or pulse-duration
modulation (PDM), is a commonly used technique for
controlling power to electrical devices.
Pulse-width-modulated voltage and
current waveforms.
22
VFD Motor Selection issues
The switching of insulated-gate bipolar transistors
(IGBTs) to accomplish PWM on the output of a
VFD creates voltage spikes on the line out to the
motor.
These spikes are amplified over distance and, in
time, break down the insulation of a motor,
shortening the motors life.
For VFD applications, Class F or higher insulation
should be selected when possible.
23
VFD Motor Selection issues Cont..
In constant power applications, for higher torque,
the speed would be low.
Reduced speed may affect the cooling of the
motor windings for high torque applications.
When a VFD applies high-frequency pulses to a
motor, the parasitic capacitance between stator
and rotor generates voltage on the motor shaft.
This creates discharge arcing and shaft current,
which may damage the shaft and bearing
surfaces.
24
Sample PWM-Equivalent Circuit
Application in Power
Plants
26
VFD APPLICATION TO CEP/ID fan
(for Energy Savings)
27
28
Variable speed control is the most energy efficient control method
Head
How VFD Saves Energy ?
12
10
7
Flow
7
10
29
VFD for CEP
P saving= 161.7 KW
30
CEP/ID Fan
There is a gap between design point
and the rated operating point.
Design margins are to take care of
extreme operating conditions.
VFD ensures energy savings by
reducing speed at the operating
point.
Margin to take care of operation at
47.5Hz. is not needed.
31
VFD APPLICATION TO COMPRESSOR
32
VFD in Compressors
Instead of loading and unloading in a cyclic
manner, the compressor is start/stop as per
desired duty requirement to maintain the set
pressure.
System saves energy as the motor does not run
in idle mode.
VFD in compressor allows frequent start/stop of
motor as per duty requirement.
Lower maintenance of the system due to smooth
start.
33
Coal Conveyors
Coal conveyors are subjected to frequent
start/stop.
Idle running of motor during stop by
disengaging the hydraulic coupling causes
energy loss.
Only 2 starts/hour are permissible.
Conveyors have to be designed to start
while fully loaded, i.e. high torque.
Generally motors are run at part load.
VFD can provide ideal solution for
Conveyors.
34
REELING DRUM APPLICATION
cont.
The present scheme
Cables reeling drum provided with brake motor
The brake motor stops and holds the drum, as
and when the paddle-feeder or stacker-reclaimer stops moving
It protects the cable from slackness.
The brake is released on restart and motor
rotates the drum to maintain safe tension in
the cable.
The motor with conical rotor with spring loaded
brake and brake-shoe arrangement are prone
to high maintenance.
Many times causes unreeling of cable resulting
in snapping or damage of it.
35
REELING DRUM APPLICATION
VFD Alternative Scheme
The arrangement is an innovative solution
of brake motor.
The VFD maintains constant torque on the
cable reeling drum continuously even at
zero speed (i.e. stop condition).
This constant torque maintains safe
tension on the cable.
Power consumption at zero speed is equal
to no load and part consumption during
movements, as and when the drum
rotates.
36
VFD APPLICATION TO BOILER AREA
37
VFD APPLICATION TO BOILER AREA
Axial blade pitch control and VFD control give the
same level of efficiency in power consumption at
part load operations
VFD control for PA fan, ID fan, Coal Feeder and
Fuel Oil motors can be implemented for old
210MW units.
VFD control for ID fans, Coal Feeder and Fuel Oil
motors can be implemented for old 500 MW units
New units should have VFD for coal feeder speed
control as against eddy current clutch control
Sipat-I coal feeder motors already have VFD
controls.
38
VFD APPLICATION TO BFP
(for smooth start)
39
Advantages of Using VFD
Increased motor life due to the lower
thermal and mechanical stressed in
view of the absence of starting inrush
currents and reduced speed operation
No limitation on the number of starts
No contribution to fault current.
One VFD can be used to start all the
MDBFPs
One more VFD can be kept as standby
40
VFD APPLICATION TO BFP 4 UNITS
OPTION-A
OPTION-B
OPTION-C
2 x50% TD+
2 x50% TD+
1x50%MD (VFD)
3x50% MDBFP (VFD)
1x50%MD(hydraulic
coupling)
VFDs
2 ( 1+1standby)
9 (8+1standby)
Turbines
Motor
12
Hydraulic couplings
Flexibility of layout
Negative
Negative
Positive
Space requirement
Negative
Negative
Positive
Maintenance
Negative
Negative
Positive
Startup time
Negative
Positive
Positive
Motor startup
Negative
Positive
Positive
Neutral
Neutral
Neutral
Low
High
Neutral
Supply side Harmonics
System Cost
41
VFD solution may be cheaper than the conventional one with other advantages as bonus
BFP for 660MW Units- OPTION-B
The BFP motor rating for 660MW (2x50%
TDBFP+1x50% MDBFP) unit is 18MW and
thus causes high electrical and mechanical
stress on the system during starting.
Instead of 1x50%, it was proposed to use
2x30% rating BFP for 660 & 800 MW units.
However with VFD it can be retained as
1x50%.
The size of each VFD for 18MW motor shall
be approximately 5MVA equal to no load
MVA rating.
42
Advantages of Using VFD with OPTION-C
BFPs can be placed at 0.0 M El.
Saving in Plant Cost due to lowering of
De-aerator Elevation
Absence of Associated Steam and
Condensate piping
Flexibility of Layout and Space Saving
Absence of voltage dip problems
This option is ruled out now because new
CERC regulation permits only 2%
additional aux. power on account of BFP,
whereas BFP power consumption will be
4% in supercritical unit.
43
PRICE OF VFD for BFP Motors
cont.
Siemens quote for VFD of 300kW Air Compressor
motor:
Rs. 4 million
Siemens quote for VFD of 4000kW ID Fan
induction motor:
Rs. 45 million
ABB quote for VFD of 4000kW ID Fan induction
motor:
Rs. 28.8 million
Expected Price of VFD of 10MW rating along with
motor
Rs. 80 millions
44
VFD WITH REMOTE RF CONTROL
FOR
EOT CRANES
INTRODUCTION
USE :
LIFTING / LOWERING
LOADS
CARRYING LOADS
ALONG /ACROSS THE
RAILS
MOTORS :
MAIN HOIST/ CREEP MOTOR
AUXILIARY HOIST / CREEP
MOTOR
CROSS TRAVEL
/ CREEP
MOTOR
LONG TRAVEL
/ CREEP
MOTOR
RANGE OF EOT CRANES
IN NTPC:
( 7.5 T 105 T )
CONVENTIONAL PRACTICE
SLIP-RING INDUCTION
MOTOR EMPLOYING
RESISTANCE CUT-IN/
CUT-OUT FOR SPEED
CONTROL
CABIN /PENDENT
CONTROL
VFD SYSTEM
SQUIRREL CAGE
INDUCTION MOTOR IN
PLACE OF SLIP RING IM
SPEED CONTROL BY
VARIABLE VOLTAGE
VARIABLE REQUENCY
DRIVE
RADIO REMOTE
FREQUENCY CONTROL
UNIT
COMPONENTS & WORKING
PHILOSOPHY
A)
B)
VARIABLE FREQUENCY DRIVE
RADIO FREQUENCY REMOTE
CONTROLLER
Transmitter unit
Encoder
Receiver
Decoder
Interface panel
Coupling system
Control gear
Battery
SALIENT FEATURES
A)
VFD SYSTEM
SQ.CAGE INDUCTION MOTOR WITH VPI INSULATION AND INSULATED
NDE BEARING
CHOICE OF MOTION CONTROL FROM OPERATORS CABIN OR REMOTE
CONTROLLER
STARTING TORQUE UPTO 400% WITH STARTING CURRENT LIMITED
TO 150%
VFD CAPABLE OF WITHSTANDING UPTO 50 C
HARMONIC REDUCTION DEVICES
SPEED CONTROL WITH 6 PULSE DESIGN
PROTECTIONS: O/L , O/V , E/F , O/ S Ckt., I/P LOSS , LOAD LOSS, I/P
TRANSIENT PROTECTION
SALIENT FEATURES CONTINUED..
B) RADIO FREQUENCY REMOTE UNIT
WIRELESS CONTROL WITH DOUBLE JOYSTIC MOVEMENT
TYPE STEPPED CONTROL WITH SPRING RETURN
TRANSMITTER & RECEIVER HAVE A UNIQUE FREQUENCY &
ADDRESS CODE TO AVOID INTERFERENCE
CAN COMMUNICATE UPTO 100 m DISTANCE
CRANE OPERATION IS LOCKED IN CASE OF
COMMUNICATION FAILURE
CHOICE OF TANDEM/SLAVE/SINGLE OPERATION
TECHNICAL ADVANTAGES
VFD SYSTEM
No slip ring related
maintenance
Creep motor not required
Gear box not required
Electrical braking before mechanical breaking-break life is more
On line fault display- hence less down time
Starting current is less than dol starting
Smooth starting and stopping offers jerk less operation longer life due
to less mechanical fatigue
Wide speed range- step less speed control
100% holding torque available at standstill
More energy efficient
TECHNICAL ADVANTAGES
RF CONTROL
EASE IN HANDLING
UNRESTRICTED OPERATOR MOBILITY
NO ROUTINE MAINTENANCE REQUIRED
WIRELESS OPERATION
COST ANALYSIS
A)
B)
VFD SYSTEM IN 105T EOT CRANE IS COSTLIER BY Rs 1,39,750
ie 0.7% OF COST OF ONE EOT CRANE (Approx. 2 crore)
RF REMOTE CONTROLLER COSTS 1.15 Lacs WHICH IS 0.57% OF
COST OF ONE EOT CRANE
BOTTOM LINE:
A) + B) COMBINED TOGETHER SUMS UP TO BE 1.27%
COSTLIER THAN THE PRESENT SYSTEM
The 1.27% extra cost is insignificant, in lieu of
benefits on energy savings, reduction in man power
and low maintenance.
AIR CONDITIONING
55
Limitations of Centralized AC
Higher space requirement for installation of
equipment. AC plant room is required.
Not suitable for frequent load variation.
Not efficient at part load operation.
Difficult to retrofit.
Operators intervention is required to control/
vary inside conditions.
Water Cooled systems although are very
efficient, require large quantity of make-up
water.
Limitations of Localized AC system
Envisaged normally for small buildings.
Available upto 15 TR capacity as a single unit.
No humidity control.
No arrangement for fresh air supply.
Distance of out door unit can not be more
than 10M.
Part load operation is not possible.
Noise in operation
VRV (Variable Refrigerant
Volume)
Based on limitation of the above two
systems a need was felt for an
intermediate of the above two
systems. VRV system has been
developed to overcome the
limitations imposed by centralised
and localised systems.
The Variable Refrigerant Volume
(VRV) system is also Known as
Variable refrigerant Flow (VRF)
system.
Schematic diagram of VRV
system
VRV (Variable Refrigerant Volume) System
Similar to split type of air conditioning.
VRV comprises of no. of indoor units which share a common
refrigerant circuit, served from a common outdoor unit
comprises of multiple compressors of varying capacity.
The refrigerant flow is varied by using inverter controlled
variable speed compressor to respond to changes in the
cooling or heating requirement.
By the combination with the inverter compressor and the
constant speed compressor, the comfortable room condition
will be obtained by changing the compressor operation
condition.
VRV conditions air for each room individually as per load
requirement.
Layout of VRV system
Freely Selectable Operation of
Indoor Units
Others System
Units
VRF
ON
Not Possible
OFF
ON
OFF
Partial Load implies 40 to 70%
less energy consumption
VRV/VRF
VRV system can work as centralised
system.
VRV system can work as localised system.
Operating cost of the system is minimised
by use of varaible refrigerant flow
concept.
Make up water is not required.
VRV system can operate at part load.
Total Piping length from outdoor to indoor
unit can be as maximum as 150M.
VRV/VRF
(Comparison with chillers)
S.No.
Features
VRV System
Water cooled Chiller
system
Benefits of
VRF System
1.
Type of System
Completely Aircooled system
with three basic
parts- Outdoor,
indoor units &
controllers
Water cooled
system with many
component chilling
machines, AHUs,
Cooling tower,
Chilled Water
pumps, Condensate
water pumps, many
types valves,
Electricals &
controls etc.
Minimum parts
thus very
simple VRF
systems
2.
Energy
Consumption
Overall 25%35% power
saving on
average basis
Only efficient at
certain load
conditions
Constant
saving by
optimal
running
VRV/VRF
(Comparison with chillers)
S.No.
Features
VRV System
Water cooled
Chiller system
Benefits of
VRV System
3.
Distribution
Piping
Network
Smaller
copper piping
Bigger MS piping
Shaft/ floor
space not
required
4.
Interiors,
Ceiling height
Different type
of Indoor
options to fit
into different
construction,
interiors
Only Ducted
Flexibility in
Systems possible. layout.
5.
Standby
Function
Inbuilt
Standby Multi tier
To be added at
extra cost
Ensured
Operation all
Times
Conclusion
VFD Can be used in CEP for future projects for
energy saving.
For All old stations, VFD can be installed in CEP
based on techno-economics.
For Large size units, VFD in BFP Motor offers a
number of advantages and can be considered in
future.
VFD can be useful for conveyor motors, compressor
and reeling drum motors.
Boiler Auxiliaries such as PA fan , ID fan ,Coal Feeder
and Fuel Oil motors can be upgraded with VFD
control, for old 210 MW and 500MW units.
New units of all sizes should have VFD for coal feeder
speed control.
VFD is becoming popular for VRV air-conditioning ,
Hoists, Lifts and EOT Cranes
66
THANK YOU
67
Speed & Motor Ratings - Major SG Auxiliaries
Aux\MW
210
500
660
FD fan
575 KW
1480 RPM
1225 KW
900 RPM
1950 KW
990 RPM
PA fan
1600 KW
1480 RPM
2850 KW
1490 RPM
3350 KW
1490 RPM
ID fan
1650 KW
120-580 RPM
3895 KW
AT 545 RPM
5250 KW
590 RPM
Coal Mill
5.5 KW
1500 RPM
425 KW
589 RPM
BCW pump
NA
5.5 KW
1500 RPM
525 KW
985 RPM
365 KW
1455 RPM
5.5 KW
VFD
690 KW
986 RPM
545 KW
2930 RPM
FO pumps
37 KW
1465 RPM
90 KW
1480 RPM
75 KW
1500 RPM
Coal Feeder
68
