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The Digital Sugar Mill
Seminar on Sugar & Ethanol Automation
Variable Frequency Drives and
Motors
Omar Javed – Business Manager Sales
Variable Frequency
Drives
Agenda
This session explains very brief overview
of Variable Frequency Drives; general
introduction followed by industrial
examples, applicable industries and
operations to be focused.
What is VFD?
What are the concerns?
What to do about it?
3
What is VFD
Electrical/electronic piece
of equipment that varies
the speed of a 3 phase or
AC motor.
Also Called:
VSD [ Variable Speed Drive]
ASD [Adjustable Speed Drive]
AFD [Adjustable frequency drive]
4
Basic VFD Operations
Convert AC power to DC power.
Filter DC power.
Invert DC power to variable voltage and variable
frequency AC power
5
VFD Block Diagram
Motor Load Groups: Constant Torque Load
100
Horsepower
Demanded
by the Load %
Speed %
100
Torque Demanded
by the Load %
Speed % 100 100
7
Constant Torque “CT” Applications
Positive Displacement Pumps
Reciprocating Compressors
Rotary Compressors
8
Variable Torque Load
Torque
Demanded
by the Load %
Speed % 100
100
Horsepower
Demanded
by the Load %
Speed %
100
100
9
Variable Torque “VT” Applications
Centrifugal Fans
Centrifugal Pumps
Centrifugal Blower
10
Output or Cable Device
Termination
Required if motor cable
lengths exceed stated
values
AC Drive*
Normal Duty vs. Heavy
Duty ratings
InputFilter**
CompactPowerFlex
drivesExternalEMC
filterrequiredforEMC
Compliance
Line Reactor
Needs Applied if:
a) Switched power factor corrections
capacitators
b) Power interruptions or voltage dips
c) Transformer larger than drive
Inputfusing&circuit
breakers
Listingsinproductuser
manuals
ACSupplySource
Inputlinereactor
recommendedwhen
linevoltage
imbalancesaregreater
than2%
11
AC Motor
Normal Duty or
Heavy Duty
If a normal duty overload characteristic
is chosen, an oversize motor allows up
to 110% torque performance for up to 1
min. in both CT and VT.
This function is used mainly for pumps
and fans, since these applications do not
require an overload torque.
If a heavy duty overload characteristic is
chosen, a rated motor with the
frequency converter obtains up to 160%
torque for 1 min. in both CT and VT
12
What do You Need to
Know to Select a
Drive?
Current
rating (A)
of the
motor
kW rating
of the
motor
Type of
Machine
(Application)
IP Rating
• IP20 = Clean
Switchroom,
Switchboard
• IP54 = Dust/Damp
Wall Mount
• IP66 = Washdown
Functionality
• How is the drive
being controlled?
• I/O?
• Communications?.
Least
Important
Most
Important
What Rockwell Automation is Offering
14
PowerFlex Family of Low Voltage Drives
PowerFlex Drives meet worldwide standards out of-the-box, achieving EMC, global voltage and
safety requirements.
All Power Flex Drives offer commonality in networks, operator interface and programming
— factors that significantly contribute to ease-of-use and faster application start-up
PowerFlex Compact Drives offer cost-effective motor control for machine-level and stand-
alone applications (PowerFlex 523, 525, 527, 40, 40P)
PowerFlex Standard Drives are designed for application flexibility and control system
integration (PowerFlex 400, 70, 700, 753)
PowerFlex Premium Drives are designed for advanced applications with tight control system
integration and extended Power Ranges (PowerFlex 700L, 700H, 700S, 755)
15
Power
Performance
Compact
Standard
Premium
PowerFlex Family of Low Voltage Drives
16
PowerFlex
750 Series
AC Drives
PowerFlex 755
Premium Integration
AC Drive
PowerFlex 753
General Purpose
AC Drive
Panel Mount Drives
0.75 to 250 kW @ 400V
1.0 to 350 Hp @ 480 V
.5 to 300 Hp @ 600V
5.5 to 250 kW @ 690V
Panel Mount Drives
0.75 to 250 kW @ 400V
1.0 to 350 Hp @ 480V
.5 to 350 Hp @ 600V
5.5 to 250 kW @ 690V
Floor Mount AC Drives
315to1400kW@400V
400to2000Hp@480V
250to1500Hp@600V
200to1500kW@690V
PowerFlex 750-Series AC Drives
Ratingsto250kW/350Hp Ratings to 1500 kW / 2000 Hp
17
Value Delivered
Faster Time
to Market
$ $$
Lower Total Cost of
Ownership
Improved Asset
Utilization
Enterprise Risk
Management
18
Timeline Review
19
Original Hardwired
System
Typically configured using:
 Two different software tools
 Two different cables or
converters
 Sometimes by two different
people
20
Early
Networks
Same as hardwired system
 Typically configured
using two different
software tools
 Two different cables or
converters
 Sometimes by two
different people
21
Use of Dual
Networks
Typically configured using
two different software tools
22
Typical Single
Network Today
Typically configured by one
person using two different
software tools
23
Integrated
Software Today
Single Software Tool
 Configure network i/o
connection to the drive
One time, in One place &
by One person
 Eliminates potential for
user error when
configuring network i/o
24
Introduction to WEG Motors
25
History of WEG
26
27
Global Presence
27
> Distributors & Agents in over 85 countries
> Over 1100 Service Centers covering all 5 continents
> Sales to over 110 countries
Factories in 5 countries
Commercial branches in 22 countries
Employees
28
28 25/08/2016
14,159
15,292
19,446
20,974
22,716
8,343
9
7,808
409
3,542
1961 1970 1980 1990 2009 2010 2011 2012 2013 2014
3542
7808
8343
Outside Brazil
Brazil
12,587
13,545
17,549
18,664
19,861
1572
1747
2310
2855
1897
29 25/08/2016
Manufacturing Plants - MOTORS
30 25/08/2016
Products
• Three phase TEFC / ODP motors / output ratings up to 1200kW (1650HP)
Types: * General Purpose
* Explosion Proof
* Brake Motors
* Inverter Duty
* Saw Arbor
* Pump Motors
* Others
• Single Phase TEFC / ODP motors / output up to 9.2kW (12.5HP)
Types: * General Purpose
* Farm Duty
* Multi-Mounting Aluminum frame motors
* Appliance Motors
* Ventilation / Others
Low Voltage Industrial Motors
31 25/08/2016
Products
• Three Phase TEFC / ODP Induction Motors
- Master Line, frames from 280 to 1800, voltages up to 15kV;
- H Line, enclosed, frames from 315 to 630, voltages from 220V to 11kV;
- DC Motors, frames up to 1800.
Applications: * Mining
* Sanitation
* Steel Plants
* Cement
* Pulp and Paper
* Petrochemical
* Cooling Systems
Medium and High Voltage Motors
32 25/08/2016
Certifications
33 25/08/2016
MOTORS
Machining Center
In operation
MOTORS
Plant VI - Frames: 160, 180,
200
In operation
MOTORS
Motors - 355 W21 + HGF up
to 400 and GTA
In operation
ENERGY New
Steel Plate Frame
Fabrication
In operation
AUTOMATION Panel Shop Buildings - In operation
AUTOMATION
New Automation Building
To be concluded in 2009> Extension of the capacitors factory and new line of contactors (CWC): US$ 2 Million
> Powder coatings production capacity increase: US$ 3 Million (2007) + US$ 7 Million
Main Investments - 2014 / 2015 (Brazil)
34 25/08/2016
China
Investments in the production capacity of the following
motor lines already available:
• W21: frame sizes 80 up to 355
• HGF: frame size up to 630
• MGF: frame sizes 315 up to 1000
Main Investments Outside Brazil - 2012 / 2013
35 25/08/2016
Main Investments Outside Brazil - 2012/2013
First Stage
• Production of MV & HV electric motors (M and S Lines)
• Frame sizes: 355 up to 1600
• Investments: US$ 50 Million (To be concluded in 2010)
Second Stage
• Production of Transformers and H Line
• Investments: US$ 60 Million (To be concluded in 2013)
New Manufacturing Plant In India
36 25/08/2016
References - OEM Ventilation
• FläktWoods
• Springer Carrier
• Riox
• Howden
• Elta Fans
• Zitron
• Penn Ventilator
• Relopa
• Sodeca
37 25/08/2016
• ITT Industries
• Sterling
• Alfa Laval
• Gusher Pumps
• Goulds Pumps
• Hidrostal
• ABS
• Envirotech
• Ebara
References - OEM Pumps
• Sulzer
• Kirloskar Brothers Limited
• KSB
• Ingersoll-Dresser Pumps
• Grundfos
• Weir Pumps
• Flowserve
• Tsurumi Pump
• Marelli Pumps
• Scot Pump
38 25/08/2016
• Ingersoll Rand
• Schulz
• Atlas Copco
• Puska
• Alup
• Sullair
• Champion
• Campbell Hausfeld
• Mitsui Seiki
• CompAir
• Boge Kompressoren
• DeVilbiss Air Power Company
• Hitachi
• Betico
References - OEM Compressors
References: Oil & Gas
25/08/2016 39
• Caltex
• Sasol
• Total
• ENAP
• PDVSA
• ESSO
• Petrobras
• Saudi Aramco
• Pemex
• Ecopetrol
• Cepsa
• Sapref
• PetroCanada
• Repsol YPF
• NION
• Conoco
• Pan American Energy
• Dresser Rand
• Dow Chemical
40 25/08/2016
Contracts with OEM‘s and End Users
• Metso Minerals
• CompAir
• Atlas Copco
• FläktWoods
• Soler & Palau
• Cenibra
• Epal
• Cargill
• Alfa Laval
• Alup Kompressoren
• Usiminas
• Votorantim
• Europac
• Ingersoll Rand
• Sandvik
• Suzano
• Boge
• Sadia
• Weir
• CSN
• Bosch
• ABS
• Klabin
• Cosipa
41 25/08/2016
• Bechtel
• Tecnimont
• Fluor
• Foster Wheeler
• Black & Veatch
• Alstom
• Cegelec
• Technip
• Saipem
• Snamprogetti
• Placer Dome
• Kvaerner
• EFACEC
• Aker Kvaerner
• SNC - Lavalin
• DRA
• Techint
• CH2Mhill
References - Engineering Companies
Question & Answers
Thank You for Your Valuable Time
42
Lahore, Pakistan
Headquarters South East Asia
19 Km Main Multan Road
Lahore, Punjab 54660
Pakistan
Phone : + 92 42 111 940 940
Dubai, UAE
Headquarters Middle East And Asia
Office FZS1 BD04, Jebel Ali Free Zone
PO Box 18590, Dubai
United Arab Emirates
Phone: +971 4 88 60 277
Exton, USA
Headquarters Americas
180 Sheree Boulevard, Suite 1400
Exton, PA 19341
United States of America
Phone +1 610 458 8700
Regional Offices and Global Headquarters

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Avanceon VFD

  • 1. The Digital Sugar Mill Seminar on Sugar & Ethanol Automation
  • 2. Variable Frequency Drives and Motors Omar Javed – Business Manager Sales
  • 3. Variable Frequency Drives Agenda This session explains very brief overview of Variable Frequency Drives; general introduction followed by industrial examples, applicable industries and operations to be focused. What is VFD? What are the concerns? What to do about it? 3
  • 4. What is VFD Electrical/electronic piece of equipment that varies the speed of a 3 phase or AC motor. Also Called: VSD [ Variable Speed Drive] ASD [Adjustable Speed Drive] AFD [Adjustable frequency drive] 4
  • 5. Basic VFD Operations Convert AC power to DC power. Filter DC power. Invert DC power to variable voltage and variable frequency AC power 5
  • 7. Motor Load Groups: Constant Torque Load 100 Horsepower Demanded by the Load % Speed % 100 Torque Demanded by the Load % Speed % 100 100 7
  • 8. Constant Torque “CT” Applications Positive Displacement Pumps Reciprocating Compressors Rotary Compressors 8
  • 9. Variable Torque Load Torque Demanded by the Load % Speed % 100 100 Horsepower Demanded by the Load % Speed % 100 100 9
  • 10. Variable Torque “VT” Applications Centrifugal Fans Centrifugal Pumps Centrifugal Blower 10
  • 11. Output or Cable Device Termination Required if motor cable lengths exceed stated values AC Drive* Normal Duty vs. Heavy Duty ratings InputFilter** CompactPowerFlex drivesExternalEMC filterrequiredforEMC Compliance Line Reactor Needs Applied if: a) Switched power factor corrections capacitators b) Power interruptions or voltage dips c) Transformer larger than drive Inputfusing&circuit breakers Listingsinproductuser manuals ACSupplySource Inputlinereactor recommendedwhen linevoltage imbalancesaregreater than2% 11 AC Motor
  • 12. Normal Duty or Heavy Duty If a normal duty overload characteristic is chosen, an oversize motor allows up to 110% torque performance for up to 1 min. in both CT and VT. This function is used mainly for pumps and fans, since these applications do not require an overload torque. If a heavy duty overload characteristic is chosen, a rated motor with the frequency converter obtains up to 160% torque for 1 min. in both CT and VT 12
  • 13. What do You Need to Know to Select a Drive? Current rating (A) of the motor kW rating of the motor Type of Machine (Application) IP Rating • IP20 = Clean Switchroom, Switchboard • IP54 = Dust/Damp Wall Mount • IP66 = Washdown Functionality • How is the drive being controlled? • I/O? • Communications?. Least Important Most Important
  • 14. What Rockwell Automation is Offering 14
  • 15. PowerFlex Family of Low Voltage Drives PowerFlex Drives meet worldwide standards out of-the-box, achieving EMC, global voltage and safety requirements. All Power Flex Drives offer commonality in networks, operator interface and programming — factors that significantly contribute to ease-of-use and faster application start-up PowerFlex Compact Drives offer cost-effective motor control for machine-level and stand- alone applications (PowerFlex 523, 525, 527, 40, 40P) PowerFlex Standard Drives are designed for application flexibility and control system integration (PowerFlex 400, 70, 700, 753) PowerFlex Premium Drives are designed for advanced applications with tight control system integration and extended Power Ranges (PowerFlex 700L, 700H, 700S, 755) 15
  • 17. PowerFlex 750 Series AC Drives PowerFlex 755 Premium Integration AC Drive PowerFlex 753 General Purpose AC Drive Panel Mount Drives 0.75 to 250 kW @ 400V 1.0 to 350 Hp @ 480 V .5 to 300 Hp @ 600V 5.5 to 250 kW @ 690V Panel Mount Drives 0.75 to 250 kW @ 400V 1.0 to 350 Hp @ 480V .5 to 350 Hp @ 600V 5.5 to 250 kW @ 690V Floor Mount AC Drives 315to1400kW@400V 400to2000Hp@480V 250to1500Hp@600V 200to1500kW@690V PowerFlex 750-Series AC Drives Ratingsto250kW/350Hp Ratings to 1500 kW / 2000 Hp 17
  • 18. Value Delivered Faster Time to Market $ $$ Lower Total Cost of Ownership Improved Asset Utilization Enterprise Risk Management 18
  • 20. Original Hardwired System Typically configured using:  Two different software tools  Two different cables or converters  Sometimes by two different people 20
  • 21. Early Networks Same as hardwired system  Typically configured using two different software tools  Two different cables or converters  Sometimes by two different people 21
  • 22. Use of Dual Networks Typically configured using two different software tools 22
  • 23. Typical Single Network Today Typically configured by one person using two different software tools 23
  • 24. Integrated Software Today Single Software Tool  Configure network i/o connection to the drive One time, in One place & by One person  Eliminates potential for user error when configuring network i/o 24
  • 25. Introduction to WEG Motors 25
  • 27. 27 Global Presence 27 > Distributors & Agents in over 85 countries > Over 1100 Service Centers covering all 5 continents > Sales to over 110 countries Factories in 5 countries Commercial branches in 22 countries
  • 28. Employees 28 28 25/08/2016 14,159 15,292 19,446 20,974 22,716 8,343 9 7,808 409 3,542 1961 1970 1980 1990 2009 2010 2011 2012 2013 2014 3542 7808 8343 Outside Brazil Brazil 12,587 13,545 17,549 18,664 19,861 1572 1747 2310 2855 1897
  • 30. 30 25/08/2016 Products • Three phase TEFC / ODP motors / output ratings up to 1200kW (1650HP) Types: * General Purpose * Explosion Proof * Brake Motors * Inverter Duty * Saw Arbor * Pump Motors * Others • Single Phase TEFC / ODP motors / output up to 9.2kW (12.5HP) Types: * General Purpose * Farm Duty * Multi-Mounting Aluminum frame motors * Appliance Motors * Ventilation / Others Low Voltage Industrial Motors
  • 31. 31 25/08/2016 Products • Three Phase TEFC / ODP Induction Motors - Master Line, frames from 280 to 1800, voltages up to 15kV; - H Line, enclosed, frames from 315 to 630, voltages from 220V to 11kV; - DC Motors, frames up to 1800. Applications: * Mining * Sanitation * Steel Plants * Cement * Pulp and Paper * Petrochemical * Cooling Systems Medium and High Voltage Motors
  • 33. 33 25/08/2016 MOTORS Machining Center In operation MOTORS Plant VI - Frames: 160, 180, 200 In operation MOTORS Motors - 355 W21 + HGF up to 400 and GTA In operation ENERGY New Steel Plate Frame Fabrication In operation AUTOMATION Panel Shop Buildings - In operation AUTOMATION New Automation Building To be concluded in 2009> Extension of the capacitors factory and new line of contactors (CWC): US$ 2 Million > Powder coatings production capacity increase: US$ 3 Million (2007) + US$ 7 Million Main Investments - 2014 / 2015 (Brazil)
  • 34. 34 25/08/2016 China Investments in the production capacity of the following motor lines already available: • W21: frame sizes 80 up to 355 • HGF: frame size up to 630 • MGF: frame sizes 315 up to 1000 Main Investments Outside Brazil - 2012 / 2013
  • 35. 35 25/08/2016 Main Investments Outside Brazil - 2012/2013 First Stage • Production of MV & HV electric motors (M and S Lines) • Frame sizes: 355 up to 1600 • Investments: US$ 50 Million (To be concluded in 2010) Second Stage • Production of Transformers and H Line • Investments: US$ 60 Million (To be concluded in 2013) New Manufacturing Plant In India
  • 36. 36 25/08/2016 References - OEM Ventilation • FläktWoods • Springer Carrier • Riox • Howden • Elta Fans • Zitron • Penn Ventilator • Relopa • Sodeca
  • 37. 37 25/08/2016 • ITT Industries • Sterling • Alfa Laval • Gusher Pumps • Goulds Pumps • Hidrostal • ABS • Envirotech • Ebara References - OEM Pumps • Sulzer • Kirloskar Brothers Limited • KSB • Ingersoll-Dresser Pumps • Grundfos • Weir Pumps • Flowserve • Tsurumi Pump • Marelli Pumps • Scot Pump
  • 38. 38 25/08/2016 • Ingersoll Rand • Schulz • Atlas Copco • Puska • Alup • Sullair • Champion • Campbell Hausfeld • Mitsui Seiki • CompAir • Boge Kompressoren • DeVilbiss Air Power Company • Hitachi • Betico References - OEM Compressors
  • 39. References: Oil & Gas 25/08/2016 39 • Caltex • Sasol • Total • ENAP • PDVSA • ESSO • Petrobras • Saudi Aramco • Pemex • Ecopetrol • Cepsa • Sapref • PetroCanada • Repsol YPF • NION • Conoco • Pan American Energy • Dresser Rand • Dow Chemical
  • 40. 40 25/08/2016 Contracts with OEM‘s and End Users • Metso Minerals • CompAir • Atlas Copco • FläktWoods • Soler & Palau • Cenibra • Epal • Cargill • Alfa Laval • Alup Kompressoren • Usiminas • Votorantim • Europac • Ingersoll Rand • Sandvik • Suzano • Boge • Sadia • Weir • CSN • Bosch • ABS • Klabin • Cosipa
  • 41. 41 25/08/2016 • Bechtel • Tecnimont • Fluor • Foster Wheeler • Black & Veatch • Alstom • Cegelec • Technip • Saipem • Snamprogetti • Placer Dome • Kvaerner • EFACEC • Aker Kvaerner • SNC - Lavalin • DRA • Techint • CH2Mhill References - Engineering Companies
  • 42. Question & Answers Thank You for Your Valuable Time 42
  • 43. Lahore, Pakistan Headquarters South East Asia 19 Km Main Multan Road Lahore, Punjab 54660 Pakistan Phone : + 92 42 111 940 940 Dubai, UAE Headquarters Middle East And Asia Office FZS1 BD04, Jebel Ali Free Zone PO Box 18590, Dubai United Arab Emirates Phone: +971 4 88 60 277 Exton, USA Headquarters Americas 180 Sheree Boulevard, Suite 1400 Exton, PA 19341 United States of America Phone +1 610 458 8700 Regional Offices and Global Headquarters