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Energy Savings with VFD Optimization

This document discusses ways to save energy and improve efficiency, including through proper maintenance, removing excess capacity, and improving equipment efficiency. It focuses on using a Matrix Lepro Seva fuzzy logic controller to optimize cooling tower fan operation at a plant. The controller allows a fan motor to operate at the minimum required torque rather than a set speed, saving an estimated 35% of energy for that fan. Benefits include equipment running cooler and longer lifespan, with savings of 30-50% estimated compared to a variable frequency drive.

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Han Han
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76 views40 pages

Energy Savings with VFD Optimization

This document discusses ways to save energy and improve efficiency, including through proper maintenance, removing excess capacity, and improving equipment efficiency. It focuses on using a Matrix Lepro Seva fuzzy logic controller to optimize cooling tower fan operation at a plant. The controller allows a fan motor to operate at the minimum required torque rather than a set speed, saving an estimated 35% of energy for that fan. Benefits include equipment running cooler and longer lifespan, with savings of 30-50% estimated compared to a variable frequency drive.

Uploaded by

Han Han
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

MATRIX LEPRO SEVA

HOW TO SAVE
THEEARTH

WAYS OF SAVINGS
1) IMPROVETHEEFFICIENCYOF
EQUIPMENT
2) REMOVINGEXCESSCAPACITY:a) Downsizing of Equipment
b) Variable Frequency Drive or VFD
c) Matrix Lepro Seva

3) PROPERMAINTENANCE

Affinity Lawson VFD


A. Flow is proportional to shaft
speed:

B. Pressure or Head is proportional


to the square of shaft speed:

C. Power is proportional to the cube


of shaft speed:

In order to save power using VFD, speed must be reduced. However, in doing so flowrate
and pressure are affected. This could affect equipment output or reliability.

Major Components
Energy Storage Capacitors
Rectifier
DCLink
Insulated-Gate Bi-Polar
Transistor(IGBT) Switches
Logic Controls

MATRIX LEPRO SEVA


adopts automatic load compensations control
technology
computer tracking fuzzy control theory
detect system load automatically, scan at 10000
times per second
make real time optimal control for the original
system
Using self proprietory software

SAVED 30% TO 50%


Oversizing
Inertia of Motor
Power Factor
Copper Losses
Hydraulic Losses

TOTALSAVINGS

10 to 15
15 to 20
5 to 8
2 to 3
2 to 3

%
%
%
%
%

30 TO 50 %

Title: Optimisation of Cooling Water Fan (XX-23030A) Implementation of Fuzzy LogicController (API
West)
Must NOT be a Merck SigmaCertification project.

K
Kaaiizzeenn C
Cllaassss iiffiiccaattiioonn::

Safety

Quality

Cost

Delivery

5S

Operation:

Problem:

Action Taken:

Results / Benefits:

Cooling Tower Fans (XX23030A/XX-23030B/XX23650/XX-23651) - API West,


operating with Two Fans at
High Speed and One Fan at
Low Speed Mode.

Currently Cooling Tower Fans (XX23030A/XX-23030B/XX-23650/XX-23651),


operated with Two fans at High Speed and
One fan at Low Speed Mode with
increased Energy cost.

Cooling Tower Fan XX-23030A Fuzzy Logic Controller was installed


to Control the required Torque for
the Fan Motor, and deriving Energy
Saving. The average consumption
83 kW (before) was reduced to 55
kW (Present), a Reduction by 35 %.
The Temperature of Cooling Water
Supply and Return was monitored,
with no abnormalities.

By optimising Cooling tower fan (XX23030A) with Fuzzy Logic Controlller, a


Total saving of:
1,93,158 kWh/ Year,
SGD 50,221/ Year.
shall be achieved.

Average Amperes
Before Kaizen (Photo/Drawing)
134 AExternal
@83 kW

Average Amperes 87
After Kaizen (Photo/Drawing) Internal
A @ 55 kW

TeamLead/ Members: Chew Eng Cheow; Ong, Tuan Lock; Sanusi, Anuar; Ghani, Noorman; Gasper, Danny; Sundaram, Suresh Kumar (ES).
Approved by: Jakkariya Mohamed, Syed Yousuff

Actual Current Measurements


KWHMeter
21.5 Amperes
Supply Side

LEPRO
52.8 Amperes
Motor Side

Motor
45KW
80FLA

Actual Pressure Readings

Pump with Lepro

Pump without Lepro

Since the motor speed iskept constant, there isno change seen in both flow
and pressure with Lepro.

40%Consumption Reduction

COM PARI SONS


V FD

MATRIX LEPRO SEVA

Motor runshotter
Bearings wear down faster
Motor Insulation damage
Pumpsmore stress
Motor life span shorter
More maintenance required
Savings 10 to 15%

Motor runscooler
Bearings last longer
Insulationslast longer
Pumpslessstress
Motor life span longer
Lessmaintenance required
Savings 30% to 50%

Emergency Switchover Configuration

Existing
Y-DStarter

Panelboard

Double
Throw
Switch

Motor

LEPRO

Applicable to Fixed Speed Loads


Chilled Water Pumps
Condenser Water Pumps
Cooling Tower Fans
Ventilation Fans
Exhaust Fans
Air Handling Units
Drinking Water Treatment
Pumps
Waste Water Treatment
Pumps
Sewage Treatment Blowers
Deepwell Pumps
Etc

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