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Anil Dave
Atlas Copco Compressor Sales-Pune
4th September 2010
Compressed Air Energy Conservation, CII Chennai
Variable Speed Drive Compressors
2 4th Sept 2010
AGENDA
What is VSD.
Why is VSD required.
How VSD works.
Benefits of VSD.
Who & When should opt for VSD compressor.
References
Leadership in Energy and Environmental Design (LEED Certification)
3 4th Sept 2010
VSD – ADVANCED TECHNOLGY
TO REDUCE ENERGY CONSUMPTION
4 4th Sept 2010
What is VSD Compressor
VSD or Variable Speed Drive Compressor is a compressor – which varies the capacity (FAD) based on the Air Demand pattern and – consumes power proportional to Air Demand.– thereby saving energy which would have gone waste in case of Fixed speed
compressor.
5 4th Sept 2010
Why VSD is required?
6 4th Sept 2010
Why VSD is required?
Because, not all applications demand continuous full load.
Because a plant may have intermittent Compressed Air Applications.
Because Air demand pattern vary within a Day (e.g.Lunch time, Air demand is negligible)
Because plants have 1 or 2 days off, so negligible air demand.
Because different production shifts do not consume same amount of Air (e.g. night shift production may need less Compressed Air then day shift.)
Finally, because we pay for Power.
7 4th Sept 2010
Cost Allocation
Investment cost consists of:– Purchase price– Installation cost
Investment cost depends on:– Proper selection of compressor
Capacity (FAD)PressureOperating Pattern
Energy cost is determined by:– Annual operating time– Load/unload utlisation– Unit energy cost.
8 4th Sept 2010
Energy savings Facts & Figures
70% of industrial electrical consumption is for electric motors
compressed air consumes 10 to 20 % of industrial electrical capacity
this accounts for over 55 million tons of CO2 emissions per year
Electricity comprises more the 70% of the total life cycle cost of acompressor
70% of industrial electrical consumption is for electric motors
compressed air consumes 10 to 20 % of industrial electrical capacity
this accounts for over 55 million tons of CO2 emissions per year
Electricity comprises more the 70% of the total life cycle cost of acompressor
The cost of compressed air…it’s not free
9 4th Sept 2010
VSD – Variable Speed Drive
10%20%
energyenergy
maintenancemaintenanceinvestmentinvestment
> 70%
Energy savings Facts & Figures
10 4th Sept 2010
VSD – Variable Speed Drive
With VSD energy savings of 35% or more can be realized over traditional compressor regulation…
Energy savings – the Potential
11 4th Sept 2010
VSD – Variable Speed Drive
Key factor: fluctuation in air demand
Defines operation & power consumption
Air consumption in a compressed air systemis proportional to the amount of equipmentin use depends on the hour of the day or the dayof the week
Key factor: fluctuation in air demand
Defines operation & power consumption
Air consumption in a compressed air systemis proportional to the amount of equipmentin use depends on the hour of the day or the dayof the week
Slide 6 of 34
Energy savings , Where do they come from ?
12 4th Sept 2010
VSD – Variable Speed DriveWHY VSD ?
Match compressed air supply to exact demand …
… with minimum energy spendings.
MondayTuesdayWednesdayThursdayFridaySaturdaySunday
l/s
hour
50
100
150
200
250
Typical air demand pattern
13 4th Sept 2010
Air Demand Profile n°3
0
20
40
60
80
100
120
140
0:15
1:30
2:45
4:00
5:15
6:30
7:45
9:00
10:1
5
11:3
0
12:4
5
14:0
0
15:1
5
16:3
0
17:4
5
19:0
0
20:1
5
21:3
0
22:4
5
0:00
Time
Cap
acity
in l/
s
SundayMondayTuesdayWednesdayThursdayFridaySaturday
Air Demand Profile n°1
0
20
40
60
80
100
1200:
15
1:30
2:45
4:00
5:15
6:30
7:45
9:00
10:1
5
11:3
0
12:4
5
14:0
0
15:1
5
16:3
0
17:4
5
19:0
0
20:1
5
21:3
0
22:4
5
0:00
Time
Cap
acity
in l/
s
SundayMondayTuesdayWednesdayThursdayFridaySaturday
Air Demand Profile n°2
0
20
40
60
80
100
120
140
0:15
1:30
2:45
4:00
5:15
6:30
7:45
9:00
10:1
5
11:3
0
12:4
5
14:0
0
15:1
5
16:3
0
17:4
5
19:0
0
20:1
5
21:3
0
22:4
5
0:00
Time
Cap
acity
in l/
s SundayMondayTuesdayWednesdayThursdayFridaySaturday
Peak load determines the compressor selection
Average load determines the
compressor’spower
consumption
88%
12%
WHY VSD ? FEW TEST RESULTS
VSD – Variable Speed Drive
14 4th Sept 2010
Why VSD – The Conclusion
For Variations in demand VSD is ultimate Energy Saver
15 4th Sept 2010
How VSD works - Basic control PhilosophyFREQUENCY CONVERTER
ELEKTRONIKON MK V
PRESSURE SENSOR
SCREW ELEMENT VSD MAIN MOTOR
AIR
NET
AIR DELIVERY
SET POINT
The system targets a constant delivery pressure (setpoint)
16 4th Sept 2010
How VSD works - Animation
17 4th Sept 2010
Fixed Speed vs VSD compressor
18 4th Sept 2010
Modulating Control Variable Speed Control
POWER V/S CAPACITY COMPARISONSUCTION MODULATION CONTROL & VSD CONTROLBENEFIT 1 : POWER CONSUMED = DEMAND REQUIRED
VSD Benefits
19 4th Sept 2010
Soft start and stop operation…
no starting current peaks
soft starting and stopping at a controlled acceleration and deceleration time
no penalties for starting current peaks
unlimited restarting meaning complete elimination of unload energy consumption
less stresses on electrical and mechanical components
Starting Current Comparison
0
100
200
300
400
500
600
700
800
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
seconds
% F
ull L
oad
Cur
rent
Star DeltaDOL
Soft StarterVSD
VSD – Variable Speed DriveBENEFIT 2
20 4th Sept 2010
BENEFITSNo pressure over-shootsLess energy cost…lower working pressureHigher process stability
Customer ProcessPressure
Pressure - VSD -1.45 psigPressure - centrifugal - 4 psigPressure - standard load-unload -7 psig or more!
7 psig
VSD – Variable Speed Drive
BENEFIT 3 :Precise pressure control…stableprocess…constant pressure control
21 4th Sept 2010
VSD – Variable Speed Drive
Electro Magnetic Compatibility
It is defined as the “compatibility of electronic equipment with the electromagnetic environment, in which they are working”
There are two parts of EMC:
-The equipment should be so designed that it does not interfere with the working of other equipment.This constitutes control
-The equipment should not be disturbed by electromagnetic emissions by other equipment. This is called immunity
VSD equipment, if uncontrolled, emits electromagnetic waves which will interfere with instrumentation signals and other equipment. If unprotected it is also susceptible to external electromagnetic waves.
BENEFIT -4
22 4th Sept 2010
CONCLUSIONSVSD compressors are designed for maximum reliability– 100 % designed and tested for Electro-Magnetic Compatibility
EMC certificate of EU – the most stringent standard
Line reactor and RFI filter included
All motors are designed for VSD and are protected against bearing currents
– Integrated controls for compressor + converter
Converter is protected against overload by ElektronikonStart/stop and pressure control by the converter and the Elektronikon are fine-tuned during design
– The compressor is mechanically adapted for the complete speed range
No speed windows for vibrations
Changes to oil circuit for the right oil pressure/temperature
VSD – Variable Speed Drive
23 4th Sept 2010
VSD – Variable Speed DriveBENEFITS
Energy savings
Low starting currents
No peak torques
Constant pressures
Low average rpms
High power factors at all loads
Electronic gearing
Large turn down ( Can be used for min – max flow rates )
Integrated design
24 4th Sept 2010
VSD – Variable Speed Drive
Atlas Copco is market leader in VSD screw compressors, Supplied first VSD screw compressor in 1994, Sixteen years experience in VSD screw compressors
Atlas Copco manufacture integrated VSD screw compressors in various capacities in lubricated and oil free range
Today, 25 out of 100 screw compressors sold are VSD and expected to be 40 % in next three years
ATLAS COPCO VSD
25 4th Sept 2010
Who and When should opt for VSD Compressor
Plants having varying demand of Air (per day / per week basis)
Plants having multiple Piston compressor installations.
Plants having very old compressor installations, thereby consuming more energy.
Ideally one should opt for VSD compressor while setting up a new plant. (1 compressor out of the bank can be VSD)
When power cost is very high.
In any case, its never too late to save Energy.
26 4th Sept 2010
How Atlas Copco can help you
MBoxLite: By studying your plant Air consumption pattern with a very good Tool called MBoxLite. It measures the Air demand pattern and suggests possible saving.
VSD Calculator program : Payback period can be arrived at by entering basic data provided by plant user.
27 4th Sept 2010
References -Two Random cases
1 Rational Business Corporation, Bahal Garh Chowk,Sonepat 132101
Around 10 kwh/hour, Earlier customer was using competiton screw air compressor.
Additional Investement for VSD Rs. 3,00,000/-
12 months Mr. Ashok Kumar Gupta, Joint Managing Director, ashok@desmat.com, 09811030019
2 MERINO PANEL PRODUCTS LTD, 44KM STONE, DELHI-ROHTAK ROAD, VILLAGE ROHAD, BAHADHURGARH-HARYANA
Around 12 kwh/hour, Earlier customer was using reciprocating air compressors.
Additional Investement for VSD Rs. 2,50,000/-
8 Months Mr. B C Dua, Technical GM, merinorohad@merinoindia.com, 09812027334,
Contact details of the company
S No Company at which
implemented
Investment (Rs Lakhs)
Approx Payback Period
(Months)
Energy Saving achieved
28 4th Sept 2010
Partial List of customers benefited with VSD -2009
29 4th Sept 2010
LEED Certificate for VSD
30 4th Sept 2010
Reach us
Toll Free Number : 1800 200 0030
www.atlascopco.com
31 4th Sept 2010
Committed tosustainable productivity.
32 4th Sept 2010
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