Speed Control

Speed Control and Customer Benefits
Structure
1. 2. 3. 4. 5.
2 | Speed Control & Customer Benefits - Ralph Hfert |
What does Variable Speed mean? Why Variable Speed? Speed Control versus Throttle Control Speed Control versus Inlet Guide Vane Control Advantages of Voith Variable Speed Couplings
1. What does Variable Speed mean?

What is being Speed controlled : Pumps Fans
Motor
(constant speed)
air
Compressors Conveyor belts Coal mills
Variable Speed means : Change of Speed of the driven Machine
2. Why Variable Speed?

Generally
Energy Saving Reduction of Emission To adapt Pressures and Flows to the Process Conditions
To minimize Wear of the Driven Machine To facilitate Start-up of the Driven Machine Reduction of Maintenance Costs
2. Why Variable Speed?

Especially for Compressor Drives
Varying Gas Compositions (Flash Gas Compressors, Injection

Compressors, Export Gas Compressors ...)
Varying Process Conditions (DHDT Recycle Compressors,

Refrigeration Compressors, BOG Compressors ...)
Varying Product Demand (Pipeline Compressors ...)

Speed Control makes the whole Plant / Process more flexible
3. Speed Control vs. Throttle Control

Throttle Control
Advantages
Low Capital Costs Only one Control Element
Disadvantages
High Maintenance Low Reliability and Availability Very low Efficiency High Noise Level High Stress for the entire System
3. Speed Control vs. Throttle Control
3. Speed Control vs. Throttle Control BFP Characteristic - Throttle Control

150 140 130 120 110 100 Pump @ Design Speed (105 %) Test
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0
Boiler Characteristic Pump Efficiency
10
20
30
40
Flow [%]
50
60
70
80
90
100
110
3. Speed Control vs. Throttle Control BFP Characteristic - Throttle Control 150
140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 110 Pump Efficiency Boiler Characteristic Pump @ Design Speed (105 %) T 100 Test
Pressure [%]
Flow [%]
140 130 120 110 100 Pump @ Design Speed (105 %) Test
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0
10
20
30
40
Flow [%]
50
60
70
80
90
100
110
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0
10
20
30
40
50
60
70
80
90
100
110
Flow [%]
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0
10
20
30
40
50
60
70
80
90
100
110
Flow [%]
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0
10
20
30
40
50
60
70
80
90
100
110
Flow [%]
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0
10
20
30
40
50
60
70
80
90
100
110
Flow [%]
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 110 Boiler Characteristic Pump Efficiency
Flow [%]
3. Speed Control vs. Throttle Control BFP Characteristic - Speed Control 150
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0
10
20
30
40
50 60 Flow [%]
70
80
90
100
110
140 130 120 110 100 Pump @ nominal Speed (100 %) S100 Pump @ Design Speed (105 %) Test
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0
Boiler Characteristic Pump Efficiency @ 100 % Speed
10
20
30
40
50 60 Flow [%]
70
80
90
100
110
140 130 120 110 100 Pump @ nominal Speed (100 %) Pump @ Design Speed (105 %) Test
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0
10
20
30
40
50 60 Flow [%]
70
80
90
100
110
140 130 120 110 100 Pump Speed Pump @ Design Speed (105 %) Test
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0
10
20
30
40
50 60 Flow [%]
70
80
90
100
110
140 130 120 110 100 Pump Speed Boiler Characteristic Pump Efficiency Pump @ Design Speed (105 %) Test
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 Flow [%] 70 80 90 100 110
140 130 120 110 100 Pump @ Design Speed (105 %) Test Pump Efficiency
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0
Pump Speed
Boiler Characteristic
10
20
30
40
50 60 Flow [%]
70
80
90
100
110
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0 10 20 Pump Speed
Pump Efficiency
Boiler Characteristic
30
40
50 60 Flow [%]
70
80
90
100
110
140 130 120 110 100
Pump Speeds
Pump @ Design Speed (105 %) Test
Pressure [%]
90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 Boiler Characteristic Pump Efficiency Curves
S100
Flow [%]
100
110
4. Speed Control vs. Inlet Guide Vane Control

Inlet Guide Vane Control
Advantages
Low Capital Costs Only one Control Element
Disadvantages
High Maintenance Low Reliability and Availability Low Efficiency Erosion and mechanical Wear
5. Advantages of Voith Variable Speed Couplings Experience

Market Leader 1,000,000 Installations

Combined Cycle Power Plants Conventional Power Stations More than
500 Units Installations
More than S - Couplings 5000 Units Installations RK Couplings

Compressor Drives More than
150 Units Installations, more than 100 of them are VORECONs
5. Advantages of Voith Variable Speed Couplings Technical Advantages

Separation of Drive Train Shock and Vibration Damping
OIL

Fan rated power: 3123 kW (4188 HP) @ 710 RPM With Fluid Coupling Torque, Speed [%] 50 100 150
No Load Start-Up
Without Fluid Coupling Torque, Speed [%] 100 150 200 600 % I IN
I 600 % IN
Motor speed
Motor & Fan speed
100 %
50
Fan speed
100 % 0 10 Time [sec] 20
25 Time [sec]
50

Integral Lube Oil System
Baseframe designed as Lube Oil Reservoir

Application under severest environmental Conditions
5. Advantages of Voith Variable Speed Couplings Economic Benefits

1.
Reliabilty, Availability, MTBF

2. Availability based on Overhaul
Reliability based on Failures
Reliability: Operating Hours - Non-Availability Time Operating Hours = 0.9994 99,94 % 3.
Operating Hours between Overhauls - Non Availability Time Operating Hours between Overhauls = 0.9983 = 99,83 %
Mean Time between Failures (MTBF) Operating Hours No. of reported Failures
MTBF:
= 281 818 Hours (over 24 Years)

Simple, compact, robust
Very easy Maintenance
only a 4-20 mA Signal is necessary to operate the Unit

Efficiency

Load Load Pattern [h/yr] No. of Pumps Power Savings [kW] Energy Savings [kWh]
Payback Time
Test 420 MW 415 MW 410 MW 400 MW 10 3330 1330 3000 330 2 2 2 2 2 -58 180 189 197 213 -1160 1 198 800 502 740 1 182 000 140 580 3 022 960 kWh x S $ 0.07/kWh = S $ 211,607 or US $ 130,000 or Baht 4.8 million S $ 100,00 3 S $ 300,00 or US $ 180,000 or Baht 6.7 million US $ 0.043 US $ 130,000 US $ 180,000
Cost Savings per year [S$] Cost per Coupling [S$] No. of Couplings Total Cost [S$] Energy Cost per kWh: Total Cost Savings per Year: Cost per 3 Units:
17 Months

Long Life
5. Advantages of Voith Variable Speed Couplings
Experience
Technical Advantages
Economic Benefits

Speed Control

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Speed Control and Customer Benefits

1. What does Variable Speed mean?

Compressors Conveyor belts Coal mills

Variable Speed means : Change of Speed of the driven Machine

2. Why Variable Speed?

2. Why Variable Speed?

Varying Gas Compositions (Flash Gas Compressors, Injection

Varying Process Conditions (DHDT Recycle Compressors,

Varying Product Demand (Pipeline Compressors ...)

3. Speed Control vs. Throttle Control

7 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

3. Speed Control vs. Throttle Control BFP Characteristic - Throttle Control

8 | Speed Control & Customer Benefits - Ralph Hfert |

Boiler Characteristic Pump Efficiency

9 | Speed Control & Customer Benefits - Ralph Hfert |

10 | Speed Control & Customer Benefits - Ralph Hfert |

Boiler Characteristic Pump Efficiency

11 | Speed Control & Customer Benefits - Ralph Hfert |

Boiler Characteristic Pump Efficiency

12 | Speed Control & Customer Benefits - Ralph Hfert |

Boiler Characteristic Pump Efficiency

13 | Speed Control & Customer Benefits - Ralph Hfert |

Boiler Characteristic Pump Efficiency

14 | Speed Control & Customer Benefits - Ralph Hfert |

Boiler Characteristic Pump Efficiency

90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 110 Boiler Characteristic Pump Efficiency

15 | Speed Control & Customer Benefits - Ralph Hfert |

16 | Speed Control & Customer Benefits - Ralph Hfert |

Boiler Characteristic Pump Efficiency

17 | Speed Control & Customer Benefits - Ralph Hfert |

Boiler Characteristic Pump Efficiency @ 100 % Speed

18 | Speed Control & Customer Benefits - Ralph Hfert |

Boiler Characteristic Pump Efficiency

19 | Speed Control & Customer Benefits - Ralph Hfert |

Boiler Characteristic Pump Efficiency

90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 Flow [%] 70 80 90 100 110

20 | Speed Control & Customer Benefits - Ralph Hfert |

21 | Speed Control & Customer Benefits - Ralph Hfert |

22 | Speed Control & Customer Benefits - Ralph Hfert |

Pump @ Design Speed (105 %) Test

90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 Boiler Characteristic Pump Efficiency Curves

23 | Speed Control & Customer Benefits - Ralph Hfert |

4. Speed Control vs. Inlet Guide Vane Control

5. Advantages of Voith Variable Speed Couplings Experience

25 | Speed Control & Customer Benefits - Ralph Hfert |

5. Advantages of Voith Variable Speed Couplings Experience

500 Units Installations

More than S - Couplings 5000 Units Installations RK Couplings

5. Advantages of Voith Variable Speed Couplings Experience

150 Units Installations, more than 100 of them are VORECONs

5. Advantages of Voith Variable Speed Couplings Technical Advantages

28 | Speed Control & Customer Benefits - Ralph Hfert |

5. Advantages of Voith Variable Speed Couplings Technical Advantages

Motor & Fan speed

100 % 0 10 Time [sec] 20

5. Advantages of Voith Variable Speed Couplings Technical Advantages

30 | Speed Control & Customer Benefits - Ralph Hfert |

Baseframe designed as Lube Oil Reservoir

5. Advantages of Voith Variable Speed Couplings Technical Advantages

31 | Speed Control & Customer Benefits - Ralph Hfert |

5. Advantages of Voith Variable Speed Couplings Economic Benefits

Reliabilty, Availability, MTBF

Reliability based on Failures