REPORT ON VFD FOR HT MOTOR

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 SECTION -II
REPORT ON VFD FOR HT MOTOR

VFD FOR HT MOTOR

M/s. Birla Tyre plant has 7 nos of Banbury motor i.e. 5 nos of HT motor and
2 nos of LT motor in Existing plant.

Banbury#1& Banbury#3 has 2 HT motor of 1500HP &1000HP.

Banbury#2, Banbury#5 has 2 HT motor of 1500HP &1000HP, AC mill of 262kw

Ac motor.

Banbury#4 has HT motor of 1500HP, AC mill of 262kw Ac motor.

Out of 7 banbury motor 2 LT motors are VFD drive and HT motors are slip ring
resistance starter.

Variable frequency drives (VFDs) are electronic devices that control the
speed of the motor by controlling the frequency of the voltage at the motor.
These devices are used in a wide range of the applications and are able to
provide constant-torque and variable-torque operation, and in the last few years
have been developed to achieve position control.

Working Principle

Single-speed drives start motors abruptly, subjecting the motor to high

torque and current surges up to 10 times the full-load current. Variable
frequency drives offer a soft start, gradually ramping up a motor to operating
speed. VFD minimizes the mechanical and electrical stress on the motors and
can reduce maintenance and repair costs and extend the motor life. Energy
savings from variable-frequency drives can be significant. For example with
centrifugal fan even a small reduction in motor speed can reduce fans energy
use by as much as 50%. For example a 25 hp motor running 23 hours per day
(2 hours at 100% speed; 8 hours at 75%: 8 hours at 67%; and 5 hours at 50%)

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a variable frequency drives can reduce energy use by 45%. Because benefits
vary depending on operating speed of the system hence it is important to
calculate benefits for each application before specifying a variable frequency
drive. As the speed is varied as per the spindle speed requirement by
optimizing the motor speed will reduce the power consumption per kg of yarn
processed. Considering the above facts and for reducing electricity
consumption in the doubling machines, it is suggested to install VFD for
machines.

BENEFITS OF USING VARIABLE FREQUENCY DRIVES

Energy efficiency

In a conventional compressor setup, the compressor is powered by a

motor directly connected to a power supply. Regardless of the requirements
of the compressor, the motor runs at a fixed speed, consuming a lot of
energy. By using a variable frequency drive, the motor rotation can be
adjusted according to the requirements of the compressor. So, depending
upon the output requirement, the input can be altered, resulting into energy
savings.

Improved load control

In addition to energy efficiency, VFDs are also widely used for improving
load controls. VFDs allow for smooth operation and acceleration as they
prevent load swings in traverse motions.

Lower starting current

VFD powered motors use lesser starting current and do not significantly
impact the torque, resulting into less stress on the energy grid. Lower
energy fluctuations also reduce the probability of electric equipment failure.

Controlled Stopping

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 Just as important as controlled acceleration, controlled stopping can be
important to reduce mechanical wear and tear -- due to shocks to the
process or loss of product due to breakage.

Adjustable Operating Speed

Use of an Adjustable Speed AC Drive enables optimizing of a process,

making changes in a process, allows starting at reduced speed, and allows
remote adjustment of speed by programmable controller or process
controller.

All Banbury drives to be installed with HT VFD's with new motor. Possibility
of using existing motors with VFD to be investigated. Installation of VFD
with energy efficient motor will result in major energy saving.

Types of Variable Frequency Drives

There are three common Variable Frequency Drives (VFDs) that offer both
advantages and disadvantages depending on the application they are used
for. The three common VFD designs used include: Current Source Inverter
(CSI), Voltage Source Inverter (VSI), and Pulse Width Modulation (PWM).
However, there is a fourth type of VFD called Flux Vector Drive, which is
emerging in popularity among end-users for its closed-loop control feature.
Each VFD consists of a Converter, DC Link and Inverter section but how
each one is constructed varies from drive to drive. Although the sections of
each VFD are similar, they require a variation in circuitry in how they supply
the frequency and voltage to the motor.

Current Source Inverter (CSI)

A Current Source Inverter (CSI) is a type of variable frequency drive (VFD)

which converts incoming AC voltage and varies the frequency and voltage

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 supplied to the AC Induction Motor. The general configuration of this type
of VFD is like that of other VFDs in that it consists of a Converter, DC Link,
and Inverter. The converter part of the CSI uses silicon-controlled rectifiers
(SCRs), gate-commutated thyristors (GCTs) or symmetrical gate-
commutated thyristors (SGCTs) to convert the incoming AC voltage to a
variable DC voltage. In order to maintain the correct voltage to frequency
(Volt/Hertz), the voltage must be regulated by the correct sequencing of
the SCRs. The DC Link for this type of variable frequency drive uses an
inductor to regulate the current ripple and to store the energy used by the
motor. The inverter, which is responsible for converting the DC Voltage
back to an AC sine-like waveform, comprises of SCRS, gate turn-off
thyristors (GTOs) or symmetrical gate-commutated thyristors (SGCTs).
These thyristors behave like switches which are turned on and off to
create pulse width modulation (PWM) output that regulates the frequency
and voltage to the motor.

CSI variable frequency drives regulate current, require a large internal

inductor and a motor load to operate. An important note about CSI VFD
designs is the requirement of input and output filters which are necessary
due to high harmonics in the power input and poor power factor. To work
around this issue, many manufacturers implement either input
transformers or reactors and harmonic filters at the point of common
coupling (users electrical system connected to the drive) to help reduce
the effects harmonics have on the drive system. Of the common VFD drive
systems, CSI VFDs are the only type of drives that have regenerative
power capability. Regenerative power capability means that power is
driven back from the motor to the power supply can be absorbed.

Advantages of CSI

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 Regenerative power capability
Simple circuitry
Reliability (Current Limiting Operation)
Clean current waveform

Disadvantages of CSI

Motor cogging when PWM output is below 6 Hz

Inductor used are large and costly
Large power harmonic generation sent back into power source
Dependent on motor load
Low input power factor

Voltage Source Inverter (VSI)

The converter section of the VSI is similar to the converter section of the
CSI in that the incoming AC Voltage is converted into a DC Voltage. The
difference from the CSI and VSI converter section is that the VSI uses a
diode bridge rectifier to convert the AC Voltage to DC Voltage. The DC
Link of the VSI uses capacitors to smooth out the ripple in the DC voltage
and to also store energy for the drive system. The inverter section is
comprised of insulated gate bipolar transistors (IGBTs), insulated gate-
commutated thyristors (IGCTs) or injection-enhanced gate transistors
(IEGTs). These transistors or thyristors behave like switches which are
turned on and off to create a pulse width modulation (PWM) output that
regulates the frequency and voltage to the motor.

Advantages of VSI

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 Simple Circuitry
Can be used with applications requiring multiple motors
Not dependent on load

Disadvantages of VSI

Large power harmonic generation into power source

Motor cogging when PWM output is below 6 Hz
Non-Regenerative operation
Low power factor

Pulse Width Modulation (PWM)

The Pulse Width Modulation (PWM) Variable Frequency Drive (VFD) is

among the most commonly used controllers and has proven to work well
with motors that range in size from 1/2HP to 500HP. Most PWM VFDs
are rated for 230V or 460V, 3-Phase operation, and provide output
frequencies in the range of 2-400Hz. Like the VSI VFD, the PWM VFD
uses a diode bridge rectifier to convert the incoming AC voltage to a DC
voltage. The DC Link uses large capacitors to remove the ripple evident
after the rectifier and creates a stable DC bus voltage. The six-step
inverter stage of this driver uses high power rated IGBTs which turn on
and off to regulate the frequency and voltage to the motor. These
transistors are controlled by a microprocessor or motor IC which
monitors various aspects of the drive to provide the correct sequencing.
This produces a sine-like waveform output to the motor. So how does
turning a transistor on and off help create the sine-like wave output? By
varying the voltage pulse width you are obtaining an average power
which is the voltage supplied to the motor. The frequency supplied to the
motor is determined by the number of positive to negative transitions per
second.

Advantage of PWM

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 No motor cogging
Efficiencies from 92% to 96%
Excellent input power factor due to fixed DC bus voltage
Low initial cost
Can be used with applications requiring multiple motors

Disadvantages of PWM

Non-Regenerative operation
High frequency switching may cause motor heating and insulation breakdown

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