VARIABLE SPEED DRIVES

Dedan Kimathi University of Technology

Department of Mechanical Engineering

EMG 5221 Energy Management

Term Paper

Variable Speed Drives as Energy Saving Measures in Electric Motors

By

Emmanuel Kazungu Foleni

E023-01-0492/2018

7th June, 2022

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1.0 Technology Overview

An electric motor is a machine that transforms electrical energy into mechanical energy. Most
electric motors work by interacting between the magnetic field of the motor and the electric
current in a wire winding. According to Faraday's Law, this interaction produces a force in the
form of torque, which is applied to the motor's shaft. Electric induction motors operate at
constant speeds and are ideal for applications requiring a constant motor output speed. However,
in some applications, varying motor output speeds are preferable to better meet the needs of the
load. While conveyors are fine for a fixed speed, some applications, such as fans, pumps,
winders, and precision tools, are better suited to running at variable speeds [1].

A variable speed drive (VSD), also known as a frequency converter, adjustable speed drive, or
inverter, is an electronic device that regulates the electrical characteristics of a motor. As a result,
it can control the speed and torque of a motor, allowing it to better match the process
requirements of the machine it is driving. So, in applications where variable control is desired,
slowing down a motor with a VSD significantly reduces energy use. The benefits of using VSDs
include increased productivity as well as energy savings in pumps, fans, compressors, and other
equipment [2].

A VSD converts a fixed frequency incoming electrical supply into a variable frequency output.
This frequency variation allows the drive to control how the motor operates — a low frequency
for slow speed and a higher frequency for fast speed. The output can also be adjusted so that the
motor generates more or less torque as needed. As a result, the motor and drive combination
could be used to turn a large load at relatively slow speeds, or a lighter load at high speeds,
maximizing efficiency. VSDs are typically 92–95% efficient, with 5–8% losses due to increased
heat dissipation caused by high–frequency electrical switching and the additional power required
by electronic components [1]. The losses are usually more than compensated for by the savings
at the motor. With the introduction of new power devices and magnetic materials in recent years,
variable speed drive technology and the prominence of speed control of existing motors have
captured many people's attention.

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2.0 A Review on The Use of VSDs In Electrical Motors as An Energy Saving Measure
An important demand-side management initiative is improving industrial energy efficiency
through the use of modern technology. Cooling systems on South African mines were identified
as large electricity consumers in a study. The widespread adoption of variable speed drive (VSD)
technology has the potential to significantly improve energy efficiency. An energy audit of 20
large mine cooling systems was performed, and potential savings and feasibility indicators were
calculated [3]. A pilot implementation study on one mine was also conducted to experimentally
validate the estimated savings. It was demonstrated that large-scale VSD implementation on
mine cooling system pumps and fans is economically feasible. Annual electrical energy savings
of 144,721 MWh, or 32.2%, are possible [3]. It is possible to save $6,938,148 in annual costs and
reduce CO2 emissions by 132 million tons [3]. Implementing VSDs on mine chiller compressors
will also result in significant energy savings, but is not currently economically feasible. The pilot
study found a 29.9% reduction in electricity consumption [3].

3.0 Basic working principle of VSDs

Rectifiers convert the incoming alternating current (AC) supply to direct current (DC). The type
of rectifier used can vary depending on the drive's performance requirements. The amount of
harmonic content in the incoming supply will be influenced by the rectifier design. It can also
control the power flow direction. The rectified DC supply is then conditioned in the intermediate
circuit, which is typically comprised of inductors and capacitors. Over 98% of drives on the
market today use a fixed–voltage DC link [1]. The inverter then converts the rectified and
conditioned DC into a variable voltage and frequency AC supply. This is typically accomplished
with a semiconductor switch. The control unit finally sends and receives signals to the rectifier,
intermediate circuit, and inverter in order for the equipment to function properly.

Figure 1 Schematic Diagram of a VSD

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4.0 Applications of VSDs as Energy Saving Measures in Electric Motors

4.1 Fans
Although dampers are frequently used to regulate fan output, reducing fan speed is a much more
energy efficient way of achieving the same effect. The graph below demonstrates this (Figure 2).
The input power decreases as the flow rate decreases with damper control. However, under VSD
control, the variable torque characteristic of the fan means that the relationship between flow and
fan speed is such that the input power decreases in a cube law relationship with the reduction in
speed. This is demonstrated by the graph, which shows that the energy expended by a VSD is
significantly less than that expended by damper–controlled motors. This type of fan application
could be used in industrial cooling, commercial ventilation systems and combustion–air control
systems for boilers [1].

Figure 2 Comparison of speed reduction in fans using dampers and VSDs [1]

4.2 Pumps
Using throttle control for pumping applications, similar to using damper control in fan
applications, results in poor efficiency because the pump is not run at its design point. This is
especially true for applications with a steep flow/head curve and a high static head, such as
underfloor heating circuits, geothermal pumps, and small pumps [1]. Using a VSD to control the
pump instead of a simple throttle can result in significant power and thus cost savings. This is
depicted in the graph (Figure 3) to the right, where the broken line represents power input to a
fixed–speed device and the solid line represents power input to a VSD. The shaded area
represents the amount of energy saved by using a VSD for a specific flow. Pump applications for
VSDs that are common include moving hot water in HVAC systems, boiler feedwater pumps,
and product flow pumps, such as chemicals or inks [1]

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Figure 3 Power saved using a VSD in a pump [1]

4.3 Compressors
Rotary screw and piston air compressors are basically constant torque loads that can benefit from
variable speed control. The savings associated with variable speed control are dependent on the
control system being replaced. Figure 5 depicts the energy savings obtained by installing a VSD
on a rotary screw compressed air unit when compared to other methods of flow control at partial
load.

If the demand in a compressor with modulating control is 50% of the rated capacity, the energy
savings associated with VSD integration are approximately 30% [4]. The introduction of screw
compressors with integral speed control has significantly reduced the additional cost of variable
speed control, resulting in typical energy savings of 15%–20% [4]. As a result, these machines
should be considered for all new applications that require long running hours and have a wide
range of demand. The use of variable speed drives (VSD) for temperature control (floating head
operation) in refrigeration pumps/compressors (e.g., walk-in freezer, Figure 4) can eliminate
on/off cycling losses and reduce the temperature difference between the condenser and the
evaporator, resulting in significant energy savings (typically 25%).

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Figure 4 Application of VSDs on a variable-speed

Figure
4.4 5 Energy saved by using a VSD on a rotary screw air
Lifts refrigeration compressor [4]
compressor [4]
New VSD topologies allow braking energy
to be injected back into the source/grid—regenerative VSDs.  This feature has the potential to
save a significant amount of energy in applications that require frequent braking, such as lifts.
This is only possible if the motor mechanical transmission allows for it. When the lift is
descending and the load weight (people inside) exceeds the counterweight, the motor torque is in
the opposite direction of the speed, indicating that the motor is braking. Similarly, when the lift
is not loaded, energy savings can be realized if the motor is controlled by a regenerative VSD.

Figure 6 depicts potential energy savings in lifts using various technologies. When compared to
a conventional system using a pole changing drive, a regenerative VSD system and efficient
transmission can reduce consumed energy by 19% [4]. In addition, permanent-magnet motors
with direct drive (no gears) coupling and regenerative braking are being used in new high-
efficiency lifts.

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4.5 Conveyors
The torque in constant torque devices (e.g., horizontal conveyors, Figure 7) is roughly
independent of the transported load (is only friction dependent). The materials handling output of
a conveyor is typically controlled by regulating the input quantity, and the torque and speed are
roughly constant. However, if the materials fed into the conveyor are changed, it is possible to
reduce the speed (the torque remains constant), and, as shown in Figure 8, significant energy
savings are achieved proportionally to the speed reduction.

Figure 7 Power required by a conveyor [4] Figure 8 Energy savings in a conveyor using speed
control, in relation to the typical constant speed [4].
5.0 Energy Conservation Opportunities with
A VSD Controller in A Boiler House
The effect of the excess air ratio on the efficiency of the boiler system was investigated in a
study using a water tube boiler capable of producing 55 tons of steam per unit time at 245 0Cand
20 bar pressure [5]. The boiler's combustion air is supplied by a fan powered by a 30-kW
induction motor turning at 1450 rpm [5]. At low loads, the excess air amount and exhaust gas
temperature were very high due to the fan motor running at nominal speed supplying the same
airflow rate. At the time, boiler efficiency was low due to thermal energy losses, which also
resulted in electrical energy losses. To improve boiler efficiency, the fan motor speed
was reduced from 1450 RPM to 400 RPM using a variable speed drive (VSD). The stack
temperature was reduced from 1950C to 450C after the VSD was installed. This resulted in a
2.5% increase in boiler efficiency and a monthly savings of 8000 kWh of electrical energy [5].

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6.0 Conclusion
The various applications of VSDs as energy saving measures in electrical motors have been
discussed in depth in this paper. VSDs are a rapidly growing market, despite the fact that only
25% of new motors are equipped with them [4]. They enable precise control of the speed and
torque of induction motors, broadening their application spectrum. They have significant
economic and technical advantages when used in variable-speed motor systems. Massive energy
savings and associated reductions in environmental emissions are possible through the
widespread use of VSDs in a wide range of loads across the economy.

References

[1] CARBON TRUST, “Introducing energy saving opportunities for business,” Variable speed
drives, March 2007.

[2] R. Saidur, S. Mekhilef, M. B. Ali, A. Safari and H. A. Mohammed, “Applications of variable

speed drive (VSD) in electrical motors energy savings,” Renewable and sustainable energy
reviews, vol. 16, no. 1, pp. 543-550, January 2012.

[3] P. Du, E. Gideon, L. Leon and H. M. Edward, “The use of variable speed drives for cost-
effective energy savings in South African mine cooling systems,” Applied Energy, vol. 111,
pp. 16-27, November 2013.

[4] A. De, T. Aníbal, J. F. Fernando and B. Dick, “Technical and economical considerations in
the application of variable-speed drives with electric motor systems,” IEEE Transactions on
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industry applications, vol. 41, no. 1, pp. 188-199, 31 January 2005.

[5] E. Ozdemir, “Energy conservation opportunities with a variable speed controller in a boiler
house,” Applied Thermal Engineering, vol. 24, no. 7, pp. 981-993, May 2004.