Welcome

1. Welcome Using Variable Speed Drives to Save Energy. Dan Reilly June 22nd 2010

2. Welcome(Lunch is now less than 90 min away!!) Agenda • Emerson Industrial Automation Overview • Industry/Application Expertise • Variable Torque Loads • Pump Control • Fan Control • Energy Savings Calculator • AC Drives Benefits • Variable Frequency drive product features • Product Solutions Overview • Summary

3. Over 50% of the electric energy consumed in the U.S. is used by electric motors. Electric motors & systems account for almost 64% of manufacturing sector electricity consumption. This translates into $30 Billion annual energy cost. A heavily-used motor may cost six to ten times its purchase price to operate per year. Saving Energy with VFDs

4. Lifetime Costs of a 100HP Motor **Over a 10 Year expected life cycle. **Purchase price represents less than 1% of the lifetime cost.

5. What does a Variable Frequency Drive Do? Motor Control Basics Q: What is motor control? A: Motor control is the means by which a motor’s speed, torque, or position is determined in some form of a controlled manner. Q: What is a drive? A: A drive is a device that convertselectricalenergy into rotarymechanicalmotion via a motorshaft. Q: Why use a drive? A: Lower costs through: • Energy savings • Reduced overhead Better Performance: • Increased productivity • Higher throughput

6. What Differentiates Industrial VFDs? ANY Motor • Exceptional motor control • Virtually any type of motor and feedback device • Control Techniques performance delivers higher throughput and quality • Best product retrofit solutions on the market AC Motor Servo Motor DC Motor

7. Industry & Applications • Aerospace • Agriculture • Asphalt and Cement • Automated Assembly • Building Materials • Chemical • Centrifuges • Converting • Crane and Hoist • Energy Generation • Extruders • Fiber and Wire • Food and Beverage • Heavy Moveable Structures • Life Sciences • Medical Devices • Mixing • Lumber and Timber • Pharmaceutical • Plastics and Rubber • Pumps • Semiconductor • Specialty Machines • Stage and Theatre • Textiles • Water/Wastewater

8. Of all the applications for Variable Speed Control, Centrifugal Pumps and Fans offer the greatest potential for Energy Savings due to the nature of the load. These loads are defined as Variable Torque. Variable Toque means that the load torque requirement varies (increases) with speed. Introduction

9. Fan Affinity Laws • Volume Flow is proportional to fan speed • Pressure proportional to the speed squared • Power used proportional to the speed cubed • Audible noise proportional to speed to 5th Power.

10. Load requires much lower torque at low speeds than at high speeds. Fan and Pump loads obey the AFFINITY LAWS. Horsepower varies approximately as the cube of the speed, and the torque varies as the square of the speed. If the motor speed is reduced 20%, motor horsepower is reduced by a cubic relationship (0.8 x 0.8 x 0.8) = 51%. If the speed is reduced significantly and often the opportunity for energy savings is great. Variable Torque Loads

11. Variable Torque Load Characteristics NOTE: At 80% Speed (Flow) the theoretical Power consumption is only 50%of rated.

12. Common applications in Industrial Process control, Building HVAC systems and Water/Wastewater. Chilled Water Pumps Condensed Water Pumps Building Supply Pumps Chemical Dosing Pumps VFDs and Pumps

13. VFDs & Pumps • Typically sized for maximum flow • Systems typically operate at less than designed levels • Flow control is normally achieved using an output control valve • Measured in GPM (this is what we want to control)

14. Control Pump Speed for process control Regulate Flow Save Energy Payback periods of 8 months to 2 years depending on: Duty Cycle Energy Costs VFDs and Pumps

15. DUTY REQUIRED POWER INPUT CONTROL VALVE Typical Fixed Speed System

16. POWER INPUT DUTY REQUIRED Control Valve Eliminated or Locked Open VFD Variable Speed Drive System

17. Provide significant energy savings when: Pumps are operated at lower flow rates Existing system has bypass control System has low static head Local electricity costs are high Pump has steep design curve VFDs and Pumps

18. Elimination of expensive valves and valve controls Reduces power surges and stress associated with across the line starting Provides accurate flow control Longer Pump and seal life Reduced wear Less noise A VFD is potentially the BEST way to regulate flow and save energy VFDs and Pumps Additional Benefits

19. Common applications in Industrial Process control and Building HVAC systems. ID (Induced Draft) and FD (Forced Draft) Fans VAV (Variable Air Volume) Fan Condenser Fans Fume Hoods Cooling Towers VFDs & Fans

20. VFDs &Fans • Typically sized for maximum flow • Systems typically operate at less than designed levels • Flow control is normally achieved using either an output damper or inlet guide vanes

21. DUTY REQUIRED POWER INPUT OUTPUT DAMPER Typical Fixed Speed System

22. POWER INPUT DUTY REQUIRED Damper Eliminated or Locked Open VFD Variable Speed Drive System

23. Energy Savings Estimator

24. Owens Corning – Fan Drives

25. 3 x 500HP fans on fiber glass production line. Changed from damper to variable speed control. VSD Installed cost - approx $390,000. Energy savings - $225,000 per year Payback period - 1 year 9 months. Increased equipment life. Reduced maintenance / noise / vibration $225k on the bottom line every year after payback! Owens Corning 500HP fans.

26. Variable Frequency Drives Fan and Pump Features • Variable (Dynamic) Volts/Hz • Maximizes Energy Savings • Is selectable for application flexibility • Independent PID • For stand alone process control of flow or pressure • Skip Frequencies • For bypassing of mechanical resonance's

27. Variable Frequency Drives Fan and Pump Key Features and Benefits PROBLEM: • Supply Dip Ride through • The drive can automatically ride through momentary power dips by reducing speed and then returning to set speed when the supply recovers without tripping. Load Speed Supply Voltage Time

28. Variable Frequency Drives Fan and Pump Key Features and Benefits PROBLEM: • Skip Frequencies • For bypassing of mechanical resonance's reduces wear on the system Actual Drive Frequency jumps past critical points Actual Drive Frequency Set Point Skip Frequency 1 Skip Frequency 2

29. Variable Frequency Drives Fan and Pump Key Features and Benefits PROBLEM: • Independent PID loops built into the VFD • For stand alone process control of flow or pressure or level • No need for external controller, save $$$ Level Set Point Reference P I D Output Drive Frequency Feedback Level Transducer

30. Electrical Supply Benefits = more cost savings Good power factor – approx. Unity. Reduced peak amps surcharges Comfort Reduced fan / pump noise Reduce water hammer and air duct rumble No light dimming on start up Maintenance Less stress on mechanical equipment Controllable via a DeltaV, PLC or fieldbus(Ethernet, DeviceNet, Profibus, Modbus, & others) reduces the need for process adjustments Variable Speed Drive Additional Benefits

31. 24 ENERGY kWh Variable Frequency Drives Fan and Pump Key Features and Benefits PROBLEM: • Energy Metering and Operating Cost Indicator • Power consumed, operating costs per hour, power up time log and maintenance flags are all standard features providing free Asset Management tools.

32. World Class AC Drives are: Specifically suited to Centrifugal fans and pumps applications Easy to set up and install Feature packed for maximum flexibility High Performance Going to save you money! Variable Frequency Drives

33. Look for: Centrifugal fans and pumps Pump systems with a low static head Duty cycle 40hrs / week. Significant installed over-capacity. Variable Frequency Drives can: Assist with payback analysis Provide Fan and Pump drives, motors, systems, fieldbus interfaces, fan/pump sequencing software. Saving Energy with VFDs

34. LOOK FOR “DUTY CYCLE”: What if I don’t know what my duty cycle needs to be? How long does the motor need to run at 100% speed? How long does the motor need to run at 50% speed? How long does the motor need to run at a minimum to keep the process running? Saving Energy with VFDs

35. A Market Leader in Intelligent Drives & Drive Systems Founded in 1973 1,500 Employees Worldwide Key Advantages Technology Leader Best Service and Support Best Value Solutions Provider Global Manufacturing facilities (USA, UK, China, Mexico) Manufacture ~400,000 drives annually Control Techniques

36. Energy Savings Demonstrator

37. Questions? Please call…or email us Dan Reilly Dan.Reilly@emerson.com 630-708-0037 Visit www.emersonct.com