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BASIC PRINCIPLES
The most commonly used motor is the threephase, asynchronous AC
motor, also called an induction motor, which is both inexpensive and very
reliable.
The two main components of an asynchronous motor are the stator
(stationary element) and the rotor (rotating element). The speed at which a
motor turns is dependant on the speed the magnetic field generated in the
stator rotates, which in turn is dependant upon the a.c supply frequency and
the number of phase windings (poles) in the stator housing. Rotation
[revs/min] is at: (f x 60)/p where f = a.c. frequency and p = no. of pole pairs.
The principles that drive the motor mean that the speed of the rotor
does not reach that of the rotating field. The slip is the difference between the
speed of the rotating field and the speed of the rotor and is often expressed
as a percentage of the synchronous speed. It is normally between 4 and 11
percent of rated speed. For example, the mains supply in most European
countries is 400V 50Hz. This gives a four-poled asynchronous AC motor an
approximate speed of 1440rpm applying a slip factor of 4 per cent.
Centrifugal fans and pumps, as frequently found in HVAC systems are
variable torque loads. With a variable torque load, the torque required to drive
the load increases in proportion to the square of speed as shown in Figure 1.
100%
90%
80%
70%
60%
50%
40%
Torque
30%
20%
Power
10%
0%
0% 20% 40% 60% 80% 100%
Speed
The load increases from zero torque at zero speed through 25 per cent
torque at 50 per cent speed to 100 per cent torque at 100 per cent speed.
Since power is proportional to torque multiplied by speed, power is
proportional to the cube of speed. At 50 per cent speed, the load requires only
12.5 per cent of maximum power. The power/speed relationship is sometimes
known as the ‘power cubed’ law or as the ‘square torque’ law. Hence
controlling flow by motor speed reduction means that a relatively small speed
change produces a large fall in absorbed power.
Obviously, there will be no energy saving if the power of the motor
matches exactly that of the load. In constant flow applications one of the most
cost-effective options for improving the operating efficiencies of oversized
motors is to replace them with adequately sized motors, which essentially
deliver a higher efficiency than the former.
However, careful consideration has to be given before arriving at any
conclusion regarding the loading of the motor. Replacing motors based on
incorrect assessment of the motor loading may lead to a motor burn out if the
assessed loading is greater then the rated capacity of the replaced motor. In
applications where there is variation in flow; speed control is the preferred
technique to other means of regulating flow because it provides the most
efficient method of flow management and presents significant energy saving
opportunities.
A machine will always operate where its pressure/flow characteristics
match those of the system. As an example, consider a fan with the
characteristics shown in Figure 2. It is operating in a system with the flow-
dependent frictional loss characteristic shown. The operating point will be at
A. The airflow can be regulated by adjusting the position of fan inlet vanes,
adjusting the position of discharge dampers, or by adjusting the speed of the
fan. Use of dampers increases the system frictional characteristics, giving a
new operating point B. Although the flow falls as desired a pressure drop must
be effected across the output damper to meet the system requirement and the
power reduction is very small (A similar effect is obtained when a throttle is
fitted to a pump system). An alternative approach is to vary the fan
characteristics by reducing the speed. The new fan characteristics for a
reduced speed give a new operating point C. Since the power used by the fan
is proportional to the flow pressure, while the flow is the same as for B, the
power is much less.
increasing
resistance as
damper closes
Pressure
Fan
B
reduced
fan speed
Pressure ! System
Characteristics
ÄP
!
System
Pressure ! A
Fan
C Characteristics
Volume flow
Figure 2: Typical fan characteristic
90%
80%
60%
Power
50%
Inlet Damper
40%
30%
20%
Variable Speed
10%
0%
0% 20% 40% 60% 80%
Flow
Recirculation
100
80 Valve
Power %
60
40
On/off
VSD
20
Id
20 40 60 80 100
Capacity in %
PERFORMANCE IN-USE
2. Which types of load offer the greatest scope for realising energy
savings by reducing output to match demand?
Variable torque loads such as centrifugal pumps and fans
Constant torque loads such as conveyors and hoists
Constant power loads such as grindstones and saws
Fixed speed loads such as calenders and rolls
6. What would the simple payback period be for a 20 per cent oversized
22kW fan that runs nine hours per day seven days a week; assuming the
installation of a variable speed drive to be £4,000 and electricity costs
6p/kWh
2 years
2.5 years
1.5 years
3 years.
8. Which of the applications listed below will not generally be suitable for
variable speed drive control?
systems with large variable flows
systems incorporating diversion or bypassing arrangements.
system operating at close to full flow for the majority of its use.
systems with long distribution networks
10. Which of the techniques listed is able to infinitely vary flow rates on
motor driven fans and pumps?
multiple speed motors
variable speed drives
changing pulley or gearbox ratios
use of a different motor