Speed Control

Speed Control and Customer Benefits
Structure
2 | Speed Control & Customer Benefits - Ralph Hfert |
1.
2.
3.
4.
5.
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)
Compressors
Conveyor belts
Coal mills
Variable Speed means :

Change of Speed of the driven Machine
air
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
Disadvantages
Low Capital Costs

Only one Control Element
High Maintenance
Low Reliability and Availability
Very low Efficiency
High Noise Level
High Stress for the entire System

BFP Characteristic - Throttle Control
150
Pump @ Design
Speed (105 %)
140
130
120
Test
110
Pressure [%]
100
90
Boiler
Characteristic
80
70
Pump Efficiency
60
50
40
30
20
10
0
0
10
20
30
40
50
60
Flow [%]
70
80
90
100
110

BFP
Characteristic - Throttle Control
150
Pump @ Design
Speed (105 %)
140
130
T 100
120
Test
Pressure [%]
110
100
90
Boiler
Characteristic
80
70
Pump Efficiency
60
50
40
30
20
10
0
0
10
20
30
40
50
60
Flow [%]
70
80
90
100
110

BFP
150
Pump @ Design
Speed (105 %)
140
130
120
Test
110
Pressure [%]
100
90
Boiler
Characteristic
80
70
Pump Efficiency
60
50
40
30
20
10
0
0
10
20
30
40
50
60
Flow [%]
70
80
90
100
110

BFP
150
Pump @ Design
Speed (105 %)
140
130
120
Test
110
Pressure [%]
100
90
Boiler
Characteristic
80
70
Pump Efficiency
60
50
40
30
20
10
0
0
10
20
30
40
50
60
Flow [%]
70
80
90
100
110

BFP
150
Pump @ Design
Speed (105 %)
140
130
120
Test
110
Pressure [%]
100
90
Boiler
Characteristic
80
70
Pump Efficiency
60
50
40
30
20
10
0
0
10
20
30
40
50
60
Flow [%]
70
80
90
100
110

BFP
150
Pump @ Design
Speed (105 %)
140
130
120
Test
110
Pressure [%]
100
90
Boiler
Characteristic
80
70
Pump Efficiency
60
50
40
30
20
10
0
0
10
20
30
40
50
60
Flow [%]
70
80
90
100
110

BFP
150
Pump @ Design
Speed (105 %)
140
130
120
Test
110
Pressure [%]
100
90
Boiler
Characteristic
80
70
Pump Efficiency
60
50
40
30
20
10
0
0
10
20
30
40
50
60
Flow [%]
70
80
90
100
110

BFP
150
Pump @ Design
Speed (105 %)
140
130
120
Test
110
Pressure [%]
100
90
80
70
Pump Efficiency
60
50
Boiler
Characteristic
40
30
20
10
0
0
10
20
30
40
50
60
Flow [%]
70
80
90
100
110

BFP
Characteristic - Speed Control
150
Pump @ Design
Speed (105 %)
140
130
120
Test
110
Pressure [%]
100
90
Boiler
Characteristic
80
70
Pump Efficiency
60
50
40
30
20
10
0
0
10
20
30
40
50
Flow
[%]60
70
80
90
100
110

BFP
150
Pump @ Design
Speed (105 %)
140
130
Pump @ nominal
Speed (100 %)
120
110
Test
Pressure [%]
100
90
S100
Boiler
Characteristic
80
70
Pump Efficiency
@ 100 % Speed
60
50
40
30
20
10
0
0
10
20
30
40
50
Flow
[%]60
70
80
90
100
110

BFP
150
Pump @ Design
Speed (105 %)
140
130
Pump @ nominal
Speed (100 %)
120
Test
110
Pressure [%]
100
90
Boiler
Characteristic
80
70
Pump Efficiency
60
50
40
30
20
10
0
0
10
20
30
40
50
Flow
[%]60
70
80
90
100
110

BFP
150
Pump @ Design
Speed (105 %)
140
130
120
Test
Pump Speed
110
Pressure [%]
100
90
Boiler
Characteristic
80
70
Pump Efficiency
60
50
40
30
20
10
0
0
10
20
30
40
50
Flow
[%]60
70
80
90
100
110

BFP
150
Pump @ Design
Speed (105 %)
140
130
120
Test
110
Pressure [%]
100
Pump Speed
90
Boiler
Characteristic
80
70
Pump Efficiency
60
50
40
30
20
10
0
0
10
20
30
40
50
Flow
[%]60
70
80
90
100
110

BFP
150
Pump @ Design
Speed (105 %)
140
130
120
Test
110
Pressure [%]
100
90
Pump Efficiency
Pump Speed
80
70
60
Boiler
Characteristic
50
40
30
20
10
0
0
10
20
30
40
50
Flow
[%]60
70
80
90
100
110

BFP
150
Pump @ Design
Speed (105 %)
140
130
120
Test
110
Pressure [%]
100
Pump Efficiency
90
Pump Speed
80
70
60
Boiler
50
Characteristic
40
30
20
10
0
0
10
20
30
40
50
Flow
[%]60
70
80
90
100
110

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

Advantages
Disadvantages
Low Capital Costs

Only one Control Element
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
5. Advantages of
Experience
Combined Cycle Power Plants
Conventional Power Stations
More than
500 Units
Installations
More than
S - Couplings
5000 Units
Installations
RK Couplings
5. Advantages of
Experience
Compressor Drives
More than
150 Units
Installations,
more than 100
of them are
VORECONs
5. Advantages of
Technical Advantages
Separation of Drive Train
Shock and Vibration Damping
OIL
5. Advantages of
No Load Start-Up
Fan rated power: 3123 kW (4188 HP) @ 710 RPM
100 %
IN
Motor & Fan

speed
100 %
Fan speed
I
600 %
50
600 % IN
Motor
speed
Without Fluid Coupling
I
Torque, Speed [%]
100 150 200
Torque, Speed [%]

50
100
150
With Fluid Coupling
25
Time [sec]
50
10
Time [sec]
20
5. Advantages of
Integral Lube Oil System
Baseframe designed as Lube Oil Reservoir
5. Advantages of
Application under severest environmental Conditions
5. Advantages of
Economic Benefits
1.
Reliabilty, Availability, MTBF

2.
Reliability based on Failures
Reliability: Operating Hours - Non-Availability Time

Operating Hours
Availability based on Overhaul
Operating Hours between Overhauls - Non Availability Time

Operating Hours between Overhauls
= 0.9983 = 99,83 %
= 0.9994 99,94 %
3.
Mean Time between Failures (MTBF)
MTBF:
Operating Hours
No. of reported Failures
= 281 818 Hours (over 24 Years)
5. Advantages of
Economic Benefits
Simple, compact, robust
Very easy
Maintenance
only a 4-20 mA Signal is

necessary to operate the Unit
5. Advantages of
Economic Benefits
Efficiency
5. Advantages of
Economic Benefits
Load
Load Pattern [h/yr]
No. of Pumps
Power Savings [kW]
Energy Savings [kWh]
Cost Savings per year [S$]

Cost per Coupling [S$]
No. of Couplings
Total Cost [S$]
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
Energy Cost per kWh:
US $ 0.043
Total Cost Savings per Year:
US $ 130,000
Cost per 3 Units:
US $ 180,000
17 Months
5. Advantages of
Economic Benefits
Long Life
5. Advantages of
Experience
Economic Benefits

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Speed Control and Customer Benefits

2 | Speed Control & Customer Benefits - Ralph Hfert |

What does Variable Speed mean?

1. What does Variable Speed mean?

Variable Speed means :

2. Why Variable Speed?

To adapt Pressures and Flows to the Process Conditions

2. Why Variable Speed?

Varying Gas Compositions (Flash Gas Compressors, Injection

Varying Process Conditions (DHDT Recycle Compressors,

Refrigeration Compressors, BOG Compressors ...)

Varying Product Demand (Pipeline Compressors ...)

3. Speed Control vs. Throttle Control

6 | Speed Control & Customer Benefits - Ralph Hfert |

Low Capital Costs

7 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

3. Speed Control vs. Throttle Control

8 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

9 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

10 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

11 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

12 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

13 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

14 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

15 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

16 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

17 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

18 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

19 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

20 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

21 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

22 | Speed Control & Customer Benefits - Ralph Hfert |

3. Speed Control vs. Throttle Control

23 | Speed Control & Customer Benefits - Ralph Hfert |

4. Speed Control vs. Inlet Guide Vane Control

24 | Speed Control & Customer Benefits - Ralph Hfert |

Inlet Guide Vane Control

Low Capital Costs

25 | Speed Control & Customer Benefits - Ralph Hfert |

Conventional Power Stations

26 | Speed Control & Customer Benefits - Ralph Hfert |

27 | Speed Control & Customer Benefits - Ralph Hfert |

28 | Speed Control & Customer Benefits - Ralph Hfert |

Separation of Drive Train