VARIABLE FREQUENCY DRIVES IN A POWER PLANT

SYNOPSIS With ever increasing cost of generation of electricity and the demand for electricity outstripping the availability, energy conservation has become the key factor of efficiency in all spherea. Power conoumption by auxiliaries In a large power plant is of the order of 6%-8%. To Reduce auxiliary power plant consumption, losses in air/ rule Gas and water/ steam flow paths because of mechanical devices Used for flow control shall be reduced. Techno-economic Analysis carried out recommend installation of energy saving devices like variable frequency drives (VFDS). Installation of site measurements have proved saving of power vis-a-vis theoretical calculations. Installation of VFDS for induced Draft fans ( ID fans) have proven their worth and have given confidence to the utility engineers to use VFDS for Boiler feed pumps in Indian power plants. INTRODUCTION In a thormal power plant, there are basically two flow paths for the fluids viz, Air/ flue gas path Water/ Steam path The major auxiliaries in the air/ flue gas path are Induced Draft ( ID) fans, Forced are one of the & primary Air (PA) fans. Induced Draft fans are one of the biggest consumers of power. Boiler Feed pumps ( BFP ) and circulating Water ( CW) pumps are the major auxilaries in the Water/ Steam path and among them BFPS are the biggest consumers of power. Hitherto it is common practice to use constant speed induction motors for fans with inlet guidevane /outlet damper for control of air/flue gas. In a low system efficiency. In the case of load commutated. Inverter type of VFD, speed of the motor is varied rather than varying the system resistance for changing the operating point. Since the power is proportional to cube of speed there will be on appreciable saving in power consumption especially when the fans are required to operate at low loads .Efficiency of hydraulic coupling is very poor at reduced speeds (at 50%) speed efficiency will be less than 50% because at 60% to 70% of rated loads even when the power plant is operating at its rated capacity, thus making the available mechanical meana for flow control highly inefficient . The typical efficiency curves of VFD, hydraulic coupling . Inlet juiie vane and outlet damper or throrttling are shown in Fig.A. The first four vaiable frequency drives (VFD) in a power plant in India were installed for ID fan drives of 500 MW unit (Unit 6) of Tata Electric Companies at Trombay, Bombay. This 500 MW unit was synchronised with the grid in March 1990. VFD has now established itself as an energy efficient flow controller in Indian Power Plants. Lot of theoretical calculations were done to find out the amount of energy that will be saved by use of variable Frequency Drives at Trombay Unit 6 and Vijaywada Unit 4. Measurements done at sites for ID fan drives are presented here. Comparison of energy consumed by VFD driven ID fans vis-a-vis other alternatives used in earlier identical rates units at the same stations is presented. Normally FD fans are axial type and VFDs are not recommended to be used. Fan design margins kept in P.A. Fans and their flow variation is much lower compared to ID fans and using a VFD may not work out to be economical in these cases.

379

However, it is desirable to check the economics on case to case basis prior to selection of the type of drive. The experience and operating confidence gained in VFDs for ID fan drives in Indian Power Plants have paved the way for use of VFD for the biggest auxiliary drives in water/ steam path, namely Boiler Feed Pumps. A technoeconomic analysis for a typical 210 MW thermal power station under normal and sliding pressure operation is presented. Description of VFDs, layout and precautions required are touched in brief below: 1.0 LCI (LOAD COMMULATED INVERTER) TYPE VFD: LCI type VFD is a variable speed mechanism, which adjusts the fan or pump speed so as to get the desired output. In this type of drive system, flow demand signal is received from the control system due to change in load conditions and the system adjusts the speed of the motor to the desired level resulting in optimum power consumption. Apart from saving in operational cost due to reduced power consumption, LCI type VFD offers the following additional advantages: Absence of voltage dip problems associated with DDL starting of large motor since the starting current in this drive is limited to about 100% of the motor full load current. Increased motor life due to the lower thermal and mechanical stresses in view of the absence of starting inrush currents and reduced speed operation. No limitation on the number of starts. No contribution to fault current. LCI type VFD can be either 6-pulse single channel type (Fig-B) or 12-pulse dual channel (Fig-C). Each channel consists of an isolating transformer, source converter, DC link inductor, and load converter. In a single channel type VFD, the synchronous motor will have one winding whereas in dual channel type VFD, the synchronous motor will have two windings, one for each channel. The source side converter operates in rectifier mode whereas the load side converter operates in inverter mode. Commutation VARs for source side converter is taken from the source whereas the leading VARs produced by the synchronous motor is used for commutation of load side converter. The DC link inductor effectively isolates load side frequency and source side frequency and smoothens the DC link current. The demand signal received from the control system prompts the source side converter to provide the required current to the DC link inductor at the DC voltage level set by the load side converter. Thus the source side converter plus the DC link inductor become current source controller tot he motor and the motor torque, frequency (hence speed), and voltage level get adjusted to the load requirements. BASIC LCI SYSTEM : The Load Commutated Inverter (LCI) is static, adjustable frequency drive system that controls a synchronous machine from near zero to rated speed. The basic system consists of line Commutated, phase controlled thyristor converter that feeds a load Commutated thyristor converter through a dc link reactor. Fig 1.1 is a simplified one-line diagram of a single channel LCI. The transformer provides isolation from the ac system bus and provides the correct voltage at the terminals of the rectifier. Also, the internal impedance of the transformer limits the magnitude of any down stream bus faults.
380

1.1

The rectifier is a thyristor bridge whose gating is controlled to produce a variable dc. Voltage at its output. The output of the rectifier is fed through the dc link reactor, whose function is to smooth the current and keep it continuous over the operating range of the system. The dc link reactor output is then fed into the inverter bridge, which provides variable frequency ac at the stator terminals of the synchronous machine. The Inverter Bridge and the Rectifier Bridge use the same power hardware and are controlled by microprocessor-based electronics. Although the bridges are labeled rectifier and Mnverter. It is possible for their roles and hence power flow to reverse. In this case, the synchronous machine would be braked by pumping its energy back into the ac line. A more general nomenclature is to call the line Side Bridge the source converter, and to call the machine Side Bridge the load converter. The synchronous motor field is usually excited by a brushless exciter coupled to the motor shaft. The brushless exciter is a wound rotor induction machine whose rotor voltage is rectified to supply field current to the synchronous machine. The stator voltage for the brushless exciter is supplied from a static excitation voltage controller included as part of the LCI control panel. This controller is gated/controlled entirely by the LCI electronic control module. The LCI controls the excitation to produce the required machine flux and provides field over / under current protection. A more detailed diagram of an LCI is shown in Fig.1.2. As shown in this figure, the electronic control receives the following signal inputs: 1. Attenuated line and load bus voltage signals. 2. Attenuated line and load current signals from current transformers. 3. Speed reference signal. 4. Process commands such as stop, start, etc. The attenuated bus voltage signals are used by the control to synchronize thyristor firing with the line and load voltage, to provide voltage feedback, and over/under voltage detection. The attenuated current signals are used for regulator current feedback, electronic over-current detection, and software implemented fault detection. The electronic control evaluates the process commands and internal status signals to determine whether the drive should be in a stopped, started, alarmed, or faulted condition. If in a started condition, the electronics provides gate signals to control the thyristor bridges and the excitation voltage controller. These signals are low level and are conditioned in the power bridge circuitry to provide the necessary isolation and power level. BASIC POWER CONVERTER OPERATION: The power bridges six pulse, double way types and the thyristor bridge legs fire in the order that are numbered in fig.1.2 and shown in fig.1.3 The source converter current is successfully transferred from one leg to the next by the synchronous machine stator voltages. The process of switching machine/converter current from one leg to the next is illustrated in Fig.1.4. The principles illustrated here apply to a rectifier bridge as well as to an inverter bridge. This phase-controlled switching is accomplished by using the following two thyristor characteristics: (1) when the voltage across the thyristor is positive, it can be triggered into conduction, and (2) it will not permit current flow in the reverse direction. Thus in an alternating voltage circuit, thyristor conduction will cease and reverse voltage will begin to appear when the current becomes zero.
381

1.2

Current transfer must be completed before voltage cross over with a positive margin angle. The angle must be long enough to allow the previously conducting leg thyristors to recover to their blocking state before forward voltage is applied. This is why the fundamental component of current must lead the voltage, from an inverter / machine viewpoint. From the rectifier / source viewpoint, the fundamental component of current will always lag the voltage; but for successful commutation, the angle <x = 180 - P = 180 . u,-r must always be less than 180; a practical limit is 155. Correspondingly, a practical minimum value for p for the Inverter Bridge is 25. The machine power factor angle is thus always grater than zero. The LCI control system must conform to the characteristics of the synchronous machine operating at leading power factor. A phasor diagram for a synchronous machine operating at leading power factor is shown in fig.1.5. With fixed amount to field excitation, the machine voltage characteristic is mainly a function of the rotor field excitation, EF, and the demagnetizing action of direct-axis current. This produces the IDXAD- Voltage in opposition to the voltage produced by field excitation. Note that an increase in stator current results in higher direct-axis current, which increases IDXAD- This in turn decreases the machine voltage EG available for commutation, thereby increasing displacement angle 6. This increase of angle further increases stator current, etc, until equilibrium is reached at a new operating point. In actual practice, the machine field excitation is fixed in the speed range of approximately 0-10%, and controlled to produce a desired profile of machine flux higher speeds. At speeds greater than 10%, the LCI operates in a flux regulated mode and adjusts the output of its static exciter voltage controller (EVC) to maintain machine flux at the desired level. 1.3 LCI CONTROL 1.3.1 Basic Operation: When operating in any mode, the electronic control must synchronize firing of the source and load converter to the ac line and synchronous machine bus voltages, respectively. The primary feedback for accomplishing this is the attenuated bus-to-ground signals for both converters. Attenuated bus-to-ground voltages are brought into the electronic control and combined to produce line-to-line analogs for both converters. These line-to-line voltages are then integrated to obtain flux signals. The zero crossings of these signals are used in the synchronization of the phase locked loop for the firing control of both source and load converters. At low speed, before the phase locked loop is effective on load side, the zero crossing marks are used as a timing reference for firing in force-Commutated operation. The source side converter for the LCI always operates line Commutated; i.e. the ac line provides the means for transferring conduction from one thyristor to the next. The load side converter may operate either load (self) Commutated or force Commutated, depending on motor speed and flux level. As the synchronous machine rotor (field) rotates, the near sinusoidally shaped field flux cuts the stator windings, producing a set of three sinusoidal voltages in the stator. These sinusoidal voltages are angularly displaced by 120 electrical degrees. The magnitude of the counter emf is proportional to speed and field strength. At low speeds, the induced emf is insufficient to commutate thyristors in the load side converter. In this mode, the load converter must operate forced commutated. 1.3.2 Starting/Force Commutated Modes: Force commutated operation is used when starting the synchronous machine from zero
382

or low speed and continues until the machine under counter emf is sufficient for self-commutation. In forced commutated operation, conduction of the load converter is stopped by phasing the source converter to invertion limit until the dc link (reactor) current is zero as shown in fig.16. Thus the dc link current is chopped into 60-degree wide segments of motor frequency (angle). There are several modes of forced commutation involved in the starting of the synchronous motor. In tachless LCI application, the starting current is made large enough to accelerate the machine to 0.5 Hz in one or two inverter firings. This is approximately the minimum frequency at which the LCI can sense machine flux and begin to control torque and speed. When a start from standstill is initiated, the LCI applies fixed current level at a fixed frequency to the stator of the motor. The frequency is set by tune-up STIM and starting current level set by tune-up CRSTART. When the LCI control senses flux of sufficient magnitude, it transitions into the segment firing mode of forced commutated operation. In this mode, inverter firing is synchronized to crossovers of the machine flux and the machine is operated near unity power factor to obtain maximum torque. Inverter firing is adjustable in 30 steps or segments in this operation. The speed regulator becomes active in segment firing mode. At approximately 2.5 Hz, the load phase locked loop is able to look and inverter-firing resolution increases to 0.35 degree. This ends segment firing mode. Forced commutated operation continues until the synchronous machine reaches a frequency where its emf is sufficient to commutate the load side converter. At this point, the control transitions to self commutated operation. For LCI drives using a pulse tach for high starting torque applications, the tach pulse are counted to keep track of the rotor position and starting from standstill does not depend on zero crossings of motor flux. In this case the stator current is ramped up until shaft rotation is detected. At that point current is frozen and firing is based on rotor position determined from the tach/counter. This continues for several firings to insure the motor is rotating and then the speed regulator is enabled. Stator current is then controlled by the speed regulator to produce the torque required to accelerate the motor as required. Force commuted operation continues until the motor emf is sufficient to commutate the load side converter. 1.3.3 Self Commutated Mode In the self-commutated mode, the machine must be operated at a leading power factor in order to be able to insure commutation of the load converter. The electronic control acts to keep the machine power factor, and therefore torque per ampere, as high as possible. This accomplished by firing the load converter as close to inversion limit as possible while maintaining sufficient margin for successful commutation of current from one cell to the next. The commutation time required is a function of machine current, machine (commutating) inductance, and the voltage difference between the lines involved in the attempted commutation. For a given load current and machine inductance, a corresponding amount of volt seconds is required for a successful commutation. The control reads the peak volt-seconds of the integrated line-to-line machine voltage and machine current. The machine commutating inductance is a constant stored in the microprocessor system memory. Using the current and inductance the amount of commutation volt-seconds required is calculated by the microprocessor. Using this value volt-seconds and the peak volt-seconds of the previous flux wave, the latest possible time to fire is calculated to give a specific margin after commutation
383

is completed. The relationship of the system voltages, currents and flux waves are illustrated in fig.1-7. The commutating notch identified in the A-C line-to-line voltage is equal in amplitude to the simultaneous commutating bump on the B-C voltage. The corresponding notch in the A-B voltage (A and B are the two lines which are commutating together at this instant ) is twice this amplitude; the notch area is twice the commutating inductance per phase times the current. The voltage at the commutating point, where the lines are temporarily connected by the thyristor legs, is practically zero during commutation; the line-to-line voltage is only the forward voltage drops of the conducting thyristor legs. At high load on the motor, the apparent power factor seen by the power source increase. This is because the source converter firing angle advances (is reduced) to obtain more current. The harmonics in the current and the resultant harmonics in the voltage, due to commutation notching, will decrease. The fundamental control strategy is: To increase motor current in response to a load torque increase, the link d.c. voltage on the source side is increased, thereby raising motor current so as to keep motor speed constant. 1.4 TWELVE-PULSE OPERATION Twelve-pulse operation is like two identical, separate six pulse drives operating from common source at the same current and firing angle, with the firing reference angles shifted 30 degrees by the isolating transformers. The two motors are combined into one frame. This reduces the motor cost, including isolation, and reduces the torque pulsation amplitude while raising the torque pulsation frequency. This is achieved by separating the stator winding into two identical windings, but isolated and phase shifted 30 degrees. This construction, utilizing a common magnetic frame, including a common field, cause the load-side converter voltage to be equal in amplitude and frequency between the two drive channels. The transformer design makes the source-side converter voltage equal, but also 30 degrees apart between the two channels. It is not necessary that source-side and load-side voltages be phase-shifted. The motor windings are shifted to obtain smoother torque for equal current. The transformer windings are shifted to reduce harmonic distortion on the power system and raise the harmonic frequencies. Inter-channel communication allows one channel to be master and the other the slave, which takes its torque reference from the master. This communication allows the two motor winding currents to be balanced. Thus the channel drivers equal power, take equal current, and fire at the same relative firing angle. This best utilizes the motor and drive capabilities and also minimizes the harmonics present in each six-pulse channel cancel (5th and 7th harmonics). Other higher-order harmonics also cancel, but their amplitudes are much smaller. A twelve-pulse system also presents the capability of shutting down one channel for maintenance while the motor continues to run on the other channel (with reduced torque and usually reduced speed range). When the out of service channel is ready for operation, it may be returned to service without interrupting the drive system. 1.5 SERIES TWELVE-PULSE OPERATION (Option). Some drive configurations include series 12-pulse operation for the source converter. This is done primarily to reduce the harmonic distortion imposed by the drive on the power system. Twelve-pulse operation eliminates half the harmonics produced by six-pulse system
384

starting with the 5th and 7th harmonics. The twelve-pulse converter consists of two identical SCR bridges connected in series, each of which is operated at roughly half of the motor voltage. The ac source for the two bridges are displaced in phase by 30 degrees, the ac sources are supplied from delta and were transformer secondary windings to give the required phase shift.The choice of 6 pulse single channel or 12 pulse dual channel VFD depends on : Harmonics that are allowed to be injected into the grid. Whether redundant fan/pump is available. 12 pulse system is recommended where lower harmonic injection is desired (weak grids) and fan/pump redundancy is not available. All the components in a channel can be rated for full capacity and hence in case of dual channel 100% redundancy can be built into the VFD system. 6-pulse system, because of lower cost, is recommended where redundant fan/pump is available and the grid is strong? 2.0 ID fans for 500 MW Units at Trombay Generating Station. Tata electrical companies Trombay generating station - B has two numbers 500 MW units. The first 500 MW unit (i.e. unit No. 5) was commissioned in January 1984 and the second 500 MW unit (i.e. Unit no. 6) was commissioned in March 1990. Both the units have 4 Nos. 33-1/3% rated ID fans of identical ratings. Flue gas is controlled by outlet dampers in ID fans of unit 5, whereas this function is achieved in unit 6 by LCI type VFD. Specification for LCI type VFD for ID fans of Trombay unit 6. Since LCI type VFD for ID fans was selected for the first time in India, as a matter of abundant precaution, dual channel was rated such that with three ID fans running and only one channel in each VFD in operation, it was possible to operate the boiler at its rated capacity. further, 12 pulse operation for VFD was specified to reduce harmonics generated by VFDs synchronous motor was specified with class F insulation with teperature rise limited to class B which is the normal practise for thermal power plants. However, for the motor as a matter of economy without sacrificing the reliability, temperature rise corresponding to class F insulation could be accepted since both channels do not operate to its rated capacity at any time. 3.0 Layout of LCI VFD: Equipment connected with LCI type VFD were located in a separate building close to the ID fans. The layout of equipment is shown in Fig-4. The equipment belonging to two channels for a drive have been installed in two different rows with sufficient clearance between them so that in the unlikely event of a fire, at least one of the channels of each drive would still be in operation ensuring full availability of ID fans. Line side and load side converter panels are installed in an air conditioned room for trouble free operation. Further as a backup feature, this room has also been provided with ambient vertilation system, so that in the event of failure of airconditining plant, temperature inside the room does not exceed 40 deg. C. 4.0 4.1 SITE MEASUREMENTS:

ID fans for 500 MW units at Trombay: To find out power consumption of ID fans of unit 5 (controlled by outlet damper) and unit 6 (controlled by LCI type VFD, site measurements were taken at various generating points and data is outlined in Table - I.
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From this table, it can be seen that there will be power saving ranging from 2900 KW to 3630 KV at various generating points. Considering an average saving of 32000 KW and operation of unit for 300 days in a year, there will be a net saving of Rs. 288 lakhs per year based on an average generating cost of Rs. 1.25/KW.HR. The extra capital investment towards installation of LCI type VFD will be approximately Rs. 500 lakhs based on present day cost which means a payback period of less than 2 years. 4.2 ID fans for 210 MW units at Vijaywada TPS: Units 3 and 4 at Vijaywada Thermal Power Station of APSEB are 210 MW units, each having two 1600 KW, 710 RPM ID fans, unit 3 ID fans are driven by sequirrel cage induction motors and hydraulic couplings are provided for speed control. Unit 4 ID fans are provided with LCI type VFDs. Power consumed by the ID fans of Unit 3 and Unit 4 at 174 MW and 207 MW generation, considering and average saving of 500 KW of power and operationg of unit for 300 days in a year, there will be a net saving of Rs. 45 lakhs per year based on an average generation cost of Rs. 1.25 KW.HR. The extra capital expenditure towards installation of LCI type VFD will be approximately Rs. 165 lakhs based on present day cost which will be recovered in 3.7 years (Refer Table-II for details) 4.3 BOILER FEED PUMP DRIVES FOR 210 MW UNITS: Table -III gives a detailed techno-economic analysis for use of VFD for Boiler Food Pump operations. The analysis is based on design parameters for a typical 210 MW unit. Again taking 7200 hrs. as the operating time per year, and 2400 working hours each at a 100%, 80% and 60% MCR, the energy saved per year working out to 3758MW hrs. and a payback period of 2.5 years. If sliding pressure operation for the boiler is considered, 5188 MW. Hr. of energy is saved per year with a payback period of 1.8 years (Ref. Table-IV for details) 5.0 5.1 ADDITIONAL RECUIREMENTS OF VFDs

Environment / Layout As the modern day VFDs are all microprocessor based system capable of self diagnostics, it is recommended to house them in an airconditioned room for a long troublefree operation. As the VFDs have forced coling fans, the noise pollution because of the cooling fans need to be taken care of past. Experience has shown that a duct should be provided to throw the hot air from the VFDs above ceiling of the VFD room to reduce noise. The layout should be such that the control panels are housed separately from the thyristor/cooling fans panels) 5.2 Harmonics: Because of the use of phase controlled thyristors, current harmonics are generated and fed to the grid to which VFDs are connected. Harmonics fed to the grid are KxP +/- 1 where P is the pulse number (6 pulse or 12 pulse) and K-1,2,3......n Amplitude of harmonics can be roughly taken as In/(KxP+/-1) where In is the fundamental current. IEEE lists down the distrotion factor (DF) allowed on different buses. DF shall be limited to less than 5% on a power plant bus. A typical distortion factor calculation for 210 MW, 6 Pulse boiler feed pump VFDs for a bus fault level of 250 MVA shows that DF is less than 2.25% under normal operation and less than 3.8% under worst case of failure of one of the VFDs. It is essential that a
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harmonic analysis study be carried our on the VFD grid and the user shall be advised to connect harmonic filters, if required. 5.3 Torsional: A feature of converter fed drives is the presence of oscillating harmonic torque superimposed upon the steady torque of the synchronous motor. It is necessary that the effect of these harmonic torque be calculated by doing torsional analysis. This analysis must cover drive start up, normal operation and fault conditions. The fault conditions normally produce maximum shaft stresses at resonance. A. flexible coupling, if required, shall be used for coupling the synbchronous motor to the fan/pump. 6.0 CONCLUSION: The use of VARIABLE FREQUENCY DRIVES for ID fans (in place of modulating damper or hydraulic coupling) and for BOILER FEED PUMPS (in place of gear box and hydraulic coupling) in a power plant reduces the auxiliary power plant reduces the auxiliary power consumption approximately by 10% at peak generation and by 15% at 60% generation. The payback period for the additional investment are quite attractive. However, provision of space is an additional requirement. Harmonic analysis and torsional analysis must be carried out corrective masures taken, if required. TABLE - I
UNIT 5 SL. NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GEN. MW 200 220 240 260 280 300 320 340 360 380 400 420 440 500 TOTAL POWER (KW) 3800 4000 4150 4250 4450 4600 4800 1900 5050 5200 5350 5450 5600 5900 ID FAN A/C (KW) 750 800 850 900 950 1050 1150 1230 1320 1500 1750 2100 2400 2900 Unit - 6 LOAD (KW) SL. 50 NO 50 50 50 50 50 50 50 50 50 50 50 50 50 AUX TOTAL LOAD (KW) UNIT 3 (KW) GEN. TOTAL 50 850 MW POWER 50 900 (KW) 50 950 174 1715 50 1000 207 2319 50 1050 50 1150 50 1250 50 1330 50 1420 50 1600 50 1850 50 2200 50 2500 50 3000 POWER SAVED (KW)
ID FAN 2950 (KW) 3100 3200 1080 3250 1815 3400 3450 3550 3570 3630 3600 3500 3250 3100 2900 Unit - 4 AUX +acLOA D (KW) 65 65

TOTAL (KW) 1145 1910

TABLE - II

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TABLE - III TECHNO - ECONOMIC ANALYSIS OF 6 PULSE VFD OVER HYDRAULIC COPLING FOR 210 MW BOILER FEED PUMP DRIVES (CONSTANT PRESSURE OPERATION) MOTOR RATING : 3500 KW, 5300 RPM NO.OF PUMPS PER BOILER : 3

SL. NO 1. 2. 3. 4. 5. 6. 7. 8. 9.

388

10.

MCR (PERCENT) SPEED (RPM) FLOW (PER HOUR) PRESSURE (MLC) Power input to pump shaft for one BFP (KW) Hydraulic coupling efficiency (includes gear box loss)% Induction motor efficiency (%) Efficiency of VFD including synch. Motor (%) Power drawn from grid/BFP (KW) Power drawn from grid by two BFPS (KW) Operating hours. Energy consumed by two BFPS (MW. HR) Energy consumed by air conditioner, other auxiliaries (MW Hr.) Total energy consumed/year (MW. HR.)

HYDRAULIC COUPLING 100% 80% 60% 4815 4596 4459 367 293 221 1965 1860 1780 1398 1693 2141 0.793 0.940 0.825 0.945 0.871 0.950

1875 3750 2400 9000

2172 4344 2400 10426

2588 5176 2400 12423

31849

TABLE - IV TECHNO - ECONOMIC ANALYSIS OF 6 PULSE VFD OVER HYDRAULIC COPLING FOR 210 MW BOILER FEED PUMP DRIVES (SLIDING PRESSURE OPERATION) MOTOR RATING : 3500 KW, 5300 RPM NO.OF PUMPS PER BOILER : 3
12. SL. NO

1. 2.
13.

3.
14. 4. 15. 5.

) Additional cost of MCR (PERCENT) system considering SPEED (RPM) hydraulic coupling cost as base (Civil, Power input to air conditining, pump shaft for one additional BFP (KW) cables, etc. included) Rs. Hydraulic coupling In lakhs. efficiency (includes Saving in energy gear box loss)% cost/year In Induction Rs. motor lakhs. efficiency (%) Excise dutyof on VFD 13 Efficiency & 17.25% (Rs. In including synch. lakhs) Motor (%) Sales on (13 & Powertax drawn from @4% (Rs. In 14) grid/BFP (KW)

HYDRAULIC COUPLING 60% 80% 100% 3193 1119 1716 734 1265 2021 0.609 0.920 0.734 0.937 0.858
46.97 0.918

6 3 7

0 1310 2620 2400 6288 1839 3678 2400 8827 2185 1970 2400 11928

6. 7. 8.

Power drawn from grid by two BFPS (KW) Operating hours. Energy consumed by two BFPS (MW. HR)

2 4

389

9.

10. 11.

12.

13. 14. 15. 16. 17.

390

Energy consumed by air conditioner, other auxiliaries (MW Hr.) Total energy consumed/year (MW. HR.) Running energy cost at Rs. 125/KW.HR (Rs. In Lakhs) Additional cost of system considering hydraulic coupling cost as base (Civil, air conditining, additional cables, etc. included) Rs. In lakhs. Saving in energy cost/year Rs. In lakhs. Excise duty on 13 & 17.25% (Rs. In lakhs) Sales tax on (13 & 14) @4% (Rs. In lakhs. Total additional (13+14+15) Rs. In lakhs) Payback period of

27013 338.04

61.85

391

392

393

Fig. 1.1 Simplified LCI One Line Diagram

Fig. 2 LCI Drive

395

396

397

Fig. 1.6 Forced Commutation Firing Mode

398

399

GENERAL LCI System Regulator Block Diagram

400