AVJ Engineering Consultants -...
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AVJ Engineering ConsultantsAVJ Engineering Consultants
AVJ Engineering Consultants
9/14/2016 1
MAGNADRI.WMV
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• AVJ Engineering Consultants was established in the year 2009 after I worked for 36 years and is based at:
Flat No.1, Plot No.21,
Mahabali Housing Society,
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Mahabali Housing Society,
Karve Nagar,
Pune – 411052
Telefax: 912025460104
Mobile: 919923413733
Mail ID: [email protected]
Website: www.avjengineering.com
AVJ Engineering Consultants will be known as AVJ Engineering & Marketing Pvt. Ltd.
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Presentation Presentation on Reduction on Reduction in in Auxiliary Power Consumption Auxiliary Power Consumption and and Reduction in Reduction in
O&M Cost ThroughO&M Cost Through
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MagnaDrive Magnetic Couplings and Adjustable Speed Drives (ASD)
“The Next Industrial Revolution”
By
Vinod Malhotra
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AVJ Engineering ConsultantsAVJ Engineering Consultants
MagnaDrive, Seattle USA
Flownetix, UK
Electromagnetic & Ultrasonic Flow
Meters
About AVJ Engineering Consultants
AVJ is Distributor & Marketing Associates for:
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Meters
Jyoti Limited, Baroda – Pumps, Motors &
Switch Gears
Essential Power Transmission for Gear
Box.
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Magnadrive Couplings and ASDMagnadrive Couplings and ASD Jyoti PumpsJyoti Pumps
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Flownetix Ultrasonic SmartFlownetix Ultrasonic Smart
Water MetersWater Meters
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AVJ Engineering ConsultantsAVJ Engineering Consultants
MagnaDrive’s Value Proposition
“MagnaDrive’s revolutionary disconnected
MagnaDrive Benefits
MagnaDrive is the Only GREEN Technology
Which Offers Dual Benefits - Saves Energy &
Reduces O&M Cost also
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torque-transfer technology reduces your total cost of ownership by lowering maintenance and operating costs, increasing process availability, and
improving system reliability.”
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Founded in 1999
• Technology of the Year by Industry Weekfor 2001
• 20 Domestic Patents and More than 200 International Patents
About MagnaDrive
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International Patents
• Installed on Over 35,000 Systems and in India 61 Systems.
• Recently Awarded $2.7 million Contract by U.S. Navy
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AVJ Engineering ConsultantsAVJ Engineering Consultants About MagnaDrive
• 2004 Inc. 500 Fastest Growing Private Companies
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AVJ Engineering ConsultantsAVJ Engineering Consultants About MagnaDrive
• 2004 Inc. 500 Fastest Growing Private Companies
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• 2004 Deloitte 500 Fastest Growing Technology Companies
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AVJ Engineering ConsultantsAVJ Engineering Consultants About MagnaDrive
• Inc. 500 Fastest Growing Private Companies
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• Deloitte 500 Fastest Growing Technology Companies
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• MagnaDrive Produces Magnetic Adjustable Speed Drives and Couplings that eliminate the physical link between the motor and load and instead uses a Magnetic field to transmit torque across an air gap. It’s a simple but effective mechanical technology that is GREEN gives following advantages
– Reduces energy consumption
– Reduces motor stress at start-up
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– Reduces motor stress at start-up
– Cushions shock loads and eliminates motor seizure– FGC Demo.wmv
– Tolerates misalignment and thermal expansion
– Extends equipment life and reduces maintenance requirements through reduced vibration and cavitations
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AVJ Engineering ConsultantsAVJ Engineering Consultants Principle of Operation
Magnet & Copper Penny Demo.wmv
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AVJ Engineering ConsultantsAVJ Engineering Consultants MagnaDrive Benefits
A Mechanical,A Mechanical,
ImagineOperates While Misaligned
Controls Load Speed
Cushioned Start
Cushions Shock Loads
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A Mechanical,
Non-Electronic Device
A Mechanical,
Non-Electronic DeviceEasy to Install
Easily UnderstoodEliminates Motor Seizure
Extends Equipment Life Reduces Vibration
Compact
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Pumps
Application Types
Target Market
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Pumps
• Fans
Application Types
Target Market
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Pumps
• Fans
• Blowers
Application Types
Target Market
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• Blowers
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Pumps
• Fans
• Blowers
Application Types
Target Market
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• Blowers
• Centrifuges
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Pumps
• Fans
• Blowers
Application Types
Target Market
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• Blowers
• Centrifuges
• Bulk Handling
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• MagnaDrive is not only a Drive but a “Total Solution”to Achieve Lower Total Cost of Ownership
A
B
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MagnaDrive is Solution
MagnaDrive “THE” Solution Module
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MagnaDrive
Energy Zero Vibration Works in Misalignment
No Throttling Lower O&M cost No Motor Seizure
L
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S
A
V
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G
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Lower Motor Ratings
LOWER COST OF OWNERSHIP
RESULT Lower Starting Current
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Couplings
Product Lines
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• Couplings• Adjustable Speed Drives (ASDs)
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AVJ Engineering ConsultantsAVJ Engineering Consultants Coupling Range and Models
• Constant and Variable Torque
• 2 to 2500 KW Applications
• Four Models:
Magnetic Couplings
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• Four Models:
– First Generation Coupling (FGC)
– Delay (MGD)
– Torque Limiting (MGTL)
– Vortex
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• FGC - First Generation Coupling
• MGD – Magnaguard Delay
Couplings:FGC
MGD
Permanent Magnet
Couplings
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• MGD – Magnaguard Delay
• MGTL- MagnaDrive Torque Limiting
• VORTEX
MGTL
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AVJ Engineering ConsultantsAVJ Engineering Consultants Product Overview -Couplings
FGC Product Line
• 2 to 2500 KW @1500• Variable and Constant
Torque applications • Can deliver higher starting
torques
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torques• Cushioned start desired• Shafts: standard or
special sizes• Dist. Between Shaft ends
(DBSE): within or beyond standard range
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AVJ Engineering ConsultantsAVJ Engineering Consultants FGC Coupling
CONDUCTOR STEEL
COPPER CONDUCTORCOPPER CONDUCTOR
CONDUCTOR STEEL
MAGNETS
AIR GAP SPACER
SHRINK DISC SHRINK DISC
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LOAD HUBMOTOR HUB
ALUMINUM MAGNET ROTOR
AIR CLEARANCE (GAP)
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Range 16 to 625 KW
• Air Gap Increases from 1/8 to 3/16 inch During Start Up
MGD Product Line
Product Overview -
Couplings
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3/16 inch During Start Up
• Gap Change Reduces Torque Transfer About 50% for Cushioned Smooth Start
• MGD Also Has Partial Disconnect Feature Built In
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AVJ Engineering ConsultantsAVJ Engineering Consultants
CONDUCTOR STEEL
COPPER CONDUCTORCOPPER CONDUCTOR
CONDUCTOR STEEL
ALUMINUM MAGNET ROTORS
MAGNETS
AIR GAP SPACER
SHRINK DISCSHRINK DISC
Product Overview -
MGD
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LOAD HUBMOTOR HUB
AIR CLEARANCE (GAP)
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• All the Features of the MGD, Plus MGTL has Complete Disconnect Feature Built In
• Complete Disconnection Results when High Torque Repelling
MGTL Product Line
Product Overview –
Couplings
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when High Torque Repelling Magnetic Force Occurs Due to Additional Slip
• Repelling Force Completely Uncouples Motor from Load for Complete Protection
• Self Resetting when Motor is Turned Off
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AVJ Engineering ConsultantsAVJ Engineering ConsultantsCoupling Benefits - MGTL
CONDUCTOR STEEL
COPPER CONDUCTORCOPPER CONDUCTOR
CONDUCTOR STEEL
ALUMINUM MAGNET ROTORS
MAGNETS
AIR GAP SPACER
SHRINK DISCSHRINK DISC
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LOAD HUBMOTOR HUB
AIR CLEARANCE (GAP)
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Offers Low Maintenance
• Simple Installation
• Efficient Torque Transfer
• Permits Shock Loadings (Load is Cushioned & Slips)
Coupling Benefits:FGC & MGE
MGD
Product Overview -
Couplings
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(Load is Cushioned & Slips)
• Greater Misalignment Tolerance
• Ideal for Applications Subject to:– Vibration
– Periodic Load Seizure
– Pulsating Loads
– Thermal Expansion
– Higher Starting Inertia/Torque
MGTL
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AVJ Engineering ConsultantsAVJ Engineering Consultants Type of Loads
• Centrifugal Loads
• Centrifugal loads are rotating loads, such as centrifugal pumps, fans, and mixers. They closely follow the affinity laws, which dictate how flow, horsepower, and torque change as speed changes:
• New Flow = Original Flow × Δ Speed
• New Torque = Original Torque × Δ Speed2
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• New HP = Original HP × Δ Speed3
• In other words, flow varies proportionally with change in speed (Δ Speed, expressed as a percentage of the original speed), torque varies with the square of the change in speed, and horsepower varies with the cube of the change in speed.
• It is important to understand that torque is demanded by the load. Attach a 2-hp motor to a 2-hp load, then attach a 10,000-hp motor to the same load and both motors will generate 2-hp (ignoring losses).
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AVJ Engineering ConsultantsAVJ Engineering Consultants
(HP1 / HP2) = (Flow1 / Flow2)3
TechnologyTechnology
Affinity (or “Fan”) Laws
Proportion of Max
Flow Flow Reduction Power Consumed Power Saved
(Flow1/Flow2) (1-Flow1/Flow2) (HP1/HP2) (1-HP1/HP2)
99% 1% 97% 3%
98% 2% 94% 6%
• Torque Transmitted & Flow Are Reduced By Increasing the ASD Air Gap
• A 1% Reduction in
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98% 2% 94% 6%
97% 3% 91% 9%
96% 4% 88% 12%
95% 5% 86% 14%
90% 10% 73% 27%
85% 15% 61% 39%
80% 20% 51% 49%
70% 30% 34% 66%
60% 40% 22% 78%
50% 50% 13% 88%
40% 60% 6% 94%
Speed and Flow Yields a 3% Energy Savings
• A 10% Reduction in Speed and Flow Yields a 27% Energy Savings
• A 50% Reduction in Speed and Flow Yields a 88% Energy Savings
Energy Savings May be Greater
Due to Reduced Vibration and
Misalignment Tolerance of
MagnaDrive Air Gap
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Why pump should not be operated at full Valve Opening?
Pump Curve:
Pump curve for 150 KW ECW pump.pdf
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Non-Centrifugal Loads• Other loads, such as screw compressors, positive displacement pumps,
positive displacement blowers, paper roll machines, conveyor belts, punch presses, and rock crushers, do not follow the affinity laws.
• Flow varies proportionally with speed.
• Torque and horsepower may decrease, remain constant or increase—it depends on the application.
• Speed changes for non-centrifugal loads do not generate the same large energy saving as with centrifugal loads, but changes in speed may be desirable for process control reasons. In other words, you may want to control the speed
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for process control reasons. In other words, you may want to control the speed of the process, even though you are not saving any energy.
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Rigid CouplingsRigid Couplings
Rigid Chain Gear Disc
Fixed Speed – Mechanical Couplings
Fixed Speed – Mechanical Couplings
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Flexible / Elastomeric CouplingsFlexible / Elastomeric Couplings
Flexible ShaftRubber (Tire) Jaw Pin
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Misalignment
• All couplings are subject to:
Fixed Speed – Mechanical Couplings
Fixed Speed – Mechanical Couplings
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Parallel / Offset
Misalignment
Axial Misalignment
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• MagnaDrive has a unique design:
Permanent Magnet
Rotor
Permanent Magnet
Rotor
Copper Conductor
Rotor
Copper Conductor
Rotor
Fixed Speed –Mechanical Couplings
Fixed Speed –Mechanical Couplings
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Motor Shaft Load Shaft
Air GapAir Gap
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Motor Shaft Load Shaft
Fixed Speed –Mechanical Couplings
Fixed Speed –Mechanical Couplings
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MagnaDrive
can operate with
Angular Misalignment
MagnaDrive
can operate with
Angular Misalignment
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Motor Shaft Motor Shaft Load Shaft Motor Shaft Load Shaft
Fixed Speed –Mechanical Couplings
Fixed Speed –Mechanical Couplings
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MagnaDrive
can operate with
Parallel Misalignment
MagnaDrive
can operate with
Parallel Misalignment
MagnaDrive
can operate with
Axial Misalignment
MagnaDrive
can operate with
Axial Misalignment
MagnaDrive
can operate with
Angular Misalignment
MagnaDrive
can operate with
Angular Misalignment
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Lower Inrush at
Startup
Cushioned Start
Coupling Technology
Reduced starting power requirementReduced starting power requirement
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• Lowers Peak
Demand
• Immediate Restarts
Energy Savings as a resultEnergy Savings as a result
of removing system of removing system
inefficiencies inefficiencies
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Motor Characteristics– Up to 5000 HP Motors @ 1500 RPM– Up to 3000 HP Motors @ 3000 RPM
• Vibration Isolation • MagnaDrive Corp - Pump - No Vibration - Lorain,
OH, USA.wmv
Couplings
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OH, USA.wmv• Alignment Problems• ..\Misalignment Demo.wmv• Need for Cushion Start • Thermal Expansion Issues• Shaft Seizure Issues• Mechanical Seals are Present• Need to Protect Critical Equipment
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Rigid & Flexible CouplingsRigid & Flexible Couplings MagnaDrive (MGE/FGC/MGD/MGTL)MagnaDrive (MGE/FGC/MGD/MGTL)
• All mechanical couplings are somehow physically connected causing:
�Misalignment
�Vibration transfer
�Premature equipment failure
�Energy waste due to misalignment
• The disconnected nature of the MagnaDrive connection (air gap) provides:
�Misalignment allowance up to 3 degrees
�No vibration transfer
�Longer equipment life (bearings, seals, etc.)
�Energy savings due to motor/load disconnection
• Installation, operation, & maintenance issues: • Installation, operation, & maintenance issues:
Fixed Speed –Mechanical Couplings
Fixed Speed –Mechanical Couplings
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• Installation, operation, & maintenance issues:
�Time and money spent on laser alignment
�Time and money spent maintaining equipment
�Production downtime costs
�No overload torque protection
�Some types require grease/oil
�“Hard” start causes extra stress on equipment and energy spikes
�No speed adjustability
• Installation, operation, & maintenance issues:
�Virtually no time and money spent on alignment
�Less time and money spent maintaining equip.
�Lower production downtime costs
�Overload protection
�MagnaDrive is a GREEN technology
� “Cushioned” and delayed start increases equipment life and provides lower peak demand and inrush (additional energy savings)
�MagnaDrive couplings can be fine tuned to save energy
Increased cost
of ownership
Lower cost
of ownership
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Fluid Couplings
• Applications:
• Bulk Material Systems Conveyors:
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• Bulk Material Systems Conveyors:
• Coal Handling
• Ash Handling
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AVJ Engineering ConsultantsAVJ Engineering Consultants Fixed Speed –Fluid / Hydraulic Couplings
Fixed Speed –Fluid / Hydraulic Couplings
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Fluid Coupling Issues - OilFluid Coupling Issues - Oil
Fixed Speed –Fluid / Hydraulic Couplings
Fixed Speed –Fluid / Hydraulic Couplings
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Fluid Coupling Issues – High MaintenanceFluid Coupling Issues – High Maintenance
"Replacement parts for fluid couplings are notoriouslyexpensive. However, we had no choice but to keeppaying out as the Dryer-Pulveriser Mill is such a keyelement within the refinery process. Unfortunately wewere in a lose-lose situation, when the applicationfaltered it not only cost us money to fix it, it was alsocosting us money for the duration it was off-line.“
Fixed Speed –Fluid / Hydraulic
Couplings
Fixed Speed –Fluid / Hydraulic
Couplings
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costing us money for the duration it was off-line.“
"The coupling requires inspection every 12 weeks withfrequent oil top ups, the oil used within a fluid coupling ishighly volatile. The coupling incorporates a fusible drainplug which is designed to discharge oil if the operatingtemperature is too high. This feature was causing aconsiderable health and safety risk to operators, we hadexperienced several fires in the past caused by hot oilblowing the fusible plug and consequently igniting.”
http://www.hub-4.com/news/696/wbb-minerals-grind-down-maintenance-costs-using-siemens-soft-startersSource:
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Fluid Coupling Issues - HazardousFluid Coupling Issues - Hazardous
Fixed Speed –Fluid / Hydraulic Couplings
Fixed Speed –Fluid / Hydraulic Couplings
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AVJ Engineering ConsultantsAVJ Engineering Consultants Fixed Speed –Fluid / Hydraulic Couplings
Fixed Speed –Fluid / Hydraulic Couplings
Fluid Coupling Issues - HazardousFluid Coupling Issues - Hazardous
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AVJ Engineering ConsultantsAVJ Engineering Consultants
2002 Fatality Accident with a
major brand Fluid Coupling
at Lone Star Quarry & Mill
Fixed Speed –Fluid / Hydraulic Couplings
Fixed Speed –Fluid / Hydraulic Couplings
Fluid Coupling Issues - HazardousFluid Coupling Issues - Hazardous
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http://www.msha.gov/fatals/2002/ftl02m17.htm
at Lone Star Quarry & Mill
Lone Star Industries, Inc.
Cape Girardeau, MO
For Official Accident Report Go To:
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AVJ Engineering ConsultantsAVJ Engineering Consultants
“Curbing the killer Conveyors”
“Recently a steel worker was injured when an inclined conveyor ranbackwards, out of control, and the fluid coupling in the drive trainexploded like a bomb, spreading shrapnel and hot hydraulic oileverywhere. It should never have happened”.
Fixed Speed –Fluid / Hydraulic Couplings
Fixed Speed –Fluid / Hydraulic Couplings
Fluid Coupling Issues - HazardousFluid Coupling Issues - Hazardous
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“The fluid coupling is sized to soft-start the conveyor and protect themotor/drive package from overloads. It is made from aluminum and isintended to run, in this case, at 1,500 to 1,800rpm. If it is run at speedsof up to 6,000rpm then the aluminum casing will be put under massivecentrifugal loads sufficient to make the whole thing explode like abomb”.
“Then, when the drive train fails and the conveyor back-drives, thefluid coupling becomes a bomb just waiting to explode”.
http://www.renold.com/Company/News/Curbing_the_killer_conveyors.aspSource:
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AVJ Engineering ConsultantsAVJ Engineering Consultants
“An undermanager and a deputy on a backshiftwere attempting to change the oil in a leaking fluidcoupling. The men were inexperienced in this task
Fixed Speed –Fluid / Hydraulic Couplings
Fixed Speed –Fluid / Hydraulic Couplings
Fluid Coupling Issues - HazardousFluid Coupling Issues - Hazardous
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which resulted in the deputy receiving oil burns tohis face”.
http://www.cfmeu.com.au/storage/documents/Apr00CC.pdfSource:
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Performance of Magnetic Couplings in Bulk Material Handling Systems:
MAGNADRIVE - BWE - ThyssenKrupp, Australia.wmv
MAGNADRIVE - CONVEYOR - 1400 Ton Per Hour Conveyor in Australia.wmv
MAGNADRIVE+-+CONVEYOR+-+Australia+-+SWCC+-+Thiess.wmv
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Apprehensions:
Weather Magnetic Couplings will work in dusty environment?
+Chile.wmvDust Flying MAGNADRIVE - Tura - TURKEY (1).wmv
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Comparative Study between VFD and Magnadrive on Energy Savings in Conveyor:
MAG Drive kilo Watt
30
35
Power consumption for Magnetic Drive
0
5
10
15
20
25
30
1 5 9 1317 21 2529 3337 41 4549 5357 61
60 Minute Interval
kW
MAG Drive kilo Watt
Power Consumption per hour - 1600.16 kWhAverage Power per hour - 26.23 kW
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AVJ Engineering ConsultantsAVJ Engineering Consultants
VSD Drive kilo Watt
40
50
60
Power consumption for Variable Speed Drive
0
10
20
30
40
1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61
60 Minute Interval
kW
VSD Drive kilo Watt
Power Consumption per hour - 1933.08 kWhAverage Power per hour - 31.68 kW
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Magnadrive/VSD Power Consumption Comparison Graph
MAG/VSD Comparison Graph
40
50
60
0
10
20
30
40
1 5 9 1317 21 2529 3337 41 4549 5357 61
60 Minute Interval
kWMAG Drive kilo Watt
VSD Drive kilo Watt
Energy Savings in conveyor Mooikraal Drive Recordings.xls
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Fluid CouplingsFluid Couplings
• Fluid Couplings are not totally disconnected and are subject to:�Misalignment and vibration transfer
�Premature equipment failure (gear boxes, bearings, seals, etc.)
�Energy waste due to misalignment and additional fluid friction losses inside the coupling
• The disconnected nature of the connection (air gap) provides:�No misalignment and vibration issues
�Longer equipment life (bearings, seals, gear boxes, etc.)
�Energy savings due to the motor/load disconnection. Because MagnaDrive operates with a cushion of air, a 3-5% savings in power can be attained in relation to the same work done by a Fluid Coupling
• Installation, operation, & maintenance issues:�Time and money spent on laser alignment
Fixed Speed –Fluid / Hydraulic Couplings
Fixed Speed –Fluid / Hydraulic Couplings
MagnaDrive (FGC/MGD/MGTL)MagnaDrive (FGC/MGD/MGTL)
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Fluid Coupling�Time and money spent on laser alignment
�Fluid Couplings are difficult to install and maintain
�Time and money spent maintaining equipment
�Most Fluid Couplings can not operate in both directions of rotation
�Fluid Couplings are filled with oil which is a hazard for the environment and people
�The Fluid Coupling overtorque protection is provided by a fusible plug which melts and sprays oil all around. When the plug fails to melt, the Fluid Coupling literately becomes a time bomb
• Installation, operation, & maintenance issues:�Virtually no time and money spent on alignment
�MagnaDrive Couplings have no oil, are lighter, and easier to install
�Less time and money spent maintaining equip.
�MagnaDrive Couplings transmit the same torque in either direction of rotation
�MagnaDrive is a GREEN technology and does not use any oil
�MagnaDrive Couplings basically slip if there is an overtorque condition, and certain models (MGTL) also offer a complete disconnect feature
Increased cost
of ownership Lower cost
of ownership
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Adjustable Speed Drive
(ASD)
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(ASD)
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AVJ Engineering ConsultantsAVJ Engineering Consultants Variable Speed –Valve / Damper Systems
Variable Speed –Valve / Damper Systems
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AVJ Engineering ConsultantsAVJ Engineering Consultants Variable Speed –VFDs (Variable Frequency Drives)
Variable Speed –VFDs (Variable Frequency Drives)
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AVJ Engineering ConsultantsAVJ Engineering Consultants Variable Speed –VFDs (Variable Frequency Drives)
Variable Speed –VFDs (Variable Frequency Drives)
Principle of OperationPrinciple of Operation
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AVJ Engineering ConsultantsAVJ Engineering Consultants Variable Speed – VFDs (Variable Frequency Drives)
Variable Speed – VFDs (Variable Frequency Drives)
VFD Issues – Installation Complexity and Space RequirementVFD Issues – Installation Complexity and Space Requirement
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Building to house VFDsBuilding to house VFDs
MagnaDrive minimal space requirement and
simple installation
MagnaDrive minimal space requirement and
simple installation
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AVJ Engineering ConsultantsAVJ Engineering Consultants Product Lines
• Variable Gap – For Adjustable Speed
• Air-Cooled:
– Sizes 20 to 500 Hp @ 1500 RPM
– Horizontal & Vertical Applications
• Water-Cooled
Adjustable Speed Drives
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• Water-Cooled
– 500 through 4,500 Hp @ 1500 RPM
– Horizontal & Vertical Applications
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Variable Speed Control for Energy Savings
• Low System Maintenance
• Accepts Greater Misalignment
• Eliminates Vibration Transfer Between
ASD Benefits
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• Eliminates Vibration Transfer Between Motor and Load
• Unloaded Startup, Controlled Ramp-Up
• Permits Shock Loading
• Increased Seal & Bearing Life
• Eliminates Electronic Harmonics
• Unaffected By Power Quality Issues
• Lightning Strikes
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Adjustable Speed Drive (ASD)
• For Speed Control and Energy Savings
– ASD Energy Savings Demo.wmv
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– ASD energy savings New.wmv
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AVJ Engineering ConsultantsAVJ Engineering Consultants
VFDsVFDs MagnaDrive ASDsMagnaDrive ASDs
Variable Speed –VFDs (Variable Frequency Drives)
Variable Speed –VFDs (Variable Frequency Drives)
• Special issues and installation requirements:�Require inverter duty motors�Are susceptible to dirty power�Require environment control (temp, dust, hum.)�Complexity of equipment and installation�Are expensive in medium/high voltage�Rapid obsolesce (6-7 years)/throw away�Motors control space requirement
• Operation & maintenance issues:�Harmonics
• MagnaDrive ASDs:�Operates with any kind of motor�Is not affected by dirty power�Is not affected by temperature, dust, humidity and other factors in the operating environment�Are simple to install and maintain�Have a life span of 20 – 25 years, depending on operating conditions
• Operation & maintenance issues:�No issues with harmonics�No issues with bearing fluting
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• The disconnected nature of the connection (air gap) provides:�No misalignment and vibration issues�Less time and money spent aligning and maintaining equipment�Longer equipment life�Cushioned start�No load start�Energy savings due to motor / load disconnection�Overload protection
Increased cost
of ownership
Lower cost
of ownership
• Equipment connected with VFDs still has a physical connection between the motor and load shaft causing:�Misalignment and vibration transfer�Premature equipment failure�Energy waste due to misalignment�No overload protection
�Harmonics�Bearing Fluting�No rapid restart capability
�No issues with bearing fluting�Rapid restart capability
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Case Study for Hindalco Muri for ID Fan and PA Fan
ID FAN Curve.pdf
PA Fan Curve -- markup.pdf
ASD Sizing for 26.5-28.5 for PA Fan for Hindalco Ranachi.xlsx
Case Study
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ASD sizing for WC-1000 for ID fan for Hindalco Ranchi.xlsx
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AVJ Engineering ConsultantsAVJ Engineering Consultants Magnadrive Capability
Magnadrive has supplied 6 Nos. ASDs WH – 4000 for 3037 HP / 980 RPM
ID Fan To China Power Plant.
MagnaDrive WH-4000 in China.pdf
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AVJ Engineering ConsultantsAVJ Engineering Consultants Success Stories
List Of Customers
List of Indian Customers as on 6th June
2016.xlsx
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• Pictures of Magnadrive Couplings at NALCO Damanjodi
• Installation of Magnadrive Couplings at NALCO Damanjodi.pdfNALCO Damanjodi.pdf
• Magnadrive Coupling Operating
• DSCN0276.AVI
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• Installation of Magnadrive Couplings in NTPC Plants.
• Magnadrive Coupling Pictures in NTPC Plants.pdfPlants.pdf
• Performance of Magnadrive Couplings in NTPC.pdf
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NTPC Kayamkulam: 132 KW / 1500 rpm
DMCW Pump installation on 10.07.2014
Performance Results:
Performance Results.pdf
Success Stories
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Before Installation of Magnadrive Coupling Power consumption was 135.61 KW and After Installation of Magnadrive Coupling power consumption reduced to 113.54 Savings of 22.07 KW.
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AVJ Engineering ConsultantsAVJ Engineering Consultants
• NTPC AuraiyaPerformance Data of Clarified Pump Coupled with Magnadrive Coupling:
– Pump Model: CPRG-80-40
– Flow: 60M3/Hr.
– Head: 45 Meters
Success Stories
– Rating in KW: 18.5 KW
– Speed in RPM: 1470
Before Magnadrive: 421.5 Volts, 24.6 Amps, 0.79 PF, 4 Kg/Cm2 Head, 14.1 KW
After Magnadrive: 416 Volts, 22.2 Amps, 0.77 PF, 4 Kg/Cm2 Head, 12.4 KW
Power Saving: 12.06%
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• NTPC Tanda:
Magnadrive Coupling
Model: FGC 18.5S.
Conveyor: 2B
Motor Rating: 110 KW
Success Stories
Motor Rating: 110 KW
Speed: 1450 RPM
No Load Current with
Fluid Coupling: 57 Amps
No Load Current with
Magnadrive Coupling: 52 Amps9/14/2016 72
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AVJ Engineering ConsultantsAVJ Engineering Consultants
Vandana Global Ltd, Raipur
Application: ACW Pump
Rating: 30 KW
Energy Savings: 19.36%
Success Stories
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Energy Savings: 19.36%
Coupling Model: FGC 10.5S
Performance of FGC 10.5S at Vandana Global.pdf
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AVJ Engineering ConsultantsAVJ Engineering Consultants Quantified Business Results
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Plant Head Mr. Nandi Inaugurating Magnadrive Magnetic Coupling Model FGC 18.5S on Conveyor No. 6A At Dahanu Thermal Power Station
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AVJ Engineering ConsultantsAVJ Engineering Consultants Quantified Business Results
Client: Dahanu Thermal Power StationApplication: ConveyorMotor Rating: 110 KWSpeed of Motor: 1485 RPMArea: Coal Handling PlantOriginal Drive: Fluid CouplingPower Consumed With Fluid Coupling: 39.5 KWPower Consumed with
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Magnadrive Magnetic Coupling Model FGC 18.5S At Dahanu Thermal Power Station
Power Consumed withMagnadrive : 37.36 KWEnergy Savings: 2.14KWHEnergy Savings / Yr: 18747 KWH
Energy Saving / Yr. in Rs.: 93732.00
Other Benefits
�Reduction in Vibration Level�Zero Maintenance�Increased MTBF
Performance report of FGC 18.5S on 110 KW Conveyor at Dahanu Thermal Power.pdf
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AVJ Engineering ConsultantsAVJ Engineering Consultants Quantified Business Results
�Client: Delhi Jal Board�Project: Rithal ETP�Application: Pump�Liquid: Water�Motor Power: 280 KW�Voltage: 3.3 KV�Speed of Pump: 1466 RPM�Quantities: 8 Nos.Performance Parameters:
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Performance Parameters:
Full Load Current: 63 Amps
Magnadrive Coupling: FGC 21.0S
Current Drawn with
Magnadrive Coupling: 46 Amps
Energy Savings: 78 KWH
Energy Saving in Rs. 40.80L / Yr.
Magnadrive Magnetic Coupling
Model FGC 21.0S
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AVJ Engineering ConsultantsAVJ Engineering Consultants
�Client: SAIL�Project: BSP�Application: Pump�Liquid: Hot Benzyl�Flow: 40m3/Hr�Motor Power: 45 KW�Voltage: 415 Volts�Speed of Pump: 2980 RPM�Quantities: 4 Nos.
Quantified Business Results
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�Quantities: 4 Nos.Performance Parameters:
Current before
Magnadrive: 53 Amps
Magnadrive Coupling: MGE - 11
Current Drawn with
Magnadrive Coupling: 43 Amps
Energy Saving in Rs. 201480 / Yr.
Reduction in CO2
Emission: 1 Ton / Day from 4 Couplings.
Magnadrive Coupling Model MGE-11 At Coke Oven Bhilai Steel PlantPerformance Certificate for MGE-11 from BSP Coke Oven.pdfE:\VKM OWN\BSP\Coke Oven\Minutes of the Meeting.pdf
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AVJ Engineering ConsultantsAVJ Engineering Consultants
�Client: SAIL�Project: BSP WMD�Application: Pump�Liquid: Water�Motor Power: 110 KW�Voltage: 415 Volts�Speed of Pump: 1480 RPM�Quantities: 6 Nos.Performance Parameters:
Current before
Quantified Business Results
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Current before
Magnadrive: 163 Amps
Magnadrive Coupling: FGC – 16.5
Current Drawn with
Magnadrive Coupling: 134 Amps
Energy Savings: 17 KWH
Energy Saving in Rs. 438000 / Yr.
Performance_certificate_from_WMD.pdf
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AVJ Engineering ConsultantsAVJ Engineering Consultants
�Client: Tata Motors Pune�Project: ETP�Application: Pump�Liquid: Effluent �Motor Power: 15 KW�Voltage: 415 Volts�Speed of Pump: 1480 RPM�Quantities: 1 Nos.Performance Parameters:
Power before
Quantified Business Results
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Power before
Magnadrive: 9.77 KW
Magnadrive Coupling: MGE-11
Power Consumed with
Magnadrive Coupling: 6.91 KWH
Energy Savings: 2.9 KWH
Energy Saving in %. 25%
Performance Report for MGE 11 from Tata Motors.pdf
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AVJ Engineering ConsultantsAVJ Engineering Consultants
�Client: Tata Steel Tata Nagar�Location: Power House - 4�Application: Pump�Liquid: Effluent �Motor Power: 75 KW�Voltage: 415 Volts�Speed of Pump: 1480 RPM�Quantities: 1 Nos.Performance Parameters:
Power before
Quantified Business Results
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Power before
Magnadrive: 50.6 KW
Magnadrive Coupling: FGC 16.5S
Power Consumed with
Magnadrive Coupling: 44.27 KWH
Energy Savings: 6.3 KWH
Energy Saving in %. 12.45%
Magnadrive Magnetic Coupling Model
FGC 16.5S at Tata Steel
PERFORMANCE REPORT FOR FGC 16.5S for pump by AVJ.pdf
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AVJ Engineering ConsultantsAVJ Engineering Consultants Quantified Business Results
�Client: Tata Steel Tata Nagar�Location: Coal Plant �Application: Conveyor No. 4A�Motor Power: 75 KW�Voltage: 415 Volts�Speed of Pump: 1480 RPM�Quantities: 1 Nos.Performance Parameters:
Power Consumption Before
Magnadrive: 54.1 KW
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Magnadrive: 54.1 KW
Magnadrive Coupling: FGC 16.5S
Power Consumed with
Magnadrive Coupling: 50.1 KW
Energy Savings: 4.0 KWH
Energy Saving in %. 8%
Continue
FGC 16.5S on Conveyor No. 4AAt Tata Steel Ltd.
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AVJ Engineering ConsultantsAVJ Engineering Consultants Quantified Business Results
Study Report by Tata Steel Ltd for 75 KW Conveyor
Study Report of MAGNA Drive r1 for conveyor of Tata Steel.pdf
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AVJ Engineering ConsultantsAVJ Engineering Consultants Quantified Business Results
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Magnadrive Magnetic Adjustable Speed Drive Model ASD 26.5 for 190 KW IDFan at Jindal Steel & Power Ltd. RaigarhPerformance parameters for ASD 26.5 from JSPL.pdf
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AVJ Engineering ConsultantsAVJ Engineering Consultants Quantified Business Results
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Magnadrive Magnetic Adjustable Speed Drive Model ASD 26.5 for 190 KW 6.6 KV ID Fan at Jindal Steel & Power Ltd. Raigarh Energy Savings around 73 KWH
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AVJ Engineering ConsultantsAVJ Engineering Consultants
The starting current reduced by: 27%Power Reduction by: 2.25 KW
Quantified Business Result for MGE 07 at Infosys Hyderabad.pdf
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% Energy savings: 26%Pay Back period:
KWH saved: 2.25Hrs of operation: 18Hrs / Year: 6570Cost of Power in Rs.: 6Per Year Energy savings: 2.25X6570X6 = Rs. 88695Per Month Saving in Rs.: 88695 / 12 = Rs. 7392Cost of MGE 07: Rs. 70478.00 Pay Back Period: 9.5 Months.
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AVJ Engineering ConsultantsAVJ Engineering Consultants Competitive Analysis
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Operation Mechanical Benefits
Variable Speed X X X s Non-contact Power Transfer X X s s
Process Control X X X s s Reduce Vibration X X
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Process Control X X X s s Reduce Vibration X XEnergy Efficiency X X s s Reduce Wear X X s
Overload/Failure Protection s X s Misalignment Tolerance X XConstant Load s X s X X Reduce Power In-Rush X X X X s
Hi/Medium Voltage (High HP) X X s X s Soft Start/Stop X X X X s
Increase Bearing, Seal, Eqpt Life X X
Cost Benefits Electrical/Electronics Issues
Ease of Installation X X s Complex to Install/Support XTroubleshooting Ease X X X s Extensive Infrastructure X
Lower Maintenace Costs X X s Sensitive to Power Quality XMaintained In-house X X X s Harmonic Distortion XLonger Service Life X X X s Frequent Parts Replacement X
Reliability/Reduce Downtime X X s Parts Obsolescence XLower Total Cost (1-50HP) XLower Total Cost (50HP+) X
X = Very Characteristics = Somewhat Characteristic
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