Siemens ROBICON Perfect Harmony Electric utility improves fuel efficiency with VFDs
Siemens ROBICON Perfect Harmony Electric utility improves fuel efficiency with VFDs
usa.siemens.com/perfectharmony Intro A global electric utility with more than 20 U.S. power plants needed to increase efficiency and throughput in order to improve profitability. The utility was using fuel-inefficient, high-emission mechanical flow control methods to control the process flow of electric motor-driven fans, pumps and compressors. The constant-speed process motors created excessive inrush current during starting, thus limiting the number of starts over a period of time and making it difficult to accurately control process speeds. Challenge Depending on each plant’s specific regulations, the utility wanted to decrease auxiliary power requirements in order to achieve one of two outcomes. Outcome one: The plant would burn the same amount of fuel and create the same level of emissions, but increase its net MW output by the value of the reduced auxiliary. Outcome two: The plant would burn less fuel and generate fewer emissions, since less auxiliary power is needed, and produce the same net MW output. Lifecycle cost was a significant factor, as the utility measured the ROI of all new purchases over a 20-year period. Plus, the utility wanted to reuse the original medium-voltage constant-speed motors, as purchasing new motors would negatively affect the project ROI. Solution The local Siemens representative worked closely with the utility to gather real-world process operating parameters and perform calculations to compare the power consumption of the existing constant speed motors with that of a medium voltage variable frequency drive (MV VFD) across the 20 power plants. The Siemens ROBICON Perfect Harmony VFD proved to offer significant energy savings, along with substantial ROI and low total cost of ownership, due to its 20-year life expectancy. The utility selected the Siemens ROBICON Perfect Harmony drive for these reasons, as well as for its built-in reliability. Siemens ROBICON Perfect Harmony Electric utility improves fuel efficiency with VFDs The unique mechanical Advanced Cell Bypass feature allows the drive to remain operational in the unlikely event of a device power failure. Other MV VFD technologies shut down under these circumstances, which could cause the entire power plant to shut down. Due to the opportunity costs associated with a power plant not producing power, other MV VFD technologies have an extremely long ROI, which the utility would not approve. Results The Siemens ROBICON Perfect Harmony improved fuel efficiency across all 20 plants. Some facilities increased net MW output, and others burned less fuel—improving profitability. And because all 20 plants used the same drive, the utility benefited from spare parts availability and service alignment across locations. Benefits • Improved reliability and performance: Advanced Cell Bypass allows the drive to bypass any one cell during operation while maintaining the full output voltage. • Broad compatibility: IGBT-based topology allows the drive to be scaled precisely for a very wide range of voltage and output power. • Increased energy efficiency: Synchronous transfer reduces stress on the power grid and equipment during simultaneous motor startup. • Reduced total cost of ownership: 50+ technologies decrease downtime, improve energy efficiency and limit wear and tear—extending the drive’s life to up to 20 years. • Fast, dependable customer service: Real medium voltage drive technicians provide support throughout the lifecycle, from quoting, commissioning and on-site training to 24 / 7 / 365 call center support and nationwide field service. About The Siemens ROBICON Perfect Harmony drive features a series of linked low-voltage cells that build the mediumvoltage power output of the drive system. With this topology, the drive can be scaled precisely for a very wide range of voltage and output power. Its ability to bypass any one cell during operation while maintaining the full output voltage offers unsurpassed availability and reliability. An integral transformer with phase-shifted secondaries eliminates the need for input harmonic filters or power factor compensation. This results in output voltage so close to perfect sine-wave shape that motors of literally any type—old or new, low-speed or high-speed—can be operated without any additional stress. And the drive’s industry-leading reliability is further backed by live, U.S.-based support. Siemens engineers are available to assist with everything from quoting and factory acceptance testing through training, commissioning and long-term technical support. With 10,000 installations, the Siemens ROBICON Perfect Harmony is the best-selling drive worldwide. Siemens Industry, LDAP 500 Hunt Valley Road New Kensington, PA 15068 [email protected] 1-800-241-4453 Subject to changes without prior notice All Rights Reserved Order No: LAFL-01800-0913 Printed in USA ©2013 Siemens Industry, Inc.
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