AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 1MAGNADRI.WMVAVJ Engineering ConsultantsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 2 AVJ Engineering Consultants was established in the year 2009 after working for 36 years and is based at:Flat No.1, Plot No.21,Mahabali Housing Society,Karve Nagar,Pune 411052Telefax: 912025460104Mobile: 919923413733Mail ID: vinod@avjengineering.comWebsite: www.avjengineering.comAVJ Engineering Consultants will be known as AVJ Engineering & Marketing Pvt. Ltd.AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 3Presentation on Reduction in Auxiliary Power Consumption and Red Presentation on Reduction in Auxiliary Power Consumption and Reduction inuction in O&M Cost Through O&M Cost ThroughMagnaDrive Magnetic Couplings and Adjustable Speed Drives (ASD)The Next Industrial RevolutionByVinod. MalhotraAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 4MagnaDrive, Seattle USAFlownetix, UKElectromagnetic & Ultrasonic Flow Meters Jyoti Limited, Baroda Pumps, Motors & Switch GearsEssential Power Transmission Gear Boxes Baldor Electric - Premium Efficiency Motors and Adjustable Speed Direct Drive Cooling Tower Motors. About AVJ Engineering ConsultantsAVJ is Distributor & Marketing Associates for:AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 5Magnadrive Magnadrive Couplings and ASD Couplings and ASDUltrasonic Flow MetersUltrasonic Flow Meters Baldor Baldor CoolingCooling Tower Direct DriveTower Direct Drive Motors MotorsFlownetix Flownetix Ultrasonic Smart Ultrasonic SmartWater Meters Water MetersAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013MagnaDrives Value PropositionMagnaDrives revolutionary disconnected torque-transfer technology reduces your total cost of ownership by lowering maintenance and operating costs, increasing process availability, and improving system reliability.MagnaDrive BenefitsMagnaDrive is the Only GREEN TechnologyWhich Offers Dual Benefits - Saves Energy & Reduces O&M Cost also AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 7 Founded in 1999 Technology of the Year by Industry Weekfor 2001 20 Domestic Patents and More than 200 International Patents Installed on Over 16,000 Systems Recently Awarded $2.7 million Contract by U.S. NavyAbout MagnaDriveAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013About MagnaDrive 2004 Inc. 500 Fastest Growing Private CompaniesAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013About MagnaDrive 2004 Inc. 500 Fastest Growing Private Companies 2004 Deloitte 500 Fastest Growing Technology CompaniesAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013About MagnaDrive Inc. 500 Fastest Growing Private Companies Deloitte 500 Fastest Growing Technology CompaniesAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 11 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. Its a simple but effective mechanical technology that is GREEN gives following advantages Reduces energy consumption Reduces motor stress at start-up Cushions shock loads and eliminates motor seizure Tolerates misalignment and thermal expansion Extends equipment life and reduces maintenance requirements through reduced vibration and cavitations AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 12Principle of OperationMagnet & Copper Penny Demo.wmvAVJ Engineering Consultants AVJ Engineering Consultants13MagnaDrive BenefitsA Mechanical,Non-Electronic DeviceA Mechanical,Non-Electronic DeviceImagineEasy to InstallEasily Understood Eliminates Motor SeizureOperates While MisalignedControls Load SpeedCushioned StartExtends Equipment LifeCushions Shock LoadsReduces VibrationCompactAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 14 PumpsApplication TypesTarget MarketAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 15 Pumps FansApplication TypesTarget MarketAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 16 Pumps Fans BlowersApplication TypesTarget MarketAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 17 Pumps Fans Blowers CentrifugesApplication TypesTarget MarketAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 18 Pumps Fans Blowers Centrifuges Bulk HandlingApplication TypesTarget MarketAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 19 MagnaDrive is not only a Drive but a Total Solutionto Achieve Lower Total Cost of OwnershipMagnaDriveEnergy Zero Vibration Works in MisalignmentNo Throttling Lower O&M cost No Motor SeizureABSOLUTESAVINGSMagnaDrive is SolutionLower Motor RatingsLOWER COST OF OWNERSHIPRESULTMagnaDrive THE Solution ModuleLower Starting CurrentAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 20 Couplings Adjustable Speed Drives (ASDs)Product LinesAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 21Coupling Range and Models Constant and Variable Torque 1 to 5,000 HP Applications Four Models: First Generation Coupling (FGC) Delay (MGD) Torque Limiting (MGTL)Magnetic CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 FGC - First Generation Coupling MGD Magnaguard Delay MGTL- MagnaDrive Torque LimitingCouplings:FGC MGTLMGDPermanent Magnet CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013Product Overview -CouplingsFGC Product Line 3 to 5000 HP @1500 Variable and Constant Torque applications Can deliver higher starting torques Cushioned start desired Shafts: standard or special sizes Dist. Between Shaft ends (DBSE): within or beyond standard rangeAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013FGC CouplingLOAD HUBMOTOR HUBCONDUCTOR STEELCOPPER CONDUCTORCOPPER CONDUCTORCONDUCTOR STEELALUMINUM MAGNET ROTORMAGNETSAIR CLEARANCE (GAP)AIR GAP SPACERSHRINK DISC SHRINK DISCAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 Air Gap Increases from 1/8 to 3/16 inch During Start Up Gap Change Reduces Torque Transfer About 50% for Cushioned Smooth Start MGD Also Has Partial Disconnect Feature Built InMGD Product LineProduct Overview -CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013LOAD HUBMOTOR HUBCONDUCTOR STEELCOPPER CONDUCTOR COPPER CONDUCTORCONDUCTOR STEELALUMINUM MAGNET ROTORSMAGNETSAIR CLEARANCE (GAP)AIR GAP SPACERSHRINK DISCSHRINK DISCProduct Overview -MGDAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 All the Features of the MGD, Plus MGTL has Complete Disconnect Feature Built In Complete Disconnection Results 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 OffMGTL Product LineProduct Overview CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013Coupling Benefits - MGTLLOAD HUB MOTOR HUBCONDUCTOR STEELCOPPER CONDUCTOR COPPER CONDUCTORCONDUCTOR STEELALUMINUM MAGNET ROTORSMAGNETSAIR CLEARANCE (GAP)AIR GAP SPACERSHRINK DISCSHRINK DISCAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 Offers Low Maintenance Simple Installation Efficient Torque Transfer Permits Shock Loadings (Load is Cushioned & Slips) Greater Misalignment Tolerance Ideal for Applications Subject to: Vibration Periodic Load Seizure Pulsating Loads Thermal Expansion Higher Starting Inertia/TorqueCoupling Benefits:FGC & MGEMGTLMGDProduct Overview -CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 30Type 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 Speed New Torque= Original Torque Speed2 New HP= Original HP Speed3 In other words, flow varies proportionally with change in speed ( 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). AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 31(HP1 / HP2) = (Flow1 / Flow2)3Technology TechnologyAffinity (or Fan) LawsProportion 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%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% Torque Transmitted & Flow Are Reduced By Increasing the ASD Air Gap A 1% Reduction in 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 SavingsEnergy Savings May be Greater Due to Reduced Vibration and Misalignment Tolerance of MagnaDrive Air GapEnergy Savings May be Greater Due to Reduced Vibration and Misalignment Tolerance of MagnaDrive Air GapAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 32 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 increaseit 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 of the process, even though you are not saving any energy.AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 33Flexible / Elastomeric CouplingsFlexible / Elastomeric CouplingsRigid Couplings Rigid CouplingsFlexible Shaft Rubber (Tire) Jaw PinRigid Chain Gear DiscFixed Speed Mechanical CouplingsFixed Speed Mechanical CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 34AngularMisalignmentParallel / OffsetMisalignmentAxial Misalignment All couplings are subject to:Fixed Speed Mechanical CouplingsFixed Speed Mechanical CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 35Motor Shaft Load Shaft MagnaDrive has a unique design:Permanent MagnetRotorPermanent MagnetRotorAir Gap Air GapCopper ConductorRotorCopper ConductorRotorFixed Speed Mechanical CouplingsFixed Speed Mechanical CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 36Motor Shaft Load ShaftMagnaDrivecan operate withAngular MisalignmentMagnaDrivecan operate withAngular MisalignmentFixed Speed Mechanical CouplingsFixed Speed Mechanical CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 37Motor Shaft Load ShaftMotor Shaft Load Shaft Motor Shaft Load ShaftMagnaDrivecan operate withParallel MisalignmentMagnaDrivecan operate withParallel MisalignmentMagnaDrivecan operate withAxial MisalignmentMagnaDrivecan operate withAxial MisalignmentMagnaDrivecan operate withAngular MisalignmentMagnaDrivecan operate withAngular MisalignmentFixed Speed Mechanical CouplingsFixed Speed Mechanical CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 38 Lower Inrush at Startup Lowers Peak Demand Immediate RestartsCushioned StartCoupling TechnologyEnergy Savings as a result Energy Savings as a resultof removing systemof removing system inefficienciesinefficiencies Reduced starting power requirement Reduced starting power requirementAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 39 Motor Characteristics Up to 5000 HP Motors @ 1500 RPM Up to 3000 HP Motors @ 3000 RPM Vibration Isolation Vibration.mpg.mpg Alignment Problems MagnaDrive Corp - Distributor Demos -Misalignment.wmv Need for Cushion Start Thermal Expansion Issues Shaft Seizure Issues Mechanical Seals are Present Need to Protect Critical EquipmentCouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 40Rigid & Flexible CouplingsRigid & Flexible CouplingsMagnaDrive (MGE/FGC/MGD/MGTL)MagnaDrive (MGE/FGC/MGD/MGTL) All mechanical couplings are somehow physically connected causing:MisalignmentVibration transferPremature equipment failureEnergy waste due to misalignment The disconnected nature of the MagnaDrive connection (air gap) provides:Misalignment allowance up to 3 degreesNo vibration transferLonger equipment life (bearings, seals, etc.)Energy savings due to motor/load disconnection Installation, operation, & maintenance issues:Time and money spent on laser alignmentTime and money spent maintaining equipmentProduction downtime costsNo overload torque protectionSome types require grease/oilHard start causes extra stress on equipment and energy spikesNo speed adjustability Installation, operation, & maintenance issues:Virtually no time and money spent on alignmentLess time and money spent maintaining equip.Lower production downtime costsOverload protectionMagnaDrive is a GREEN technologyCushioned and delayed start increases equipment life and provides lower peak demand and inrush (additional energy savings)MagnaDrive couplings can be fine tuned to save energyIncreased costof ownershipLower costof ownershipFixed Speed Mechanical CouplingsFixed Speed Mechanical CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 41 Fluid Couplings Applications: Bulk Material Systems Conveyors: Coal Handling Ash HandlingAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 42Fixed Speed Fluid / Hydraulic CouplingsFixed Speed Fluid / Hydraulic CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 43Fluid Coupling Issues - OilFluid Coupling Issues - OilFixed Speed Fluid / Hydraulic CouplingsFixed Speed Fluid / Hydraulic CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 44Fluid Coupling Issues High MaintenanceFluid Coupling Issues High Maintenance"Replacementpartsforfluidcouplingsarenotoriously expensive.However,wehadnochoicebuttokeep payingoutastheDryer-PulveriserMillissuchakey elementwithintherefineryprocess.Unfortunatelywe wereinalose-losesituation,whentheapplication faltereditnotonlycostusmoneytofixit,itwasalso costing us money for the duration it was off-line."Thecouplingrequiresinspectionevery12weekswith frequentoiltopups, theoilusedwithinafluidcoupling ishighlyvolatile.Thecouplingincorporatesafusible drainplugwhichisdesignedtodischargeoilifthe operatingtemperatureistoohigh.Thisfeaturewas causingaconsiderablehealthandsafetyriskto operators, we had experienced several fires in the past causedbyhotoilblowingthefusibleplugand consequently igniting.http://www.hub-4.com/news/696/wbb-minerals-grind-down-maintenance-costs-using-siemens-soft-startersFixed Speed Fluid / Hydraulic CouplingsFixed Speed Fluid / Hydraulic CouplingsSource:AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 45Fluid Coupling Issues - HazardousFluid Coupling Issues - HazardousFixed Speed Fluid / Hydraulic CouplingsFixed Speed Fluid / Hydraulic CouplingsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 46Fixed Speed Fluid / Hydraulic CouplingsFixed Speed Fluid / Hydraulic CouplingsFluid Coupling Issues - HazardousFluid Coupling Issues - HazardousAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 47http://www.msha.gov/fatals/2002/ftl02m17.htm2002 Fatality Accident with a major brandFluid Couplingat Lone Star Quarry & MillLone Star Industries, Inc.Cape Girardeau, MOFor Official Accident Report Go To:Fixed Speed Fluid / Hydraulic CouplingsFixed Speed Fluid / Hydraulic CouplingsFluid Coupling Issues - HazardousFluid Coupling Issues - HazardousAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 48Curbing the killer ConveyorsRecentlyasteelworkerwasinjuredwhenaninclinedconveyorran backwards,outofcontrol,andthefluidcouplinginthedrivetrain explodedlikeabomb,spreadingshrapnelandhothydraulicoil everywhere. It should never have happened.Thefluidcouplingissizedtosoft-starttheconveyorandprotectthe motor/drive package from overloads. It is made from aluminum and is intended to run, in this case, at 1,500 to 1,800rpm. If it is run at speeds of up to 6,000rpm then the aluminum casing will be put under massive centrifugalloadssufficienttomakethewholethingexplodelikea bomb.Then,whenthedrivetrainfailsandtheconveyorback-drives,the fluid coupling becomes a bomb just waiting to explode.http://www.renold.com/Company/News/Curbing_the_killer_conveyors.aspFixed Speed Fluid / Hydraulic CouplingsFixed Speed Fluid / Hydraulic CouplingsSource:Fluid Coupling Issues - HazardousFluid Coupling Issues - HazardousAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 49Anundermanagerandadeputyonabackshift were attempting to change the oil in a leaking fluid coupling.Themenwereinexperiencedinthistask whichresultedinthedeputyreceivingoilburnsto his face.http://www.cfmeu.com.au/storage/documents/Apr00CC.pdfFixed Speed Fluid / Hydraulic CouplingsFixed Speed Fluid / Hydraulic CouplingsSource:Fluid Coupling Issues - HazardousFluid Coupling Issues - HazardousAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 50Performance of Magnetic Couplings in Bulk Material Handling Systems:MAGNADRIVE - BWE - ThyssenKrupp, Australia.wmvMAGNADRIVE - CONVEYOR - 1400 Ton Per Hour Conveyor in Australia.wmvMAGNADRIVE+-+CONVEYOR+-+Australia+-+SWCC+-+Thiess.wmvApprehensions:Weather Magnetic Couplings will work in dusty environment?+Chile.wmvDust Flying MAGNADRIVE - Tura - TURKEY (1).wmvAVJ Engineering Consultants AVJ Engineering Consultants Comparative Study between VFD and Magnadrive on Energy Savings in Conveyor:MAG Drive kilo Watt051015202530351 5 9 1317 21 2529 3337 41 4549 5357 6160 Minute IntervalkWMAG Dri ve ki l o WattPower consumption for Magnetic DrivePower Consumption per hour - 1600.16 kWhAverage Power per hour - 26.23 kWAVJ Engineering Consultants AVJ Engineering ConsultantsVSD Drive kilo Watt01020304050601 5 9 13 17 21 25 29 33 37 41 45 49 53 57 6160 Minute IntervalkWVSD Dri ve ki lo WattPower consumption for Variable Speed DrivePower Consumption per hour - 1933.08 kWhAverage Power per hour - 31.68 kWAVJ Engineering Consultants AVJ Engineering Consultants Magnadrive/VSD Power Consumption Comparison GraphMAG/VSD Comparison Graph01020304050601 5 9 1317 21 2529 3337 41 4549 5357 6160 Minute IntervalkWMAG Dri ve ki l o WattVSD Dri ve ki l o WattEnergy Savings in conveyor Mooikraal Drive Recordings.xlsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 54Fluid CouplingsFluid Couplings Fluid Couplings are not totally disconnected and are subject to:Misalignment and vibration transferPremature 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 issuesLonger 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 alignmentFluid Couplings are difficult to install and maintainTime and money spent maintaining equipmentMost Fluid Couplings can not operate in both directions of rotationFluid Couplings are filled with oil which is a hazard for the environment and peopleThe Fluid Coupling over torque 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 alignmentMagnaDrive Couplings have no oil, are lighter, and easier to install and are safe for people and environmentLess time and money spent maintaining equip.MagnaDrive Couplings transmit the same torque in either direction of rotationMagnaDrive is a GREEN technology and does not use any oilMagnaDrive Couplings basically slip if there is an over torque condition, and certain models (MGTL) also offer a complete disconnect featureIncreased costof ownershipLower costof ownershipFixed Speed Fluid / Hydraulic CouplingsFixed Speed Fluid / Hydraulic CouplingsMagnaDrive (FGC/MGD/MGTL)MagnaDrive (FGC/MGD/MGTL)AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 55Adjustable Speed Drive (ASD)AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 56Variable Speed Valve / Damper SystemsVariable Speed Valve / Damper SystemsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 57Variable Speed VFDs (Variable Frequency Drives)Variable Speed VFDs (Variable Frequency Drives)AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 58Variable Speed VFDs (Variable Frequency Drives)Variable Speed VFDs (Variable Frequency Drives)Principle of OperationPrinciple of OperationAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 59Variable Speed VFDs (Variable Frequency Drives)Variable Speed VFDs (Variable Frequency Drives)VFD Issues Installation Complexity and Space RequirementVFD Issues Installation Complexity and Space RequirementBuilding to house VFDsBuilding to house VFDsMagnaDrive minimal space requirement and simple installationMagnaDrive minimal space requirement and simple installationAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 60Product Lines Variable Gap For Adjustable Speed Air-Cooled: Sizes 20 to 500 Hp @ 1500 RPM Horizontal & Vertical Applications Water-Cooled 500 through 4,500 Hp @ 1500 RPM Horizontal & Vertical ApplicationsAdjustable Speed DrivesAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 61 Variable Speed Control for Energy Savings Low System Maintenance Accepts Greater Misalignment 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 StrikesASD BenefitsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 62Adjustable Speed Drive (ASD) For Speed Control and Energy Savings ASD Energy Savings Demo.wmv ASD energy savings New.wmvAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 63Largest ASD Supplied by Magnadrive for ID fan of 3037 HP / 980 rpm6 Nos. To China.MagnaDrive Corp - Fan - ID Fan on Power Plant, China.wmvAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 64VFDsVFDsMagnaDrive ASDsMagnaDrive ASDs The disconnected nature of the connection (air gap) provides:No misalignment and vibration issuesLess time and money spent aligning and maintaining equipmentLonger equipment lifeCushioned startNo load startEnergy savings due to motor / load disconnectionOverload protectionIncreased costof ownershipLower costof ownershipVariable Speed VFDs (Variable Frequency Drives)Variable Speed VFDs (Variable Frequency Drives) Equipment connected with VFDs still has a physical connection between the motor and load shaft causing:Misalignment and vibration transferPremature equipment failureEnergy waste due to misalignmentNo overload protection Special issues and installation requirements:Require inverter duty motorsAre susceptible to dirty powerRequire environment control (temp, dust, hum.)Complexity of equipment and installationAre expensive in medium/high voltageRapid obsolesce (6-7 years)/throw awayMotors control space requirement Operation & maintenance issues:HarmonicsBearing FlutingNo rapid restart capability MagnaDrive ASDs:Operates with any kind of motorIs not affected by dirty powerIs not affected by temperature, dust, humidity and other factors in the operating environmentAre simple to install and maintainHave a life span of 20 25 years, depending on operating conditions Operation & maintenance issues:No issues with harmonicsNo issues with bearing flutingRapid restart capabilityAVJ Engineering Consultants AVJ Engineering ConsultantsName of Customer Loation!t"# in Nos#Appliation Drive $o%er in &W StatusDelhi 'al (oar) Delhi * $ump Couplin+ ,-0 Installe)(hilai Steel $lant Coke .ven / $ump Couplin+ /0 Installe)(hilai Steel $lant WMD 6 $ump Couplin+ 110 Installe)'in)al Steel 2 $o%er $o%er 3ouse 1 ID 4an ASD 1-0 Installe)5ata Motors $une 1 $ump Couplin+ 10 Installe)5ata Steel $o%er 3ouse / 1 $ump Couplin+ 60 Installe)5ata Steel Coal $lant 1 Conve"or Couplin+ 60 Installe)7eliane 8ner+" C3$ 1 Conve"or Couplin+ 110 Installe)(hilai Steel $lant Sinter $lant 1 Conve"or Couplin+ 00 Supplie)(hushan Steel Lt) De%aterin+ 1 $ump Couplin+ 1*#0 Installe)Infos"s Lt) 85$ 1 $ump Couplin+ 6#0 Installe)NALC.C3$ 1 Conve"or Couplin+ 96#0 Installe)5ata Steel Coke $lant 1 Crusher Couplin+ 000 :n)er Installation'in)al $o%er $o%er 3ouse 1 $ump Couplin+ 11 Installe)Calutta 8letri Suppl" Compan" C3$ 1 Conve"or Couplin+ /0 Installe):nite) $hosphrous Lt) Compressor 3ouse 1 Compressor Couplin+ -0 Installe)7eliane 8ner+" 7osa C3$ 1 Air $re 3eater Couplin+ 1*#0 Shippe)7eliane 8ner+" Dahanu Ash 3an)lin+ $lant 1 Ash 3an)linp $ump Couplin+ ,90 Installe)N5$C Aurai"a Gas $lant DM $lant 1 DM 5ransfer $ump Couplin+ 1*#0 Installe)N5$C 5an)a 5hermal $o%er $lant C3$ 1 Crusher Couplin+ /00 :n)er ShipmentN5$C 5an)a 5hermal $o%er $lant C3$ 1 Conve"or Couplin+ 110 Shippe)Infos"s (an+alore 3VAC 1 Chiller $ump Couplin+ 1*#0 :n)er ShipmentList of Indian CustomersAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 66Plant Head Mr. Nandi Inaugurating Magnadrive Magnetic Coupling Model FGC 18.5Son Conveyor No. 6A At Dahanu Thermal Power StationQuantified Business ResultsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 67Magnadrive Magnetic Coupling Model FGC 18.5S At Dahanu Thermal Power StationQuantified Business ResultsClient: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 withMagnadrive : 37.36 KWEnergy Savings: 2.14KWHEnergy Savings / Yr: 18747 KWHEnergy Saving / Yr. in Rs.: 93732.00Other BenefitsReduction in Vibration LevelZero MaintenanceIncreased MTBFPerformance report of FGC 18.5S on 110 KW Conveyor at Dahanu Thermal Power.pdfAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 68Quantified Business ResultsClient: Delhi Jal BoardProject: Rithal ETPApplication: PumpLiquid: WaterMotor Power: 280 KWVoltage: 3.3 KVSpeed of Pump: 1466 RPMQuantities: 8 Nos.Performance Parameters:Full Load Current:63 AmpsMagnadriveCoupling: FGC 21.0SCurrent Drawn withMagnadrive Coupling: 46 AmpsEnergy Savings: 78 KWHEnergy Saving in Rs. 40.80L / Yr.Magnadrive Magnetic CouplingModel FGC 21.0SAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 69Client: SAILProject: BSPApplication: PumpLiquid: Hot BenzylFlow: 40m3/HrMotor Power: 45 KWVoltage: 415 VoltsSpeed of Pump: 2980 RPMQuantities: 4 Nos.Performance Parameters:Current before Magnadrive:53 AmpsMagnadriveCoupling: MGE - 11Current Drawn withMagnadrive Coupling: 43 AmpsEnergy 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.pdfQuantified Business ResultsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 70Client: SAILProject: BSP WMDApplication: PumpLiquid: WaterMotor Power: 110 KWVoltage: 415 VoltsSpeed of Pump: 1480 RPMQuantities: 6 Nos.Performance Parameters:Current before Magnadrive:163 AmpsMagnadriveCoupling: FGC 16.5Current Drawn withMagnadrive Coupling: 134 AmpsEnergy Savings: 17 KWHEnergy Saving in Rs. 438000 / Yr.Quantified Business ResultsPerformance_certificate_from_WMD.pdfAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 71Client: Tata Motors PuneProject: ETPApplication: PumpLiquid: Effluent Motor Power: 15 KWVoltage: 415 VoltsSpeed of Pump: 1480 RPMQuantities: 1 Nos.Performance Parameters:Power before Magnadrive:9.77 KWMagnadriveCoupling: MGE-11Power Consumed withMagnadrive Coupling: 6.91 KWHEnergy Savings: 2.9 KWHEnergy Saving in %. 25%Quantified Business ResultsPerformance Report for MGE 11 from Tata Motors.pdfAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 72Client: Tata Steel Tata NagarLocation: Power House - 4Application: PumpLiquid: Effluent Motor Power: 75 KWVoltage: 415 VoltsSpeed of Pump: 1480 RPMQuantities: 1 Nos.Performance Parameters:Power before Magnadrive:50.6 KWMagnadriveCoupling: FGC 16.5SPower Consumed withMagnadrive Coupling: 44.27 KWHEnergy Savings: 6.3 KWHEnergy Saving in %. 12.45%Magnadrive Magnetic Coupling Model FGC 16.5S at Tata SteelQuantified Business ResultsPERFORMANCE REPORT FOR FGC 16.5S for pump by AVJ.pdfAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 73Quantified Business ResultsClient: Tata Steel Tata NagarLocation: Coal Plant Application: Conveyor No. 4AMotor Power: 75 KWVoltage: 415 VoltsSpeed of Pump: 1480 RPMQuantities: 1 Nos.Performance Parameters:Power Consumption Before Magnadrive:54.1 KWMagnadriveCoupling: FGC 16.5SPower Consumed withMagnadrive Coupling: 50.1 KWEnergy Savings: 4.0 KWHEnergy Saving in %. 8%ContinueFGC 16.5S on Conveyor No. 4AAt Tata Steel Ltd.AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 74Quantified Business ResultsStudy Report by Tata Steel Ltd for 75 KW ConveyorStudy Report of MAGNA Drive r1 for conveyor of Tata Steel.pdfAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 75Magnadrive Magnetic Adjustable Speed Drive Model ASD 26.5 for 190 KW IDFan at Jindal Steel & Power Ltd. Raigarh Performance parameters for ASD 26.5 from JSPL.pdfQuantified Business ResultsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 76Quantified Business ResultsMagnadrive 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 AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 77The starting current reduced by: 27%Power Reduction by: 2.25 KW% 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.Quantified Business Result for MGE 07 at Infosys Hyderabad.pdfAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 78Competitive AnalysisMagnaDrive ASDMagnaDrive Coupling VFDEddy CurrentMechanical DevicesFluid and Belt DrivesMagnaDrive ASDMagnaDrive CouplingVFDEddy CurrentMechanical DevicesFluid and Belt DrivesOperation Mechanical BenefitsVariable Speed X X X s Non-contact Power Transfer X X s sProcess Control X X X s s Reduce Vibration X XEnergy Efficiency X X s s Reduce Wear X X sOverload/Failure Protection s X s Misalignment Tolerance X XConstant Load s X s X X Reduce Power In-Rush X X X X sHi/Medium Voltage (High HP) X X s X s Soft Start/Stop X X X X sIncrease Bearing, Seal, Eqpt Life X XCost Benefits Electrical/Electronics IssuesEase of Installation X X s Complex to Install/Support XTroubleshooting Ease X X X s Extensive Infrastructure XLower 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 XReliability/Reduce Downtime X X s Parts Obsolescence XLower Total Cost (1-50HP) XLower Total Cost (50HP+) XX = Very Characteristics = Somewhat CharacteristicAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013 79AVJ Engineering Consultants AVJ Engineering Consultants8/23/2013US NavyAbout MagnaDrive Over 1,000 Couplings Delivered Applications from 40 to 500 hp No Electromagnetic Interference (EMI) Issues Fire Suppression System Pumps Seawater Pumps Aircraft Carrier JP-5 Fuel Pumps Testing Adjustable Speed Drive ApplicationsAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013US Navy Seawater PumpAbout MagnaDriveAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013MagnaDrive UpdateAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013MagnaDrive UpdateAVJ Engineering Consultants AVJ Engineering Consultants8/23/2013