Across the globe the surge of technology and smarter approach on industrial processes has also brought in an increasing demand for energy saving devices. Amongst all industrial sectors the one which is in strict need for implementing energy saving microprocessors and drivers is in A.C induction motors and other areas of mechanics. However, when the question of power efficiency arises confusion comes in between the VFD and traditional FCV.
From an entrepreneur’s point of view which of the one if used rightly can save up to targeted 10-60% of energy, hence leveraging the ROI in 6-24 months turns into a big and confusing question. Here is a brief take on both VFD and FCV to chalk out which one is more effective on the efficiency front.
To put simply, Variable Frequency Drive has high-end precision and is specifically designed to control the speed of a.c induction motors. The precision of VFD lies in the fact that it controls the speed of flow in induction motors without affecting its electric consumption, torque, magnetic flux, electric impedance and other associated factors.
Nowadays, with improvements in technology field traditional VFDs are evolving into new age powerful microprocessor controllers with even more powerful high-frequency drivers.
Traditionally the flow in centrifugal pumps or fans was controlled with the help of valves and louvers. Although the fact that such techniques are referred to as the most standardized techniques in classroom programs. In reality they fail to reduce any significant consumption loss.
Using VFD in cost efficiency
Now the advantages of using high end powerful microprocessors like VFD are vast. Here’s a few impacts it has on business economics front
1. Drastic reduction in energy cost
While operating chemical plants, oil refineries or paper mills the flow of ingredient liquids through pumps take high head energy to a certain zenith only to drop it at across valve points. Such losses in energy can account up to 60% of pump energy and 25% of total energy. Use of VFD from the beginning into devices can cut this loss in half or even less
2. Reduced variability leading to better control
Introduction of various hysteresis while tuning of PID loops, or the lag introduced by the mechanical motion of the valve all collaborates to the suboptimal performance of machines. Use of VFD can very well replace these control value errors for a better optimized performance hence result in better ROI.
3. Reduced maintenance
Replacement of control valve takes up a hefty sum of money which can be saved by using VFD microprocessors. Also, as VFDs operate at much lower pressure the longevity of machine lifespan increases reducing frequent maintenance costs
4. Eliminating the need for external capacitor banks
In many plants, expensive and high maintenance capacitor power banks are used for their overall power factor. Use of lower power incurring VFDs eliminates the need for such high maintenance devices saving chunks of dollars.
Now it doesn’t need any further elaboration to state that VFDs are in every way better in performance, efficiency, cost-effectiveness and can result in significant increase in business ROIs.