Power Generation

Energy Efficient Design of Auxiliary Systems

in Fossil-Fuel Power Plants

The Smart Grid begins with

Efficient Generation
Energy Efficient Design of Auxiliary
Systems in Fossil-Fuel Power Plants
A technology overview for design of drive power,
electrical power and plant automation systems

ABB, Inc.
in collaboration with Rocky Mountain Institute, USA

Table of contents

Introduction
Scope

11
12

Technologies Scope

12

Industry and Plant Scope

13

Why Focus on Auxiliaries?

Role of Auxiliaries in Operation

14
14

Auxiliaries Consume High-Quality Power

14

Auxiliaries Impact on Reliability has Energy Consequences

15

Auxiliaries Enable New Duty Cycles

15

Auxiliaries Redesigns and Retrofits are Justifiable

15

Justifying the Focus on Design and Engineering

16

Energy Management versus Energy Engineering

16

Operational Energy Assessment versus Design Audit

16

Design versus Engineering

17

Why an Engineering Handbook and Course

17

Commodity Product versus Custom Engineering

18

Industry versus Academia

18

Who Should Read this Handbook

18

Acknowledgements

19

Notice

19

Copyright and Confidentiality

20

Acronyms and Abbreviations

20

Industry-Specific Terminology

21

Keywords

21

Module 1A: The Need for Efficient Power Generation

23

Module Summary

23

Trends in Power Demand and Supply

23

Trends in Steam Plant Designs and Efficiency

25

Sub-Critical Plant Types

25

Super-Critical Coal-Fired Steam Plants

25

Combined-Cycle Gas Turbine (CCGT)

26

Some Steam Plants are Lagging

26

Plant Auxiliary Power Usage is on the Rise

27

Plant Auxiliary Energy Efficiency Improvements

28

2 | ABB Energy Efficiency Handbook

Module 1B: The Potential for Energy Efficiency

29

Technical Efficiency Improvement Potential

29

Energy Efficiency is Attracting Interest and Investment

31

From Corporate Energy Managers

31

From Industry Investors

31

Carbon Dioxide Emissions Must be Reduced

31

Energy Efficiency is Key to CO2 Mitigation

32

Multiple Benefits of Energy Efficiency

34

Non-Technical Barriers to Energy Efficient Design

Local, State, National and International Regulatory Authorities

35
36

Shareholders & Investors

36

Facility Operators

37

Design and Engineering Companies

38

Equipment Vendors and Design Tool Providers

39

Professional and Standards Organizations

40

Educators and Academia

40

Standards, Best Practice, Incentives, and Regulations

41

Role of Standards in Energy Efficiency

41

Standards and Best Practice

41

Efficiency and Lifecycle Cost Calculations

46

Efficiency Calculations

46

Energy and Power Calculations

46

Savings Calculations

47

Lifecycle Costing Methods

48

Energy Accounting for Reliability

52

Module 2: Drive Power Systems

53

Module Summary

53

Introduction to Drive Power

53

Role of Drive Power in Energy Efficiency

54

Potential for Energy Efficiency

Pump Systems

54
56

Pump Types and Concepts

56

Pump Characteristics

57

Pump System Load Curves

59

Table of Contents | 3

Table of Contents

Pump Power and Energy Efficiency

60

Pump Flow Control Methods

63

Pump System Pipes, Valves and Fittings

72

Pump System Design & Engineering

73

Multiple Pump Systems

76

Pump Automation

77

Pump System Design Guidelines - Summary

78

Pump Drive Train

79

Pump System Maintenance

81

Pump System Cost Calculations

83

Fan Systems

84

Fan Types and Concepts

85

Fan Characteristics

85

Fan Power and Energy Efficiency

86

Fan System Load Curves

87

Fan Flow Control Methods

89

Fan System Design and Engineering

93

Multiple Fan Systems

97

Fan Automation

98

Fan System Design Guidelines - Summary

98

Fan Drive Trains

99

Fan System Maintenance

101

Fan System Cost Calculations

102

Other Drive Power Loads

Conveying & Grinding Systems

103
103

HVAC Systems

104

Compressed Air Systems

104

Motors and Drive Trains

Motor Types and Concepts

105
106

Motor System Loads

111

Motor Characteristics

116

Motor Power and Efficiency

119

Motor Couplings, Speed Control & Variable Frequency Drives

125

Motor System Design & Engineering

128

4 | ABB Energy Efficiency Handbook

Motor Sizing and Selection

131

Motors in Retrofit Situations

133

Motor Sizing and Selection Tools

135

Motor System Guidelines Summary

135

Motor System Maintenance

135

Motor System Cost Calculations

136

Variable Frequency Drives

VFD Concepts

136
136

VFD Types and Applications

143

VFD Topologies

146

VFD Control Methods

148

VFD Performance & Efficiencies

154

VFD Harmonics

156

VFD Application Design and Engineering

157

VFD Selection and Sizing

157

VFD Maintenance

171

VFD Cost and Technical Calculations

172

Module 3: Electric Power Systems for Auxilaries

175

Module Summary

175

Role of Power Systems in Energy Efficiency

176

Need for an Integrative Design Approach

Power System Overview
Power System Concepts

176
177
177

Electrical Power

177

Electrical Power Losses

179

Power Factor
Reactive Power Compensation Concepts

180
181

Motor Soft-Starting

182

VAR Compensators

183

Active Rectifier Units on Motor Drives

186

Power Quality Harmonics

187

Harmonics Concepts

187

Harmonics Mitigation

189

Table of Contents | 5

Table of Contents

Power Quality - Voltage and Frequency Variation

Transient Effects
Sustained Voltage Variations
Power Quality - Phase Voltage Unbalance

193
193
194
195

Voltage Unbalance Causes and Effects

195

Mitigation through Design

196

Power System Control and Protection

Efficient Power System Design and Engineering
Power System Studies

196
198
201

Load List and Analysis

201

Load Analysis

201

Power Flow and System Voltages

202

Startup Analysis (Motor Starting)

202

Harmonic Analysis

203

Equipment Sizing and Bus Design

204

Short Circuit Analysis

205

Power Transformers

205

Transformer Concepts

205

Transformer Losses & Efficiency

207

Estimating Transformer Losses

208

Selection & Sizing

214

Transformer Retrofits

217

Transformer Cost Calculations

218

Plant Power System Layout & Cabling

219

Cable Selection & Sizing

219

Power and Load Management

222

Power System Design and Analysis Tools

223

Power System Maintenance

223

On-Line Condition Monitoring & Control

223

Off-Line Condition Monitoring

225

Power System Assessments

225

Power System Efficiency Guidelines Summary

226

Module 4: Automation Systems

227

Module Summary

227

Automation Concepts

227

6 | ABB Energy Efficiency Handbook

Role of Automation in Energy Efficiency

228

Instruments and Actuators

229

Process Instruments

229

Analytical Instruments

231

Process Actuators

231

Control Valves

232

Dampers and Louvers

233

Sequential Control
Feedback Control
Process Characteristics
Advanced Control and Optimization
Model-Based Control

234
235
236
238
239

Inferential Control

240

Linear Programming with Mixed Integer Programming (LP/MIP)

240

Multi-Level Real-Time Optimization

240

Process Model-Based Real-Time Optimization

242

Lifecycle Model-Based Real-Time Optimization

243

Supervisory Control
Performance Monitoring Systems
Condition Monitoring Systems

243
243
245

Rotating Machinery

245

Heat Exchanger Monitoring

246

Control Systems

246

Evolution of Control Systems

246

Motor Control Centers

248

Automation System Design and Engineering

Automation System Design Guidelines Summary
Module 5: Power Plant Automation Systems
Module Summary
Gross Heat Rate and Capacity
Power Plant Efficiency Concepts
Parameters for Increased Thermal Efficiency
Power Plant Automation Standards and Best Practice
Plant Operating Modes

250
251
253
253
253
254
255
258
259

Table of Contents | 7

Table of Contents

Boiler-Turbine Control

258

Boiler vs. Turbine Following Modes

258

Constant Pressure vs. Sliding Pressure Operation

259

Coordinated Boiler-Turbine Control

263

Combustion Control

265

Feedwater Flow Control

268

Flue Gas Recirculation Control

270

Turbine-Generator Control

271

Excess Air Control

274

Steam Temperature Controls

Burner Management Systems

277
282

Burner Controls

282

Boiler Startup and Protection

282

Emissions Controls

285

Condenser Systems

289

Condensate System

292

Fuel Handling Systems

295

Sootblowing Systems

297

Ash Handling Systems

298

Module 6: Case Studies In Integrative Design

299

Module Summary

299

Causes of Energy Inefficiency

299

Energy Efficiency Design Assessments

301

Integrative Design for Auxiliaries

302

Energy Efficiency Design Improvements

304

Base Case Unit

304

Change of Duty from Baseload to Intermediate

304

Efficiency Design Improvements

304

Unit Improvement Targets

306

Implementation Issues

306

Base Case Plant Design and Performance Data

Plant Unit Assumptions
Base Case Plant Improvement
#1 Improved Fan Flow Control

8 | ABB Energy Efficiency Handbook

307
308
311
311

#2 Improved Pump Flow Control

312

#3 High-Efficiency Motors & Drive-trains

313

#4 Boiler Turbine Coordinated Controls and Sliding Pressure Operation

315

#5 Advanced Steam Temperature Control

315

#6 Stabilization of Firing Rate

316

#7 Improved Airflow Control - Excess O2 Reduction

317

#8 Improved Feedwater Pressure & Level Control

318

#9 Electric Power System Improvement

319

Summary of Benefits

321

Module 7: Managing Energy Efficiency Improvement

323

Module Summary

323

Indicators of Energy Inefficiency

323

Energy Assessment Processes

324

Plant Design & Modeling Tools

325

Importance of Design Documentation

Large Capital Project Processes

326
327

Project Phases and Energy Efficiency Impact

327

Integrated Approach to Energy Project Management

328

Benefits of Integrated Project Management

328

Module 8: High Performance Energy Design

331

Module Summary

331

Tunneling thru the Cost Barrier

331

Auxiliaries in Best-Available-Technology Plants

331

Supercritical and Ultra-Supercritical Boilers

331

Circulating Fluidized Bed (CFB) Furnaces

332

Combined Cycle Gas Turbines

332

Integrated Gasification - Combined Cycle IGCC

333

Powering and Re-Powering with Biomass

333

Combined Heat and Power / Co-Generation

334

Energy Storage Systems

335

Carbon Capture and Storage

336

Alternative Design Options

Smart Grid and Efficient Generation Technologies

336
338

Table of Contents | 9

Table of Contents

Appendix A: Technical Symbols

339

Appendix B: Steam Plant Cycle & Equipment

341

Thermodynamic Cycle

341

Steam Cycle Equipment

342

Cycle Operation

342

Boiler Operation

343

Appendix C: Integrative Design Principles

345

References

349

On-Line Resources

353

Revision History

356

10 | ABB Energy Efficiency Handbook

Introduction
Energy Efficient Design of Fossil-Fuel-Fired
Steam Power Plant Auxiliary Systems
It is the greatest of all mistakes to do nothing because
you can only do a little Sydney Smith (17711845)
Energy efficiency is the least expensive way for power and process industries to
meet a growing demand for cleaner energy, and this applies to the power generating
industry as well.

In most fossil-fuel steam power plants, between 7 to 15 percent of the

generated power never makes it past the plant gate, as it is diverted back to
the facilitys own pumps, fans and other auxiliary systems.

This auxiliary equipment has a critical role in the safe operation of the plant and can
be found in all plant systems. Perhaps the diversity of applications is one reason
why a comprehensive approach to auxiliaries is needed to reduce their proportion of
gross power and to decrease plant heat rate.
This handbook takes a comprehensive view of auxiliary systems and describes some
common approaches to energy efficient design which can be applied in retrofit and
new plant projects. This handbook reviews drive-power concepts, and provides
useful design and engineering guidelines that can help to improve energy efficiency.
The extent of these energy savings are shown in fully worked-out numerical
examples and in actual plant case histories throughout the text.
This handbook may be used as part of a training course for managers and
technical staff in operating and engineering service companies, and may also be
used in mechanical or electrical engineering university programs. This handbook
complements existing best practices for power plant engineering and is not a
substitute for detailed plant design and safety guidelines published by standards
bodies and industry associations. The relevant sources for detailed guidelines are
listed in the References section.

Introduction | 11

Scope
Technologies Scope
This handbook defines plant auxiliaries to include all motor-driven loads, all electrical
power conversion and distribution equipment, and all instruments and controls.
Process chemical and thermodynamic efficiency is not directly within the scope of this
handbook. The controllable losses which are within the reach of automation systems
are of interest, as are methods of recovering waste heat or energy from the cycle
using drivepower technologies.
Some industry sources may use the overly-narrow term auxiliary to refer only
to certain fan and pump systems. An overly-broad term that includes all auxiliary
systems (and much more) is balance of plant: (BoP). Starting from this level, we can
define three categories of auxiliary systems:
A subset of BoP that encompasses drive power components such as pumps, fans,
motors and their power electronics such as variable-frequency drives. These provide
drive power for fuel handling, furnace draft, and feedwater pumping. These systems and
components will be referred to as Drivepower.
A subset of BoP that encompasses only the electrical power systems conversion,
protection, and distribution equipment, excluding motors and variable-frequency drives.
This subset includes power transformers and LV and MV equipment. These systems
and components will be referred to as Eelectrical BoP (EeBoP) or Electric Power
Systems.
A subset of BoP that encompasses only the instruments, control, and optimization
systems. These provide boiler-turbine and other control functions. These systems and
components will be referred to as I&C or simply Automation
Some examples of auxiliary equipment from these categories are shown on the cutaway
view of a plant on the following page. A common aspect of auxiliary technologies is that
they handle all the electrical power and control signals throughout the entire plant.
All the technologies discussed are commercially available and the engineering practices
described in this handbook are non-proprietary. Some newer technologies and their
energy efficiency potential are reviewed in the final module of the handbook.

12 | ABB Energy Efficiency Handbook

Industry and Plant Scope

The material and guidelines in this handbook are generally applicable to all power
generation and process industries. These industries generally are more energyintensive than the discrete manufacturing sector. Material which is industry-specific
for particular version of the handbook is shown in a blue box.

Plant Type Scope

The focus of this handbook version is on fossil-fuel-fired electrical power
generating plants that have a steam cycle. The fuels these plants use include
coal, oil, gas, biomass, and solid waste. Pulverized coal (PC) sub-critical boiler
plants receive special attention in this handbook due to the large number of
existing plants (and continued construction of them globally), their heavy-duty
cycle as base-loaded plants, their poor average efficiency, and their considerable
carbon dioxide emissions. PC plants also use up to twice as much auxiliary power
as compared to liquid or gas-fueled plants
Industrial boilers and co-generation systems share many of the same technologies
and designs as their counterparts in utility power generation. An industrial power
generation facility is sometimes referred to as a power house to distinguish it
from the larger power plants used by power generation companies. The term
utility includes all operators of large-scale power generation facilities, regardless
of the form of ownership.

Figure I.1 - Plant cutaway showing location and type of auxiliary equipment (ABB Inc. USA Products
for Power Generation Industry)

Introduction | 13

Why Focus on Auxiliaries?

Role of Auxiliaries in Operation
In power plants, auxiliaries serve to keep the steam-water cycle safely
circulating, and to return it to its thermodynamic starting point. Without
these auxiliary systems, the steam-water cycle would suffer either an
immediate collapse or a dangerous and non-sustainable expansion. The basic
thermodynamic shape and efficiency of the cycle, shown on a Pressure-Volume
diagram below, is the job of the cycle designer. The main purpose of the
auxiliary systems is to preserve the designed shape of this cycle across a wide
range of conditions and over time, using a minimum of input energy and with a
maximum of availability.
In power plant terminology, auxiliary power is sometimes referred to as station
load, house load or even parasitic load.

Auxiliaries Consume High-Quality Power

Auxiliaries consume the highest quality energy in the plant, namely electrical energy.
The power supplied to in-house loads is power that could otherwise have been saved
(or sold, in the case of a power plant operating at full load). The convenience and
controllability of electrical power is behind the trend towards electric motors displacing
other forms of auxiliary drive power, such as steam for turbine-driven pumps.
Auxiliary power consumption is downstream power; efficiency improvements in
auxiliary loads have a multiplier effect as one moves upstream to the primary energy
source, within or outside the plant.
Based on the typical 33 percent thermal efficiency that many older power plants
achieve, the generated electricity is at least three times the price of the input fuel
energy, when all the added fixed and financial costs of electricity generation are also
included.
14 | ABB Energy Efficiency Handbook

The share of auxiliary drivepower of total plant power has been increasing for other
reasons too, mainly from the installation of mandatory anti-pollution equipment,
increased fuel variability, and general performance degradation due to the
accumulated effects of aging on plant equipment.

Auxiliaries Impact on Reliability has Energy Consequences

No other resource affects plant availability and the bottom line like reliable
electrical power. What may not be so apparent is the energy efficiency
dimension of reliability problems. Many metrics exist to account for planned or
unplanned (forced outage) downtime, but the general assumption has always
been that downtime does not affect plant energy efficiency, which is normally
calculated under some steady state operating condition.
Long periods of unsalable production (or power generation in the case of
power plants) during unit startup and shutdown caused by reliability-related
downtime events should be considered as the reduced efficiency of a
reliability asset. The efficiency of this virtual asset is proportional to reliability
percentage, at plant, unit, and equipment levels. A temporary de-rating due to
a reliability issue will have energy efficiency consequences as well. The energy
costs of poor reliability have been hiding behind the much greater opportunity
costs of downtime and now deserve a proper accounting, as shown in the
Energy Accounting for Reliability section.

Auxiliaries Enable New Duty Cycles

Perhaps the most compelling reason to address auxiliary systems design is the
movement of the power generation industry towards deregulation, more renewable
supply, and carbon dioxide emissions limits. All these factors can turn the duty cycle
of todays fleet of plants on its head, with the workhorse base-loaded coal-fired units
moving into mid-range or even peaking duty, and lower-emissions combined-cycle
plants being base-loaded instead. Auxiliary systems design improvement is important to
prop up the older plants efficiency under all load scenarios, to improve control response
(ramp rate) for more rapid load changes, and to automate for more rapid startups.
Auxiliaries Redesigns and Retrofits are Justifiable
Finally, it is economically relatively easy to justify a closer look at the economics
of auxiliary systems improvements because, unlike main process equipment, they
are generally less expensive and easier to retrofit, at much lower installed cost and
incurring little or no downtime. The relatively modest costs associated with auxiliary
redesigns and retrofits, compared to main process equipment, are reflected in their

Introduction | 15

relative new plant contract prices. The following data is for power plants, but applies
to most other large process plants as well:
Fans and motors :

2.2% of total contract price

Controls and instruments:

1.5% of total contract price

Electrical equipment (EBoP):

0.9% of total contract price

(IEA CoalOnline, 2007)

In power plants, the cost to build one new MW of coal-fired capacity is

approximately $1.3M-$2.2M USD. The capital cost and risks associated with
new central plant construction have increased more rapidly than the price since
the mid 1980s. Plant licensing and staffing issues can be the largest stumbling
blocks for getting to the point of ground-breaking of new plant projects.

Justifying the Focus on Design and Engineering

Energy Management versus Energy Engineering
The scope of this handbook is energy design and engineering in the context of
new plant and retrofit projects of modest capital investment. Energy management
works through ongoing operational maintenance and monitoring activities and seeks
incremental efficiency improvements within the technical constraints of existing plant
systems.
Operational Energy Assessment versus Design Audit
An Energy Assessment is a process that evaluates existing plant performance. The
customer for an energy assessment is usually a facility operator, who will set the
frame of reference for the assessment at the start. If only operational or energy
management and budgets are involved, then the assessment will naturally focus on
operational improvements. A wider scope and larger budget may lead assessors to
investigate design and engineering modifications.
There is continuum between design and operational assessments, depending on
the project context and timeframe. The sooner an assessment is performed in the
plants lifecycle, the greater the efficiency improvement potential. There are many
good references available on traditional energy assessment procedures, which focus
strongly on measurement and prioritization techniques. A design handbook typically
focuses on the theory of energy performance so that good practice can be applied
even in a conceptual design review, before there are any operational data. This
handbook is therefore a complementary reference to design guidelines, to help guide
the focus of energy assessments, and energy performance improvement projects.

16 | ABB Energy Efficiency Handbook

In large capital engineering projects, the early design phase accounts for just 1
percent of a projects up-front costs, but at that point up to 70 percent of its lifecycle costs may already have been committed (Lovins, 1999). Energy-inefficient
designs are then frozen-in, often for several decades in the case of large
process or power plants. Therefore, it is important for designers and engineers
to learn how to quickly review their energy design options and perform relative
cost analyses before the final design concept is firmly established; the focus is on
quickly, because that 1 percent time window is not very long at all. For example, in
a three year project, that window will be less than two weeks.

High
Investment

Design
review

Design
Audit

Modest
Investment

Energy
Audit
Low
Investment
Conceptual
Design

Detail
Engineering

Operation

Retrofit
& Upgrade

Figure I.2 - Investment return vs. project phase for energy design assessments

Design versus Engineering

Design comes before engineering, and is concerned with overall process flows
and capacities. Design determines the mass balances and energy balances, and
how the system is controlled. Engineering is concerned with implementation of a
design - selection and sizing of process equipment and how it is to be instrumented
and controlled. Designers have the most freedom to improve energy efficiency
during new projects and large re-development projects. In typical retrofit situations,
however, it is the engineering function that has the most freedom. A special word
of encouragement, therefore, to engineers starting a retrofit project: You may have
more freedom and opportunity than you realize to improve plant energy performance!
Why an Engineering Handbook and Course
Utilities, state or local authorities, and other public entities offer operational efficiency
programs to support corporate energy management goalsparticularly at the plant
level (Hoffmann, 2008), but there are fewer on-the-job learning options for generation
or company staff to learn about energy efficiency design and engineering techniques,
which can yield much greater improvements.

Introduction | 17

The market for learning about industrial plant energy efficiency is large and growing.
According to a recent survey of corporate energy managers (Johnson Controls,
2008), 70 percent have invested in educating staff and other facility users to increase
support for improving internal energy efficiency.
Commodity Product versus Custom Engineering
Many of the technologies that comprise plant auxiliaries are becoming less customengineered items and taking on more of a commodity status. This commercialization
of technology advances brings benefits to customers such as lower price,
shorter delivery times, and increased reliability. On the other hand, more complex
technologies, such as variable speed drives, may not be plug-and-play ready for
all applications. Operating and engineering staff need to learn to recognize these
situations so that commodity solutions can be still be applied successfully without
the deep involvement of supplier engineers. The guidelines and information in this
handbook provide a bridge between off-the-shelf auxiliary equipment, such as VFDs,
motors, and some DCS packages, and the plant applications they are supposed to
serve.
Industry versus Academia
Academic training of engineers is important, but there is also a history of technical
education for power generation and process industries within the engineering and
supplier industries. For example, ABBs Automation University, as well as GEs
Power Systems Engineering Course and its accompanying Design Guides, which
have been taught to practicing engineers for 60 years. and AspenTechs University
are all examples of the industry educating their own.

Who Should Read this Handbook

Anyone who can influence the design, engineering, technical procurement and
execution activities should read this handbook.

Plant electrical and mechanical department engineers

Operating company energy managers, at all levels
Plant operators, plant managers, and project managers
Engineering planners
Financial officers and procurement managers
Supplier company technical staff
Engineering company process, mechanical, and electrical engineers
Industry regulators technical staff

18 | ABB Energy Efficiency Handbook

The fossil fuel plant version of this handbook assumes that the reader is familiar
with the basic design and operation of a fossil-fuel steam boiler. The Appendix
has a brief overview of sub-critical boilers main components and their function.

Acknowledgements
This handbook is the result of collaboration between ABB Inc., Power Systems
Division, and the Rocky Mountain Institute. Rocky Mountain Institute (RMI) is an
independent, entrepreneurial, nonprofit organization. Special thanks to Dr. Amory
Lovins, Chief Scientist of RMI for his valuable comments and inspiring work on
energy efficiency for industry, and for the opportunity to complete this work at RMI
offices in Snowmass, Colorado, USA. The RMI-Competitek DrivePower and Cooling
Manuals are an often-cited, valuable source of reference material for this handbook.
Thanks also to all the ABB engineers and scientists without whose contribution of
time and material this handbook would not have been possible; for automation:
Daniel J. Lee, Pekka Immonen, and Robert Herdman. For motors and VFDs:
Moledina M. Varvani, Dennis Kron, and Jiuping Pan. For electrical power systems:
Hamid SaharKhiz, Majid Rahimi, Brian D.Scott.
Special thanks to Richard W. Vesel of ABB Power Systems USA for his generous
support, technical guidance and encouragement, and to Arash Babaee of ABB
Power Systems Canada for his review and comments. The ABB Application
Guides were a valuable reference for this handbook, and have been frequently
cited, although no special permissions have been yet been sought for internally
copyrighted graphics and case examples from this ABB-owned material.
This handbook was written and edited by Robert P. Martinez at RMI, Snowmass,
USA while on sabbatical leave generously provided by the ABB Norway, Strategic
R&D department, led by John Pretlove. Thanks to Cameron Burns of RMI for copyediting the first draft and for being a friend during my familys stay at RMI. Final
editing, review and publication was carried out by Richard Vesel, with support from
program manager Milovan Grbic and marketing director Andy Gavrilos.
Notice
The information in this document is subject to change without notice and should
not be construed as a commitment by ABB. ABB assumes no responsibility for any
errors that may appear in this document.
In no event shall ABB be liable for direct, indirect, special, incidental or consequential
damages of any nature or kind arising from the use of this document, nor shall ABB
Introduction | 19

be liable for incidental or consequential damages arising from use of any software or
hardware described in this document. This document and parts thereof cannot be
reproduced or copied without written permission from ABB, and the contents thereof
must not be imparted to a third party nor used for any unauthorized purpose.
Copyright and Confidentiality
This handbook is published in two versions: one version will be made broadly
available to educators and other public consumers as part of Rocky Mountain
Institutes public service efforts to increase awareness of energy efficient design
though their 10xE program. Another version will be published internally by ABB and
may contain confidential portions not intended for wide circulation.

Acronyms and Abbreviations

BoP
Balance of Plant
CCGT
Combined-Cycle Gas Turbine
CFB
Circulating Fluidized Bed
CHP
Combined Heat and Power
DCS
Distributed Control System
DoE
US Department of Energy
EBoP
BoP but same as above, but limited only to electrical equipment
EHV
Extra High Voltage (345000-765000 V)
FOF
Forced Outage Factor
FOR
Forced Outage Rate
GT
Gas Turbine
HV
High Voltage (115000-230000)
IEA
International Energy Agency
IGCC
Integrated Gasification Combined Cycle
LV
Low Voltage (IEEE Std. 666-2007:0 -1000V)
MCR
Maximum Continuous Rating
MPC
Model Predictive Control
MV
Medium Voltage (typically 2400V,4160V,4800V,13,800V)
NEMA
National Electrical Manufacturers Association
NPHR
Net Plant Heat Rate
POF
Planned Outage Factor
SST
Station Service / Startup Transformer
UAT
Unit Auxiliary Transformer
UCF
Unit Capability Factor
USC
Ultra Supercritical
VFD
Variable Frequency Drive
VSD/ASD Variable Speed Drive, Adjustable Speed Drive
UT
Unit (Step-up) Transformer
20 | ABB Energy Efficiency Handbook

MPC
Model Predictive Control
MV
Medium Voltage (typically 2400V,4160V,4800V,13,800V)
NEMA
National Electrical Manufacturers Association
NPHR
Net Plant Heat Rate
POF
Planned Outage Factor
SST
Station Service / Startup Transformer
UAT
Unit Auxiliary Transformer
UCF
Unit Capability Factor
USC
Ultra Supercritical
VFD
Variable Frequency Drive
VSD/ASD Variable Speed Drive, Adjustable Speed Drive
UT
Unit (Step-up) Transformer

Industry-Specific Terminology
Backpressure power

Higher pressure steam at turbine output; good for CHP

Banked

A unit in reduced load (spinning reserve) operation

Base loading unit

Unit operated at constant load 24 hrs/day, 7 days week

Condensing power

Low pressure steam at turbine output

Day/night loading

Unit operated at constant load during day, then banked or shutdown

overnight

Dispatchable/mid-range

A plant which receives dispatch commands to follow load; may be

cycled, does not operate much at capacity

Frequency response

Operated at nominal load (one of above) but modulated to compensate

for network frequency disturbances

Gross Plant Heat Rate

Fuel heat input per gross power output as measured at generator

busbar

Annual Capacity Factor

Actual generated energy divided by rated annual output (accounts for

outages and low load operation)

Heat rate

Required input fuel heat to generate a unit of electric power (Btu/kW).

The higher the heat rate, the less efficient a plant is.

Shift loading

Unit operated at constant load during each 8-hour shift.

Spinning reserve

A unit operated at low load, in anticipation of rapid ramp-up

Unit

An integrated single boiler system sending steam to a single multi-stage

turbine powering a single main generator (typically).

Keywords
Energy Assessment, Energy Efficiency, Energy Management, Generating Station,
Power Plant, Variable Frequency Drives, Transformers, Power Factor

Introduction | 21

22 | ABB Energy Efficiency Handbook

Module 1A
The Need for Efficient Power Generation

Module Summary
This module makes the business case for energy efficient plant auxiliary systems and
discusses some trends in electricity markets and power generation technologies.

The information in this module section is specific to power generation industries

and/or process plants with large on-site power and/or steam heat generation.

Trends in Power Demand and Supply

Currently growing 2.6 percent per year, world electricity demand is projected to
double by 2030. The share of coal-fired generation in total generation will likely
increase from 40 percent in 2006 to 44 percent in 2030. The share of coal in the
global energy consumption mix is shown in the figure below. This share is now
increasing because of relatively high natural gas prices and strong electricity demand
in Asia, where coal is abundant. Coal has been the least expensive fossil fuel on an
energy-per-Btu basis since 1976.
China expanded coal use by 11 percent in 2005 and surpasses U.S. as the number
one coal user in 2009. Coal is the most abundant fossil fuel, with proven global
reserves at the end of 2005 of 909 billion metric tons, equivalent to 164 years of
production at current rates (International Energy Agency, 2006).
In the U.S., coal-fired plants currently provide 51 percent of total generating capacity
(Woodruff, 2005), or about 400 GW , from about 600 power plants . Total electrical
generation capacity additions are estimated to be 750 GW by 2030 (International
Energy Agency, 2006). Of that new capacity, 156 GW is projected to be provided
by coal plants (Ferrer, Green Strategies for Aging Coal Plants: Alternatives, Risks
& Benefits, 2008). Other estimates put capacity addition to 2030 at 280 coal-fired
500MW plants (Takahashi, 2007).
Higher natural gas prices are reversing a trend toward more energy efficient and
lower-emission plant designs. The generating costs of combined-cycle gas turbine
(CCGT) plants, which use natural gas, are expected to be between 57 cents per
kWh, while coal-fired plants are in the range 46 cents/kWh (International Energy
Module 1A | 23

Agency, 2006). Integrated gasification combined cycle (IGCC) plants are not yet
competitive as of 2008 (which is why government is subsidizing many such projects).
Their low relative costs make coal-fired plants competitive in the U.S. with other
large central generating plants.

Figure 1A.1 Trends in energy consumption, (2007 BP Statistical Review of World Energy)

Many new coal plants were being planned or constructed as of 2008, but with
some uncertainty regarding the future trend due to carbon footprint and other
environmental concerns over current coal-fired plant technology. Regulations
imposing carbon dioxide emissions charges will eventually change the economics
in favor of CCGT and other more efficient fossil plant types. Even without emissions
taxes, the licensing of new plants is threatened by growing grass-roots opposition
at local and state levels. According to the US Department. of Energy (DoE), 59 of
151 planned new coal plants were either refused licenses or abandoned in 2007,
and 50 plants are being challenged in court. Environmental groups have successfully
challenged these new plants by arguing that the additional capacity could be gained
through energy efficiency and renewable sources of power. With the industry facing
a possible moratorium on new plants, it is more important than ever to make existing
plants as energy efficient as possible.
Whether limited by emissions or supplies, the fossil-fuel power generation industry
must sooner or later reduce the carbon per unit energy produced. The prominence
of coal means that it will play an important role in the transition to a low-carbon
future. Dr. Amory Lovins, a leading US energy analyst, anticipated the need for such
a transition many years ago when he said; It is above all the sophisticated use
of coal, chiefly at modest scale, that needs development. Technical measures to

24 | ABB Energy Efficiency Handbook

permit the highly efficient use of this widely available fuel would be the most valuable
transitional technologies. (A. Lovins, Energy Strategy: The Road Not Taken 1976)

Trends in Steam Plant Designs and Efficiency

Large fossil-fuel-fired steam plants use a closed steam cycle in which water is
converted to steam in a boiler. This steam is then superheated and then expanded
through the blades of a turbine whose shaft rotates an electrical generator. The
steam exits the turbine and condenses to water, which is pumped back up to boiler
pressure. The Appendix section of this handbook discusses the steam cycle in
greater detail, and describes some variations on this design which improve the
cycle efficiency.
Sub-Critical Plant Types
The most common type of plant using this design is alternatively referred to as
drum boiler or subcritical, because water is circulated within the boiler between
a vessel (the drum) and the furnace water-wall tubing where it absorbs combustion
heat, but does not exceed critical pressure. Existing subcritical pulverized coal (PC)
boiler steam power plants can theoretically achieve up to 3640 percent efficiency
at full load. Due to major process design changes such as supercritical boilers and
other technology improvements, the average efficiencies of the newest coal-fired
plants are up to 46 percent compared to 42 percent for new plants in the 1990s (IEA
CoalOnline, 2008).
Energy efficiency improvements of several percentage points in new plants have
resulted from improved designs of the main components and auxiliaries in steam
power plants: including auxiliary drivepower:

Improvements in turbine blade design

Improvements in fans and flue gas treatment methods
Reduction of furnace exit gas temperature
Increase of feed water temperature
Reduction of condensing pressure
Use of double reheat on main steam flow
Optimization and reduction of the consumption of auxiliary drivepower

Super-Critical Coal-Fired Steam Plants

Supercritical plants, also called once-through plants because boiler water does
not circulate multiple times as it does in drum-boiler designs, have efficiencies in
the mid-40 percent range. New ultra critical designs using pressures of 4,400 psi
(30 MPa) and dual stage reheat are capable of reaching about 48 percent efficiency
(IEA Coal Online - 2, 2007). Plant availability problems with the first generation of
Module 1A | 25

large supercritical boilers led to the conclusion that pulverized coal-fired electricity
generation was a mature technology, with an efficiency limited by practical and
economic considerations to around 40 percent. However, improvements in
construction materials and in computerized control systems led to new designs for
supercritical boilers that have overcome the problems of the earlier plants (IEA Coal
Online - 2, 2007). Although most new coal-fired plants are expected to use drum
steam boilers, the share of supercritical technology is rising gradually (International
Energy Agency, 2006).
Combined-Cycle Gas Turbine (CCGT)
A combined-cycle gas turbine (CCGT) power plant uses a gas turbine in conjunction
with a heat recovery steam generator (HRSG). It is referred to as a combined-cycle
power plant because it combines the Brayton cycle of the gas turbine with the
Rankine cycle of the HRSG. The thermal efficiency of these plants has reached a
record heat rate of 5690 Btu/kWh, or just under 60 percent.
Some Steam Plants are Lagging
At the beginning of the 21st century, it was believed that a single-cycle coal-fired
power station with an efficiency of more than 50 percent would be possible by 2015
(Kjr and Boisen, 1996 in IEA Coal Online - 2, 2007). The efficiency of some new
design plants may be high, but almost 75 percent of the existing coal-based fleet of
plants in the U.S. is over 35 years old, with an average net plant efficiency of only
slightly above 30 percent (Ferrer, Green Strategies for Aging Coal Plants, 2008).
In addition to the less efficient design of core equipment, these older plants suffer
an additional efficiency handicap due to plant aging; they become less reliable and
generally less efficient due to leakage, fouling, and other mechanical factors. Another
trend which lowers efficiency is the change in fuel supply systems toward off-design
coals for which the boiler has not been optimized (IEA Coal Online - 2, 2007). Fuel
supplies may be subject to further tweaking as generating companies seek to reduce
their carbon footprint by substituting a portion of the coal they use with biomass.
Another important reason that older plants are lagging in efficiency is that many of
them are operating at 3050 percent below their rated capacities, where efficiencies
of all sub-systems are lower. The realities of a more deregulated and competitive
marketplace, with renewable and distributed energy sources and new system
operating reserve requirements, have led to previously baseloaded plants being
operated as dispatchable plants; an unforeseen operating regime (ABB Power
Systems, 2008). One view of this latter issue is the global distribution of load factor
of nominally baseloaded steam turbine plants less than 500MW for the period 2001
2005. The following figure shows that the median load factor is only 64 percent.

26 | ABB Energy Efficiency Handbook

Figure 1A.2 - Distribution of load factor of base-loaded plants, (World Energy Council, 2007)

Plant Auxiliary Power Usage is on the Rise

The share of total plant auxiliary electrical power in the fleet of fossil-fuel steam
plants has been increasing due to these main factors:
Addition of anti-pollution devices such as precipitators and sulfur dioxide
scrubbers which restrict stack flow and require in-plant electric drive power.
About 40 percent of the cost of building a new coal plant is spent on pollution
controls, and they use up about 5 percent of gross power generated (Masters,
2004).
Additional cooling water pumping demands to satisfy environmental thermal
discharge rules.
A trend away from mechanical (e.g. condensing steam turbine) drives toward
electrical motors as the prime mover for in-plant auxiliary pump and fan drives.
For PC power plants, the auxiliary power requirements are now in the range of
715 percent of a generating units gross power output for PC plants. Older
PC plants with mechanical drives and fewer anti-pollution devices had auxiliary
power requirements of only 5 to 10 percent (GE Electric Utility Engineering, 1983).
These figures are for traditional drum boiler type plants, but the auxiliary power
requirements of supercritical boilers are not any lower. The feedwater pump power
required to reach the much higher boiler pressure is approximately 50 percent
Module 1A | 27

greater than in drum boiler designs. Increased demand for auxiliary power increases
a plants net heat rate and reduces the amount of salable power.

Plant Auxiliary Energy Efficiency Improvements

In-plant electrical power, when taken from the generator bus, may be priced
artificially low in some utility companies auxiliary lifecycle calculations. A process
industry customer, however, must always pay high commercial rates (and sometimes
penalties), thus providing a strong incentive to improve their auxiliary energy
efficiency. Price dis-incentives, regulations permitting cost-pass thru, and other nontechnical barriers are discussed in the handbook section on Barriers to Increased
Energy Efficiency.
These barriers may result in sub-optimal energy designs for power plant auxiliaries,
most commonly in oversized motors, fans and pumps. These design decisions
have particularly negative consequences when the base-loaded plant then moves
to a new operating mode at 5070 percent capacity (see previous section for a
discussion of this trend). Auxiliaries such as pumps and fans that use constant
speed motors and some form of flow restriction for control will waste much more
power when operating under such partial-load conditions. Other plant systems
will also run less effectively below their design points. Boilers at partial loads, for
example, run with relatively higher excess air to achieve complete combustion,
which lowers efficiency; these topics are discussed in greater detail in the handbook
sections on Drivepower and Automation.

28 | ABB Energy Efficiency Handbook

Module 1B
The Potential for Energy Efficiency
Technical Efficiency Improvement Potential
A recent study by the International Energy Agency (IEA) suggests a technical
efficiency improvement potential of 1826 percent for the manufacturing industry
worldwide if the best available (proven) technologies were applied. Most of the
underlying energy-saving measures would be cost-effective in the long term. Another
study, by the U.S. Dept. of Energy, focused on the energy efficiency opportunity
provided by automation and electric power systems in process industries. An
improvement potential of 1025 percent was suggested by industry experts, who
were asked to consider improvements within the context of operational or retrofit
situations. The results of that study are shown in the figure below, and in more detail
in the Automation module sections of this handbook.

Figure 1B.1 - Process industry survey results on potential of energy efficiency, (US DoE, 2004)

Potential Revealed Through Performance Benchmarking

Access to power generation plant performance data is important for identifying
areas for improvement and for showing the results of best practice. Market
fragmentation and the increased competitiveness of de-regulated markets
in the past have made access to data difficult. There has also been a lack of
standards or practices for measuring performance.

Module 1B | 29

The World Energy Council (WEC), through its Performance of Generating Plant
(PGP) Committee, is now gathering and normalizing such data so that valid
comparisons can be made across countries and markets.
Similar performance benchmarking efforts are done in the U.S., but through
industry-funded organizations like EPRI. Standardization efforts are best
represented by IEEE Std 762-2006 IEEE Standard for Definitions for Use in
Reporting Electric Generating Unit Reliability, Availability, and Productivity.
Interestingly, the WEC found that new drivers geared toward profitability,
cost control, environmental stewardship, and market economics are shifting
the focus away from traditional measures of technical excellence such as
availability, reliability, forced outage rate, and heat rate (World Energy Council,
2007). Their PGP database has added individual unit design and performance
indices that can be used to compare efficiency and reliability across designs.
The published performance data will help industry improve practices, and will
put a spotlight on under-performing plants and companies.
Efficiency Potential Revealed by Country Comparisons
The potential for energy efficiency, at least from a U.S. perspective, is also
indicated in a recent (2007) comparison of fossil-fuel-based power generation
efficiencies between nations that together generate 65 percent of worldwide
fossil-fuel-based power. The Nordic countries, Japan, the United Kingdom,
and Ireland were found to perform best in terms of fossil-fuel-based generating
efficiency and were, respectively, 8 percent, 8 percent and 7 percent above
average in 2003. The United States is 2 percent below average. Australia,
China, and India perform 7 percent, 9 percent and 13 percent, respectively,
below average. The energy savings potential and carbon dioxide emissions
reduction potential if all countries produce electricity at the highest efficiencies
observed (42 percent for coal, 52 percent for natural gas and 45 percent for
oil-fired power generation), corresponds to potential reductions of 10 exajoules
of consumed thermal energy and 860 million metric tons of carbon dioxide,
respectively (Graus, 2007).
The IEA analysis mentions that more than half of the estimated energy and
carbon dioxide savings potential is in whole-system approaches that often
extend beyond the process level (Gielen, 2008). Integrative Design is this
handbooks approach to the most challenging energy efficiency issues in plant
auxiliary design.

30 | ABB Energy Efficiency Handbook

Energy Efficiency is Attracting Interest and Investment

The previous sections showed an engineers view of the importance of energy
efficiency. What are the views and plans of corporate energy decision makers
and investors?
From Corporate Energy Managers
According to a recent survey on energy efficiency of corporate and plant-level energy
managers at more than 1,100 North American companies (Johnson Controls, 2008):
57 percent expect to make energy-efficiency improvements during the same
time period, devoting an average of 8 percent of capital expenditure budgets on
energy-efficiency projects.
64 percent anticipate using funds from operating budgets, allocating 6 percent to
energy-efficiency improvements.
40 percent have replaced inefficient equipment before the end of its useful life in
the past year.
70 percent have invested in educating staff and other facility users as a way to
increase support for increasing internal energy efficiency.
From Industry Investors
When 18 U.S. investment organizations were surveyed about energy efficiency, the
results indicated that the technologists should have no trouble funding their projects.
According to that study (Martin, 2004), the energy technology attracting the greatest
investment interest is energy intelligence (smart instruments, advanced control,
and automation). The handbook sections on Instruments, Controls & Automation
discuss these technologies and how they can be used to improve plant energy
efficiency.

Carbon Dioxide Emissions Must be Reduced

According to a 2005 report from the World Wide Fund for Nature (WWF), coal-based
power stations are at the top of the list of least carbon efficient power stations
in terms of the level of carbon dioxide produced per unit of electricity generated.
Based on current developments in Europe and in the U.S., regulations which limit or
tax carbon dioxide emissions seem inevitable for all Western economies. A carbon
charge of $25 per metric tonne (carbon dioxide) is a conservative estimate used in
IEA scenarios. The impact of carbon pricing on fossil-fuel plant generating costs,
shown in the figure below, is dramatic compared to most other generation methods.
At prices above $20 per metric tonne coal-based plants become the most expensive
type to operate at current non-optimized cost levels.

Module 1B | 31

China and India account for four-fifths of the incremental demand for coal, mainly
for power generation. For the first time, Chinas carbon dioxide power emissions in
2008 exceeded the United States emissions; the lower quality coal used in India and
other rapidly expanding economies, decreases plant efficiency and leads to increased
carbon dioxide emissions per unit electricity (International Energy Agency, 2006).

Energy Efficiency is Key to CO2 Mitigation

The IEA Energy Technology Perspectives model is a bottom-up, least-cost
optimization program. The model was developed to describe the global potential
for energy efficiency and carbon dioxide emissions reduction in the period to 2050,
particularly in the industrial sector. In the accelerated technology scenario (ACT),
the potentials for carbon dioxide reduction on all power consumption are shown
in the figure below. This figure illustrates the scenario in which carbon dioxide
emissions are stabilized globally in 2050 to 2005 levels, and the world narrowly
avoids a costly climate crisis.

Figure 1B.2 Relative share of CO2 mitigation efforts, all consumption, (International Energy Agency,
2006)

The Role of Power Generation in Reducing Emissions

The IEAs ACT scenario suggests that power generation efficiency can
contribute significantly to the overall global effort to stabilize carbon dioxide
emissions by 2050 at or near 2005 levels. Surprisingly, the model shows that
power generation efficiency alone, which includes improved auxiliaries and
other measures, has a larger climate impact than even nuclear power.
32 | ABB Energy Efficiency Handbook

When the model is applied to process industries alone, the impact of energy
efficiency is proportionately larger. The figure below shows the blue scenario,
which uses the same ACT scenario describe above, but with a higher carbon
dioxide charge of $50 per (metric) tonne, instead of $25/tonne (Taylor, 2008).

Figure 1B.3 - Relative share of CO2 mitigation efforts in process industries, (Taylor, 2008)

Applying this model to the power generation sector in particular suggests that
its carbon dioxide emissions are cut by 36 percent using all of the approaches
shown. Half of those savings (18% of total) can be attributed to relatively lowtechnology energy efficiency measures alone.
Energy efficiency measures are the most important of all the carbon dioxide
mitigation approaches for process industries, contributing to almost half of
the impact on emissions (Martin, 2004). Although these predictions apply to
process industries, the relative potentials are likely to be valid for the steam
power generation sub-sector as well.

Module 1B | 33

Multiple Benefits of Energy Efficiency

The primary benefits of a increased plant energy efficiency are reduced emissions
and energy or fuel costs.

Power plants which operate partially or wholly at full load will have more salable
power. At less than capacity, the fuel savings are significant. In coal-fired steam
power plants, fuel costs are 60-70% of operating costs.

The following is a more complete list of benefits accompanying energy efficiency

design improvements for plant auxiliaries:
Operational Benefits
Improved reliability/availability. As has been found with stricter safety design
regulations, any extra attention to the process is rewarded with improved uptime.
Improved controllability: energy is wasted in a swinging, unstable process, partly
through inertia in the swings, but mainly because operators in such situations do
not dare operate closer to the plants optimum constraints.
Reduced noise and vibration, reduced maintenance costs.

Results of Improved Efficiency on Plant Operations and Profitability

Better allocation: under deregulation, as utilities dispatch plants within a fleet,
heat rate improvement can earn plants a better position on the dispatch list
(Larsen, 2007).
Avoiding a plant de-rating due to efficiency losses after anti-pollution retrofits or
other plant design changes.
Improved fuel flexibilityby efficiently using a wider variety of fuels (coal
varieties) and, in some cases, increasing the firing of biomass, for example.
Improved operational flexibility 1) Improved plant-wide integration between
units will reduce startup-shutdown times; this benefit applies mainly to deregulated markets. 2) The heat rate versus capacity curve is made flatter and
lower, which allows the plant to operate more efficiently across a wider loading
range.

Plant Investment Benefits

Avoiding forced retirement due to pollution non-compliance: An ambitious retrofit
programme may save some older plants from early retirement due to noncompliance with regulations.

34 | ABB Energy Efficiency Handbook

 Tax creditstake advantage of newer policies such as EPACT 2005, which may
provide tax credits for efficiency efforts. Similar policies are in effect in the EU and
China.
Mainstream industry authority Engineering NewsRecords influential Top Lists
rankings now include Top Green Design Firms and Top Green Contractors:
The market for sustainable design has passed the tipping point and is rapidly
becoming mainstream (http://enr.construction.com/).
Increasingly, shareholders and capital markets are rewarding companies who treat
their environmental mitigation costs as investments (Russel, 2005).

Retrofitting may save some older plants from early retirement due to noncompliance with regulations such as the EUs Large Combustion Plant
Directive on pollution (nitrous oxides, sulfur dioxide, mercury, and particulates)
(International Energy Agency, 2006). In the US, increased compliance may
smooth permitting of new units or plants.
All of the dirty dozen in Carbon Monitoring For Actions (CARMA) list of
top carbon dioxide emitting sources in the U.S. are coal-fired power plants,
emitting an average of about 20 million tonnes of carbon dioxide per year
per plant. Blacklists like these, which include rankings by company as well,
are increasingly being consulted by large institutional investors and sovereign
wealth funds. With tightened credit markets, there is therefore an even
greater incentive for top management to watch carbon dioxide emissions.
See the section on Benchmarking for other global efforts toward increased
transparency.

Non-Technical Barriers to Energy Efficient Design

Despite all of the benefits and incentives, and the low-capital-cost improvement
potential described in previous sections, the implementation of integrative, energy
efficient design and operation is still hindered by several obstacles. Methods for
improved design are known and the required technologies are widely available off
the shelf. Individual components are generally available in high-efficiency variants.
So why are power and industrial process plants energy inefficient in their design as
a whole? One clue, is the fragmentation found in engineering disciplines, vendor
equipment packages, and even in the way projects are executed.
The current situation with energy efficiency is analogous to the status of safety in
process industries a decade or two ago. Operational safety was acknowledged as
important and was codified, but there were no standards on how safety could be
managed during the design processon how it could be designed-in from the
Module 1B | 35

start. The recent Functional Safety standards IEC-61508 and 61511 point the way
forward for energy design and management standards evolution.
Many of the barriers listed below are managerial or procedural rather than technical
in nature. These important non-technical aspects are discussed in the final module of
this handbook. The discussion is generic for most large power and process facilities,
but a specific industry will have additional competitive and regulatory pressures.
Local, State, National and International Regulatory Authorities
Authorities provide the regulatory framework for the activities of all the other
stakeholders. The efforts of authorities are closely linked with those of the standards
organizations. These factors, however, may contribute to inefficient plant designs:
Regulations often permit pass-thru of all fuel-related costs directly to the rate
base. This financially discourages any economization efforts related to fuel
consumption, i.e. efficiency.
Lack of clarity, unity and commitment to emissions charging makes investors wary
of long-term investments in energy efficiency and/or carbon dioxide emissions
reduction.
Deregulation and the ensuing volatility in fuel and energy prices may also
discourage the long-term thinking necessary to make some efficiency and carbon
dioxide emissions reduction schemes justifiable.
Shareholders & Investors
The observations in this paragraph regarding shareholders and investors apply
mainly to new construction or large-scale redevelopment projects. See the following
paragraphs for barriers more applicable to facility owner/operators of older plants
and retrofit project contexts. Shareholders and investors often influence project
schedules, contract clauses, functional specs for new construction and major
retrofits of plants. These factors, however, may contribute to plants that are
ultimately energy inefficient:
Project schedules are compressed; front-end design and concept studies are
underfunded or curtailed.
Scope of redevelopment projects is narrow because investors generally want
to avoid changes to the long remaining lifespan of the standing capital stock
(International Energy Agency, 2006).
Designs are frozen early by a pre-established milestone date, even if important
data may be missing.
Cost analysis methods are too crude, or not coupled tightly enough to the
conceptual process design, or have wrong initial assumptions regarding risk,
return, and lifetime; calculations may ignore significant indirect costs and savings
such as substitution costs, maintenance savings, and peak energy prices.
36 | ABB Energy Efficiency Handbook

 Operational energy costs may be treated as a fixed cost and therefore receive
much less attention than a variable cost.
Low-bid, fixed-price contracting without strong, well-defined and enforceable
energy performance guarantees, at the plant, unit and equipment levels.
Purchasing managers seek multiple suppliers to reduce cost; this strategy leads
to increased design and data fragmentation. Purchasing managers may still prefer
individual vendors versus full-service/system integrators.
Energy-expert consulting companies are usually the last to be hired, and therefore
have much less influence over the conceptual design.
Drawings are issued for construction before even the first vendor drawing is
seen, much less approved (Mansfield, 1993), leading to hasty, often energyinefficient re-design at the interfaces.
Capital scarcity might favor smaller plants with lower efficiency (Gielen, 2008).
Facility Operators
Facility Operators craft the original specifications, validate the design during
commissioning and acceptance trials, determine operational loading and
maintenance of facility, and usually initiate and manage retrofit projects. These
factors, however, may contribute to plants that are ultimately energy inefficient:
Retrofit projects to improve energy efficiency are funded from operating budgets,
not from larger capital expenditure budgets; payback expectations and discount
rates are all generally much higher than in green-field projects.
Managers focus on optimizing process productivity, in which energy is only one
of several other cost functions and may not receive the consideration it deserves;
many modern plant-wide optimization systems optimize for productivity, which
only indirectly improves energy efficiency.
There is a war for money between process improvement and energy efficiency
camps in a typical plant; process improvement teams and their measures seem to
get more respect.
An increasing number of plants are centralizing purchasing, which means less
engineer involvement in purchasing decisions. Since purchasing centralization
weve seen companies shift away from using a lifecycle cost model, which seems
very short-sighted to us. Some of the decisions customers have been making are
committing them to a stream of ongoing expenses that could have been reduced.
(Control Engineering article 8/15/2005).
Facility operators receiving a new/retrofitted plant/unit are under-pressure to begin
operations as soon as possible so they are therefore less critical with respect to
energy targets during acceptance tests.
Facility operators do not or cannot operate plant at design capacities due to
changes in market or other factors.

Module 1B | 37

 Plant engineering and maintenance teams are losing experienced older staff;
facility operators do not provide adequate training for staff on energy efficiency.
Power plant/power house energy managers (superintendents or maintenance
directors) lack the necessary communication and salesmanship skills to push through
good energy efficiency proposals. (a post on J. Cahills blog, 2007).
Reluctance to admit non-optimal, energy inefficient, operation to upper
management the perception is that this reflects badly on plant management and
their plant operations team.
Fear of production disruptions from new equipment or new procedures to improve
efficiency (International Energy Agency, 2006); doubts about safety, controllability
or maintainability
Expansion projects will simply duplicate an existing unit on the same site,
repeating many of the same design mistakes, to reduce the up-front engineering
hours; low-labor copy-and-paste projects may also overlook opportunities for
rationalization & integration with the existing unit(s).
Design and Engineering Companies
Design and engineering companies determine design specs of facility, select
components and execute the design. These factors, however, may contribute to
energy inefficient plants:
A tendency to oversize pumps, fans, and motors by one rating, and oversize them
again after handoff to another discipline, and then again by project leaders:
Bottom limits in standards already have a safety margin, but these limits
are interpreted as a bare minimum (from fear of litigation) and an additional
safety margin is added.
Overload maximums received from process engineer are interpreted by
mechanical and electrical teams as continuous minimums; fat margins are
added in lieu of detailed loading study.
Additional margins are then added for future, but unplanned, capacity
increases.
Engineers on auxiliary systems are inordinately fearful of undersizing and risk
being singled out as the bottleneck that prevents operation at full design
capacity of other, more expensive, hardware
Large, commodity motors and fans are commercially available only in discrete
sizes. After all the margins, an engineer will choose the next size up if the
design point falls between two sizes.
A tendency to aggressively reduce engineering hours to increase margins on
fixed-priced contracts and to avoid selecting premium components for such
contracts.

38 | ABB Energy Efficiency Handbook

 Trade-offs between floor space and pipe/ductwork efficiency are not life-cycle
cost-estimated; civil and architectural concerns are the default winners due to
their early head start in most projects.
Trade-offs between reliability and energy efficiency are not life-cycle costestimated. Higher energy costs are seen as insurance against large, but virtual
opportunity costs.
Lack of energy design criteria and efficiency assessment steps in the standard
engineering workflow. There is typically a design optimization step for cost, safety,
reliability, and other concerns, but not for energy efficiency.
Shortage of engineers in key industries; junior and outsourced engineers are
making higher-impact decisions.
A reluctant to deviate from their standard design templates, especially on
expansion projects where the design has been delivered on previous units. This
leads to short cuts and uncritical copying-and-pasting of older, non-optimal
designs.
Engineers work mainly within the confines of their discipline and do not see
opportunities for inter-disciplinary optimization of the total design. For example:
Mechanical engineers miss out on optimizations from chemical engineering
to use waste heat and to optimize plant thermodynamics or create useful
by-products.
Process engineers do not leverage the full potential of automation, selecting
instead familiar equipment like valves to perform control tasks better suited to a
variable frequency drive.
Electrical engineers do not fully understand the process needs for power, such
as duty cycles, and therefore do not fully optimize their designs.
None of the engineers mentioned above are typically very quick to leverage
advances in materials science, which enable higher operating parameters.
Equipment Vendors and Design Tool Providers
Equipment Vendors and Design Tool Providers determine component energy
efficiencies. The vendors tools directly affect the engineers workflow, models, and
documentation. These factors, however, may contribute to energy inefficient plants:
Vendors provide black-box components with closed/proprietary/rigid interfaces,
which are not easily optimized for the whole system; this is the result of a trend
toward commoditization.
Proliferation of design tools and data formats which are non-integrated and their
design model is non-navigable between vendor tools; this hinders integrative
design.
Lack of full-scope energy-optimization functionality in the leading design and
modeling tools

Module 1B | 39

 As components become commodities, salesmen are replacing sales engineers,

and misapplications are increasing (Plant Services.com, 2008)
Professional and Standards Organizations
Professional and standards organizations provide basic education standards and
best practice certifications. These factors, however, may contribute to energy
inefficient designs:
No widely accepted standards specifically for energy efficient designs of entire
plants; some operational energy management standards are in development,
however.
No widely accepted certification for energy design for whole plant systems; an
energy manager certification is available in the USA, however.
Lack of mandatory international labeling system for industrial motors,
transformers, and other equipment to enable comparison.
Protectionism and turf wars limit the global adoption of a single set of standards;
the divisions between English and SI units are a cause for some confusion, design
errors, and incompatibilities.
Educators and Academia
Educators and academia provide basic skills and certification (by diploma) of the
next generation of designers and engineers. These factors, however, may contribute
to inefficient designs:
Educators tend to focus on the abstract and theoretical, as opposed to best
practice design using state-of-the art commercially available engineering
components.
Systems engineering courses are not mandatory or sometimes not even offered in
the average curriculum.
Electrical engineering curricula increasingly favor more modern topics of
electronics and discrete logic at the expense of courses on old-fashioned power
engineering; courses on power station design have been dropped.
Programs or degrees toward industrial or engineering management are too
general: the specifics of each discipline cannot be made more abstract.
Some engineering schools offer no capstone design course that encourages
synthesis of all the disciplines toward a single design task.

40 | ABB Energy Efficiency Handbook

Standards, Best Practice, Incentives, and Regulations

Standards are the designers and engineers best design guidelines. Standards also
offer customers and authorities an objective measure for applying regulation and
incentives. Best practices encompass more than standards, and include case
studies, more application details, and some costing information.
Role of Standards in Energy Efficiency
Energy efficiency is an invisible quality and is subject to various interpretations; it is
important, therefore, for engineers and managers to be able to have some common
definitions and methodologies when assessing efficiency performance. International
standards for energy design and management are emerging and some countries,
including the U.S., have some standards in these areas. It is likely that these
standards will be closely linked to future carbon dioxide compensation schemes,
whether at national or international levels (ISO, 2007).
Common benchmarking for performance is good, but at a deeper level, standards
can provide the equipment and system inter-operability that can enable a higher
performance design. Highly efficient components which are mismatched or
poorly integrated make for an inefficient overall system. A joint ISO/IEA technical
committee that was recently formed to identify gaps in industrial standards coverage
recommended more emphasis on the systemic approach and encouraged a focus
on energy efficiency of overall systems and processes as well as retrofitting and
refurbishing.This expert committee also recommended that standards should
address efficiency improvements through industrial automation.
Standards and Best Practice
The standardization efforts relevant to plant auxiliaries energy performance cover a
wide variety of disciplines. The list far below refers to existing standards relevant to
the systems in this handbook that specify design, application, labeling and minimum
energy performance standards. The list focus is on U.S. standards, but some
important international standards are also mentioned, in italicized text. The premier,
official sources of unbiased standards are the national standards bodies such as
American National Standard Institute (ANSI) for the U.S., CEN/CENELEC (for the
EU) and the international bodies such as the IEC and the ISO. A convenient way to
search for U.S. and global standards is by using the ANSI NSSN search engine at
www.nssn.org. Search by title power station design or power plant.

Module 1B | 41

Other sources of objective standards are the professional societies and industry
associations, although the latter may show more bias toward their industry in certain
situations:

Institute of Electrical and Electronic Engineers (IEEE)

Instrumentation, Systems, and Automation Society (ISA)
The Hydraulic Institute (HI)
National Fluid Power Association (NFPA)
Air Movement and Control Association (AMCA)
American Society of Mechanical Engineers (ASME)
National Fire Protection Association (NFPA)

Many standards for steam-water cycle design of cycle equipment can be found
in the various ASME and NFPA codes, but these are not within the scope of this
handbook. The ASME test codes for determining efficiency, however, are of interest.
Energy is a political as well as a technical subject; some associations (not those
mentioned above) promoting best practice are actually lobby groups with strong,
but not obvious, links to commercial or political entities with various agendas. These
sources can be useful if their advice is taken together with the objective sources
listed above. Some of these unofficial sources of design guidance are listed in the
Reference section of this handbook. The following list is not a comprehensive list
of all relevant standards; appearing here are only those that have some relevance to
plant auxiliaries energy performance and design.

Power Plant Facilities

IEEE Std 666-2007 IEEE Design Guide for Electric Power Service Systems for
Generating Stations (Revision of IEEE Std 666-1991)
IEEE Std 762-2006: Standard for Definitions for Use in Reporting Electric
Generating Unit Reliability, Availability, and Productivity
ANSI/ISA S77.43.01-1994 (R2002) : Fossil Fuel Power Plant Unit/Plant
Demand Development (formerly ANSI/ISA S77.43-1994)
ANSI/ASME PTC 46-1996: Overall Plant Performance codes
ASME PTC 47-2006: Integrated Gasification Combined-Cycle Plants
IEEE 803.1-1992 : Recommended Practice for Unique Identification in Power
Plants and Related Facilities - Principles and Definitions
ISO 13600 series (19972002): Technical energy systems. Methods for analysis
of technical energy systems, - enabling the full costing and life cycle analysis

42 | ABB Energy Efficiency Handbook

Best Practices
DoE EERE Best Practice guides for Steam, Pumping Systems, Fans www1.
eere.energy.gov/industry/bestpractices
EPRI studies and reports there is a large population of useful reports
ABB Electrical Transmission and Distribution Reference Book (the T&D
manual)

Pump and Fan Systems

ANSI/HI 1.3-2007 : Rotodynamic (Centrifugal) Pumps for Design and Application
ANSI /HI Pump Standards : Available through the Hydraulic Institute, a standards
partner (www.pumps.org/)
Best Practices for Pump and Fan Systems
ANSI/HI Optimizing Pumping Systems Guidebook
US DoE Sourcebook (2006). Improving Pump System Performance, from EERE
Industrial Technologies Program:
US DoE Sourcebook (2006). Improving Fan System Performance. from EERE
Industrial Technologies Program
Air Movement and Control Association (AMCA) International
Motors and Drives
NEMA MG 1 : Motors and Generators
NEMA ANSI C50.41:2000 : Polyphase induction motors for power generating
stations
IEEE Std 958-2003 : Guide for Application of AC Adjustable-Speed Drives on
2400 to 13,800 Volt Auxiliary Systems in Electric Power Generating Stations
IEC 60034-3 Ed. 6.0 b:2007 Revises IEC 60034-3 Ed. 5.0 b:2005 Rotating
electrical machines - Part 3: Specific requirements for synchronous generators
driven by steam turbines or combustion gas turbines
IEC 60034-2-1: Motor efficiency testing (September 2007); published as EN
60034-2-1 at CENELEC level.
Best Practices for Motors and Drives
DoE Motor System Best Practices
The Energy Independence and Security Act of 2007 (EISA) calls for increased
efficiency of motors manufactured after December 19, 2010.

Module 1B | 43

Electric Power Systems

IEEE 493 Design of Reliable Industrial and Commercial Power Systems, also has
useful equipment reliability data.
C57.116-1989 IEEE Guide for Transformers Directly Connected to Generators
IEEE Std C37.010, IEEE Standard Application Guide for AC High-Voltage Circuit
Breakers Rated on a Symmetrical Current Basis.64, 65
IEEE 519-2006 Harmonic voltage and current distortion limits
IEEE Std 946-2004
IEEE Recommended Practice for the Design of DC
Auxiliary Power Systems for Generating Stations
IEEE Std C37.21-2005 IEEE Standard for Control Switchboards
525-1992 IEEE Guide for the Design and Installation of Cable Systems in Substations
C62.92-1993 IEEE Guide for the Application of Neutral Grounding in Electrical
Utility Systems, Part III-Generator Auxiliary Systems
IEC 60076-1 Power Transformers (VDE 0532 Part 101)
IEC 62271-1 Ed. 1.0 b:2007 High-voltage switchgear and controlgear
IEC 61000-2-4 (Worldwide) Harmonic voltage and current distortion limits
Best Practices for Electric Power Systems
ABB Switchgear Manual, 11th edition, 2006 (available online)
ABB Transformer Manual, 2007
Energy & Environmental Management
ISO 14064 and ISO 14065 provide a methodology to help organizations assess
carbon footprints and implement emissions trading schemes
ISO 14001 is an internationally recognized framework for environmental
legislation, regulation, management, measurement, evaluation, and
auditingassessing.
ISO 13600 series provides guidelines on technical energy systems
Instrumentation & Control Automation Systems
ANSI/ISA-77.44.01-2007 - Fossil Fuel Power Plant - Steam Temperature Controls
ANSI/ISA-RP77.60.05-2001 (R2007) - Fossil Fuel Power Plant Human-Machine
Interface: Task Analysis
ANSI/ISA-77.42.01-1999 (R2006) - Fossil Fuel Power Plant Feedwater Control
System Drum-Type
ANSI/ISA-77.20-1993 (R2005) - Fossil Fuel Power Plant Simulators - Functional
Requirements
ANSI/ISA-77.41.01-2005 - Fossil Fuel Power Plant Boiler Combustion Controls
ANSI/ISA-RP77.60.02-2000 (R2005) - Fossil Fuel Power Plant Human-Machine
Interface: Alarms

44 | ABB Energy Efficiency Handbook

 ANSI/ISA-77.70-1994 (R2005) - Fossil Fuel Power Plant Instrument Piping

Installation
ANSI/ISA-77.43.01-1994 (R2002) - Fossil Fuel Power Plant Unit/ Demand
Development-Drum Type
ANSI/ISA-77.13.01-1999 - Fossil Fuel Power Plant Steam Turbine Bypass System
502-1985 IEEE Guide for Protection, Interlocking, and Control of Fossil-Fueled
Unit-Connected Steam Stations
ASME PTC PM-1993 Performance Monitoring Guidelines for Steam Power Plants
ISO 13380:2002 Condition monitoring and diagnostics of machines - General
guidelines on using performance parameters
ISO/TS 18876-1:2003 Industrial automation systems and integration - Integration
of industrial data for exchange, access and sharing
Best I&C Practices
ISA Instruments and Automation Society, http://isa.org/, both a standards and
industry organization with sources on best practice

Power Generation Regulations and Incentives

The regulatory environment for coal-fired plants appears likely to change
significantly before 2010. Some US states (2008) are considering a moratorium
on new coal plant construction, and may slow or stop permitting of plants
under construction. A US Supreme Court ruling in 2007 determined that CO2 is
an air pollutant; this raises the possibility that CO2 will soon be regulated as such
under the Clean Air Act. Some of the most relevant existing regulations are listed
below:
EPACT: Energy Policy Act (1992)
EPACT: Energy Policy Act (2005)
CAAA: Clean Air Act (1970, 1990) and National Ambient Air Quality Standards
(NAAQS)
EPACT 2005: tax credits for the construction of coal-fired generation projects
requisite on meeting efficiency and emissions targets. (International Energy
Agency, 2006): According to the IEA, this leads to an increased share of IGCC
and clean coal projects, but may also have impact on traditional coal-fired plant
designs and operation.
The recent legislation in the Energy Independence and Security Act of 2007 (EISA)
will also have an impact on the design and operation of fossil-fuel fired power
plants. EISA calls for increased efficiency of motors manufactured after December
19, 2010, for example.

Module 1B | 45

Engineering Basic Standards

IEEE 280: Standard Letter Symbols for Quantities Used in Electrical Science and
Electrical Engineering
ISO 15926: A meta-structure for information concerning engineering, construction
and operation of production facilities.
ISO 31: Quantities and units, International Organization for Standardization, 1992,
now being superseded by the harmonized ISO/IEC 80000 standard.

Efficiency and Lifecycle Cost Calculations

Efficiency Calculations
Efficiency is a measure of how effective a system or component can convert input
to output. Efficiency is normally given in units of percentage, or as a value from 0 (0
percent) to 1.0 (100 percent). Energy efficiency can be calculated using either energy
(kW/h) or power (kW)
Efficiency percent = (Useful Power Out (kW) / Power In (kW)) x 100
Energy and Power Calculations
Energy must always be defined relative to a given time period or to a given volume,
etc. The energy consumed by a system or components during a given time period
is determined by multiplying its input power over a time period. The common term
losses means wasted energy. Losses can be treated as energy (kWh) in all the
calculations in this section. The common term loads means output power. Most
energy calculations are based on a years time, and a year is conventionally assumed
to be only 8,000 hours to account for system downtime, when energy consumption
is 0. (There are otherwise 8,760 hours in a full year.)
Annual energy consumption (kWhr) = 8,000 (hrs/year) x Power (kW)
Load Profile
In practice, power levels (or loads) are not constant, as assumed in the formula
above. Loads vary over a given period due to changes in the process or ambient
conditions. This variation is described by the components load profile, which
describes the percentage of time (in hours per year) at each loading level (as a
percentage of full load) as shown in the sample load profile below:

46 | ABB Energy Efficiency Handbook

Hours

% of Full Load

5%

400

100

10%

800

90

15%

1200

80

20%

1600

70

20%

1600

60

15%

1200

50

10%

800

40

5%

400

30

0%

20

1 00%

8,000 hrs

Weighted Avg 65

A more accurate view of annual energy consumption for the above components
profile is the sum of the energies at each load level:
Annual Energy (kWhr) = (hrs) at load level(i) x (%) full load at load level(i) x full
load (kW)
Duty cycle is similar to load profile, but is used to refer to shorter time periods (days
or hours) and for cycling (on-off) loads, rather than more continuously variable loads.
Energy and Power Units
Energy has many forms and can be described using many units. The most common
units and their conversion factors are given in the Appendix.
1 horsepower (hp) = 0.7457 kW = 2546 Btu/hr
Savings Calculations
Savings calculations are used to determine the difference in energy and cost
between two components or systems.
By combining the formulas above, one can compare the annual savings of energy for
two components or systems of varying efficiency E1(%) and E2(%). The result is an
energy saving (Se) in kW per year (assume 8,000 hrs in absence of data):
Annual Energy Savings (kWhr) = 0.746(kW/hp) x P(hp) x 8,000 x 100(%) x (1/E2
1/E1)

Module 1B | 47

One can then multiply by the cost of energy (in $/Kwh) to determine the financial (or
capitalized) cost of the annual energy savings calculated above, in $:
Annual Dollar Savings ($) = Se (kWh) x Q ($/kWh), where Q is the price per kWh of
electricity
In these calculations the price (Q) of energy is assumed to be constant. In fact,
energy prices may change as often as every 15 minutes in a de-regulated market,
with much higher prices during peak periods. The average annual price of electricity
shows a rising trend. See the section on present value for methods to account for
this change.
Lifecycle Costing Methods
Life-cycle costing (LCC) is a method of calculating the cost of a system over its
entire lifespan. LCC is calculated in the same way as total cost of ownership
(TCO). A technical accounting of systems costs includes initial costs, installation and
commissioning costs, energy, operation, maintenance and repair costs as well as
down time, environmental, decommissioning and disposal costs. These technical
costs, for an example transformer, are listed below.
n

LCC = CA + CE + CI + (CPM + CCM + COP + CO0 + CR) + CD

0
where CA = cost of apparatus

C E = cost of erection

CI = cost of infrastructure

CPM = cost of planned maintenance

CC M = cost of corrective maintenance

CO P = cost of operation (load and no-load losses)

CR = cost of refurbishment or replacement

C D = cost of disposal

n = years of operational life span
Additional, non-technical costs that should be accounted for in budgetary estimates
include insurance premiums, taxes, and depreciation.
All costs in an LCC calculation should be discounted to present value (PV) dollars
using the present value formulas in the following section. A very simplified LCC
calculation with fewer terms considers only the cost of apparatus and the cost of
operation, and does not consider inflation or variation in price of energy per kWh.
The operational cost term in an LCC formula is typically the annual energy costs
calculated using the formulas above, discounted to PV dollars. See the section
Motor System Calculations for a numerical example.

48 | ABB Energy Efficiency Handbook

For systems that directly emit carbon dioxide or other pollutants, the cost of
operation should include remediation costs, and the taxes which authorities charge
(or may charge) per unit of emissions. For electrical loads powered from a fossil-fuelbased source, the carbon dioxide amounts (in tons) are still relevant, but the carbon
dioxide tax (in $) should not be added to that components operational costs if the
tax has already been factored into the price of the consumed electricity.

Carbon dioxide cost calculations

For coal-fired power plants, 1.3 tons of carbon dioxide is emitted per MW hour
(C.P. Robie, P.A. Ireland, for EPRI, 1991). A conservative estimate for a future
carbon dioxide tax is $25 per metric ton, globally and in the U.S. The tax may
take many forms, ether as a direct tax or a traded quota, etc. A metric ton
(1,000kg = 2240 lbs) is also written tonne.
The energy and dollar savings calculations can now be applied, using the above
data, to give a carbon dioxide (tons) saving and a carbon dioxide dollar savings
($) for reducing power from a fossil-fuel-based source:
Annual carbon dioxide savings (tonnes) = 0.746(kW/hp) x P(hp) x 8,000 x
100(%) x (1/E2 1/E1) x 1,300
Annual carbon dioxide tax savings ($) = $25/tonne x annual carbon dioxide
savings (tonnes)
A rule of thumb for coal-fired plants: a 2 percent steam cycle efficiency
improvement can reduce carbon dioxide emissions by up to 5 percent (Ferrer,
Small-Buck Change Yields Big-Bang Gain, 2007).

Limitations of LCC Methods

LCC analyses often count only single benefits, such as the electricity directly saved
by a new motors higher nameplate efficiency. In fact, there are numerous other
benefits to reduce electricity consumption on the size and wear of upstream, power
system components. Other benefits that are hard to quantify in LCC analysis include
reduced maintenance via the elimination of the control valve, for example. In a
detailed LCC calculation it is important to consider substitution cost.
Present Value Formulas
Most of the costs shown in the LCC calculation accrue in the future. These
payments must be translated into present values using the time-value of money
formulas given here.
Module 1B | 49

Present value (PV) of a future amount (FV) at period n in the future at i interest
rate is:
PV = FVn x 1/(1 + i)n
Present value of a uniform series of payments, each of size US (for Uniform Series):
PVus = US x ((1 + i)n - 1 )/i(1 + i)n
Where i is the interest rate from 0-1 (for a 6% rate, i = 0.06)
The formula for PV of a uniform series can be used to determine the value of annual
energy savings, where the annual cost is calculated as shown at the start of this
section.
If the average annual price of electricity rises at p% per year, then the flat rate Q
must be multiplied by the following rising price factor f:
f = (qn 1) / (q 1)
Where: q = 1 + p/100
And p is the price increase in %
Using the formula for a 1 kW loss after 20 years shows an accumulated cost which
is 41 times the cost of the first year if the average annual increase in the energy price
is 7 percent (ABB Ltd,Transformers, 2007).
Payback Calculations
If the PV of the energy savings over n periods (years) exceeds that of the
investment cost (X), then the investment should be made. The number of periods
required for PV to equal X is the payback period. For a given value of X, therefore,
the payback period n can be calculated.
The monetary value of energy losses, called the capitalized loss value, is defined as the
maximum amount of money the user is willing to invest to invest to reduce losses by 1 kW.
Levelized Cost Calculations
For non-uniform payments, use the levelized cost (LC) method to determine the
levelized amount. This method simply uses the PV formula on each amount to
determine the total PV of the stream, then applies the inverse of the PVus formula
to determine a levelized amount for each period. To evaluate projects, one can use
either the total PV or the LC method. Both will reach the same conclusion, except
that the LC shows a comparison by period. In evaluating energy efficiency project
alternatives, it may be useful to calculate the capital equivalent cost (CEC). The

50 | ABB Energy Efficiency Handbook

CEC is found by adding the capital cost to the PV of all the operating costs over the
units lifetime. This calculation provides a sound basis for comparing bids.
Limitations of PV Methods
Present value methods make assumptions regarding lifetime (number of periods n)
and discount (interest) rate i which have a large impact on the calculated value. In
evaluating energy efficiency projects or components, the conventional assumptions
tend to undervalue the savings. High-quality, high efficiency motors, for example,
may have a longer lifespan (n) than standard motors. Also, the lower risk of energy
efficiency projects should be reflected in a lower discount rate, especially in common
comparisons with new capacity. This comparison is between negawatts (energy
efficiency) and Megawatts (new capacity).

Plant Heat Rate Calculations

In power plants, efficiency is often expressed as heat rate, which is the amount of
energy generated (kWh) per unit of fuel heating value (Btu = British Thermal Units).
Energy Value: 1kWh= 3414.4 Btu = 3.6 MJ
For a plant with Net Plant Heat Rate of 10,000 Btu/kWh (10.54 MJ/kWh), then the
thermal efficiency = 34.14 percent.
Note that heat rate is the inverse of efficiency; a reduction in heat rate is an
improvement in efficiency. Sub-critical steam plants use the fuels higher heating
value (HHV) as basis for heat rate and efficiency calculations, whether the fuel
is coal, oil, or gas. Combined-cycle gas turbine plants are usually evaluated
on the basis of the lower heating value (LHV) of their fuel. This can lead to the
differences in apparent efficiency being somewhat greater than they actually are
(Eng-tips.com, Fowler, 2006).
Coals vary considerably in their composition, which determines their heating
value and carbon dioxide emissions during combustion. A typical coal has
a heating value of about 8,000 Btu/pound, a carbon content of about 48
percent by weight and a moisture content of about 20 percent by weight and is
combusted with up to 10 percent excess combustion air.
The ASME performance test codes 6 and 6A for steam turbines describe the
method to determine steam turbine efficiency in existing plants. Whole plant
international test codes are ASME PTC 46 and ISO 2314.

Module 1B | 51

Energy Accounting for Reliability

Reliability Concepts
The methods and terminology in this section are common to the field of quantitative
reliability analysis. Reliability (R) is the probability that a unit is still operational after
one year, based on the units mean time between failure (MTBF) specification.
Reliability is expressed as failure rate on per year basis.
R = e(-8760hr/MTBF)
Availability (A) of a unit can be calculated as:
A = MTBF / (MTBF + MTTR)
Where:
MTTR = mean time to repair
Energy Cost of Plant Trips
The total cost of a plant trip is composed of many parts, including opportunity cost
of lost power sales, cost of substitute purchased power, ISO fines, trip-induced
repairs, and energy.
The energy wasted per year due to trip events is therefore R multiplied by energy
wasted during startup/shutdown procedures (R x Ess). The wasted energy due to a
complete shutdown and cold restart (Ess) is composed of two parts:
E(shutdown energy) + E(startup energy) =Ess
Where:
E(startup energy) = hours duration of startup x energy input/hr
E(shutdown energy) = rotational energy in all machinery + chemical energy in
process lines
E for shutdown is more difficult to measure and calculate. As a rough estimation,
therefore, E shutdown is assumed to be of the E startup. So ultimately, the annual
energy costs of plant trips :
R x Ess = R x 1.75 x hours duration of startup x energy input (MMBtu)/hr x Energy
price ($/MMBtu)

52 | ABB Energy Efficiency Handbook

Module 2
Drive Power Systems
To the optimist, the glass is half full.
To the pessimist, the glass is half empty.
To the efficiency engineer, the glass is twice as big as it needs to be.

Module Summary
This module describes the impact of design and engineering on the energy-efficiency
performance of auxiliary drive power systems; motors, fans & pump systems, and
variable speed drives.

The information in this module may be generally applied to process industries;

industry-specific text is indented with a rule above and below as shown here.

This section examines drive power systems from an energy efficiency perspective only
and does not provide guidance on critical aspects of drive power engineering such as
safety interlocking or fault-tolerant design. See the References and Standards sections
for more complete guidance on all other aspects of drive power design & engineering.

Introduction to Drive Power

Drive power is the combination of a prime mover, such as an electric motor, a coupling,
and a speed controller that drives the shaft load of the final element, such as a pump,
which puts power into an industrial process. Pump, fan and compressor systems are
so-called cube-law applications because their power requirements increase as the third
power of their speed. A pump or fan running at half speed consumes only one-eighth of
the energy compared to one running at full speed. These cube-law systems represent
more than half of all industrial motor applications and electrical consumption. The focus
in this handbook is on large drive power requirements (200 hp (150 kW) or greater)
involving pumps and fans. The prime mover for the vast majority of drive power systems
are electric motors, so these will also be examined in detail.
This handbook takes an integrative design approach that considers the entire drive
power system from energy input to its end-use on the fluid or gas of the process, as
shown in the figure below:

Module 2 | 53

Figure 2.1 Schematic of an entire drivepower system (Plant Engineering 10/1/2000)

Role of Drive Power in Energy Efficiency

Pumping represents the worlds largest use of electric motors, and fans are in second
place. Taken together, these two applications account for half of all motors in use.
Pumping systems alone account for nearly 20% of all energy used by electric motors
(US DoE, 2008).
A large motor, running constantly, uses its capital cost in electricity every few weeks;
this explains why more than 90% of the total cost of pump ownership (TCO) is energy
consumption. Every one percent improvement in a continuous-duty induction motor
system has a present value of $70/kW, assuming a 5%/yr real discount rate for 20 yrs,
$0.05/Kwh, no reactive losses, heating or demand charges (Lovins, 2008).
Potential for Energy Efficiency
Two leading energy research institutions, RMI (1989) and EPRI (1990), found that half
of all typical industrial motor-system energy could be saved by retrofits, paying back
their initial investment in about 16 months, and in much less time at todays higher
energy prices. In other studies, ABB (2005) found that pump energy consumption could
typically be reduced by up to 20% using well-proven technologies.
Where is the wasted energy in industrial fan & pumping systems that allows such large
savings?

Oversized and under-loaded motors.

Inefficient motors and couplings.
Inefficient applications, especially those which use throttling for flow control.
Equipment running unnecessarily, or for unnecessarily long hours, such as stirrers
on empty tanks, deadheading pumps, and ventilation fans running continuously.

54 | ABB Energy Efficiency Handbook

This handbook module offers design and engineering guidelines that may help prevent
some of this energy waste in new and retrofitted power plants and industrial process
applications.

Auxiliary drive power is used in a variety of applications in a steam generating

plant, from coal conveyors, grinders and pulverizers to furnace draft fans,
condensate and feed water pumps (when electrically driven), circulating water
pumps, and various emission control equipment. The table below shows estimates
of some major auxiliary drive power loads as % of gross generation:
Electrically driven boiler feed pump
Draft fans and pulverizers
Flue gas desulphurization (FGD)
Remaining auxiliaries

2.5% (Goodall, 1981)

2.0% (Juniper and Pohl, 1996)
1.5% (IEA Coal Online - 2, 2007)
1.5% (IEA Coal Online - 2, 2007)

A more complete list of drive power consumers found in fossil-fuel steam

power plants:
Boiler feed water pumping:
feed water pumps
feed water booster pumps
boiler recirculating pumps
Condensate and coolant pumps and fans
condensate or hot well pumps
condensate booster pumps
circulating water pumps
cooling tower pumps and fans
Furnace draft and combustion air fans
primary air (PA) fans
forced draft (FD) fans
induced draft (ID) fans
Fuel handling drive power
drive power for conveyors, coal mills & pulverizers
ash handling pumps
fuel gas booster compressors (for GT plants)
Emissions control drive power (for flue gas desulphurization, catalytic reduction
etc.)
flue gas ID booster fans
Module 2 | 55

 limestone slurry-feed and absorbent circulation pumps

oxidation air compressors
Gas turbine (GT) power plants-specific drive power
GT starter motors
boiler (HRSG) feed-water pumps
Utility systems drive power
soot blower pumps, air compressors
service water pumps
compressors for instrument & service air
Oil lubrication pumps for large rotating machinery
HVAC fans and air heating/cooling loads

Pump Systems
An entire pumping system is a network of fluid handling components such as pumps,
valves, pipes and tanks. The purpose of the pumping system is to provide a certain flow
and pressure to the fluid needed by the process unit.
Pump Types and Concepts
There are many different pump types, but two basic categories are 1) kinetic and 2)
positive displacement. Positive displacement pumps are more suitable for constant flow
applications. Where there is flow variation, then kinetic pumps like the centrifugal (also
known as rotodynamic) and axial flow (also known as turbine type) pumps discussed in
this section, are more suitable. See the References section for sources of information
on other pump types, applications and standards.

Figure 2.2 - Centrifugal pump system and internal design, ABB Drives, 2005

56 | ABB Energy Efficiency Handbook

In a centrifugal pump, the fluid enters the pump at the impeller eye, the center of the
pump. This is the suction part of the pump. The rotating impeller imparts velocity
(kinetic energy) to the fluid as it is accelerated along the impeller blades and squeezed
through the narrow volute, at right angle to its line of entry. As the volute cross-section
area increases, the fluid velocity decreases and a higher pressure (head) develops
towards the discharge end of the pump.
In an axial pump, the fluid is accelerated by the action of a propeller and moves parallel
to the axis or shaft of the pump. In mixed flow pumps, the impeller uses both radial and
axial motion to accelerate the fluid along a path that exits the pump at an angle with the
pump axis or shaft.
Pump Characteristics
The performance of the pump is given by pump curves, which show how much pressure
(Head) can be developed at various flow rates (capacities) at a given speed. Note that
Head (H) has units of length (ft.) but is actually a measure of a fluids energy per unit
weight. The distance refers to the height that a column of the fluid could support under
gravity. A useful approximate conversion formula between Head and psi is:
H (ft) = ( H (psi) x 2.31 ) / Sp
H (m) = (H (kp) x 9.8) / Sp

Sp =1 (for water, approximately)

The head of a fluid has four components:

Static head, which is independent of flow, increases with vertical height above the
pump centerline and is negative for heights below the pump.
Pressure head, which is due to other forces such as backpressure in a closed
tank, and is also independent of flow.
Friction head, which is due to resistance in elements such as pipes, valves &
fittings, and increases with flow.
Dynamic head, which is a function of the velocity of the fluid, and is given by :
Hv = V2 / 2g.
Where:
Hv = velocity head (ft or m)
V = fluid velocity (ft/s or m/s)
g = acceleration due to gravity (32.2 ft/s2 or 9.8 m/s2)
Note that the dynamic head is usually rather small and may be ignored in most
pumping applications.

Module 2 | 57

Axial-flow pump performance curves are steep, meaning that they can deliver
nearly constant flow over a wide range of pressure. Centrifugal pump curves are
much flatter, meaning that they can provide a range of flows over a relatively narrow
pressure range.

Power Plant Pump Applications:

In a power plant, the circulating pump supplies cooling water at large flow rate
and low head to the condenser for heat exchange. Condensate (also known
as hotwell) pumps are medium flow, medium head pumps which move the
condensed steam from the condenser, through feedwater heat exchangers, to the
de-aerator tank. The boiler feedwater booster pump moves water from the deaerator to the man boiler feedwater pump, which supplies water at high pressure
to the steam generator (boiler).
Circulating water pumps:
Circulating pumps are usually mixed flow pumps, with axial designs being
used for very low head applications. Note that although dynamic (velocity)
head is typically ignored in most pump applications, it is a significant factor in
low head, high capacity systems such as the plant cooling water-circulating
system. Typical flow rates for circulating water pumps are between 0.35gpm
and 0.75gpm per generated kW. (GE Utility Division 1983)
Condensate pumps:
Condensate pumps are usually 2-stage pumps that operate with a high
vacuum on the inlet. The discharge pressure must be sufficient to overcome
the friction in the piping and low-pressure feed-water heaters, and any static
lift required to pump the condensate to the level of the low-pressure feedwater heaters. (Homer M. Rustebakke, GE Utility Division, 1983).Typical power
required by condensate pumps is on the order of 3hp per MW of generating
capacity
Boiler feedwater (BFW) pumps:
Boiler feedwater (BFW) pumps are usually multi-stage, volute type centrifugal
pumps. Typical boiler feed pump power requirements are about 10,000hp
(7500kW) for a 300MW plant, then increase by 3300hp (2500kW) for every
100MW (Homer M. Rustebakke, GE Utility Division, 1983). The head of boiler
feed pump depends upon the boiler load and thus steam pressure, which
varies with plant loading. On large units, there is still usually a feed water
control valve for filling and very low load, with pump speed taking over as load
rises past some threshold (ISA 2005). Feed-water pumps are characterized by
high reliability requirements and fairly high dynamics during plant load changes.
58 | ABB Energy Efficiency Handbook

They normally make the biggest contribution to the plants in-house energy
consumption. Another estimate for boiler-feedwater pump consumption is
around 15 MWe on a 600 MWe plant, or around 2.5% of gross power (Goodall,
1981).

Total Developed Head

From the perspective of the pump, the process unit is a load that is a combination of
pressure, static and friction heads. These latter two exist on the inlet and discharge
sides of the pump. On the suction (inlet) side, the pump must lift the fluid if it is
coming from a lower elevation and overcome any friction pressure drops through
the inlet, together called the Total Suction Head. On the discharge side, the pump
must push the fluid against systems static head, pressure and friction pressure
drops, together called the Total Discharge Head. The pump(s) must develop enough
pressure (head) to meet the combined effect of these energies when delivering
the required flow. An important design criterion for any pump is therefore the Total
Developed Head (TDH):
TDH = Total Discharge Head Total Suction Head
Pump Net Positive Suction Head
On the suction side, the system must also provide sufficient suction head so that
the pump does not cavitate. Cavitation is a low-pressure phenomenon that reduces
performance and may lead to pump damage. Sufficient suction head is called
NPSHA (Net Positive Suction Head Available) and designers must compare this with
the pumps characteristic curve for NPSHR (Net Positive Suction Head Required)
provided by the supplier.

In power plants, the typical margins over this published NPSHR values may run
from 50% to100% for a complex boiler feedwater (BFW) system with transient
suction condition operations. Particular attention to NPSH margin should be
given to boiler feedwater system where load rejection and system transients
are expected, (Black & Veatch, 1996)
The suction requirements of BFW pumps are sometimes met by specifying a
lower-head booster pump upstream of the main BFW pump.

Pump System Load Curves

The typical load curve shows a system with fixed static and pressure head as well as
friction that increases exponentially with flow. Systems without any static or pressure
Module 2 | 59

head have curves starting at the zero point. Systems with high friction have steeper
curves. Systems with low friction but high flow requirement will have flatter curves.
The figure below shows the pump curve for a typical centrifugal pump as well as the
system load curve for the head and flow it must deliver. The pump will operate at
the values of head and flow where the two curves intersect, known as the operating
point, where supply meets demand.
If two pumps operate in parallel, their pump curves are added horizontally, giving
a single equivalent pump curve with higher capacity, but with heads the same as
one of the pumps operating singly.
If two pumps operate in series, then their characteristic curves are summed
vertically, to give a single equivalent pump curve with higher heads, but capacities
the same as one of the pumps operating singly.

H (Head)

Pump curve

Operating point

Friction
losses
System curve

Static
& pressure head

Q (flow)

Figure 2.3 Pump head vs. flow performance and system curves

Pump Power and Energy Efficiency

Pump output power (water horsepower: WHP) to the fluid is given by:
WHP = (Q x H x Sp) / 3960

kW = (Q x H x Sp) / 6128

Where:
Q = capacity: in GPM (Gallons Per Minute)
H = total developed head (ft)
60 | ABB Energy Efficiency Handbook

(l/min)
(m)

Sp = specific gravity (density) of the pumped fluid

(water = 1)

Pump input power required (also known as Brake Horsepower: (BHP) is the water
horsepower divided by the pump efficiency: Eff
BHP = WHP / Eff

Motor Power = kW/ ( = EFF)

For estimation of efficiency (using SI units) in centrifugal pumps with developed head
(H) between 15 to 100m water and flowrate (Q) between 20 and 300 cu.m/hr one
can use the following pump model (Rajan 2003) which has a standard error of about
1%:
Eff (%) = 65.08 x H -0.12446 x Q0.094734
Affinity Laws
Pumps of similar design but different impeller sizes can be compared by using
the pump affinity laws. These affinity laws (see below) below describe the relation
between the rotational speeds of the pump (n), flow rate (Q), head generated (H) and
power absorbed (P) by the fluid:

Figure 2.4 Pump affinity laws, (ABB Oy. Drives, 2006)

For a given speed, a pump curve has an operating point where efficiency is
maximum, referred to as the Best Efficiency Point (BEP). The region of high efficiency
close to the BEP is called the bullseye. Designers strive to make this the actual
operating range for the system, as this will reduce both energy and maintenance
costs. When the operating point moves away from the BEP , then relatively more
brake horsepower (input power) is required per unit water horsepower output.

Module 2 | 61

Losses and Efficiency

The main losses within a centrifugal pump are due to: circulation within the casing
(decreases with flow), shock losses, and friction loss (Rajan 2003). The friction
loss varies with the square of flowrate and is the largest loss component when
the pump is operating at higher loads. The effect of these losses is revealed in the
efficiency vs. flow curve supplied by the pump manufacturer. Older pumps may
suffer from impeller wear, internal leakage and bearing losses as well, and should
be continuously monitored for performance degradation.
The difference between input and output power is mostly lost as heat energy to
the fluid. In the minority of applications which call for heating of the fluid anyway,
engineers should resist the temptation to include this effect to justify less efficient
pumps or designs. Pumps operating far from their BEP will experience greater
bearing and other mechanical stresses which lead to increased maintenance costs
and downtime. In such applications, it is better to let heat exchangers do the job for
which they were designed.
The affinity laws explain the shape and distribution of the family of pump curves
which show pump head vs. flow at different pump speeds, where each curve shows
pump performance at a given speed. These curves are shown in the figure below,
together with the lines of constant efficiency, also determined by the Affinity Laws for
pumps.
80
70
Iso efficiency lines

1480 r/min

60

h=71%

h=85%
h=83%

1184 r/min

40
30

150
Operating points

Power kW

Total Head m

System curve

h=83%

1350 r/min

50

1480 r/min
1350 r/min
1184 r/min

100
50
0

200

400
600
800
Rate of Flow m3/h
m: meter
kW: kilowatt

1000

1200

m3/h: cubic meters per hour

r/min: revolutions per minute

Figure 2.5 Variable speed pump performance curves, (US DoE Sourcebook, 2006)

Due to the similarity of the efficiency and system curves, there is little loss of
efficiency when a pump operates at lower rotational speed. The new operating
point is still in the pump efficiency bullseye, its ideal operating region for that speed.
Pump efficiency curves at the BEP do not change significantly with pump speed
62 | ABB Energy Efficiency Handbook

within the family of pump performance curves. When speed is reduced by half of
the rated speed, pump efficiency at the new speeds BEP may only be reduced by
3%, for example. Pump efficiency is relatively unchanged, but the decrease in power
consumption at the lower pump speed is substantial.

H (Head)

Pump curve

BEP

Efficiency

BHP

Q (flow)

Figure 2.6 Pump power and efficiency curves

Recall that pumps and fans are cube-law applications because their power
consumption varies with the cube of the speed of the pump or fan.
This relationship yields large power savings even from modest speed reductions,
and favors designs that seek to reduce speed, such as using Variable Speed
Drives (VSDs). See section on Pump Flow Control Methods.
The cube law also strongly favors selecting the right size of pump for the
operating conditions. See section on Pump System Design & Engineering for
guidelines on correct pump sizing.
Designers can also benefit from selecting high efficiency pumps, which are generally
4% to 7% more efficient and may cost little or no more than standard efficiency
pumps. Using a lifecycle approach, super-efficient pumps are even more cost
effective. Efficiency varies widely with pump type and flow range; according to the
Hydraulic Institute, the pump efficiency of large single-stage end-suction pumps
operating at their BEP and at flow rates in the 100 cu.m/h range is 81%.
Pump Flow Control Methods
Some of this section is adapted from the application guide: Using Variable Speed
Drives in Pump Applications (ABB Oy. Drives, 2006)
The process system will usually require variable flow rates from the pump. There
are four common methods to control the output of a pumping system: Throttling,
Module 2 | 63

Bypassing, On-Off, and Variable speed control, as shown in the figure below.
Variable speed control may be achieved by motor frequency modulation using a
Variable Frequency Drive, or by using gears and hydraulic couplings.

Figure 2.7 - Common flow control methods, (ABB Oy) Drives, 2006)

The relative power consumption of the different control methods can be estimated
from the area between the x and y-axes and the operating point on a pressure-flow
curve as shown in the figure below. This comparison is based on the formula for
pump power (P): flow x head (P=Q x H). In the example shown, the relative power
consumption for an average flow rate of 70% (of full flow) is calculated using typical
values for the different flow control methods.
Throttling
Flow control can be achieved by modulating a valve immediately downstream from
the pump. Throttling effectively changes the process system curve seen by the
pump: the valve introduces friction into the system; this makes the system curve
steeper so that it intersects the pump curve at the lower, desired flow rate, as shown
in the top left chart in the figure below. In this example, the operating point is moved
from (Q = 10, H = 10) to (Q = 7, H = 12.7). The relative power consumption can be
calculated by P = 7 x 12.7 = 89.

64 | ABB Energy Efficiency Handbook

This method has low capital costs, but throttled systems waste energy in two main
ways: pressure drop across the valve, and because at reduced capacity the pump
performs below its optimum efficiency point.

Figure 2.8 - Energy efficiency impact of various flow control methods, (ABB Oy. Drives, 2006)

In power plants, excess pump and throttling energy is not entirely wasted in
applications that call for heating of the fluid anyway; as is the case in boiler
feedwater regenerative heating. There are three reasons to avoid using such
indirect heating to justify continued use of throttling control:
Higher maintenance costs of the pump operating far from its BEP
A highly-oversized valve will operate in a nearly closed state, which is not
stable. This situation arises in constant speed pumping systems where each
layer of engineering bureaucracy adds its own safety margin in calculating
pressure drops through pipes, heat exchangers etc. and then, finally,
in selecting the pumps. The control valve ends up with all these safety
margins, as added pressure drops. (Liptak, 2005)

Module 2 | 65

 Most importantly, for high pressure systems such as power plant boiler
feedwater, is the severe wear on valve components from throttling at 2,400
psig (16.5 MPa) (Black & Veatch, 1996)

Bypassing
Although not commonly used for flow control, bypassing (also known as
recirculation) is applied mainly to circulation duty pumps. The flow output to the
system is reduced by bypassing part of the pump discharge flow to the pump
suction. Flow through the bypass system is controlled by valves. This means that the
total flow increases (from 10 to 12.4), but the head decreases (from 10 to 6.6). The
relative power consumption is P = 12.4 x 6.6 = 82.
A minimum flow recirculation system is sometimes necessary if the pump operates for
extended periods at low flow rates, when the pressure is too low to induce adequate
flow into the system. Recirculating flow wastes energy and should therefore be kept
to a minimum. Automatic modulating control of the recirculating flow system will
ensure that that the recirculation flow control valve only opens when measured pump
flow drops below a certain minimum threshold. Recirculating systems are sometimes
required on systems equipped with variable speed flow control to guard against low
flow conditions. The drive logic of a VFD speed controller may also be programmed to
warn operators and to shut off the pump in these cases.

In power plants, this type of pump control may be used in boiler feed
and condensate pumping systems to provide flow control and to prevent
overheating of the pump at low flow rates. (Black & Veatch, 1996)
Another reason why designers may add a recirculating flow loop is to keep the
pump at a higher state of readiness for increased demand. An improved design
may make use of any existing, smaller and more responsive startup pump
instead of a recirculation loop.

On-Off Control
On-off control is often used where stepless control is not necessary, such as
keeping the pressure in a tank between preset limits; in these applications, the pump
is either running or stopped. The average flow is the relationship between the on
time and the total time, on plus off. The relative power consumption can then be
easily calculated by P = 0.7 x 100 = 70.

66 | ABB Energy Efficiency Handbook

Variable Speed Control

The Best Efficiency Points (BEPs), when plotted for each pump curve, follow a
quadratic shape that is in accordance with the affinity laws; pressure ratios are
proportional to the square of flow ratios. In low static head, mostly friction systems,
the system curve has approximately the same quadratic shape as the pumps best
efficiency curve. By varying the speed, therefore, the operating point can be made to
follow the unchanged system curve along a line which is close to the BEP line. If the
pump impeller speed is reduced, the pump curve moves downwards. If the speed
is increased, then it moves upwards. This relationship ensures that the pumping
capacity is exactly matched to the process requirements.
According to the earlier example, both flow rate (from 10 to 7) and head (from 10 to
6.4) are reduced at the new operating point. The relative power consumption can be
calculated by P = 7 x 6.4 = 45. This simple example shows that the variable speed
control method is the most energy efficient for pumping applications.
The examples were calculated for one flow rate only (70%), but the relative power
consumption with different control methods depends on the flow rate. This
relationship is shown in the figure below. In these curves, the pump, motor and
drive efficiencies are also taken into account and for that reason the results differ
somewhat to those in the previous similar figure.

Figure 2.9 - Energy efficiency impact of various flow control methods, (ABB Oy. Drives, 2006)

In power plants, boiler feedwater (BFW) pumps are driven by one or more, or
combinations of: squirrel cage induction motor, synchronous motor, mechanical
drive steam turbines, or gear drive from main shaft of turbine. Traditionally,
pump drivers have been selected focusing on reliability at the expense of
efficiency due to their critical role in the steam cycle. Ref ABB Drives. There
Module 2 | 67

have been several studies (Black & Veatch 1996, EPRI 1995, ABB 2008) to
compare the different options for pump drivers (prime movers) on base-loaded
pulverized coal steam power plans, and the effect on net plant heat rate.
In all studies the option with a constant speed motor-driven BFW pump using
throttle valve control is the least efficient, wasting significant energy at loads
<100% throttle flows. The two basic options involving speed control are sliptype adjustable speed drives and non-slip VFD drives.
In all options except the VFD there is likely a need for mechanical reducing gear
if the pump has a design speed greater than the motor rated speed. Reducing
gears are efficient, but still lose up to 1.5% of the input shaft power. For an
8MW pump, this loss represents almost 1GWh lost per year.
In all studies, the VFD option to vary motor output speed achieved better net
turbine heat rate and better turbine output at all throttle flows when compared
with speed control via slip-type hydraulic coupling. (Black & Veatch, 1996)
A third option is the steam turbine-driven feed pump. This pump is driven
by a condensing turbine that takes steam extracted from the IP/LP turbine
and exhausts to the main condenser. The disadvantages of this type of drive
arrangement are the extra valving and piping, plus added complexity in startup,
requiring an additional startup electrical motor. The VFD alternatives output
does not directly depend on the available steam flows, which vary with loading
and season.
In the comparison between the different drivers, a slightly better heat rate is
achieved with the turbine driven alternative. At the cost of more valve and
piping complexity, the turbine exhaust may be used in feedwater regenerative
heating, further enhancing the viability of this alternative.
Still another design option, found in some older plants, is a main turbine shaft
drive. These require variable speed coupling for speed control and gears,
plus an additional startup electrical motor. (Homer M. Rustebakke, GE Utility
Division, 1983). The added complexity and lower reliability has made this
design less common on newer plants.
A comparison of the above four BFWP drive alternatives was done for a
500MW unit with 2 x 50% capacity BFPs in parallel (Black & Veatch 1996).
The comparison was done at 3 different load rates: 100, 75 and 50% throttle
flow and considers net turbine heat rate (NTHR) and electrical output (NTO).
In that comparison, the VFD alternative offers better NTHR and NTO than the
68 | ABB Energy Efficiency Handbook

hydraulic coupling alternative, at all throttle flows. At 50% load, the throttle
alternative has bhp=14,459 (10.8 MW) whereas the VFD alternative has bhp=
9,185 (6.9 MW).
This difference is a substantial 36% improvement, representing a net
reduction of 3.9 MW continuous power consumption.

High Static Head or High Pressure Systems

In high static head or high pressure systems, the system curve is more horizontal
than vertical. Referring to the family of pump speed curves, a lower pump speed
intersects the system curve at a point of much lower flow and efficiency, which has
these consequences:
The required speed reductions are smaller, and so are the power savings, in high
head systems.
The efficiencies are lower at lower speeds; this further reduces the power savings
from the above speed reduction.
The lower speed pump curves may not form a well-defined operating point with
the flatter system curve, leading to large changes in flow for small changes in
speed and hence a more challenging flow control task.
Despite the reduced savings compared to mostly frictional systems, pump speed
control in this case is still more economical than throttling the flow with a control
valve. The added mechanical stresses on pump, motor and valve also favor speed
control even in this case.
A compromise design of high-static head systems combines one constant speed
pump and one speed-controlled pump. The constant speed pump overcomes the
high static head, and the VSD-equipped pump provides the additional, variable
capacity. According to the ISA, the use of only one VSD-equipped pump is the right
selection if the static head of the system is between 50% and 67% of the pumps
TDH.

Case Example
Helsinki Energy, Finland
Helsinki Energy is one of the leading experts in the world in the field of
Combined Heat and Power (CHP) technology and one of the biggest energy
companies producing and distributing electricity and district heat in Finland.
Helsinki Energys Hanasaari B power plant is located by the seaside in the
city of Helsinki and has a capacity of 220 MW for electricity and 445 MW for
Module 2 | 69

district heating. The power plants efficiency is 85%. In 1990 Helsinki Energy
was granted the UN International Environmental Award for its pioneering
and determined work in developing CHP technology and the consequent
improvement of the citys air quality.

Originally, the Hanasaari power plants equipment was selected among the
best available technologies at the time of construction to fulfill the requirements
of high availability and efficiency. However, since the time of construction,
variable speed drive technology had taken a big leap forward. Even though
the old ASEA and Strmberg wound-rotor motors with slip recovery control
systems operated very well, Helsinki Energy decided to upgrade them in order
to reduce maintenance work and to further improve the plants efficiency. Given
the efficiency problem of boiler feedwater pumps driven by fixed speed motors
at partial loads, the most economic control is achieved with a variable speed
drive system. The boiler feed-water pump is rated at 4500 kW (6050 hp).
In the spring of 1999, Helsinki Energy ordered from ABB four water-cooled
ACS 1000 drive systems with AMB 560 motors and oil-immersed 3-winding
supply transformers. The Hanasaari B power plants automation upgrade
project was executed together with Helsinki Energys Helen Engineering that
specializes in the design of energy production and distribution equipment
as well as in the related project management. The aim of these design and
construction services is to support the profitability of business operations
throughout the life cycle of the equipment.

Boiler feed-water pumps are one of the biggest energy consumers in a power plant.
Operating feedwater pumps with variable speed drives can significantly increase the
efficiency of a power plant. Outside the boiler feed-water pumps nominal range, the
capacity needs to be sufficient to handle rare but possible abnormal situations in a boiler
that operates under very high pressure. Depending on the local authorities requirements,
the pump, and the supplying drive, must be capable of delivering 10-25 % over pressure
70 | ABB Energy Efficiency Handbook

or overflow. As a consequence, the drive operates practically all the time under partial
load, a situation where a variable speed drive offers the best available efficiency.
Using ACS1000 variable speed drives as level control devices for feedwater drums
can reduce maintenance of the feedwater throttling valves. These havent necessarily
been designed for the full pressure differential resulting from throttling the flow with
fixed speed motors. Further savings can be achieved by designing a new generating
units electricity distribution network for feedwater pumps operated by Variable
Frequency Drives. As main loads, their across-the-line starting behavior typically
impacts on - depending on impedance of the plant transformer- capital cost, either
through a more expensive transformer, through higher fault currents, or a more
expensive switchboard. Variable speed drives as such act as soft starters and cause
no starting current peaks. The ACS1000 can be connected via the most common
fieldbuses to become an integral part of the plants control system. Original case text
from ABB Switzerland , MV Drives, 2008.

Case Example
Power Losses in KW
300

Fluid Coupling
250

Energy
Savings

200
150

Speed Range
100
50

VFD

0
3567

3645

3724

3850

3976

4150

4322

Pump Speed in RPM

A European power plant was comparing fluid coupling with AC drive for its feed
pump (1,450 kW) control. The comparison shows that within the speed range
needed, the AC drive consumed about 150 kW less than the fluid drive.
Energy saving: about 1,200,000 kWh/year
Reduction in CO2 emissions: 600,000 kg/year (660 tons)
Reduced reactive power
Reduced stress to the supply
Reduced need for maintenance
Case text provided by: (ABB Oy. Drives, 2006)
Module 2 | 71

Pump System Pipes, Valves and Fittings

Pipes, valves and fittings serve to direct and control the flow, but all of these
components can introduce extra friction that requires more input power. Many
references exist on how to reduce friction in pump systems. In this section, only the
energy efficiency impact of piping elements are discussed.
Valves
There are many types of valves, and these have varying degrees of resistance to
flow. Wide-open friction is 25 to 35% larger for globe valves (which are common in
throttling applications) when compared to ball or gate type valves. Further reductions
in friction can also be achieved by optimizing pipe layout such that redundant and
3-way valves may be eliminated. The case for eliminating control valves for flow
control is made in the Flow Control section in this module. A close look at all fittings
and valves to eliminate unnecessary flow restrictions is worthwhile from a lifecycle
energy perspective.
Pipes & Fittings
Friction in pipes is related to:
Pipe diameter and length
Internal smoothness of the pipe
Pipe layout with regard to bends, elbows and size changes.
Friction is proportional to almost the fifth power of the diameter. Lifecycle costing
may reveal that very large pipes are the most economical choice, even when
the high price of steel is considered. It is important to include the capital cost of
pumping power in such a calculation, as smaller pumps and motors are the reward
for reducing downstream friction.
Pipe wall roughness also increases friction. If application standards and materials
allow, then a smooth pipe design should be lifecycle cost estimated and then
compared to the standard design. Pipe layout, which is typically done after
equipment layout, may have sharp bends and elbows that increase the friction in
the system. Short, straight, fat pipes not only reduce friction and upstream pumping
costs, but have lower capital cost. The potential for energy efficiency through
improved piping engineering is often limited by project phase considerations and
even by the design tools that engineers use. Popular pipe layout design software
packages may not even be capable of optimizing layout according to the criteria
discussed here; such computer aided engineering (CAE) tools are indispensable on
all but the smallest projects. RMI found that manual review of one automatic layout
reduced the number of elbows from 28 to only 3 (Lovins,A, 17/72008)

72 | ABB Energy Efficiency Handbook

Taken together, all the above effects make the efficiency of an average length
industrial, rough-walled, average diameter pipe typically about 69% (deAlmeida,
2006). Using low friction piping techniques can increase the efficiency of piping to
90%.

In power plants, steam temperature is controlled by attemperation, which

involves spraying feedwater into the superheated steam. In designs that
take the water from the economizer inlet, throttling of the main feedwater
flow path may be required to ensure adequate pressure drop & flow thru the
attemperation line.
Around 25% of the main flow may be diverted for attemperation of the
superheated and reheated steam, so the pumping power wasted across this
throttle valve is significant.

Pump System Design & Engineering

The pump (or fan) sizing and selection process generally follows this sequence:
Gather data on the system flow configuration : from PFDs
Flow paths ( i.e.: single, parallel or serial configurations)
Liquid specification with density, temperature etc.
Gather data on the general piping layout; from rough P&IDs
Pipe run lengths
Vertical head changes
Valves and other fittings
Determine the basic output hydraulic requirements
Required flow (capacity) with variation ranges for average AND peak flows.
Flows are determined by process requirements and flow paths from step 1)
Calculate or measure the pressure drops across components from step 2),
using standard formulae; sum these pressure drops to determine system head
and flow characteristic.
Based on the above, calculate average and maximum pump power
Determine the input basic hydraulic requirements
Required suction & discharge pressure ,with variation ranges
Specify pump material and casing
Depends on fluid composition, temperature
Module 2 | 73

 Maximum differential pressure for the pump casing

Ambient and mounting specifications
Working conditions
Any special conditions in the mounting space
The sizing and selection process then moves to the electrical engineering domain
and is discussed in the Motors and VFD sections of this module:
Specify pump prime mover and drive train
Electric motor vs. other types
Exceptional starting, stopping and other running conditions
Shaft coupling method
Specify sequencing and/or pump flow control method
VFD or other methods of speed control (VSD)
Additional components for power system compatibility
Pump Sizing and Selection
The following simplified small pump example reveals some basic steps in the sizing
process.
Required flow = 300 l/s (79.2 gps)
Required discharge pressure head = 30m (98.4 ft)
Using the pump curves from the manufacturers catalog shown in the figure below:
Find the required flow, 300 l/s
Move upwards to match the required head, 30 m
Required performance is achieved with pump of 1400 rpm speed
For needed power, move down to the lower curve set along with 300l/s line
When crossing the 1400 rpm curve move to left to read the power needed at the
operating point (110 kW)
Margins and Oversizing
The selected pump is the smallest one capable for the operating point required. If we
know that there is no need for higher capacity, either now or in the future, there is no
need to choose a larger pump, as it would lead to both higher initial and operating costs.
It is estimated that 75% of pump systems are oversized, many by more than 20%.
Uncertainty about static head and/or load flow variation leads designers to specify a
large pump with consequently larger efficiency bullseye to handle this variation.

74 | ABB Energy Efficiency Handbook

Engineers may also tend to oversize pumps so that the ratio between minimum
and maximum energy loss is not large. This means that the gain will not change
much with load (Liptak, 2005), making their control task easier, but at the expense
of wasted energy. Pumping system authorities provide these additional sizing
guidelines for selecting a centrifugal pump in combination with a VFD:
For a system with some static head, a pump should be chosen such that the
maximum flow rate is slightly to the right-hand side of the best efficiency point
(BEP). The exception is for a constant flow regulated system, in which case the
recommendation is to select a pump that operates to the left of BEP at maximum
pressure. This approach optimizes pump operating efficiency (US DoE, 2008).

Figure 2.10 - Pump sizing example, (ABB Oy. Drives, 2006)

Power Plant Pump Design Requirements:

In power plants, the design criteria for boiler feedwater (BFW) pumps,
condensate pumps and other plant components are typically for the valveswide-open (VWO) and a 5% overpressure full load condition. However, new
market situations may require plants initially intended for base-load operation
near their full load design point to now operate in a low to medium load range,
and to do so efficiently.
Flow Requirements:
The main flow requirements come from the cycle mass and energy balances at
the VWO load condition. Some flows, such as attemperation, soot blowing and
boiler blow down, do not contribute to power generation but require pumping
Module 2 | 75

power nevertheless. These flows should be minimized wherever possible. A 5%

margin is commonly added to the final maximum flow value.
For steam temperature control, the careful control of combustion, possibly with
the aid of tilting burners, will reduce the need for steam attemperation flows.
Attemperation flows (and their cycle efficiency impact) can be eliminated on
supercritical boilers by controlling the firing rate to match the feedwater flow
(IEA Coal Online - 2, 2007).
Attemperation is from 2 to 5% of the main steam flow. Soot blowing uses
up to 0.5% of the main steam flow and, like attemperation, is taken only
intermittently. Boiler blow down on drum boilers to control the water quality will
also result in some loss of heat from the cycle and additional pumping power.
Once-through (supercritical) boilers do not have blowdown, because they have
no drum to store a supply of blowdown water (IEA Coal Online - 2, 2007).
Head Requirements:
The BFW pump(s) must have a combined total developed head (TDH), plus
a design margin of 5 to 10%, to meet the following pressure requirements:
throttle pressure at turbine valve, pressure drop due to friction through
superheater, reheater, economizer, and high-pressure feedwater heaters, plus
the static heads due to height difference between pump outlet and drum water
level. (Black & Veatch 1996)
Under infrequent circumstances, perhaps to satisfy peak demand in a hot
summer day, the BFW pump may be required to operate for a short time
10-15% above its nominal range. The pump and motor must be capable of
supplying this added power, so they are specified accordingly. Speed control
(using a VFD for example) will provide efficient power modulation at partial
loads, where the BFW pump operates for most of the time.

Multiple Pump Systems

It is worthwhile to consider specifying multiple pumps, each optimized for a piece
of the load curve; this design is efficient when VFDs are not used. Another energyefficiency strategy is to consider two or more smaller pumps instead of one larger
pump so that excess pump capacity can be turned off. If VFDs are available to the
designer, then one or more of the pumps in the system can have a VFD for top-end
speed control. The section on VFD Multi-Drive describes an efficient and flexible
architecture for driving and controlling multiple motors.

76 | ABB Energy Efficiency Handbook

Recall that the combined performance characteristic of a multiple pump system can
be determined as follows:
Pumps operating in series have a combined performance curve which is calculated
by adding the individual curves vertically, providing increased total head.
Pumps operating in parallel have a combined performance curve which is calculated
by adding the individual curves horizontally, providing increased total flow.
The advantages (right-sizing, reliability) of using multiple pumps must be weighed
against some additional costs; the extra equipment requires additional cabling,
piping and space. Isolation or check valves between multiple pumps in parallel may
be necessary to avoid fluid flow through inactive pumps. The LCC analysis of this
configuration should also consider the generally lower efficiency of smaller motors
compared to larger ones. The direct on-line (DOL) motors will also incur a power
factor penalty, compared to using a VFD for speed control on a single larger motor.
The reliability advantage of parallel pumps, each controlled with a VSD, is that if one
pump fails, the remaining pumps can continue uninterrupted.

In power plant applications that require high availability and redundancy,

additional BFW pumps are specified. If the main BFW pump trips then a backup auxiliary feed pump is started and the boilers firing rate is rapidly reduced in
order to prevent the furnace-tubing temperature from rising excessively (Kirmse
and others, 2000). Another common pump configuration for increased reliability
consists of 2 x 50% capacity BFW pumps operating in parallel.
The high-flow, low-head requirements of circulating condenser cooling water
also leads to multiple pump configurations. Pump automation can cycle these
pumps to provide a range of flows without the need for excessive throttling.
A 4-pump configuration would be more efficient than a system with fewer,
larger pumps, and the greater efficiency would offset the higher capital costs
of the extra pumps; this rule is still recommended in some design guidelines:
(Black & Veatch 1996) The evolution of reliable and lower cost VFDs, however,
favor parallelism mainly for reliability reasons only, because the flow can be
continuously controlled through varying the pump speed.

Pump Automation
Proper control of multiple pump arrangements is essential to realizing their full
energy saving potential. Pump priority control balances the operating time of all
the pumps in the system over the long term. This can boost energy efficiency by

Module 2 | 77

operating pumps closer to their best efficiency point according to the required flow
(duration curve or actual signal) and pump capacities.
Pump automation is important to take advantage of the speed control provided by
VFD-equipped pumps. The applications are varied, but one common design uses
signals from flow or pressure transmitters as input to a feedback loop, which then
modulates the output to the VFD. The desired flow or head setpoint is provided
by a unit-level control system. In head-controlled systems, differential pressure
transmitters (PDTs) are commonly used to provide the pressure drop across unit
loads. For proper head control, the placement of PDTs must span the target load
plus the additional loads incurred by piping and valves. If the unit has a common
supply header to supply multiple loads, then the ISA recommends that pressure
transmitters for this header should not be located near any major load junctions.
In some multiple pump systems, a VFD-driven pump is combined with a constantspeed pump. In these cases, automation can be used to provide additional flow
control on either (or both) sides of the constant speed pumps BEP. For low-flow
control when the VFD pump approaches its maximum speed, then a switch or signal
will auto-start the constant speed pump. According to the ISA guidelines (ISA 2005),
extra increments of pumping capacity are started by pressure (when demand is
increasing), but stopped by flow (when demand is decreasing).
See the section in Automation module on Feedwater Control systems for a
description of typical pump automation applications in power plants.
Pump System Design Guidelines - Summary
Sources for this section are RMI (Lovins A. 2007), the US DoE EERE (US DoE Best
Practices, 2008) Pumping Tip Sheet, Hydraulic Institute and Europump.
Reduce Static & Pressure Head and Flow Requirements
Gather data to understand the actual loading requirements, especially the duty cycle
and load profile of the pump.
Consider process design or operational control alternatives that reduce the
maximum and average flows and static or pressure head required.

In power plant auxiliaries, a good example of this rule is adopting a sliding

pressure control strategy, which reduces the boiler pressure head and hence
pump power requirements, assuming that pump speed control is used

78 | ABB Energy Efficiency Handbook

instead of flow throttling; see the section on sliding pressure control in the
Automation module of this handbook.

Right-Size the Components

Do not oversize for flexibility: do not choose a larger pump than what is
necessary; the larger size leads to both higher initial and operating costs.
If conditions change, it may be cheaper to trim the impeller or retrofit the entire
pump than running an oversized pump over the entire period; specify pad and
geometry to accommodate other sizes.
Employ a control strategy that optimizes multiple pump systems.
Where possible, use pumps operating as turbines to recover pressure energy that
would otherwise be wasted, as described in the section on VFD Regenerative
Braking
Reduce Friction in Pumping Systems
Select gate or ball valves instead of globe valves where appropriate; strive to use
larger pipes and smaller pumps instead of vice versa.
For above efforts, start downstream so that sizing calculations of upstream
components can benefit from efforts at reducing friction downstream.
Use Variable Speed for Flow Control
Use variable frequency drives to control flow, rather than throttling, bypassing or
sequencing.
The benefits of VFDs are larger on low static head, high friction systems &
systems with varying flow
Select Energy Efficient Components
Select an energy-efficient centrifugal pump design.
Select an energy-efficient motor to drive the pump.
Install Components Correctly
If using control valves, ensure that they are properly linearized for good control
response.
For pump hookups, allow at least > 5 clear pipe diameters on inlet and > 3 pipe
diameters on outlet.
Ensure that there is sufficient suction head or suction lift.
Pump Drive Train
Speed and Slip
The inevitable slip of induction motors means that actual RPMs will be slightly less,
approximately 1% to 5%, than the motors nameplate speed rating. The amount of
Module 2 | 79

slip is generally lower if high-efficiency motors are used; the extra rotational speed
from a motor efficiency retrofit must be accounted for in the new application design.
Startup Conditions
The inertia of centrifugal pumps is normally small enough to be ignored where the
prime mover is an induction motor. However, this inertia should be considered
together with motor pull-in torque requirements if a synchronous motor is used.
Torque developed by an induction motor varies roughly with the square of the
applied voltage. Voltage drops during startup of large motors may lead to insufficient
startup torque. On most true centrifugal pumps, closing the discharge valve will
reduce the power requirement during early startup. On axial pumps the opposite is
true, so the discharge valve should remain open during startup. On mixed design
pumps, the discharge valve is opened at some point during startup, when axial
behavior begins to dominate (IEEE, 2007).
The reduced torque demand will make it less likely for the electrical engineer to trade
away optimum running efficiency for a design with high starting torque capability.
Pump startup against very high static head or system pressures will increase the
starting torque requirements of the prime mover, which is most often an electric
motor. If the process allows it, then any method should be used to reduce a high
startup torque requirement.

In power plants, the check valve on the boiler feedwater pump discharge line
isolates the pump from boiler drum pressure during startup to at least 70%
full speed. When the check valve opens, torque and speed demand increases
rapidly, the 10% margin of motor over load torque may disappear and startup
may not succeed (IEEE, 2007). The concern over long startups and overheating
may prompt the electrical engineer to trade away optimum running efficiency
for a design with high starting torque capability. The inrush of power late in the
startup may lead the engineer to oversize other power system components,
such as a unit auxiliary transformer, at the expense of lower continuous
operating efficiency.
In some plant designs a motor-driven startup boiler feedwater pump is specified.
This is a requirement for steam-turbine driven main BFW pumps, but has
advantages even when the prime mover is an electric motor. Depending on its
design, this pump may also be used outside of its startup role to provide additional
capacity and response. (Black & Veatch 1996). Turbine driven pumps have lower

80 | ABB Energy Efficiency Handbook

efficiency at low loads compared to motor-driven pumps. A units efficiency could

be increased by using the motor-driven startup pumps at low loads.

See the Power Systems, Transformer section for details on transformer sizing
for startup and the Motor Startup section for details on motor sizing for reduced
voltage startup.
Power Factor
The chosen speed control method also has a significant impact on power factor
(PF). Lower PF leads to oversized power supply equipment and reduced efficiency.
The following figure shows how PF suffers when a motor operates much below its
rated speed, as is the case in throttling flow with a control valve.

Figure 2.11 - Effect on PF of different flow control methods, (ABB Motors & Drives, 2004 S. Weingarth)

Pump System Maintenance

Impeller wear will lead to increased agitation and the resulting heating of the fluid
can be revealed by monitoring the temperature differential across the pump. Close
running tolerances should be maintained between stationary and rotating wear rings;
the losses from a C% change in this clearance (Rajan 2003) can be estimated by the
following model:
BHP % = 141.49 x C0.85836 x Ns-1.10219
Where:
C%Wr = p
 ercent change in clearance from design (C is 1 for a 1% change, 2 for
2%, etc.)
Ns = suction specific speed
Module 2 | 81

Pump electrical horsepower can be compared to water horsepower calculated

from real-time measurements of flow and head. Any protracted deviation from the
expected pump efficiency at given flowrates is a likely indicator of pump degradation
and signals the need for maintenance.
Another, more precise method of monitoring pump efficiency uses a thermodynamic
measuring method (according to the British Standard EN ISO 51983). This method
requires the installation of extremely sensitive temperature sensors precisely
calibrated measure the pumps suction and delivery water temperature a shown
in the figure below. One vendor (ABB) has patented a highly accuracy delta-T
transmitter (HADTT) device. The HADTT enables extremely accurate (in the milliKelvin range) temperature differences. High-accuracy water pressure measurements
are also required for the unit to calculate the enthalpy gain and water horsepower.
These measurements are provided by intelligent pressure transducers with typical
accuracies of 0.075 percent. Continuous monitoring of pump efficiency and flow
measurements will inevitably lead to saved energy and reduced operating costs.
A Pump Efficiency Monitoring System (PEMS) can perform continual analysis of the
pump historical data and propose specific maintenance activity. Additionally, it can
enable the operator to choose the most efficient pump or combinations of pumps to
use in a complex system (ABB Review 2/2008).
Other elements of the pump drive train can be monitored by the methods described
in the section on Condition Monitoring of Rotating Machinery.

Figure 2.12 Pump Efficiency Monitoring System, (ABB Review 2/2008)

82 | ABB Energy Efficiency Handbook

Pump System Cost Calculations

For pumping systems, the three main lifecycle costs (LCC) are energy, initial
investment and maintenance. The initial investment cost is composed of hardware,
engineering and installation costs (including civil costs). Energy consumption is
the dominating element of the LCC, especially if a pump runs more than 2,000
hours per year. To perform a lifecycle cost valuation one needs the following data
parameters, shown with sample units:
Pump type and Impeller type
Nominal flow (l/s or gpm)
Liquid density (lb/cu.ft, kg/l)
Efficiency (%)
Static head (ft or m)
Nominal head (ft or m)
Max head (ft or m)
Flow control method
Transmission nominal efficiency (%)
Motor efficiency (%)
Motor supply voltage (V)
Annual running time (hrs)
Operating profile (% hrs for % nominal flow)
Energy price ($/kWh or /kWh)
Investment cost ($ or )
Interest rate (%/yr)
Service life (yrs)
The output of system cost calculations are usually the following parameters:
Specific pump power (kW/(l/s)) (kW/(cf/s) or kW/gpm)
Required input motor power (hp or kW)
Annual energy consumption (kWh)
Annual energy saving (kWh)
Annual money saving ($ or )
Payback period
Net Present Value ($ or )
See the Case Studies section for fully worked-out examples lifecycle cost
calculations with benefits.
Pump Power Calculation Tools
There are several freely available software tools for calculating fan power
consumption and savings from certain optimization upgrades. A comprehensive list
of tools is available from the US DoE web site.
The Pumping System Assessment Tool (PSAT), from the US DoE , EERE program.
Module 2 | 83

 The ABBs PumpSave calculation tool estimates the energy and cost savings when
using variable speed AC drives compared to other flow control methods (throttling,
ON/OFF, and adjustable speed using hydraulic or other slipping type drives).
Many pump manufacturers support their products with power and efficiency
calculation tools.

Fan Systems
Industrial fan systems in the US annually consume 78.7 billion kWh of electricity,
representing 15 percent of the electricity used by motors (US DoE Sourcebook,
2006). An entire fan system is a network of fans, dampers and/or inlet guide vanes,
and ductwork. The purpose of the fan system may be to provide a certain flowrate
of air, or to maintain a partial vacuum. Fans can supply large volumes of air, up to 1
million cubic feet per minute, but typically only at low pressures.

In power plant combustion processes, the largest demands for auxiliary drive
power come from the ID and FD fans. Typically, FD and ID fan motors consume
enormous amounts of energy in a plant, with motor sizes approaching 14 MW
to 18 MW in many larger plants. When a boiler is operating at non-peak loads
and the traditional fan-motor-damper system is in use, a good deal of energy is
wasted in the fan/motor combination. If a 15 MW motor is wasting 20 percent
of its energy due to inefficient flow control, that waste amounts to 3 MWh during
each hour of operation. At current prices, that equates to roughly $100 an hour.
At 5,000 hours a year of operation, it represents a half-million dollar loss.

Figure 2.13 - Centrifugal fan and motor

84 | ABB Energy Efficiency Handbook

Fan Types and Concepts

In a centrifugal fan, air moves perpendicular to the shaft. Centrifugal fans accelerate
air as it moves along an impeller blade toward the outer rim. This extra kinetic energy
is converted to static pressure as it slows in the fan discharge. Centrifugal fans can
generate high pressures and can host blade designs suitable for applications with
high particulate count and high moisture.
In axial fans, air moves parallel to the shaft, where it is pressurized by fan blades
with an airfoil shape. Axial fans have less rotation mass (inertia) than equivalent
centrifugal fans, and higher rotational speeds (US DoE Sourcebook, 2006). Axial
fans can maintain higher efficiencies over a wider load range than can constant
speed centrifugal fans controlled with inlet dampers or vanes. Axial fans have a
higher capital cost than centrifugal fans, and because of more numerous parts and
complexity, they also require more maintenance (Black & Veatch, 1996)
Fans must develop enough static pressure (SP, usually measured in inches of
water) to overcome the resistance if the system of ducts and elbows and deliver the
required volumetric flow (usually measured in aCFM (actual cubic feet per minute).
Unlike pumps, centrifugal fan output pressure drops to zero at maximum flow, a
phenomenon that is called fan runout.
Fan Characteristics
The pressure and flow characteristics of fans are dependent on the orientation and
shape of the fan blades. Backward-curved blades have the highest efficiency, up
to 90%, higher than straighter radial designs that achieve up to 75% efficiency.
Backward-curved blade fans also have the advantage of a non-overloading
horsepower characteristic (Black & Veatch, 1996). Fans whose blade design has
overloading characteristics have a sharply increasing power demand as flow
increases past the fans best efficiency point (BEP). The lower air velocities along
backward-curved blades, however, promote more build-up of contaminants and may
preclude their use in dirty applications.
An additional blade design factor is the cross-sectional shape of the blade, which
may be flat, curved or airfoil shapes. Airfoil shapes are the most energy efficient.
The airfoil shape, however, creates regions of unstable operation leading to stalling.
To avoid operation in these stall regions may require installation of energy-wasting
devices such as recirculation or bleed valves (US DoE Sourcebook, 2006).

In power plants, fans used to supply combustion air are termed forced
draft (FD) fans, and fans used to exhaust combustion flue gases are termed
induced draft (ID) fans. Primary air (PA) fans supply air to carry an air+fuel
Module 2 | 85

mixture through ducts to the burner nozzle (or fuel bed) and on into the steam
generator. Together, all the fans electric drive power may add up to 2-3% of the
plants rated output.
Single stage (one rotor/blade set) axial fans are typically used in FD service
on balanced draft steam generators. FD fans are sometimes referred to as
blowers. If a centrifugal fan is used, then it is likely to have backward curved
blades for improved efficiency.
Axial fans in ID service have higher pressure needs that require a 2-stage fan.
Axial fans with variable pitch blades are expected to be used more often in
ID service, due to more stringent emission control requirements. A lowered
particulate count can reduce some concerns associated with axial fan blade
fouling (Black & Veatch, 1996). If a centrifugal fan is used instead of an axial
fan, then it is likely to have forward-curved blades. The higher stack pressure
drop due to emissions control equipment has led to increased horsepower
requirements of ID fans and booster fans. The ID hp is typically doubled by the
addition of a wet limestone scrubber, with some units requiring up to 4 times
more horsepower (GE Utility Division, 1983).
On larger plants, all these fans are typically configured in pairs working in parallel,
mainly for reasons of redundancy. See section on Multiple Fan Systems for more
details.

Fan curve

Pressure

BEP
Efficiency

BHP

Flow

Figure 2.14 -Typical fan performance curve, showing efficiency and power relationships

Fan Power and Energy Efficiency

The input shaft brake horsepower (BHP) required by a fan is proportional to the
product of pressure rise and flow, and is given by:
86 | ABB Energy Efficiency Handbook

BHP = (k)(P)(FLOW) / (EFFm)(6354)

Where:
EFFm =
FLOW =
P
=
k
=
BHP =

(kW = kPF/EFFm)

mechanical efficiency, %
airflow, cubic feet per minute
total pressure rise across the fan, inches of water
compressibility factor, dimensionless
brake horsepower

(m3/sec)
(millibar)
(kW)

Stated another way, efficiency is given by:

EFFm = (k)(P)(FLOW )/ (BHP x 6354)

Values for k depend on the absolute inlet and outlet pressures. Using a range
of typical k factors, the mechanical efficiency of different fan types and designs
can be calculated:
Centrifugal fan; forward-curved blade
45-60%
Centrifugal fan; radial-tipped blade
60-70%
Centrifugal fan; backward-curved blade 75-85%
Centrifugal fan; airfoil blade
80-90%
Axial flow fan
85-90%
Ref : (Babcock & Wilcox, 2005)

Static pressure (SP) is often used instead of total pressure in discussing fan
performance. Fans are rated by either their total efficiency or their static efficiency.
For large fans at design speed, most of the fan total pressure is in the form of static
pressure, so the difference between the two efficiency measures is small.
The Affinity Laws for fans are the same as for pumps, but with an additional factor to
account for change in air or gas density. Fans, like pumps, are cube-law applications
whose power consumption increases with the cube of fan rotational speed.
Fan System Load Curves
The system of ducts, elbows, dampers etc. create a resistance load that is
proportional to the square of the volumetric flow. When plotted as Pressure vs. Flow,
the system load curve has a parabolic (quadratic) shape. In reality, the pressure
drops are slightly greater, and the curve slightly steeper, due to losses in flow
irregularities such as vortices and swirls (US DoE Sourcebook, 2006).

Module 2 | 87

Pressure

Fan curve

Operating point
Efficiency

System curve

Flow

Figure 2.15- Typical system load curve, showing efficiency and power

Supply fans generally work against a system back pressure, while return fans
exhaust to low-pressure i.e.: the atmosphere. The system curve for supply fans is
therefore typically shifted higher up the vertical axis than that of return fans. In high
constant pressure systems, the system curve is shifted vertically up the pressure
axis and is flatter at operating flows.

In power plants terminology, the supply fans are the Primary Air (PA), Forced
Draft (FD) and the Gas Recirculation (GR) fans which supply air to the furnace
chamber. The return fans are the Induced Draft (ID) and FGD booster fans.
Designs with both FD and ID fans are termed balanced draft plants, and the
balance point of zero gauge pressure is the furnace.
FD fans must develop pressure to overcome system resistance in ductwork,
air heater, burner or fuel bed and the furnace itself. FD fans must supply
enough flow to serve needs of fuel combustion plus flow lost due to air leaks
in the heater and other areas. FD fans draw fresh air and therefore are more
vulnerable to density changes due to outside air temperature change than ID
fans. Colder, denser air increases the mass flow and power requirements.

Fan Stability
At low flow, there may be no clear intersection of the fan and system curves, and
thus no clear stable operating point,. This causes unstable operation in which the
fan pulsates as it hunts back and forth for an operating point, reducing the energy
efficiency and increasing the wear on fan components. On most fans, this unstable
region occurs to the left of the maximum pressure point, so fans should always
88 | ABB Energy Efficiency Handbook

operate to the right of that point. Pulsation is more likely in fans whose pressure rise
exceeds 10 in. of water. (ISA, 2005)
These unstable modes are more likely to occur in variable speed operation at
very low speeds, or when outlet dampers are throttling the flow to create high
backpressure conditions, or in multiple parallel fan systems operating at low flow
rates. If a VFD is used for flow control, then it can be easily programmed to avoid
these areas of operation.
Pipes, Ducts and Elbows
Resistance pressure drops vary generally with the square of the flow rate. Some
additional useful rules of thumb for energy-conscious designers of ductwork:
Pressure drops along ducts vary roughly with the fourth power of the duct
diameter and are responsible for much of the total system resistance. Even small
increases in diameter will have a large impact on energy efficiency of the system.
Energy is wasted in irregular flows such as swirls and vortices. Elbows, especially
near fan inlet or outlet, cause especially high losses, decreasing the flow by up to
30% (US DoE Sourcebook, 2006). These resistances are also known as system
effects.
Round ducts have less surface area per unit of cross-section, and smoother flow
compared to ducts with square cross-sections.
Fan Flow Control Methods
When centrifugal fans are required to operate at variable loads, the pressure and
flow may be controlled by one of the following methods:

Inlet dampers
Inlet guide vanes
Outlet dampers
Two-speed motor control
Variable speed control by VFD or hydraulic coupling methods

When inlet dampers and guide vanes are partially closed they create a pre-swirl in
the direction of rotation of the fan. This motion reduces the relative velocity of the air
with respect to the fan blades and therefore reduces the fan capacity and pressure.
(Black & Veatch, 1996)
Inlet guide vane control is more efficient than inlet dampers due to reduced friction in
creating the pre-swirl movement.

Module 2 | 89

Outlet dampers are least efficient of all methods; they throttle the airflow to remove
power supplied by the fan. As outlet dampers close, the system curve becomes
steeper, intersecting the fan curve at the required lower flow rate, and at a point
below the fans BEP.
Vane or damper control is highly non-linear, and little control is possible near the fullopen position
Inlet guide vanes are more effective on forward-curved than backward-curved fans;
an important consideration in some retrofit situations (Competitek, 1995). The struts
and actuators needed for inlet guide vanes obstruct flow and will slightly reduce
efficiency.

In power plants, VFDs are an increasingly popular solution for variable speed
control, but ID fan speed control in may also be achieved by other means, such as
single-speed motors with variable speed fluid couplings. The relative performance
and merits of these alternatives in are explored in the Pump Flow Control section,
but the conclusions apply generally to most fan applications as well.

Axial fan control is provided by variable pitch fan blades whose angle can be
changed in real-time to adjust the load on the fan. The effect of variable pitch fan
blade has a similar effect as inlet guide vanes on the flow. In large applications, the
blade pitch is changed using hydraulic actuators. If speed changes are infrequent,
then manually adjustable pitch blades or belt-drive systems with different diameters
may be used, but these methods require the fan to be at standstill for some time.
The efficiency of variable pitch fan control is similar to that of VFD speed control,
but the increased number of moving parts and decreased motor efficiency at offcapacity loading make a VSD an attractive alternative, even on axial fans. In large
two-speed induction motors, typically, the low speed is selected for the most
common operating point and the higher speed for all the higher loads. Switching
between speeds in large motors, however, is neither trivial nor smooth and may lead
to process transients and upsets.

Some power generating plants that have experienced problems with speed
changes simply keep the fan at high constant speed with consequently higher
energy loss. (Black & Veatch, 1996), due to the sensitivity of furnace conditions
to fan pressure fluctuations. Also, if the 2-speed fan has been oversized, a

90 | ABB Energy Efficiency Handbook

very common engineering practice, then it is likely that the top speed will
never be used.

VFD Speed Control

In applications requiring variable flow and pressure, VFDs are the most efficient
method of control. Varying the speed of the fan adjusts the flowrate to the system
requirements without the need of additional mechanical devices, and at high
efficiency. The benefits of VFDs are diminished in applications with higher system
(back) pressures, where the system curve is flatter. The relative power requirements
for the different control methods are shown in the graph below:

Figure 2.16 - Input power for different centrifugal fan control methods, (ABB Drives, 2005)

In power plants, ID fans are ideal candidates for VFD control, as the following
short case histories illustrate. Axial ID fans in particular, with their inherently low
turndown capability and steep pressure vs. flow curves compared to centrifugal
fans, are also well suited for VSD control. Good control can be achieved either
by VFD motor speed control or by variable pitch blades, which have a good,
nearly linear response.
In PC plants, the relatively high and constant system pressures (mostly due
to the windbox and burner pressures) to be overcome by PA fans over a large
range of flow, may make them less attractive for VSD speed control. PA fans
are typically matched and packaged together with the burner assembly and
may therefore not lend themselves to retrofit engineering.

Module 2 | 91

Case Example #1
Power Plant, UK

The ID fans at a UK power plant (200 kW + 150 kW) were running at full speed
with flow control by dampers, but as the boiler ran at low loads for long periods,
management believed that energy could be saved with variable speed control. When
variable speed AC drives were installed for flow control, and dampers locked in open
position, these benefits were noted:
Energy saving: 1,000,000 kWh/year
Reduction in CO2 emissions: 500,000 kg/year
Faster response to load changes (Immonen, 2003)
Noise level reduced from 89 dBA to 77 dBA
Payback period of just 16 months
Case Example #2
Industrial Power Plant
Inlet Vanes
AC Drive
Fan shaft power
120
100
80
60
40
20
0

0 30

60 90

A Finnish pulp mills industrial power plant compared hydraulic coupling to AC

drive (1,370 kW) for its power plant ID (Induced Draft) fan. The power plant is
running continuously and the flue gas flow varies from 50% to 90% of the maximum
capacity. With AC drive:
Energy saving: 376,000 kWh/year
Reduction in CO2 emissions: 188,000 kg/year
Better pressure control
Less maintenance by soft starting
Fan critical speeds can be avoided

92 | ABB Energy Efficiency Handbook

Case Example #3
Industrial Power Plant
Inlet Vanes
AC Drive
Fan shaft power
120
100
80
60
40
20
0

0 30

60 90

An industrial power plant compared inlet guide vanes to AC drives (110 kW each) for
its FD (Forced Draft) fan. The power plant is running continuously and the fresh air
flow varies from 50% to 90% of the maximum capacity. With AC drives: Power plant
FD fan - AC drive instead of inlet guide vanes, Power plant booster fan - AC drive
instead of inlet guide vanes
Energy saving: 482,000 kWh/year
Reduction in CO2 emissions: 241,000 kg/year
Better pressure control with varying loads
Less maintenance by soft starting
Efficient combustion
Case Example #4
Abbott Power Plant, UI, USA
In a drive to reduce the plants operational costs, Abbott Power Plant engineers
selected ABBs ACS1000 standard medium-voltage (MV) drive to control a 1000 hp
fixed speed scrubber booster fan that was previously regulated by inlet vanes, and
thereby improved the overall efficiency with reduced maintenance effort.
Energy savings of USD $63,000 per year, an improvement by 25% on inlet vanes
Reduced maintenance and hardware savings : USD $10,000 per year
Payback on investment period was 24 months
Additional benefits of the variable speed drives include:
no motor start-up problems
total process controllability
Fan System Design and Engineering
Fan selection and sizing is based on many factors. The most important criteria are
the systems pressure and flow requirements and how these vary under operating
conditions.

Module 2 | 93

Margins and Oversizing

As with other turbo-machinery, most industrial fans are oversized or under loaded,
for a variety of reasons. First, there is uncertainty in the flow requirement due to
changes in demand, changes in temperature and air density, and system leakage
increases due to deteriorating seals. Second, there is uncertainty in the pressure
requirements due to system resistance. The common practice of freezing the
equipment layout before the connections between equipment creates sub-optimal
designs; from higher losses due to convoluted ductwork and/or from gross
oversizing of the fan drive system.
The latter point is a common problem, as the ductwork contractor may decide late in
the detail engineering phase to add additional turns to avoid interference with certain
equipment; the number of 90-degree elbow turns is not known for certain until later
in the project. The uncertainty surrounding these and other criteria is behind the
unfortunate practice of high design margins and oversizing. A 15% design margin
on flow is accepted in industrial applications. Given that power is proportional to
the cube of flow, this margin will mean a 50% increase in power consumption at
capacity unless counteracted by VFD speed control or, far less efficiently, by guide
vanes or dampers.
Oversizing of the fan usually also entails oversizing of the motor plus drive train and
the power supply equipment. The Fan Drive Train section discusses the futility
of oversizing motors on non-overloading type of fans. All this equipment is less
efficient when operated much below their rated loads; the Motors and Power System
sections list other negative consequences of oversizing. In existing fans, an indicator
of gross oversizing is that vanes or dampers are almost always in a nearly closed
position.
For axial fans, there is an additional penalty for operating an oversized machine. The
lower flow brings the operating point closer to the fans stall line, increasing the risk
of stall during transient downstream pressure conditions (Black & Veatch, 1996).
A fan can operate in stalled condition, but is much less efficient and at the cost of
increased vibration stress on fan components.

In power plants, fans in furnace draft service may be oversized by engineers

to be quite certain that the fans will not be a bottleneck for (the much more
expensive) boiler capacity. Chief among these concerns is uncertainty in the
flow requirement due to changes in fuel quality and granularity. Power plant
engineering texts advise a 20-30% margin on fan head capacity and a 15-20%
margin on flow. (Babcock & Wilcox, 2005). In some plants, boiler fan capacity
does in fact limit plant capacity during peak power production on very hot
94 | ABB Energy Efficiency Handbook

days. Energy efficiency efforts, including radial leakage reduction in air heaters,
could be sufficient to remove such a capacity restriction in these plants
ID fan capacity may, however, be a real bottleneck for some plants potential
to burn waste fuels. VFD overspeed may provide the additional short-duration
capacity needed to burn a small inventory of waste fuel. For longer term firing
with waste fuel, a fan retrofit or booster fan may be required. Generally, use
of VFDs is the only way to get additional capacity from a fan system if
the overall combustion process is fan limited when running full out at
nominal frequency. Running a VFD at 5-10% overfrequency is possible, as
long as the overall design of the fan/motor/drive system is appropriate for
overspeed operation.

Fan Selection and Sizing

Calculating or measuring the system resistance curve is essential to proper sizing
and selection of the fans that will supply it. The design analysis steps are:
1. Gather data: Plant capacity and estimated or historical performance data, Process
flow diagrams, P&ID drawings to determine system configuration.
2. Determine the system flow requirements at maximum continuous rating (MCR)
conditions, taking air density, moisture content and leakage flows into account,
plus only a small margin (<10%).The flow requirement is based on process needs.
3. Calculate the pressure drop across all the individual components using the
governing equation and coefficient for that component (duct, damper, elbow etc.),
and include the boiler furnace pressure. The resulting curve is called the boiler
resistance line.
4. Add the above pressure drops to determine overall system pressure required at
the MCR flow condition.
5. Estimate or measure the load profile and duty cycle of the fan in operation: % of
time at % of loading, including vane and damper positions.
6. Estimate or measure the particulate levels, air temperature ranges, floor space
which influences the selection of fan and blade types.
7. From previous steps requirements, narrow down selection to fan type (axial
vs. centrifugal), blade orientation, and shape. Gather data from fan supplier,
especially pressure and power curves showing efficiencies, stall line. A fan
selection diagram may also be provided.
8. Using data from previous step, apply the system curve to an appropriate fans
performance curve (specific speed and specific size) to verify that the fans BEP is
at 100% system rated capacity.

Module 2 | 95

The load factor determination of existing fan systems should also include the
position of any mechanical flow control devices (inlet vanes, dampers etc.), as this
may reveal an energy-saving retrofit opportunity for variable frequency control.

In power plants, the basic flow requirement for FD fans is the stoichiometric
amount of air given by the chemical oxidation reaction equation, plus a certain
amount of excess air to compensate for imperfect mixing during combustion,
less the flows to the PA fans. The stoichiometric amount varies with the coal or
fuel type. Values for these are available from ASME standards and test codes.
For ID fans, the basic flow requirement is given by the stoichiometric (chemical
equation) products of combustion, plus leakage flows.
On balanced draft boilers, where the furnace is under slight negative pressure,
air tends to leak in, especially as boilers age. Leakage in air heaters is a source
of 1) reduced cycle efficiency and 2) increased auxiliary power. Air heaters are
used to recycle heat from the flue gas back into the boiler, by pre-heating the
fresh air for prior to combustion. Air heaters increase the boiler efficiency by
10% to 15% (Babcock & Wilcox 2005) and are typically located immediately
downstream of the economizer. Air heater leakage reduction will improve heat
transfer in the air heater and therefore will also improve overall cycle efficiency.
Regenerative air heaters transfer heat from hot to cold sides by warming up
metal tubing set into a slowly rotating rotor. The efficiency of the air heater itself
is typically 85% to 90% (Rajan 2003). Typical leakage values for regenerative
air heaters range from 6-15%, and values increase with age and consequent
wear of seals, and air leakage rates of 20% are not uncommon (Guffre 2007).
Tubular and heat-pipe (recuperative) air heaters have no mechanical seals and
therefore have low leakage rates, typically under 3%.
Process design attention to reducing air leakages will reduce the loading on
the ID fans. At typical rates, air seal leakage accounts for up to 25% of fan
horsepower (Guffre 2007), which represents between 0.5MW to 2.0MW of
fan auxiliary power, depending on plant design. Radial leakage in regenerative
air heaters is unwanted flow from cold to hot sides of the heater. Radial
leakage adds to the fan load and, because it is not pre-heated, does not
aid combustion either. Leakage also disturbs the balance between primary
and secondary flow and has been observed to cause poor flame stability
and increased desuperheating (attemperation) spray flows (McIlvaine, 2008).
The leakage of fresh air into the flue gas stream decreases the efficiency of
downstream emissions control equipment such as the electrostatic precipitator.

96 | ABB Energy Efficiency Handbook

The fan pressure requirements at unit MCR conditions can be estimated using
component pressure drop equations, but the industry sources named above
have typical, empirically determined values. For FD fans, the largest pressure
drops are across the burner/windboxes and across the air heater. For ID fans,
the largest pressure drops are across the scrubber, air heater, and economizer
outlet. Special attention to the design of these components, especially the
regenerative air heater, will have a beneficial effect on auxiliary system and
thermal energy efficiency. The rotary design of regenerative air heaters still
used in new plants dates back to 1923. Reducing gaps and installing modern
seals can lead to a 50% reduction in radial leakage on existing regenerative air
heaters (McIlvaine, 2008).
See power generation industry texts (Black & Veatch, 1996) and (Babcock &
Wilcox, 2005) for details on the individual leakage flows and pressure drops for
FD, ID and PA fans.

Multiple Fan Systems

In applications with very wide range of flow, it is worthwhile to consider specifying
multiple fans, each optimized for a piece of the system load curve, where they can
operate close to their BEP. With two or more smaller fans instead of one larger fan,
excess fan capacity can be turned off. One or more of the fans in the system can
have a VFD for some finer degree of flow control. Redundancy is the more likely
reason to favor pairs of fans in large industrial applications, however.
The combined performance curve of fans operating in series (typically no more than
2 fans operate in series) is calculated by adding the individual curves vertically.
Fans operating in parallel have their curves added horizontally. One or more of
the fans in the system can have a VFD for top-end speed control. When operating
fans in parallel, it is most energy efficient to split the load equally between the fans
(Babcock & Wilcox, 2005). The References section contains references to fan
system guidelines on how to determine rating of fans in parallel and series.

Supply and exhaust fans operating on opposite ends of a system decrease

the pressure build-up in a duct or space compared to a single fan. It is usually
easier to control a zero point location or maintain low pressures, such as
the draft in a boiler, if supply and exhaust fans are used (Greenheck, 2008).
Another advantage of forced/induced fan combination is that the lower
pressures will help to reduce leaks (US DoE Sourcebook, 2006).

Module 2 | 97

Fan Automation
Proper control of multiple fan arrangements is essential to realizing their full energy
saving potential and to avoid unstable or stall operation due to interactions between
multiple fans at low flows, especially for fans in parallel. Isolation dampers between
multiple fans in parallel may also be necessary to avoid air flow through inactive
fans. In fans with damper control, a flow cascade loop is typical, with the master
comparing actual to demanded airflow. The setpoint is sent to the cascade slave
loop for comparison with a sum of the damper position signals. The ISA Control &
Optimization handbook contains details on this loop and additional control loops
for optimizing cycling fans with dampers (ISA, 2005). Good fan flow control is
very important if the downstream process is combustion, in which air supply will
determine the intensity and the safety of the process.
In power plants, stable FD fan pressure is essential to the stability and efficiency of
the combustion process downstream in the furnace. Smooth variation of pressure
with flow is necessary, and this can be achieved through either adjustable pitch
blades on axial fans or with VFD speed control. Multiple fans pose a special
challenge for smooth control; to ensure smooth performance design requires the
combined effort of both the controls and mechanical engineering disciplines.
Fan flow control is important to several critical boiler & turbine control systems:
Combustion control (firing rate, fuel/air) control , involving FD fans, - Excess air (O2)
control involving ID fans, Furnace draft (pressure) control, involving ID fans, Gas flow
distribution (recirculation) control, involving GR fans.
Correct instrumentation and actuation is also important to the overall controllability
of these loops. Flow transmitters are typically not calibrated or not capable at low
flow rates (<25%). Louver-damper fan systems pose a particular control challenge,
due to the non-linearity, hysteresis and leakage (up to 10%) of dampers (ISA, 2005).
Dampers with smart positioners will increase the controllability of these actuators.
Automation also plays an important energy efficiency role in reducing power
requirements during large fan startup; see the Fan Drive Train section for details.
Fan System Design Guidelines - Summary
Sources for this summary section are: (Lovins A. 2007) and the DoE EERE (US DoE
Best Practices, 2008) Fan SourceBook.
Reduce Static & Pressure Head and Flow Requirements
Consider process design or operational control alternatives that reduce the
maximum and average static or pressure head required. Consider these aspects
also under startup conditions.
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Right-Size the Components

Gather data, take time to understand and document the real loading
requirements; the actual duty cycle and load profile of the fan.
If implementing a multiple-fan system, use a control strategy which optimizes parallel fans
Reduce Friction in Fan Systems
Be aware of trade-off in floor space vs. fan system pressure drops caused by
elbows and ductwork.
Reduce system effects by using flow straighteners and other passive fittings that
eliminate energy-sapping vortices and swirls.
Reduce system duct friction by specifying larger diameter ducts, and shorter runs.
For the above efforts, start downstream so that sizing calculations of upstream
components can benefit from efforts at reducing friction downstream.
Use Variable Speed Drives for Flow Control
Use variable speed drives to control flow, rather than outlet or inlet dampers or
even guide vanes.
The benefits of VSDs are larger on lower static head, high friction systems, and on
systems with varying flow rates.
Select Energy Efficient Components
Select an energy-efficient fan type and blade design where the application allows
Select an energy-efficient motor to drive the fan, as described in Motor Power
and Efficiency
Install Equipment Correctly
If using dampers for flow control, ensure that they have minimal hysteresis and
their control function has been linearized for good control response.
Ensure that there is sufficient distance from an elbow on the fan inlet and outlet.
Fan Drive Trains
Motor and Coupling
Axial fans with direct drive expose the motor to potential damage from particulates
and/or high temperatures. Belt drives are sometimes specified in axial fans for this
reason, as the motor can then be located outside of the air stream. Motors for
centrifugal fans can more easily be located for direct drive outside of the enclosure
(US DoE Sourcebook, 2006).

In power plants, Gas Recirculation (GR) fans operate in high temperature and
particulate airflows, making them unsuitable for axial fans with directly exposed motors.

Module 2 | 99

Fans with non-overloading blade design, common in power plant draft service,
have absolutely no benefit from an oversized motor, because horsepower
drops with increasing flow beyond the BEP.

Speed and Slip

The inevitable slip of induction motors means that actual RPMs will be slightly less
(approx 1- 5%) less than nameplate speed. Synchronous motors do not exhibit slip.
Startup Conditions
Fans, especially centrifugal fans more so than axial fans, have a large rotating
mass and hence high inertia, given approximately by mR2 (where m is the mass
and R is the fan radius). According to Newtons law, Torque = (mR2) x A, where A
is the angular acceleration. The larger the inertia, the greater the torque required to
accelerate the fan to its normal operating speed. Air mass within the fan adds to the
starting torque requirements (US DoE Sourcebook, 2006). An example of applying
Newtons formula to determine acceleration time for a fan is described in the Motor
section on Torque ,Inertia and Acceleration
The Motor Selection and Sizing section discusses the trade-offs between high
startup torque and good running efficiency in motors. Large centrifugal fans typically
exceed the NEMA normal inertia limits and require special designs. (IEEE, 2007). For
smaller fans the NEMA high-slip design D offers high torque starting capability, but
reduced running efficiency.
Soft-starters and VFDs are useful in fan applications to reduce the high startup
current and resulting stress on the power system and the motor.
The motor windings receive an amount of thermal energy equivalent to the
kinetic energy of the rotating mass of the fan at operating speed. Higher winding
temperatures may lead to maintenance problems and reduced motor efficiency.
Given the high inertia of fans, it is good design practice to use any means to reduce
the inertia and/or load on the motor during startup. For centrifugal fan types, the
power requirement can be reduced by closing inlet vanes or dampers during startup. Axial fans with certain blade profiles may require a different strategy, depending
on the power vs. flow curve for that particular fan. Axial fans with variable pitch
control typically should be started with reduced blade pitch. Starting multiple vane
axial fans should be done with both at the same reduced pitch. When both fans are
up to speed and aerodynamically balanced, increase the blade pitch of both fans to
the desired operating condition (Greenheck, 2008).

100 | ABB Energy Efficiency Handbook

In older designs, piggyback or pony motors were used to allow engineers to specify a
right-sized, highefficiency main motor. If the application allows some method to keep
the fan rotating at low speed, then a VFD with flying start capability can then use that
rotational energy in the startup sequence, thus reducing the heat load on the motor.
The Motor Startup section has some guidelines for reduced voltage startup.

In power plants, a 1500-hp ID fan motor may use its full rated starting torque
with a safety margin of only 10%, but then drop to 30 to 50% of full load once
it has settled to run at normal speed. This motor will typically lose, at 50% load,
about 1.8% points in efficiency and over 2% points in power factor. At 30%
load the motor does much worse, perhaps a 4% efficiency loss (Competitek,
1996).
ID fans have a high duty factor, and each % point of efficiency loss in such large
motors is worth tens of thousands of dollars per year. The savings will justify
many efforts to provide some form of starting assistance to these motors.

Fan System Maintenance

Continuous and pro-active maintenance is essential to preserving energy efficiency
of the system during operation. Fans used in air streams with high levels of
particulates may become fouled or eroded, with consequent reduction in energy
efficiency and performance. Backward-curved blade designs are more prone to
build-up of such contaminants than straighter, radial designs.
Vibration monitoring and analysis equipment will usually reveal build-up of
contaminants on the fan blades, in addition to other imbalance problems. This
equipment can be installed to run continuously and provide real-time data to plant
maintenance staff and alarms to plant operators. See the section on Condition
Monitoring Systems.
Another condition that deserves real-time monitoring is the stalling potential of axial
fans. Stall operation is very energy inefficient and is accompanied by damaging
vibrations. Instrumenting the fan with upstream flow and pressure sensors will
provide detection of pre-stall conditions and warning to operators. (Black & Veatch,
1996)

Module 2 | 101

Fan System Cost Calculations

For fan systems, the three main lifecycle costs (LCC) are energy, initial investment
and maintenance. The initial investment cost is composed of hardware, engineering
and installation costs (including civil costs). Energy consumption is by far the
dominant element of the LCC, especially if the fan runs more than 2,000 hours per
year. To perform a lifecycle cost valuation, one needs the following data, shown with
sample units:

Fan type (centrifugal vs. axial flow)

Air or gas temperature or density (lb.cu ft, kg/cu m.)
Impeller type (Forward curved, backward curved, radial blades)
Nominal volume flow (cfm, cms)
Total pressure increase (inches of water, psi, or millibar)
Nominal Efficiency (%)
Flow control method
Transmission nominal efficiency (%)
Motor efficiency (%)
Motor supply voltage (V)
Annual running time (hrs)
Operating profile (% hrs for % nominal flow)
Energy price ($/kWh or /kWh)
Investment cost ($ or )
Interest rate (%/yr)
Service life (yrs)
Drive data: Nominal efficiency 95%

The output of system cost calculations are usually:

Specific fan power (kW/(cu.m/s) or kW/(cf/m))
Required input motor power (hp or kW)
Annual energy consumption (kWh)
Annual energy saving (kWh)
Annual money saving ($ or )
Payback period
Net Present Value ($ or )
The Case Studies section has a fully worked-out example of retrofit cost
calculations.
Fan Power Calculation Tools
There are several freely available software tools for calculating fan power
consumption and savings from certain optimization upgrades:

102 | ABB Energy Efficiency Handbook

 The Fan System Assessment Tool (FSAT) from US DoE. The FSAT calculates
power consumption and efficiency of upgraded fan systems.
ABBs FanSave calculation tool compares AC VFD drive control against
traditional flow control methods for fans (outlet damper, inlet vane or pitch control
methods). The tool provides financial and environmental estimates for each
control method retrofit project and recommends a suitable VFD drive type.
Note that some fan calculation tools assume a parabolic fan curve and a system
curve with zero constant pressure. This latter assumption may invalidate some of the
results for high constant-pressure applications.

Other Drive Power Loads

Conveying & Grinding Systems
Material handling systems involving conveying and grinding are typically constant
torque applications. These are linear-law applications; the required power varies
with the square of the motor speed. The design guidelines in the motor sizing &
selection section still apply to these applications. These types of applications vary
greatly, but they share a common need for control of torque as well as speed. The
use of Variable Frequency Drives (VFDs) for Variable Torque Control of conveyors
can save energy through improved controllability and a more direct drive train with
fewer losses.
Large conveying systems with up and downhill sections may benefit from energy
recovery through 4-quadrant VFD speed control. The braking power generated by
downhill conveyors is transferred to the common DC busbar by means of an energy
recovery unit, significantly reducing the energy consumption of the complete system.

Figure 2.17 Conveyor systems and VSD energy savings diagrams (De Almeida, 2006 )

Module 2 | 103

In many conveyor systems, the conveyors are running at maximum speed and the
feeder controls the flow of material. Energy can be saved by using some form of
variable speed control via a VFD on the motor; the speed of the conveyor can then
be varied with the amount of material flow. When there is no flow, the conveyor runs
at minimum speed; material sensors can be used to detect if the conveyor is empty
or not.
HVAC Systems
The large fans at the heart of HVAC systems are cube-law applications whose power
requirement increases as the cube of the motor speed. Commercial and residential
buildings offer the highest energy saving potential, but even industrial facilities
HVAC systems can yield energy efficiency gains through careful redesign of their
air handling components. Most of the design guidelines from the section on Fan
Systems also apply to HVAC air handling systems, but are re-stated here only in
summary form.
The most efficient HVAC fans (70-85 % total efficiency) are axial design or backwardcurved centrifugal fans. Large, round ducts with a minimum of sharp elbows will
reduce pressure requirements. A right-sized and energy-efficient electric motor will
save from 5-15% over a standard, oversized one. VFD speed control can save a
further 20-40% for fans operating at lower loads and dramatically reduce noise. Even
when compared to axial fans with variable pitch blades, VFDs are still a slightly more
efficient method of air flow control.
Compressed Air Systems
Reciprocating pumps and rotary screw pumps which are used in compressed air
systems are a linear law load, whose power requirements vary linearly with motor
speed, as shown in the figure below. Air compressors account for 10% of industrial
consumption of electricity, yet they have poor energy efficiency. Estimates of the
potential energy savings are in the range from 5% to 50% (De Almeida, 2006),
and average savings are estimated to be 25%. These estimated are based on the
following assumptions: Power-110 kW, Equipment life span-15 years, Operating
hours-4000 h/year, Electricity price- 5 c/kWh.
In linear-law systems, it is the running time of the motor at various speeds which
will determine the energy demand and the potential for savings. (Competitek 1996).
Some systems have their compressors running continuously just to maintain the
minimum required pressure; a smaller helper motor could be used to handle such
situations more efficiently. An even better option is to use a variable frequency
drive (VFD) to control the speed of the compressor. The figure below shows energy
saved by using a VFD for speed control on a rotary screw air compressor:

104 | ABB Energy Efficiency Handbook

Figure 2.18 Compressed air power required by control method, (De Almeida, 2006)

Motors and Drive Trains

The purpose of a motor is to provide torque greater than or equal to the load torque
of the machine being driven, such as a pump or fan. The driven machines shaft will
then rotate and perform useful work within a process unit. Electric motors use twothirds of industrys electricity, and this consumption is reflected in the high operating
costs; for a large motor in continuous duty the operating costs represent more than
95% of the total cost of ownership.
Industry surveys show that there is room for improvement in the engineering of
energy efficient motor systems. Data from the US electric power utility PG&E showed
that one-half of industrial motors are operating at less than 60% of their rated load,
and one-third are operating at less than half their rated load (cited in (Competitek
1996) Ch.9). These underloaded motors suffer an efficiency penalty from 0.5 to 4.0
percentage points.
Many References already exist on the subject of electric motors and drive trains.
This handbook section provides information to help engineers and designers
understand the energy impact of their choices and guidelines to help improve the
efficiency of the motor drive train from power supply to motor shaft. The Pump and
Fan sections discuss energy efficiency of the application.

Module 2 | 105

Figure 2.19 - Small LV (left) and large (right) MV induction motors, (ABB Drives, 2008)

Motor Types and Concepts

By far the most common large motor types used in power and process industries
are AC synchronous and AC induction motors. In both these motor types a magnetic
field, rotating in a physically fixed outer stator, exerts a force on another magnetic
field within the inner rotor, whose rotating shaft provides power needed by the
industrial process. Unless otherwise specified, the common motor type assumed in
this handbook is assumed to be an induction motor.
Induction Motor Types
In an AC induction motor, the rotating stator magnetic field induces a current in
the rotor conductors. The two magnetic fields interact to produce a torque on the
rotating rotor shaft. This torque continues as long as there is relative motion of the
two magnetic fields, which is why the rotor lags the stator rotation by an amount
known as slip. Slip is defined at the motors nominal point, which occurs when
the motor is powered at the nameplate voltage, frequency and current. Due to slip,
the nominal (nameplate) speed (nn) will be less than the synchronous speed (ns) at
that frequency, which is why motors of this type are also known as asynchronous;
motors. Slip is defined according to this difference, as shown by the following
formula:
sn (%) = 100 x ( ns nn ) / ns
From the above, it can be seen that slip is equal to zero at synchronous speed.
The synchronous speed, (n s in RPM) of a synchronous motor is proportional to the
nominal frequency of the power supply (f n in Hz ) and inversely proportional to the
number of pairs of poles in the winding, according to the formula:
n s (RPM) = ( 2 x fn x 60 ) / pole number

106 | ABB Energy Efficiency Handbook

For example, a 60Hz , 4-pole motor with 1.5 % slip has a synchronous speed ns = (2
x 60 x 60 ) / 4 = 1,800 RPM, and a nominal speed nn = (100 1.5)/100 x 1800 = of
1,773 RPM.
The motors maximum torque (also called breakdown torque and pull-out torque)
occurs at about 80% of nominal speed. A standard induction motors maximum
torque is typically 2 to 3 times the nominal torque. The maximum torque Tmax occurs
at slip smax, which is greater than nominal slip.
The slip at which maximum torque occurs is proportional to rotor resistance. In
order to use an induction motor efficiently the motor slip should be in the range 0 to
smax. This can be achieved through right-sizing of the motor to its application, or by
controlling voltage and frequency by using a variable frequency drive (VFD).
In a squirrel cage type of induction motor, shown in the figure below, the rotor
conductors are placed longitudinally. The cross-section of these bars determines
the torque and speed characteristics of the motor. Their simple operation and
construction make squirrel cage induction motors the workhorses of industry. These
motors exhibit versatility, reliability, and are available in all sizes up to 18MW. Other
basic types of induction motors are wound rotor motors and some variations on
these two designs, such as multispeed motors.

Figure 2.20 - Induction motor cutaway view, ABB Motors & Drives, 2007

Synchronous Motor Type

In a synchronous motor the rotor moves in lockstep with the rotating field in the
stator, whereas in asynchronous (induction) motors there is slip between rotor
and stator fields. Since there is no slip, the rotor magnetic field must be created
through a separate DC excitation system. For the same reason, starting of a
Module 2 | 107

synchronous motor requires temporary use of the induction principle; a small number
of conducting bars in the rotor are used to develop startup torque until the rotor
has sufficient speed to pull-in to the stator speed, at about 85% full speed, and
thereafter operate fully synchronously. The standard horsepower, speed, and voltage
ratings of synchronous motors are listed in Sections 21.10 and 21.12 of NEMA
standard MG1
Synchronous Motor vs. Gas Turbine
The following section is based on information from ABB and IEEE Std.666-2005,
paragraph 11.3.1.1:
For very high-power applications, four-pole synchronous motors are a cost-effective
alternative to powerful mechanical drives such as turbines; this may be the reason
behind a trend toward ever larger synchronous motors. Compared to steam or
gas turbine drive, synchronous motors are more energy efficient and require less
maintenance. A gas turbine averages only 25 to 38% efficiency and less than 25%
at off-peak loads. The efficiency of a large synchronous motor is between 97 and
99%. Gas turbines require frequent costly attention and have other drawbacks
compared to electric drive, as shown in the table below. One facility (Statoil Snhvit
plant) reported an additional 10 normalized on-stream days per year for their LNG
liquefaction compression application after converting to a motorized drive system.
Characteristic

Gas Turbine

Synchronous Motor

Weight and space

Light unit, but large &

Similar to that for gas turbines

heavy auxiliaries
Efficiency
Average operational efficiency

Narrow peak range

25-38%

High over wide range

97% Drive (+ 95% HVDC
Transmission + 60-80% generation)

Major maintenance cycle

20,000 hrs

100,000 hrs

Minor maintenance cycle

2,500 - 4,000 hours

25,000 hours

Minor maintenance duration

6-10 days

1-2 days

In operation system MTBF

4,000 hours

> 25,000 hours

Control Response

Slow

Medium to quick

Logistics Delivery time

3-4 years

1-2 years

Synchronous Motor Power and Efficiency

Electrical drives have more than 10 times faster response and excellent dynamic
performance. This improved controllability has an energy efficiency benefit for the
application as well. In the case of compression, the improved controllability allows
better balance between compressor stages and consequently less energy-wasting
recirculation flow. An electrically-driven compressor can operate with a lower surge
margin which improves the thermodynamic performance range. Higher efficiency and
108 | ABB Energy Efficiency Handbook

reliability in the drive means that larger trains are possible; and large compressors
are more efficient, too. The cumulative effect of these benefits yields an average
of between 3.5% to 5.0% efficiency improvement in large (e.g. LNG) compressor
applications (ABB Inc, Oil & Gas Norway, 2008). The payback compared to a
conventional gas turbine drive is less than half a year.
Synchronous motors are generally more efficient than induction motors at higher
power ratings, as shown in the following figure (data up to1600 hp). At even higher
power ratings (above 9000 hp) this improved efficiency favors synchronous motors
in lifecycle costs when compared to induction motors. Synchronous motors are
typically used at lower speeds relative to induction motor applications, but are more
expensive, more complicated, and have higher maintenance costs compared to
squirrel-cage induction motors.
In the past, synchronous motors were favored due to their speed control capability
by simple frequency variation, and also for their ability be used for plant-wide power
factor correction . Variable Frequency Drives (VFDs), however, can now provide
the precise speed control of induction motors that was previously only possible
through frequency control on synchronous motors. Some drive types equipped with
active front-end power electronics may also be used in plant-wide PF correction as
well. One area where synchronism has the advantage; the inherent slip of induction
motors, which increases with load, may lead to slower speed response to load
changes. Fast response is necessary to reduce the risk of pressure fluctuations in
some dynamic pumping applications, for example.

1000 hp = 746 kW

Figure 2.21 - Typical Full Load Efficiencies for synchronous vs. induction motors, (IEEE, 2007)

Module 2 | 109

The pulling-in requirement of synchronous motors makes them generally

unsuitable for large fan applications as found in power generating stations
forced and induced draft drive power.

Switched Reluctance Motors

Switched reluctance motors offer very high efficiency, but are still limited to relatively
low-power applications, typically up to only 75 kW. This motor technology is in rapid
development and may lead to higher power ratings in the near future.
Permanent Magnet Motors
In PM motors a magnet is used in the stator for generating a magnetic field. The
position of the rotor is determined by motor control electronics, which then adjust
the modulated stator field accordingly. By eliminating one set of windings and the
associated ohmic losses, this motor design is more efficient than induction motor
types. High cost of the magnet material has restricted this motor type to relatively
low power (< 2kW) applications. Changes in the relative prices of magnets and
copper, coupled with lower prices of motor electronics, may eventually make this
motor feasible for higher power situations.
Motor Nameplate Terminology
Standards bodies such as the NEC and NEMA have agreed on definitions for the
following induction motor parameters which must be prominently displayed on the
motor nameplate and provided with the vendors documentation.
Rated voltage or voltages: This value has a 10% tolerance covering common
voltage variation in some industrial networks
Rated full-load amps for each voltage level: The nameplate FLA is used
to select the correct wire size, motor starter, and overload protection devices
necessary to serve and protect the motor.
Frequency: This value is either 60 Hz in North America, and 50 or 60 Hz
elsewhere.
Phase: Either single or 3-phase
Rated full-load speed (rpm): The motor speed under full load conditions.
Insulation class and rated ambient temperature: A measure of motors ability
to dissipate heat.
Rated horsepower: The work available from motor at full load torque and speed
Time rating: Standard motors can operate continuously at their full-load torque
and speed. For intermittent duty applications, a time rated motor can be selected
to reduce weight, size and costs.

110 | ABB Energy Efficiency Handbook

 Locked-rotor code letter: A code letter that defines an inrush current a motor
requires when starting it.
Manufacturers name and address
In addition to this required information, motor nameplates may also include data
such as frame size, NEMA design letter, service factor, full-load efficiency, and power
factor.
Motor System Loads
A motor application is fundamentally defined by the loads torque-speed
requirement, the duty cycle, and the load profile.
Load Torque vs. Speed Requirement
According to these definitions from ABBs Technical Guide (ABB Drives 2002) and
the Competitek Drive Power manual (Competitek 1996), the applications can be
categorized by how the power varies with motor speed.
Linear-law loads require constant torque across the entire speed range, and
power consumption varies linearly with speed. Examples of this type of load are:
reciprocating compressors , positive displacement pumps, drilling machines,
conveyors and grinding systems (curve (a) on page 112).
Cube law loads require a torque which varies with the square of speed, and
power consumption varies with the cube of that speed. Examples of this
type of load are: pumps and fans and winders. The prevalence and high
power consumption of these loads is why they deserve special attention in
designs for improved energy efficiency (curve (b)).
Constant power loads; A constant power load is normal in steelmaking when
material is being rolled and the diameter changes during rolling. The power is
constant and the torque is inversely proportional to the speed (curve (c)).
Constant torque, then constant power loads. This load type is common in the
paper industry. It is a combination of constant power and constant torque
load types. This load type is often a consequence of dimensioning the system
according to the need for certain power at high speed (curve (d)).
Square law loads require a torque which is directly proportional to speed, and
power consumption varies with the square of that speed. Examples of this type of
load are hoists and winches.
Constant speed loads are applications which require constant speed but varying
torque. Examples of such applications are grinding and milling machines, sawmill
blade cutters and escalators (Competitek 1996), and extruders, all of which must
run at the same speed regardless of loading.

Module 2 | 111

(a) Constant torque

(b) Cube-law loads

(c) Constant power

(d) Constant torque, then constant power

Figure 2.22 Load types by torque vs. speed performance, (ABB Drives 2002)

Load Duty Cycle and Load Profile

The term duty describes how the load is used over a fixed time period. Loads
which are frequently turned off and on are known as cycling loads. A repeating
pattern of load activation over a time period is known as the duty cycle.
Near-continuous loads are known as heavy-duty loads. These loads are best
characterized by their loading profile over a fixed period of time. This profile is the %
of time spent at various discrete % of load levels, as shown in the figure below.

112 | ABB Energy Efficiency Handbook

Figure 2.23 Load profile showing %-load versus %-total time (annual)

Load Startup Requirement

Startup torque requirements vary widely, from a fraction of the full-load torque to
applications that require several times the full-load torque for starting. The load curve
for a high starting torque type of application is shown in the figure below. Typical
applications for this load type are centrifugal fans, extruders and screw pumps/
compressors.

Figure 2.24 Load type curve where high starting torque is needed, (ABB Drives 2002)

Motor soft-starting is needed in applications which are sensitive to shock or high

motor torque during startup. For example, NEMA Design B motors produce a
starting torque which is about twice its full load torque (Competitek 1996). Other
drive-train components can also benefit from the smooth acceleration provided by
soft-starting.

Module 2 | 113

Dynamic Torque and Acceleration

The load characteristic curves shown above reflect the steady-state torque required
at different speeds. Accelerating (or decelerating) between different speeds requires
a positive (or negative, braking) dynamic torque to be supplied by the motor
drive system in addition to the load torque which the application (pump or fan, for
example) requires.
The driving torque of a motor during startup is the run-up torque and the
acceleration time to achieve nominal speed is known as run-up time. The driving
torque must exceed the load torque by a margin in order for satisfactory acceleration
to occur.
Torque T [Nm] is related to speed through Newtons Law for rotating bodies of inertia
J [kgm2]. Torque is proportional to the rate of change of this speed n [rpm], when
expressed as [radians/s2]. The change of rotational speed within a given time period
is its acceleration (or deceleration) and is as follows:
T = T m - T load = J x (n / t) x 2/60
Moment of inertia J is the sum of the load and motor moments of inertia, as supplied
by the machine builders. If the rotating components are circular, with radius r and a
relatively homogenous mass m, then J can be found by:
J = x m x r2
The above formula can be applied to large fans, for example. If there is a mechanical
gearbox between motor shaft (1) and load shaft (2), then all load-side inertias must
be reduced by the square of the inverse of the gear ratio (the ratio of the number of
teeth) as follows:
J = J2 x (n2/n1)2
These formulas are useful for determining acceleration times of large inertia loads, as
shown in the following example from an ABB Technical Guide (ABB Drives 2002);
For example: accelerating a fan to nominal speed is done with nominal torque.
At nominal speed, torque is 87%. The fans moment of inertia is 1200 kgm2 and
the motors moment of inertia is 11 kgm 2. The load characteristic of the fan Tload is
quadratic as shown in the figure below, relative to nominal. Motor nominal power is
200 kW and nominal speed is 991 rpm. Calculate the approximate starting time from
zero speed to nominal speed.

114 | ABB Energy Efficiency Handbook

Figure 2.25 Fan torque vs. speed, with relative values at five equidistant speed points, (ABB Drives
2002)

Motor nominal torque is:

T n = 9550 x 200 / 991 =1927 Nm
The starting time is calculated by dividing the speed range into five sectors. In
each sector (198 rpm wide) the torque is assumed to be constant. Torque for each
sector is taken from the middle point of the sector. This is acceptable because
the quadratic behavior is reasonably approximated to be linear in each sector. The
time to accelerate the motor (fan) with nominal torque can found by re-arranging
Newtons formula as follows:
t = J x n /( T m - T load) x 2/60
Acceleration times for each of the five different speed sections are:
0 to 198.2 rpm
198.2 to 396.4rpm
396.4 to 594.6rpm
594.6 to 792.8 rpm
792.8 to 991 rpm

t
t
t
t
t

=
=
=
=
=

1211
1211
1211
1211
1211

x
x
x
x
x

198.2
198.2
198.2
198.2
198.2

/(
/(
/(
/(
/(

0.99
0.92
0.78
0.57
0.29

x
x
x
x
x

1927)
1927)
1927)
1927)
1927)

x
x
x
x
x

2/60
2/60
2/60
2/60
2/60

=
=
=
=
=

13.2
14.3
16.7
22.9
45.0

s
s
s
s
s

The total starting time from 0 to 991 rpm is approximately 112 seconds.
Module 2 | 115

The above formula in English units is:

t = WK2 x RPM / (308 x (Tm - Tload) )
Where:
T
= Torques in lb-ft
WK 2 = Total inertia (motor and load) in lb-ft2
RPM = Change in motor speed in rpm,
Motor Characteristics
This section is based on information in the standards NEMA MG-1, IEEE Design
Guide 666.
Since the majority of motors in process and power plants are of the squirrel-cage
induction type, this is the type which will be the main focus of the following sections.
Torque vs. Speed Performance
The fundamental characteristic of any induction motor is its torque vs. speed
performance. The points of interest on a torque-speed curve are shown on the figure
below.

Locked-rotor torque point (a) occurs at zero speed,

Pull-up torque point (b) occurs during acceleration,
Maximum motor torque point (c)
Operating point (d) on the figure is the nominal, full-load operating point of the
motor. This point is the source of the nameplate parameters on the motor. The
full-load speed is typically 96% to 99% of the synchronous (no-load) speed.

Note that when the machine operates with negative slip, it is in generator mode
(region G on the figure) and the torque versus speed performance is inverted.

116 | ABB Energy Efficiency Handbook

Figure 2.26 - Torque vs. speed for squirrel cage induction motor, (ABB Drives 2002)

Small to medium-sized motors are a commodity item. For these standardized,

polyphase induction motors NEMA has developed a rating designation (A,B,C,D,E)
for different application requirements. Large motors, however, are typically custom
engineered to a specific set of loading and service conditions, and are therefore not
subject to easy rating or classification. Large motors still share some characteristics
with the NEMA motor classes described below.
Normal Starting Torque Motors
Normal starting torque, normal starting current, low-slip and high efficiency.
Centrifugal pumps and motor generator sets, infrequent starting duty; used where
high efficiency and high full-load speed are required. Modification of the motor
design can provide variations in torque characteristics and increased thermal
capability required for drives such as high inertia fans.
High Starting Torque Motors
High starting torque, normal starting current Centrifugal pumps, fans, unloaded
conveyor, vacuum pumps. This is the general-purpose motor suitable for pump
and fan drives.
High torque, high slip motor; has relatively high starting torque and normal efficiency
at full load. Positive displacement pumps, compressors, loaded conveyors,
crushers without flywheels, pulverizers. This motor has the high starting torque
motor with almost constant torque throughout the entire speed range

Module 2 | 117

 High torque, high starting torque, but with lower starting current. Car puller,
crusher with flywheel, pulverizers, and high inertia drives that do not require high
efficiency. Design D has higher starting torque than C, but motor efficiency is
lower.
Motor Service Factor
Motors will have a service factor (SF), typically 1.0, or 1.1, or 1.15. As an example;
a 1000hp motor with an SF of 1.15 means that the motor could be run at 1150 hp
indefinitely without risk of overheating, but only at the rated voltage and frequency
conditions. The standards specify that the motor can operate at a nameplate
temperature rise of 90C at service factor horsepower. SF offers a means to avoid
oversizing a motor to handle temporary modest increases in load and uncertainty
about loading.
Designers must be aware that higher temperatures will reduce a motors ability to
withstand some of the other effects, such as increased harmonics, which stress the
insulation. The IEEE offers some further warning; the efficiency and power factor at
service factor load can be different from the respective values at rated nameplate
levels. It may not be energy-efficient to run for long periods at SF horsepower.
Another consideration for designers wishing to actually use the SF margin is that the
motors starting and breakdown torque capability is based on rated horsepower only.
If the starting torque requirement was high to begin with, and was then significantly
increased under the new SF operating conditions, then there is no guarantee that
the motor will be able to start within an acceptable time limit.
With careful design of the power system, as described in the Power Systems
section, a well understood loading condition, and with robust real-time monitoring of
the motor, it is worthwhile and defensible to exploit allowable SF margins of a highquality motor. The motor will be more correctly sized to its application and will offer
improved efficiency at normal operating conditions.

In some applications, extra drive power is required for short durations; for
example to maintain condenser performance during peak supply on a hot
summer day. In these cases, a VFD will be able to increase speed to within
the SF limits, while the VFD drive diagnostics continually monitors motor
temperature.

A NEMA committee warned a long time ago (in the 1960s) against use of SF on
large motors as an alternative to a higher standard horsepower rating. Their advice
on this issue is reproduced below:
118 | ABB Energy Efficiency Handbook

 Standard horsepower increments in the larger ratings are usually within a 1.15
range, so that the next larger standard horsepower can be reasonably selected in
lieu of the service factor.
Use of a larger horsepower when overload is required avoids exceeding the
nominal temperature rating for the class of insulation system used and avoids any
encroachments upon the thermal life of these larger, vital motors.
Use of a larger horsepower when overload is required eliminates any reduction in
torque margin.
Advances in motor technology over the last half-century, however, may eventually
lead NEMA to a revision of their old guidelines and allow designers the room to
improve energy efficiency without any fear of compromising reliability.
Motor Power and Efficiency
The power and speed requirements are set by the applications load profile. For
example, in pump and fan applications, the load torque decreases with the square of
the speed; this is a direct result of the Affinity Laws discussed in the Pump and Fan
systems sections. The power rating of a motor indicates its output mechanical power,
often stated in horsepower or kW. Motor electrical (input) power is usually stated in kVA.
Motor Mechanical Power
The motors mechanical output power is simply the output torque multiplied by
motor speed. In SI units:
Pm = T x N
Where:
T = torque, (Nm)
Pm = mechanical power at the shaft (watts)
N = speed, (rad/s)

The same formula with power in kW and speed N in rpm (where 1 rpm = 2 x / 60) is:

Pm = T x N / 9550

Where:

T = torque, (Nm)

Pm = mechanical power at the shaft (kW)

N = speed, (rpm)

Module 2 | 119

The same formula again, in all English units is:

Pm = T x N / 5252
Where:
T = torque, (lb.ft)
Pm = mechanical power at the shaft (rated hp)
N = speed, (rpm)
For example: a motor has nominal power of 250 hp and nominal speed is 1480 rpm.
What is the nominal torque of the motor (in lb.ft)? Using the last of the above formulas:
T n = P m x 5252 / N = 250 x 5252 / 1480 = 887 lb-ft.
Motor Input Power and Current
The nominal electrical motor input power (in kW) can be calculated based on
the mechanical output power, as was calculated in the above formulas, and the
nameplate efficiency:
Pin = P m /
Where:
Pin = input power (kW)
P m = mechanical output power (kW)
= per-unit efficiency of the motor (0 to 1)
If the output power is given in horsepower (hp), then use the conversion factor 1 hp
= 0.746 kW. The total input power in kVA can be expressed as:
S = (Pm x 0.746 ) / ( * FP )
Where:
S =
Pm =
=
PF P =

total input power (kVA)

mechanical output power (hp)
per-unit efficiency of the motor (0 to 1)
per-unit power factor

The active power (kW) at the motor terminals can also be calculated from electrical
parameters Pin = 3 x VL-L x IL x PFP

120 | ABB Energy Efficiency Handbook

Where:
Pin = power (kW)
V L-L = three phase line-to-line voltage (kV)
PF P = per-unit power factor (cos(n))
For example: What is the nominal efficiency of a 400 kW ( V= 4.16kV, 71A and PFP =
0.85) motor?
The above formulas can be used to calculate the nominal efficiency of the motor as
follows
n = Pm / Pin = 400 / (3 x 4.16 x 71 x 0.85 ) = 0.92 (approx)
To calculate the input electrical energy cost for R running hours, given input voltage
and current and a Price:
Cost= 31/2 x VL-L x IL x PFP x R x Price$/kWh /1000
The VFD section contains additional formulas for estimating motor current, and
additional electric power formulas are in the Electric Power System part of this
handbook.
Motor Efficiency
Motor efficiency refers to the amount of input electrical power required to achieve
a particular output from the motor. Using the power formula from above, a 100 hp
rated motor with 93% efficiency at rated load will draw 89.1 kVA from the supply
when running at full load and 0.9 power factor. The motor current at this operating
point is shown as the FLA (full load amp) rating on the motor nameplate.
Most motors will the show nominal full load efficiency value on their nameplate as
determined by a highly-accurate dynamometer and a procedure described by IEEE
Standard 112, Method B. These measurements provide average values from a large
test sample of motors. The motor efficiency of an individual motor in the field can
only be determined by field testing methods, such as measurements with a wattmeter. Statistics on the manufacturers test sample provide a minimum efficiency
value which also appears as the guaranteed minimum efficiency on the nameplate;
this value assumes that the worst motor in the sample could have losses as much
as 20% higher than the average. These minimum values are in Table 12-8 in NEMA
MG-1 (Cowern, Baldor Electric, 2004).
Standard motors tend to operate most efficiently at between 75110% of full load
speed. Smaller motors are less efficient than larger motors. Standard motors below
Module 2 | 121

200 hp have efficiency between 80 to 90%, while the efficiency for motors in the
range of 250 to 5000 hp varies between 90 to 96%. Larger motors with higher peak
efficiencies tend to have flatter efficiency curves above 50% load, as shown by
curves (1) and (2) in the figure below. For these larger motors, maximum efficiency is
still at about 95%, but with only a small (0.3 to 1.0%) decrease to full load.

Figure 2.27- Efficiency vs. Load for squirrel cage induction motors, (IEEE, 2007)

As the curve shows, efficiency drops sharply below 50% load for all motors. An
average 100 hp standard- efficiency motor loses 15% in efficiency as load decreases
from 50% to 25% of full load (Competitek 1996). As a general rule, smaller motors
lose more efficiency than larger motors at lower loads.
Motor Losses and Efficiency
The greatest losses in a motor are the iron losses that occur in the rotor and
stator, accounting for 50 percent of the total loss. This can be improved by using
low loss steel and thinner laminations. Copper losses account for 20 percent.
Using an optimum slot fill design and larger conductors can reduce these losses.
Bearing friction and windage losses total 23 percent and can be reduced by using
a smaller cooling fan. Stray losses, which account for 7 percent of the total, can
be reduced by improving the slot geometry. The main sources of motor losses and
corresponding design improvements are shown in the figure below from the ABB
Review Special Report on Motors & Drives, 2005. By virtue of these design changes,
motors have improved in efficiency by an average of 3 percent in the last decade
(from 1995 to 2005).
There are important design trade-offs between losses and torque performance; low
rotor resistance results in high full load speed (low slip), high efficiency (low rotor
losses), and slightly higher starting current. High rotor resistance results in high
starting torque for line current drawn and slightly lower current during starting, but
results in lower full load speed and lower efficiency (high rotor losses).
122 | ABB Energy Efficiency Handbook

Figure 2.28 Cutaway view showing sources of motor losses, (ABB Drives, 2006)

Rotor ohmic (I2R) losses are proportional to slip and are in the rotor winding of
a squirrel cage motor. Higher-efficiency motors tend to have lower slip and will
therefore rotate faster under the same loading conditions: one percent increase in
efficiency is equal to about a 1/3 of a percentage point decrease in induction motor
slip. Voltage at the motor terminals also has an effect on efficiency, as discussed in
the section on Power Quality - Voltage and Frequency Variation
Power Factor
Power factor (PF) is a measure of the amount of reactive power which the motor
draws from the power source. A PF less than 1.0 means that some reactive power,
which is induced by the motor coils, must be generated and carried by the power
supply system. Industrial end-users pay a demand charge based on maximum
reactive power usage within a certain time period. This charge is in addition to the
regular cost of energy, charged per kWh, and covers the providers cost for the
increased size of their power delivery equipment. An oversized electric motor will
typically decrease (i.e. worsen) the PF by 10% compared to a right-sized motor.
PF in induction motors generally follows the same shape as the efficiency curves
with respect to % loading.
PF is a minimum at no load and reaches a maximum near full-load condition. This
relationship between PF and motor speed is shown in the figure below, from IEEE
Module 2 | 123

Std 666. The average 100 hp standard-efficiency motor loses about 10% points in
PF from full load to 50% load, and almost 20 more points moving down to 25% load.
The PF as listed on the nameplate applies to the full load operating condition.

Figure 2.29 - PF vs. Load for squirrel cage induction motors, (IEEE, 2007)

The capacity of the power system to deliver real power (the only kind which can do
real work) can be increased by applying various reactive power compensation
methods, either at the motor, or centrally in the electrical power supply system.
High-Efficiency Motors
With the Energy Policy Act (the EPAct) of 1992, the USA and Canada imposed
new, minimum efficiency standards, effective from October 1997, for generalpurpose induction motors of NEMA designs A and B. These motors are typically 38
percentage points higher in efficiency than standard motors. The EPAct specifically
targets motors from 1 to 110 hp (0.75 to 150 kW) as prime candidates for
improvement, with a published list of high-efficiency motors and reduced electricity
tariffs for users of these motors..
A similar program by the Danish Energy Authority published a list of high efficiency
motors and offers subsidies for motors purchased from this list: US$ 10 per kilowatt
for both new plant and for replacements. In the EU there are three class levels of
efficiency, known as Eff1, Eff2 and Eff3, applying to low voltage two- and four-pole
motors with ratings between 1.1 and 90 kW. Both the US DoE and the EU require
that a motors efficiency rating be prominently displayed on the motors nameplate.
A higher-efficiency, premium NEMA class of motors is also available, known as
class E. The price of these premium, higher efficiency motors ranges from 10 to
20 percent higher than standard motors in continuous duty applications (US DoE
124 | ABB Energy Efficiency Handbook

Sourcebook, 2006). A high efficiency motor has lower energy losses (described
in the figure below), hence lower running temperature and improved reliability; all
desirable characteristics in critical and high-duty applications. These NEMA premium
efficiency 3-phase motors have efficiencies ranging from 86.5% at 1 hp (750 W) to
95.8% at 300 hp (220 kW).
The recent legislation in the Energy Independence and Security Act of 2007 (EISA)
calls for increased efficiency of motors manufactured after December 19, 2010.
EISA regulation re-classifies EPACT minimum efficiency motors as Subtype I, so
these motors will be required to have nominal full-load efficiencies that meet the
levels defined as premium by NEMA MG-1 (2006). The EISA law also creates a
completely new category (Subtype 2) of motors which regulates efficiency for motor
designs that were not covered under previous legislation, such as polyphase motors
rated at less than 600 volts.
Motor Slip and Energy Efficiency
High efficiency motors tend to have less slip at a given load compared to standard
efficiency motors. The reduced slip may provide improved torque vs. speed
characteristics, but the increased speed at operating point may incur power losses
greater than the gains of increased motor efficiency. The increased speed is an
important factor to consider when facing a motor retrofit situation. A general
rule of thumb is that every 1% increase in efficiency is equivalent to about a 1/3%
decrease in slip (Competitek, 1996). The losses due to increased speed occur only
in constant speed applications, and are largest in cube-law applications such as fan
and pump systems. The gains from using high-efficiency motors can be preserved
by 1) specifying a variable speed drive to reduce speed, 2) specifying a smaller rated
motor (if peak loads allow) or 3) compensate by trimming the pump impeller or fan
blades (Competitek, 1996) 4) specifying a high-slip, but still relatively more efficient
replacement motor.
Motor Couplings, Speed Control & Variable Frequency Drives
Motor Shaft Couplings
A motors shaft can be either directly coupled to the drive shaft of a pump or fan,
or indirectly coupled by using chains, belts or gears. Indirect coupling is necessary
when physical space or layout restrictions prevent the motor from being in-line with
the drive shaft, or to allow for mechanical speed adjustment.
Speed adjustment is not the same as speed control, in which speed can be varied
continuously by a signal from an operator or an automatic controller. The pros and
cons of the various coupling methods are discussed below, but direct shaft-to-shaft
coupling is the only method with zero drive-train losses.

Module 2 | 125

Chain Drives
Chain drives have no slip and are suitable for low speed, high torque applications.
They are high-maintenance couplings, but can achieve efficiency up to 98%. The
desired speed adjustment is achieved by changing the diameters of teeth of the
chain wheels.
Belt Drives
Belts have the lowest efficiency of all the common coupling methods, V-belts are
the least efficient belt type due to inherent slip, followed by cogged V-belts flat
belts, and synchronous belts. Synchronous belts are the most efficient belt type
(up to 97%), but are intolerant of abrupt changes in loading (Competitek, 1996).
The desired speed adjustment is achieved by changing the diameters of the belt
pulleys. In standard belts, wear leads to increased slippage and reduced efficiency.
Synchronous belt pulleys are available only in discrete sizes; and adjusting belt
drives to achieve the optimum speed may be impossible.
Gear Drives
Gear reducer efficiencies depend on the type of gear and reach 98% for helical and
conic gears. Screw and worm type gear drives have efficiencies from 66 to 96%.
(Competitek, 1996) Due to higher cost, however, gear drives are less common than
other coupling methods. Gear drives are more suitable for low speed, high torque
loads. The desired speed adjustment is achieved by changing the number of teeth of
the gear wheels.
Coupling Alignment
Torque is reduced by about 1% per degree of misalignment up to 5 degrees, after
which failure is likely. (Competitek, 1996) Flexible couplings compensate for minor
alignment errors and reduce the risk of bearing failure, but at the cost of reduced
efficiency. Rigid couplings with laser-aided alignment are recommended practice on
high-performance machinery.
Multiple Speed Motors
A form of speed control is possible with multiple speed motors, constructed to
be able to operate at one of several discrete speed settings. There are two basic
designs: motors with multiple poles or motors with multiple windings. Selective
energizing allows these motors to achieve different multiples of speed. The former
design (also known as a consequent pole motor) has only two speeds, but the
motor with multiple windings and poles can have 2, 3 or 4 speeds. For example, a
2-speed, 2-winding motor can provide ratios of 2:1, 3:2, or 4:3 (Competitek 1996).
In two-speed induction motors, the low speed is typically selected for the most
common operating point and the higher speed for all the higher loads, including test
block load (Black & Veatch 1996).
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Multiple speed motor systems have some inherent disadvantages; 1) for large
motors, switching between speeds is neither trivial nor smooth and may lead to
process transients and upsets. The sequence of power breaker and pole switching
must be closely coordinated with motor speed 2) Multiple speed motors tend to
be slightly less efficient than single speed motors, due to compromises in their
design to allow for multiple sets of windings. Although they deliver savings in cubelaw applications, they are still less efficient than the VFD plus single-speed motor
combination.
Wound Rotor Motors
Wound rotor motors are induction motors with a slip-ring and brush assembly which
connects the rotor to an external variable resistor. Varying this resistance will change
the rotor resistance and slip, hence speed of the motor. The disadvantage of this
motor type is that significant slip energy is dissipated in the resistor (Competitek
1996). Slip-recovery variations (Kramer and Scherbius drives) on wound rotor
designs increase the efficiency to VFD plus motor levels (Competitek 1996). The
brush assembly is similar to that found on DC motors and is a source for the same
maintenance and reliability issues associated with DC motors.
Variable Speed Control Technologies
There are a number of different coupling technologies specifically for continuous
speed control which are commercially available and feasible for large industrial
machinery: hydrodynamic, hydro-viscous, magnetic, and DC or AC variable speed
drives (known as a Variable Frequency Drive (VFD) for AC systems). All of these
technologies provide the necessary speed control and achieve energy savings over
the less efficient flow control methods such as control valve or damper throttling.
In hydrodynamic type couplings, the shaft drives an impeller which imparts energy
to oil which then transfers it to blades of a runner fixed to another shaft. Control
is achieved by varying the amount of oil via a scoop tube. The hydrodynamic
coupling will always have slip losses, even at rated speed, typically 2%-3%. The
hydraulic coupling offers a form of soft-start capability, but this comes at the
expense of controllability at low speeds (Competitek 1996). This type of variable
speed arrangement is still common in many existing plants (Black & Veatch,
1996).
In the hydro-viscous type of variable speed control, a thin film of oil between a
series of discs transfers energy from the driving shaft to the output shaft through
shear forces. Speed control is achieved by varying the pressure on the discs. The
hydro-viscous coupling can be locked at rated speed, incurring no losses, which
make this type of drive useful as a clutch for starting.

Module 2 | 127

 In a magnetic variable speed coupling, torque is transmitted from the motor to

the load across an air gap. The torque is created by the interaction of powerful
rare-earth magnets on one side of the drive with induced magnetic fields on the
other side. By varying the air gap spacing, the amount of torque transmitted can
be controlled, thus permitting speed control. In magnetic coupling torque at full
rated motor speed, the slip is between 1% and 3% (Magnadrive, 2008). However,
demagnetization occurs at about 300F for some of these drives, which may be a
problem in some application environments.
Permanent magnet eddy current couplings allow for vibration isolation between
the load and the motor, but are large, have poor turndown characteristics and
poor efficiency at lower speeds.
For a technical description of a typical Variable Frequency Drive, see section on
VFD Concepts in this handbook. For more details on the other variable speed
technologies, see references such as RMI-Competiteks Drivepower Manual. When
compared to the other variable speed methods, VFDs are generally more efficient,
have better power factor and offer more precise speed control (Competitek 1996).
The fast and direct action of a VFD on the prime mover also means it is better able
to mitigate common problems created by resonant frequencies at certain speeds. A
great advantage of VFDs over most other methods is the ease with which they can
be retrofitted; they make no extra demands on the physical space and layout of the
process area. This area is typically highly engineered, compact, and often difficult
to re-arrange. Even greenfield designs benefit from the layout flexibility that VFDs
provide compared to the bulky in-line equipment required by other forms of variable
speed control
Motor System Design & Engineering
The common motor system design & engineering steps are summarized below.
Step 1: Gather data on load and power system requirements:
Gather data on the application peak and continuous power & speed requirements;
inputs are the pump or fan system ratings
Gather data on motor duty cycle; its cycling pattern (# of start, stop per period)
and its load profile (% time at % loading )
Gather data on any special needs for braking or regeneration of power.
Gather data on the power supply system; voltage levels, frequency, power
capacity
Gather data to determine other requirements for physical and environmental
factors; such as required IP class, mounting type etc. see (IEEE, 2007)11.6.1 for
complete list of motor selection factors
Step 2: Determine motor ratings
128 | ABB Energy Efficiency Handbook

 Calculate maximum running torque and input power, using average or peak-load
sizing methods
For VFD speed control, follow the design guidelines in that section to determine
motor loadability.
Determine starting conditions based on process requirements & power supply;
inertia, starting time requirements, load torques during startup, voltage drop on
bus due to high starting current, resonance vibration frequencies during startup.
Use the minimum voltage if starting with reduced voltage as basis for calculating
motor speed vs. Torque, and ensure at least 10% margin over the pump torque
vs. speed during startup
Step 3: Select motor type and rating based on the above work; the minimum motor
specifications needed are listed below.
Design type: Induction vs. Synchronous
Power rating
Efficiency Rating and efficiency vs. speed
Speed, Frequency and Slip (vs. speed)
Voltage Level : LV or MV
Service Factor
Frame size : NEMA frames or IEC frames
Required IP class enclosure, mounting type (vertical vs. horizontal)
Synchronous speed and number of poles
Problem of Motor Oversizing
Oversizing of motors is a very common, but hidden cause of energy inefficiency.
Oversizing does not lead to any highly visible failure events, but it is a continuous,
low-level problem as energy costs and total emissions accumulate. Oversized
motors, those operating an average of less than 60% of rated load, will incur three
operational penalties:
Reduced motor efficiency
Reduced slip (hence higher speed); important for cube-law load applications
Reduced (worsened) Power Factor (PF)
Data from the US electric power utility PG&E showed that one-half of industrial
motors are operating at less than 60% of their rated load, and one-third are
operating at less than half their rated load (cited in Competitek, 1996, Ch.9).
According to the same source, motors operating below 60% load incur an efficiency
penalty of 0.5 to 1.5 percentage points. Motors operating at half their rated load are
2.0 to 4.0% less efficient than at rated load.

Module 2 | 129

Starting a Direct-On-Line (DOL) over-sized motor means the motor starter and
other power system components will need to be oversized, as the majority of
starting current is reactive and dependent on the motor size; larger motors take
more starting current. For this reason, VFDs and Soft Starters should be evaluated
for suitability during the motor specification process. As the section on Variable
Frequency Drives explains, these devices can correct for all accumulated design
margins and also provide the required soft-start capability.
Engineers may wish to believe that the widespread problem of oversizing is actually
due to under-loading; in other words, that the plant is operating at much less than
its target rated capacity due to prevailing market conditions beyond their control.
An analysis of the large motors in a US pulp and paper mill, however, revealed an
average load times capacity factor of 43% at a time when the mills where operating
at nearly full rated capacity (cited in Drive Power manual Competitek, 1996). Data
such as these suggest that the problem of oversizing is real, and that it must be
solved by engineers and technical managers.
Causes of Motor Oversizing
The causes of technical oversizing are investigated in detail throughout this
handbook, but the story of how margins creep in a typical project is told below, in
the case of a large industrial motor:
The process designer, following the guidelines in the Pump and Fan Systems
sections of this handbook, will provide the electrical engineer with the maximum
required pump or fan torque at the required operating speed. This process
specification is often misinterpreted, by the electrical engineer, to mean the minimum
acceptable continuous torque for the motor even if the requirement is actually a
peak load which must be sustained only for a small fraction of the motors duty
(Competitek, 1996).
The electrical engineer may further oversize the motor in the face of uncertain,
high-starting torque requirements and other power system uncertainties, just as
the process designer may have overstated the torque and speed requirements
to account for later changes in piping design or capacity demands. Customer or
company guidelines may force the electrical engineer to specify a high service factor
(1.15) machine and class F insulation, all of which add even more unnecessary
margin.
The project lead engineer may add further layers of margin fat by applying an acrossthe board-design margin of error or safety, as well as a generous future capacity
increase margin. Finally, if the resulting specification is only slightly higher than a
standard commercial rating, then the next and higher rating is usually selected. The
130 | ABB Energy Efficiency Handbook

gap between standard ratings is larger as motor power increases, which makes this
common practice costly in the long run. Most of the above margins are compounded
(margin as a percentage of the margin below), the end-result is a motor which is
often twice as large as it needs to be.
Motor Sizing and Selection
The motor design and engineering procedure described previously will help to
establish whether the maximum torque specification is a normal maximum or a
short-duration peak maximum. If the value represents a transient peak torque, then
other methods, such as a motor service factor margin should be investigated
before this value is used as the baseline for sizing. The design procedure then
calculates, from the maximum required torque at the required operating speed, the
motors power rating according to the motor power formulas and will establish
the system (bus) voltages. (See ANSI C50.41-1982 for list of preferred motor rated
voltages.) The nominal system voltages are slightly higher than the rated motor
voltage due to anticipated steady state voltage regulation in the power supply
system. Special attention to motor starting conditions is important for energy
efficient design. As with peak running loads, transient conditions should be carefully
vetted before they are allowed to form a minimum requirement. Other transient
conditions such as high ambient temperature should receive the same critical
profiling analysis as duty cycle. Worst-case estimation of ambient temperature may
lead to extra thermal margins and larger than necessary machines.
Average Load Sizing
Maximum load sizing is the default method for sizing, but the alternative Andreas
method uses average-load power. This average load sizing is only for applications
that do not require high inertia load starting or frequent starting, and which
operate at varying loads. Since motor heating is a limiting factor in sizing a motor,
this method uses the RMS (root-mean-square) losses, approximated by RMS
horsepower over the load cycle, to determine the thermal suitability of a motor. The
RMS horsepower is defined as that equivalent steady-state hp which would result
in the same motor temperature rise as that of a defined load cycle (See reference
Competitek, 1996, for an example calculation.) The calculated RMS hp will indicate
the required motor rating from thermal considerations, but the maximum peak load
must still be within the range of that motors service factor.
Motor Starting Conditions - Acceleration
The NEMA MG1 and ANSI C50.41 standards provide sizing rules based on the
torque required for accelerating the inertia of a rotating mass. Induction motors built
according to these standards develop at least 70% of their full load torque during
startup, which should be sufficient for most load applications.

Module 2 | 131

Motors serving high inertia loads such as fans, however, exceed the NEMA normal
inertia limits. These special motors required for those applications tend to be
oversized with additional thermal capacity to account for load torque and possible
low voltage conditions, factors which slow the acceleration time period and thus
allow the motor to accumulate more heat. See the example for determining
acceleration time of an industrial fan in the Fan Systems section.
Motor Starting Conditions - Voltage
Low voltage conditions during startup are a particular challenge for large motor
applications. The effect of low voltage starting conditions on developed torque is
magnified, because torque drops with the square of the applied voltage. Very long
acceleration times and increased heating or even the inability to reach full operating
speed are some of the consequences of inadequate design for startup.
For motors running in island mode networks, such as oil platforms, even smaller
motors might require starting methods other than DOL due to the lower short circuit
capacity of such networks (ABB Review, Ahlinder, 2001).
The three most common designs for motor startup are: 1) Direct-On-Line (DOL), 2)
Star-Delta 3) Soft-starters, which also include VFDs. Direct-on-line simply connects
the motor terminals directly to the supply network. DOL is the lowest capital cost
and most used system to start small squirrel-cage asynchronous motors. As shown
on the figure (left) below, starting is carried out at full voltage, high current and
with constant frequency; this develops a high starting torque with much reduced
acceleration times. This method is useful for full-load starting applications. High
inrush currents, first of 10-12 times rated current, then holding at up to 6-8 times
well into startup, will stress both the power system and motor.
Star-delta and soft-starters or VFDs are collectively referred to as reduced voltage
methods, with star-delta being the most common. In star-delta, inrush currents are
reduced by using first a star circuit, then switching over to a delta circuit during later
startup.

132 | ABB Energy Efficiency Handbook

Figure 2.30 - Relative startup characteristics for different starting methods Ref (ABB Motors & Drives,
2007)

Carefully designed special lubrication and cooling systems will provide some extra
thermal support margin needed by the motor for high transient load conditions.
Existing motors can avoid being de-rated if extra cooling is available for such
situations. Learning more about the process load and duty cycle, then careful
calculation and proper mitigation efforts will help in right-sizing a motor under all
conditions.
A high-starting torque design motor has lower operating efficiency at full load. For
some applications with many starts & stops and short running times, however, a
high-starting torque motor may be the overall most energy efficient selection.
Motors in Retrofit Situations
Downsize an Underloaded Motor
An underloaded motor has poorer efficiency and power factor. These motors can be
identified in an energy assessment process. The replacement motor can be sized
based on the actual load factor; a 100 hp (75 kW) motor at 50% loading can be
replaced by a 50 hp (37 kW) motor. This replacement motor should be chosen to
have higher efficiency, but careful attention to slip is important.
In an economic analysis of motor downsizing performed by RMI in their Competitek
Drivepower Manual, an average 100 hp (75 kW) standard motor at less than 50%
loading can be downsized (to a much smaller, but slightly more efficient model)
for a payback in under 3 years, in a cube-law application. Additional benefits
of a downsized replacement motor are a smaller motor starter and smaller, less
expensive conductors (Competitek 1996).
Module 2 | 133

Motor Upgrade to Higher Efficiency Model

In a fixed speed application, a motor upgrade to a higher-efficiency model with the
same rating may inadvertently lead to increased power consumption if the new
motor runs faster than the previous one, due to lower slip. The section on Motor
Energy Efficiency offers guidelines on how to avoid this situation. See the section
on Lifecycle Costing (LCC) for methods to calculate the energy and money savings
related to motor efficiency improvements; a numerical LCC case example is provided
at the end of this module.
Motor Rewinding
Another pitfall in retrofits is the loss of efficiency due to successive rewinds of an
old motor. Typical rewinding practice degrades motor efficiency by between 0.5% to
2.5% for each rewind (Competitek, 1996)
A study by Ontario Hydro found an average efficiency reduction of 1.1% in small (<
15kW) rewound motors, concluding that an upgrade to a higher efficiency model
was more worthwhile on motor failure.
Efficiency is lost in rewinds for several reasons: core losses increase due to the high
temperatures experienced during failure; stripping the motor for repair also damages
the laminations; copper losses increase because of the practice of using smaller
conductors, increasing I2R losses. Finally, fitting of universal cooling fans, which
may not be designed for the particular motor, leads to an increase in windage losses
(ABB Review, Special Report Motors & Drives, 2003).
Older, standard motors which have been rewound several times will be more
than 10% less efficient than a high-efficiency motor. Rewound motors are also
at risk of increased phase unbalance within the motor. The negative effects of
phase unbalance are described in the section on Power Quality - Phase Voltage
Unbalance.
Upgrade from DC to AC
A common retrofit opportunity involves upgrading older DC drives and motors to
new AC ones. This upgrade is an opportunity to improve harmonics, power factor,
uptime, spare part savings and other maintenance costs. In the past, DC drives and
motors were the only solution for high starting torque and accurate speed control
but this is not the case today. DC drives generate a high level of harmonic distortion
and are high maintenance due to brush and collector wearing. Both of these factors
reduce energy efficiency. The upgrade potential to AC is larger in certain industries
which have a population of older, energy-inefficient DC motor controls; typically in
the steel, cement and paper industries.

134 | ABB Energy Efficiency Handbook

A DC motor upgrade may be an opportunity to use a VFD with variable torque

technology. This drive can provide high starting torque and accurate speed control,
along with the side benefits of reduced maintenance, improved PF, and reduced
harmonics.
Motor Sizing and Selection Tools
A software package, MotorMaster+ 3.0 is available from the US DoEs Best
Practices Program to assist with motor selection. The software includes a builtin database of more than 27,000 U.S. motors and has the capability to compare
different motors and compute relative costs (including initial, annual energy, and life
cycle costs) and savings for the motors being considered.
Another package, DriveSize, is available from ABB Drives to help select a motor and
a drive, and then calculate combined motor & drive efficiency.
Motor System Guidelines Summary
The following design guidelines will generally improve the energy efficiency of the
design or re-design of a motor system, at relatively low capital cost, with a short
payback period:

Downsize underloaded motors

Upgrade to higher efficiency motors
Upgrade old DC motors and controls to AC
Use VFDs for speed control
Avoid margin creep; follow proper sizing procedures

Many more tips for energy efficient motor systems can be found in the DoE EERE
(US DoE Best Practices, 2008) Motor Tip Sheet.
Motor System Maintenance
The large number of motors in a plant requires a comprehensive motor management
program to ensure they are managed cost-effectively. Such a policy helps bring
together capital, maintenance and revenue budgets, showing the effect they have
on each other when different types of motors are selected. Industrial users benefit
from such a policy through reduced energy costs, by upgrading to high-efficiency
motors at the most cost-effective time. The forward planning inherent in the practice
helps reduce downtime. Inventory can also be reduced through a fast track delivery
agreement. (ABB Review, Special report, Motors & Drives, 2005). Many technical
tips for motor systems maintenance can be found in the DoE EERE (US DoE Best
Practices, 2008) Motor Tip Sheet.

Module 2 | 135

Motor System Cost Calculations

The investment costs for a motor are mainly hardware, engineering and installation
costs. Combined, these costs are referred to as the total installed cost (TIC) of the
motor. The hardware cost per hp generally decreases with the size of the motor, but
varies greatly with motor type and other factors. As a first approximation, a large
(>500 hp) standard induction motor has a hardware cost of about $100 per hp. The
total installed cost can be approximated by adding 60% of the hardware cost, so the
TIC in this case will be $160 per hp. A motor rewind can cost between $25 to $40
per hp.
Value Calculation Case
Sample comparison of two 2000 hp (1.5 MW) motors at 85 and 97 % efficiency over
1 year:
Energy Savings = 2000 hp x 0.746 kW/hp x 8,000 hrs/yr x 100(1/85 1/97) =
1,737,198 kWh
Dollar Savings = 1,737,198 kWh x $0.07/kWh = $121,603
Now applying LCC methods to determine the present value of the savings over 20
years at 6% RoR:
PV = 121,600 x ((1 + 0.06)20 - 1 ) / 0.06(1 + 0.06)20
PV = $1,394,742
The Case Studies section has a fully worked-out example of retrofit cost
calculations with payback.

Variable Frequency Drives

VFD Concepts
Electric AC motors are the most common source of process industry drivepower
due to their reliability and low cost. An additional feature of electric motors is that
shaft speed or torque can be controlled by varying the electrical supply at the motor
terminals. This feature is exploited by a separate piece of power electronic hardware
known as the Variable Frequency Drive (VFD), some of which are pictured in the
figure below.

136 | ABB Energy Efficiency Handbook

Figure 2.31 - Torque-speed curves for idealized VFD, (ABB Drives 2002)

VFD Energy Efficiency Potential

The main benefits of applying VFDs come from matching the input power to the
needs of the process. These benefits are magnified in cube-law applications such
as pumps and fan systems, where power requirements increase with the cube of
speed, and the savings are typically between 30 and 50%. The following sections
introduce the technical features of VFDs with the greatest potential for energy
efficiency.
Speed Control instead of Throttling
Of the estimated 65 percent of industrial energy used by electric motors, some
20 percent is lost by wasteful flow throttling mechanisms. The mechanics of flow
throttling is described in the fan and pump sections of this handbook. Additional
energy is wasted in inefficient variable speed coupling methods. VFDs allow
application speed to be controlled without energy-wasting flow throttling or inefficient
belts and hydraulic couplings.
VFD controlled pumps and fans can respond faster and more reliably than flow
throttling valves or dampers, especially at flow extremes when control valves
become highly non-linear. VFDs avoid the problem of poorly-sized control valves
which may be unstable for control at less than 10% opening. In fan systems, the use
of a VFD for speed control avoids the deadband and hysteresis found in mechanical
dampers or inlet guide vanes control methods. Damper leakage is also avoided
when using VFDs for flow control. Compared to throttling control methods, VFDs
have lower inspection & maintenance costs. Any reduction in speed achieved by

Module 2 | 137

using a VFD has major benefits in reducing pump wear, particularly in impellers,
bearings and seals.
There are some additional side-benefits for VFD-flow control in pumping systems.
With a VFD receiving a signal from a pressure transmitter, it is possible to monitor
the pressure of the incoming pipeline and configure the converter to take steps if
the risk of cavitation is high; i.e. if pressure falls below NPSHR plus a margin. Water
hammer is caused by rapid changes in flow. These flow changes are followed by
rapid pressure transients that cause pipes, pipe supports and valves to be damaged
causing leakage. VFDs allow the user to gradually ramp pump acceleration at a safe
rate to avoid hammering.
Despite the potential for 60% savings in many cube-law applications, only 5%
of all industrial motors are controlled by VFDs, and it is estimated that 30% of
existing motors can be cost-effectively retrofitted with VFDs (ABB Drives, 2006).
The potential is larger in smaller applications (under 2.2 kW) where 97 percent of all
motors have no form of speed control at all, equating to some 37 million industrial
motors sold annually worldwide (ABB Review, Special Report Motors & Drives,
2003). 40 percent of the value (and 90 percent in units) of all drives shipped are
rated at less than 40 kW.
Improved Motor Efficiency
Another benefit of VFDs is the improved energy performance of the motor itself. The
VFD control allows the motor to operate closer to its best efficiency point. The drive
can generate a family of characteristic curves for the motor, in the same way that a
speed-controlled motor generates a family of characteristic pump curves. In both
cases, the intersection with the load characteristic curve gives an operating point
which is near to the area of optimum efficiency for the equipment.
VFDs can correct for oversized motors by running them at reduced speed. The
operational benefits of such correction can justify a VFD even in applications which
do not call for speed control.
Compared to most other speed control methods described in the Motors and
DriveTrains section, with a VFD there is no loss due to mechanical slip between
motor and load.
Two and Four Quadrant Operation
Quadrant operation is the term used to describe a drives ability to provide braking,
reversing (2-quadrant) and regenerative (4-quadrant) power. The quadrant refers to
the space these modes occupy on a torque-speed axis shown in the figure below.

138 | ABB Energy Efficiency Handbook

For loads which generate power for only a short time, then it is typical to offer only a
braking resistor where the power generated is dissipated as heat losses.
4

Decelerating

Accelerating

Accelerating

Decelerating

Figure 2.32 Four quadrants of VFD operation

Active rectifiers will allow these losses to be regenerated into electrical power for the
network. The type of rectifier will determine if power can flow in both directions. A
conventional passive diode rectifier only supports motor loads where the power flow
is only in one direction.
Motor Soft-Starting
VFDs provide the same functionality as a dedicated soft-starter - a power-electronics
device installed in-line with the motor that slowly ramps up the voltage for a smoother
startup. Soft starting is mainly used to limit large motor starting currents and to better
manage power factor during startup so that the electric power system is not unduly
stressed. Soft-starting therefore improves voltage bus stability, reduces currents
and allows reduction in transformer size, and other power system hardware. There
is also reduced risk of process disturbance due to voltage drops; and fewer trips of
other electrical devices connected to the same bus. Most motors experience startup
in-rush currents that are 5 to 6 times higher than normal operating currents, which is
reduced to 1.5 with VFDs, thus reducing wear on the motor. Soft starting reduces heat
load and allows a greater number of starts within a given time period, increasing the
flexibility of the control system to optimize the process. (Motors not equipped with a
VFD or other form of soft startup power electronics are referred to as Direct-On-Line
(DOL) motors. ) Note that the load itself may also benefit from a smooth ramping up
of torque and speed. The sections on Motor Starting Conditions and VFD Starting
Torque Conditions discuss design criteria for startup conditions.

Module 2 | 139

Power Factor Correction

The internal design of a VFD helps to improve a motors power factor (PF). When
a VFD is installed, the reactive power that is the source of low PF circulates mainly
between the DC link and the motor, and therefore it cannot affect the input AC
electric power supply system. Higher power factor will reduce I2R losses in the
power network transformers and cables. A VFD-equipped motor system will typically
have high PF of 0.98 compared to 0.83 for a typical DOL motor. The PF when using
a VFD does not degrade with decreased speed, as is the case with DOL motors.
The VFDs rectifier unit can optionally be of the active type that performs leading
and lagging PF correction, which is to the benefit of the entire input side of the
electric power system. The potential for such an Active Rectifier Unit (ARU), also
known as active front end is discussed in the handbook section on reactive power
compensation.
Slip Compensation
Without a VFD, when the motor load torque is increased, the speed of the motor
will decrease as shown in the figure below. To compensate for this slip, the torque
vs. speed curve is modified with use of a VFD so that the torque increase can be
accomplished while maintaining a constant speed (ABB Oy. Drives, 2002). This slipcompensation is a standard function on most VFD drives and is especially useful in
applications which require constant speed but varying torque.

Figure 2.33 Slip compensation of a VFD shown on motor torque vs. speed curve, (ABB Oy. Drives,
2002)

Speed Setpoint Control

The VFD drive is more than just a speed control actuator - most VFDs are also
equipped with programmable PID loop control functionality to maintain a desired
140 | ABB Energy Efficiency Handbook

motor speed or torque setpoint. Having the PID controller onboard the drive reduces
loop latency to a minimum and allows faster response to process changes when
compared to central speed control. The extra responsiveness is useful in a few
applications with highly varying load torques, where precise speed control is a
requirement. VFD control can hold the process at a steady set point, instead of
exhibiting cycling that may occur with other means of speed control.
VFD programming tools are equipped with libraries of application-specific control
functions for pumps, fans, cranes etc. The control blocks in these libraries have predefined Input-Output characteristics and are optimized for these applications
Regenerative Braking
Some VFDs are able to harvest wasted energy through motors acting as
generators. This is also known as 4-quadrant operation. The LCI and VSI drive
types (described below) can be ordered with inverter-equipped front-ends that are
capable of such 4-quadrant operation. In conveyor systems with uphill and downhill
conveying, some VFD drives can manage energy sources and sinks using a common
bus principle, with optimum efficiency and energy flow between motors of motoring
and generating mode (ABB Switzerland, MV Drives, 2002 p.16, Fact Pack #2).
Inherent Motor Monitoring and Protection
VFDs have built-in power functionality needed to protect a motor from abnormal
conditions in the power supply or within the motor itself. Most critically, VFDs have
acceleration and deceleration ramp limiting functions and motor current limiters
to prevent driving torques which cannot be sustained by the motor. VFDs isolate
motors from the electrical supply line, which can reduce motor stress and inefficiency
caused by varying line voltages, phase imbalance and poor input waveform.
Many of these vital protective functions would otherwise require the installation
of separate devices. The most common protective functions are: short-circuit,
over current, unbalanced phase, ground fault, motor temperature, and motor
stall. VFDs also monitor for underloaded situations, as in the activation of safety
release mechanisms in the driven equipment, and will also detectphase loss on the
incoming side. If a problem is detected, the VFD will send a warning or an alarm to
operators, and initiate a drive trip.
Built-in monitoring of motor current and temperature, plus many other parameters
allows the VFD to detect, warn and even take action to mitigate the effects of certain
drive system problems. For example, if the motor current is oscillating, this may
indicate a problem at the couplings. No extra current transducer is required for this
monitoring. VFDs may also be programmed to take action when a faulty gearbox
or bearing sends a high-temperature signal when operating at full load, but no
Module 2 | 141

such warning at lower loads. In this situation, the VFD can decrease the load until
an appropriate time for maintenance on the faulty equipment. These monitoring
functions can improve the uptime of a plant, with benefits as described in the section
on Lifecycle Costing Calculations - Energy cost of a trip
Overspeed Capability
By controlling the frequency and voltage, VFDs can achieve higher motor speeds
than otherwise possible from only a fixed electric power supply. This overspeed
capability may be sufficient to handle modest production capacity increases without
the investment needed to replace the motor or actuator. Speed increases of 5-20
percent are not a problem for VFDs on most motors. This extra capacity is within the
ratings of most installed motors, which are specified with generous margins plus a
service factor. Margins and more details on over-speeding can be found in the NEMA
MG-1 standard.
Variable torque applications, such as pumps and fans, require increasing torque
with speed. If the intention is to run above the motors nominal speed, then it may
be necessary to oversize the motor due to the reduced torque in the field weakening
region.
Voltage Fluctuation Ride-Through
This feature is especially useful on weaker networks (for example, in industrial boiler
applications) with transient voltage dips; VFDs allow the motor to ride through
such dips thus avoiding a trip. Dips may last from a few cycles to a few hundred
milliseconds. See the section on Lifecycle Costing Calculations - Energy cost of
a trip
Voltage Boost and IR Compensation
At low speeds during startup (<20 Hz), a VFD can provide a temporary increase in
voltage to help motors achieve a higher breakaway torque, without the high currents
associated with DOL starting. One pitfall with voltage boost is the risk of overheating
of very lightly loaded motors at speeds under 10 Hz (Bezesky 2001). Voltage
boost applies a fixed extra voltage, but with IR compensation the extra voltage is
proportional to the motor current, as shown in the figure below. IR compensation
will therefore only provide extra voltage for motors under load and drawing current,
reducing the risk of saturation and overheating.
Both of these features apply only to voltage/frequency (scalar) drives, or vector
drives operating in scalar mode. Vector drives by design can generate higher
starting torques and do not need a voltage boost feature; these drives can provide
several hundred percent higher than nominal torque for motor starting. The ability of

142 | ABB Energy Efficiency Handbook

drives to boost starting torque allows engineers in some cases to avoid oversizing or
selecting less-efficient high-torque motor designs.

Figure 2.34 Voltage boost at low speed, ABB VFD Programmable Features

Figure 2.35 - Small (LV) and large (MV) VFD hardware (ABB Drives, 2008)

VFD Types and Applications

Industrial VFDs cover a wide power range, from 100 hp (75 kW) to more than 30,000
hp (22 MW). Most large industrial plant VFD applications require a medium voltage
AC drive, which are normally in the power range from 500 hp (380 kW) to 7000 hp
(5 MW) and operate at bus voltages from 2.3 to 6.9 kV.
There are several different drive types, and the choice of drive type depends on
many factors, starting with the basic motor type: Induction motors are typically
controlled by Voltage Source Inverter (VSI) or Current Source Inverter (CSI) system
Module 2 | 143

topologies. Synchronous motors are typically controlled by Load Commuted

Inverters or Cycloconverters, all described in the following sections.
The internal converter control method also varies between topologies, and there may
even be more than one control method to choose from for any given topology. See
the ABB Guide to Standard MV VFDs (Fact Packs #1 and #2)
VFD Internal Design
VFDs are power electronics devices that convert a constant input frequency and
voltage into variable frequency and voltage output for the motor. A complete VFD
system may consist of all these elements: cabling, an input isolation transformer,
power factor correction equipment, harmonic filters, the frequency converter itself,
output filter, and an electric motor. The combination of all the above elements is the
physical topology of the AC drive system. The converter elements power switching
function is the motor control platform, which should not be confused with a lowvoltage Motor Control Center described elsewhere in this handbook.
The physical topology provides the electrical hardware and the motor control is the
software which performs the power switching routine.
Variable Speed Drive
Supply Side

Motor

Converter

3
Rectifier

Intermediate
DC Link

Load

Inverter

Figure 2.36 Diagram showing VFD nomenclature, (ABB Switzerland, MV Drives, 2002)

The most common converter topology is composed of three main equipment stages:
A front-end rectifier unit on the 3-phase supply side to convert AC to DC power
and to ensure that harmonics drawn from the network are kept within tolerance.
A DC link composed of one or more capacitors and inductors which filter and
smooth the DC voltage
An inverter unit, using one of the power electronics technologies described in the
sections below, performs the inversion and modulation of the voltage which is
applied to the motor windings.
The effect of these stages on the sinusoidal input AC supply is shown in the figure
below:

144 | ABB Energy Efficiency Handbook

Figure 2.37 - VFD waveform at different stages, using PWM-type drive as an example (ABB Inc. 1998)

VFD Power Electronics

The switching elements at the heart of much power electronics are thyristors, also
known as Silicon Controlled Rectifiers (SCRs). These are turned on (conduct power)
by a control signal and will continue conducting until current drops near zero, a
feature known as self-commutation (Competitek 1996). The number of switching
elements (or pulses) in the converter is a measure of the resolution of the drive
in supplying output to the motor. The number of pulses will roughly determine the
amount of VFD harmonics induced in the motor and drawn from the power supply.
The power electronics switching technologies that are in use today are:
IGCTs (Integrated Gate Commutated Thyristor) offer fast switching (like a
transistor) and inherently low losses (conducts like a thyristor); in other words,
it combines the best of both technologies above. IGCT technology is the most
common switch in MV drives sold today.
IGBTs (Insulated Gate Bipolar Transistor) are fast switching and low cost, but
losses are high at medium to high voltage levels. Used in LV applications.
GTOs (Gate Turn-Off Thyristor) are thyristors with a controllable off switch,
additional circuitry that lowers overall reliability, slows the switching and increases
expense. GTOs are used in high-current, high-power applications, but have
relatively high MV losses.
From an energy efficiency perspective, a semiconductor drive technology that has
low losses means greater energy efficiency, less cooling equipment, and greater
reliability of the VFD device.
Module 2 | 145

VFD Topologies
The main drive topologies which are in wide usage today are listed below, based on
descriptions from the ABB Drives Fact Pack #1, 2005.
Voltage Source Inverter (VSI)
This section is based on information in (Competitek 1996), (IEEE, 2007), and (ABB
MV Drives, 2002)
The VSI drive is sometimes referred to as a Variable Voltage Inverter (VVI) because
it achieves speed control by varying the voltage fed to the motor. In its simplest and
earliest form, the VSI inverters switching elements produced a 6 (or 12 or higher)
step voltage waveform output for the motor. The design of the VSI topology is shown
in the figure below. A common topology and control combination for low to medium
horsepower AC machines today is VSI hardware using PWM inverter control. The
high-speed PWM switching converter provides fast response, precise speed control
and maintains high PF over the entire speed range.
Un

Um

Rectifier

L1
Supply

L2
L3

Monitoring
Control

Um

DC
L

Inverter

Motor

+
c

V1

V3

V5

V4

V6

V2

U1
V1
w

M3-

Control electronics
control, manufacturing, communications

Figure 2.38 - VSI design schematic ABB (ABB Switzerland, MV Drives, 2002)

The main characteristics of a VSI drive with PWM are summarized below.

power range
: up to 8,000 kW (for 3-level inverters)
motor voltage levels : 2.3 to 6.9 kV
speed range
: 0 100%
has low starting current
does not contribute short-circuit current
not capable of regenerative operation,
high ac input power factor, near unity for entire speed range
converter efficiency >= 98%
PF is high and constant over entire speed range
low network harmonics, voltage reflections & voltage stress

146 | ABB Energy Efficiency Handbook

 full torque even at standstill & very low speed

standard drives for pumps, fans, compressors, conveyors
Although PWM is the most common converter control method, other methods such
as Flux Vector can also be used together with the underlying VSI topology.
Current Source Inverter (CSI)
This section was adapted from these sources: (IEEE, 2007) and (ABB Switzerland,
MV Drives, 2002)
The CSI drive system controls current output to the motor using a gate-turn-offthyristor current source inverter on the load side. The inverter is operated in a selfcommutating mode over the full speed range of the drive; they turn off by themselves
every time current passes through zero. The amplitude of the motor current is
adjusted by the supply-side rectifier, whereas the frequency and thus motor speed
is controlled by the load-side inverter. Most modern CSI drives are configured with a
12-pulse output (Competitek 1996). A simpler, but less efficient design makes these
drives suitable for larger induction motors operating at higher speeds. The main
characteristics of a CSI drive type are summarized below.
Suitable for larger induction motors
Horsepower range typically 500-10 000 hp (380 kW7.5 MW) (but is rated up to
80 MW)
Often applied as a retrofit adjustable speed drive system for existing motors.
Output voltage 2.3 to 6.9 kV
Typical applications are pumps, blowers and fans
Capable of regenerative operation
High efficiency at speeds above 50%
Continuous operation at very low speeds is not always possible.
PF is not constant over entire speed range, and is poor at low speed
The large filter capacitor (DClink) introduces additional losses and larger size.
Converter efficiency: 97%
Speed control range 2-100%
Load Commutated Inverter (LCI)
For conventional synchronous motors, the most common power electronics drive
technology is Load Commutated inverter (LCI). Permanent magnet synchronous
motors also use the PWM drive technology.
The following section is based on information from (IEEE, 2007) and (ABB
Switzerland, MV Drives, 2002).

Module 2 | 147

In the LCI design the DC current is switched directly to the synchronous machines
windings, which behave like a DC machine. LCI drives have a simple and robust
design because no special switching circuit is needed; the thyristors are switched
by the action of the current waveform of the load itself (Competitek 1996). A control
function using a feedback sensor in the motor prevents the rotor from falling out of
step. The LCI drive system can be furnished with regenerative braking capability,
which is discussed in the section on VFD Regenerative Braking. The main
characteristics of this drive type are:
Unmodified, it is suitable only for synchronous motors, with brushless or slip ring
excitation
Wide speed and power range 1- 80 MW
Speed control range (0)-10-100%
More expensive than other drives
Poor power factor at low speed
Suitable for continuous operation
Fans & pumps, compressors
Converter efficiency > 99%
A modified LCI drive with a large DC-link capacitor can use CSI technology to drive
either synchronous or induction motors. The capacitor also servers to shape the
waveform so that harmonic heating in the motor is reduced (Competitek 1996).
Cycloconverter
The Cycloconverter design does not use any intermediate DC circuit, which limits the
load frequency to a maximum of 83% of the line frequency (for cross-current type
of drive). Cycloconverters are used for high power, low speed synchronous motor
drives such as rolling mill drives, and ship propulsion. The main characteristics of
this drive type are:

Power range 1.5 30MW

Excellent performance and speed control at low speeds
Non-constant PF
High harmonic distortion
Capable of regenerative operation
Maximum speed limitation 600/720 for 50/60 Hz supply

VFD Control Methods

Also referred to as Motor Control Platform, the drive control method is the logic which
switches the power electronics elements to produce a certain output waveform.

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Pulse Width Modulation (PWM)

In small to medium-sizes, the voltage amplitude is held constant and the PWM
controls average (RMS) voltage by varying the pulse duration and frequency
(Competitek 1996) as shown in the figure below. In larger drives the voltage amplitude
is also modulated. PWM outputs current to the motor as a nearly sinusoidal waveform.
PWM control is also sometimes referred to as scalar or voltage/frequency (V/F)
control because a certain voltage is generated for a given frequency.

Voltage

Figure 2.39 Modulated width voltage pulses from a PWM drive

Scalar vs. Vector Drives

The V/F control method is open-loop because it does not receive any feedback
from the motor itself. In these drives, a fixed volts/Hz pattern is applied to the motor,
and the actual torque is then determined by the motor and its load. Precise torque
control is not possible with these drives, and speed control is not possible below
10Hz; limitations also commonly associated with DC motors.
Vector drive control emulates the operating characteristics of a DC motor by
tracking the spatial position of the rotor magnetic flux in an AC induction motor.
Some common limitations of vector drives: 1) they cannot be used in multidrive configurations of the type described in the next section 2) they cannot be
used if there is a transformer between the drive and the motor. However, vector
drives can produce much higher torques at lower speeds ( 3 to 5 Hz) than PWM
drives, and have torque response and speed accuracy which is several orders of
magnitude greater than PWM (ABB Oy. Drives 2002). Pump, fan and other cube-law
applications, however, do not normally require the enhanced torque and low-speed
control provided by vector drives. In these applications, lower-cost scalar drives are
sufficient.
[ The following descriptions of these drive technologies was adapted from the ABB
Technical Guide (ABB Switzerland, MV Drives, 2002).]

Module 2 | 149

Flux Vector Control

Flux vector control (often simply called vector control) can produce full torque
at much lower speeds than V/F drive types. By closing the loop with motor state
feedback, vector drives provide a torque response and speed accuracy that are
several orders of magnitude greater than with open-loop scalar drives. Flux vector
control, however, requires an extra speed feedback device (encoder) between motor
and the drive control system to sense the speed and position of the shaft.
Sensor-less Vector Control
The sensor-less flux vector technology uses a motor model to eliminate the need
for feedback from a tachometer or encoder. The model uses internal measurements
of motor current within the drive to determine torque and flux. An algorithm
estimates motor slip, speed and shaft position. The drive can then calculate the
necessary voltage and frequency to produce the desired torque and speed.
When a vector drive operates in torque control mode the speed is then determined
by the load. In screw pumps a drive using torque control technology will be able to
adjust itself for sufficient starting torque for a guaranteed start. In conveyor systems,
torque control may be used to control feed rates where one section is allowed to run
faster than another.
Vector drives can be selected to operate in either torque-control (vector) or speedcontrol (scalar) modes. Note that at very low speeds (< 5Hz), sensor-less vector
drives cannot easily determine magnetic parameters, and motor slip estimates then
become inaccurate. This inaccuracy makes sensor-less drives generally unsuitable
for crane and hoist operations; other vector drive designs avoid this limitation.
Direct Torque Control
ABBs proprietary variant of sensor-less vector drive, Direct Torque Control (DTC)
allows the motors torque and flux to be used as primary control variables, without
the need for an additional modulation processing step. Torque response time is
an order of magnitude faster than with other vector drive designs. Using the DTC
technique, the torque accuracy is 2% within a speed range of 2-100% and a load
range of 10-100%. A DTC drive can work with any type of induction motor of
asynchronous, squirrel cage design.
A feature of DTC that contributes to energy efficiency is a development called motor
flux optimization. With this feature, the efficiency of the total drive (that is controller
and motor) is greatly improved in fan, pump, and other variable speed applications.
The efficiency gains are greatest at lower speeds, as shown in the figure below. For
example, with 25% load there is up to 10% total energy efficiency improvement. At
50% load there can be 2% total efficiency improvement.
150 | ABB Energy Efficiency Handbook

Unlike traditional AC drives, where up to 30% of all of the modulators power

electronic switchings are wasted, a drive using DTC technology knows precisely
where the shaft is and so does not waste any of its switchings (ABB Drives 2002).
100

Efficiency/%

90

80

70

Flux Optimization off

Flux Optimization on
60

50
0

10

20

30

40

70

100

Frequency/Hz
Figure 2.40 Efficiency improvement with DTC flux optimization, (ABB DTC Presentation, 2008)

Multi-Drive
In the multi-drive architecture, multiple inverters are fed from a common DC-link bus
and central rectifier unit. The individual inverters do not all have to have the same
power rating: a multi-drive package can consist of drives of very different sizes. A
higher overall VFD efficiency is achieved by eliminating the separate rectifier and
DC-link for each drive. In a plant with many drives, the total lifecycle savings can be
significant.
A multi-drive architecture also allows a cost-effective way to reduce energy-wasting
harmonics by installing a single active front-end supply unit or at least a 12-pulse
line supply. Another advantage of this technology is to be able to supply energy from
VFD Regenerative Braking from one motor to another motor in the group, without
the need for any additional power inter-connection equipment.

Module 2 | 151

Figure 2.41 - Multi-drive system1) rectifier section 2) common DC-link 3) drive sections 4) power supply (ABB Drives 2002)

Multi-drive systems are cost-effective in applications where there are several motors
installed close together, such as sets of conveyors, fan banks, pump banks or
in master-slave applications which require motor synchronization, such as paper
machines. Compared to set of single drives, these systems save cabling on the
power input side and allow faster replacement of faulty units. The cost of multi-drives
are decreasing, but these systems still require some engineering when compared
to single drive applications; this may explain why multi-drives are generally underutilized in industry. A lifecycle cost (LCC) analysis, however, may reveal energy
savings large enough to overcome a preference for standard, non-engineered single
drive products.
AC Motor Control Terminology
Discussions on motor speed or torque control require clarification of a few basic terms
in common usage. The Variable Speed Drive (VSD) term, as used in the Pump and
Fan sections of this handbook, refers to any means of modulating the output shaft
speed given a constant input shaft speed from the source of drive power. Another
common and equivalent term to VSD is ASD: Adjustable Speed Drive. A variety of
methods to vary shaft speed are discussed in the Motors and Drive Trains section.
In some industry texts the broader term VSD is used even when VFD control is meant.
Sometimes, only the word drive or converter is used to refer to a VFD, and some
technical sources may incorrectly refer to the entire VFD as only the inverter. The
naming situation is further complicated when AC torque control drives, also known as
vector drives, are included. The preferred, and least ambiguous, term for all these AC
drive technologies is Variable Frequency Drive, abbreviated as VFD.
152 | ABB Energy Efficiency Handbook

The discussion in this section is limited to the application of VFDs within an industrial
process, and the drives interaction with the motor and the load. For a discussion on
how VFDs may impact power quality of the electric power system, see the section
on Electric Power Systems.
Speed and Torque Performance
If a motor is driven without a VFD, then its performance characteristics cannot be
modified; the motor will produce only the torque at a certain speed given by its
torque vs. speed curve and specified values for starting, breakdown and full-load
torque as shown in the figure below (left side). When started direct-on-line (DOL),
the motor accelerates continuously, passing through these points until it reaches its
nominal operating torque and speed.

Figure 2.42 Torque-speed curve for a motor (left) and a VFD-equipped motor (right), (ABB Drives
2002)

With a VFD, however, the input voltage and frequency can be continuously
modulated so that a family of characteristic torque-speed curves is available over the
nominal speed range, as shown on the figures right side. The actual operating point
of the drive system is the intersection between the active torque-speed curve of the
drive-motor combination with the torque-speed characteristic curve of the load.
A VFD is commonly used in speed-control mode, in which the torque is determined
by the load. Some VFD designs allow a torque control mode, in which the speed is
then determined by the load.
A VFD can drive and hold the motor at any point along any of these characteristic
motor curves, limited only by the thermal capability of the motor and the load on the
motor. The VFD can hold the motor at Tmax for short-term overloads. In practice,
VFDs typically will limit the maximum available torque to 70% of Tmax.
Newer VFD designs, however, can achieve high breakaway torques, typically 2 times
nominal torque.

Module 2 | 153

VFD Operating Regions

For speeds below the nominal speed, the magnetic flux in the motor is constant.
At speeds above the nominal frequency/speed the motor operates in the fieldweakening range, in which magnetic flux density is sacrificed for higher speed. The
maximum torque of an induction motor is proportional to the square of the magnetic
flux. Below Ns the Tmax is constant; above Ns the Tmax decrease is inversely
proportional to the square of the frequency.
For example, a 100 hp, 460 V, 60 Hz, 1775 RPM (4 pole) motor supplied with 460
V, 75 Hz (6.134 V/Hz), would be limited to (60/75)2 = 64% torque at 125% speed
(2218.75 RPM) = 100% power.
In most applications a VFD approach is chosen to provide different torque vs. speed
performance than would be possible for the motor by itself. This performance is
usually matched to the loads torquespeed performance curve. For example,
constant torque over a wide range of speed is a common requirement for many
applications. The figure below shows how voltage and speed control can achieve
theoretical constant Tmax over the range of speed from zero to synchronous speed
(n/ns =1.). At higher speeds, the weakening magnetic field causes torque to drop in
quadratic fashion, known as the constant power region of operation.
VFD Performance & Efficiencies
Motors are developed and optimized to run at constant voltage and frequency and
at full load. Adding another device, a VFD, cannot improve the combined efficiency
of the system operating at full load. In fact, the non-sinusoidal electrical output plus
the internal losses created by the VFD actually lower the combined efficiency at full
load by several percentage points, compared to the motor acting alone. (Competitek
1996).
A VFD saves energy when it can modulate the motor power to match loads which
are less than 100% full load. Variable flow applications are obvious candidates, but
constant speed applications would benefit as their loads are seldom perfectly and
forever matched to the rating of the motor. Many well-matched, constant-speed
applications could still profit from VFD soft start, power-factor correction and other
VFD Features.
Motor Current Estimation
Estimating motor current is important for dimensioning a VFD, and can be done once
the motor torque characteristic is known. The total current in a motor (Im) has active
(I q) and reactive (Id) including magnetizing current components, as described in the
section on the power triangle. Only the active current component can produce
torque; when torque is zero, so is the active current. The active current can always
154 | ABB Energy Efficiency Handbook

be calculated by multiplying the total current by the power factor, also shown as
cos(n).
In the constant flux region (below field weakening point):
In the constant flux region the motor currents do not depend on speed. The active
current can be approximated as follows:
I a = In x (Tload/Tn) x cos(n)
Where:

In = nominal (nameplate) current
At higher torque values motor current becomes nearly proportional to the torque. A
good approximation for total motor current at a given load is as follows:
Im = In x (Tload/Tn) when Tload is between 0.8 x Tn and 0.7 x Tmax
For example: a 150 kW motors nominal current is 320 A at power factor 0.85.
What are the approximate active and total currents at 120% torque, below the field
weakening point? Using the approximation formulas from above:
Ia = 320 x 1.2 x 0.85 = 326 A
Im = 320 x 1.2 = 384 A
In the decreasing flux region (above field weakening point), the motor currents
depend on speed. The active current can be approximated as follows:
Ia = In x (Tload/Tn) x ( n/nn ) x cos(n) = In x (Pload/Pn) x cos(n)
Where:
P n = nominal (nameplate) power
Within a certain operating region the total motor current becomes proportional to the
relative power.
I m = In x (Tload/Tn) x ( n/nn ) = = In x (Pload/Pn) when Tload is between 0.8 x (nn/n) and
0.7 x (nn/n)2 x Tmax

Module 2 | 155

For example: a 150 kW motors nominal current is 320 A. How much current is
needed to maintain the 100% torque level at 1.3 times nominal speed (assume Tmax
=3 x Tn)? Using the approximation formula above:
Im = 320 x 1.3 = 416 A
For additional motor power and torque formulas see the Motor and Drive Train
section.
Drive Efficiency
Efficiency levels of MV AC drives vary from 95 to 99%, including the supply
transformer, power factor correction equipment and any harmonic filters. A typical
VFD efficiency curve stays relatively high (above 90%) and constant until about 20%
of full load. At loads below 20% full load, the VFD efficiency drops to between 75%
and 90%. This drop is partly because the losses in the drive electronics account
for an increasing proportion of the input power. The extra protective circuits which
are often built-into modern VFDs, such as suppressors and line reactors, improve
reliability but they come at a slight cost in drive efficiency (Liptak, 2005). Vendors of
VFDs may promote small drive efficiency margins over other vendors, but these are
tiny compared to the efficiency gains of the entire drive power system, VFD, drive
train and pump or fan. Engineering support, programmability and other factors will
likely play a more important role in total drivepower system efficiency, which is the
only valid basis for comparisons and design decisions.
VFD Harmonics
A harmonic is a sinusoidal component of a periodic wave or quantity having a
frequency that is an integral multiple of the fundamental frequency. Harmonics are
caused by the non-linear switching action of VFD inverter electronics. The rapid step
changes in voltage levels found in most drive outputs, and especially in PWM drives,
create flux harmonics and heating within the motor. Rotor heating from PWM drives
can range from 30% to over 300% more than with only 60Hz input power, depending
on the type of modulation control used (Competitek 1996).
High harmonic content coming from early frequency converters led to heating
of motor windings and the practice of de-rating the motor 5-10% for use with
VFDs. Modern VFD drives now output low levels of harmonic content and
perform according to the detailed standards in IEEE 519 and NEMA MG1 Part 31
specifications (or G5/3 n the UK); it is usually no longer necessary to de-rate a motor
for use with a VFD (US DoE, 2008).
Harmonics tend to be drawn from the supply network and may affect other electrical
equipment. For a discussion of the energy impact of these supply-side harmonics,
156 | ABB Energy Efficiency Handbook

and of ways to mitigate their effects, see the Electric Power Systems section
Harmonics Mitigation.
VFD Application Design and Engineering
After two decades on industrial service, VFDs have evolved to high levels of reliability
and functionality. Early VFD pitfalls have been eliminated in modern VFD designs.
On the motor side, early pitfalls encountered with VFD applications were related to
harmonics and voltage spikes, which induced heating and led to motor damage.
On the power side, early pitfalls with VFDs were line interference, power system
harmonics and poor power factor at low speeds.
VFD Trends
Advancements in power electronics and usability are moving drives toward the
status of a commodity item. In the past, all drives were considered engineered
items which suppliers (such as ABB) would configure based on detailed application
specifications that the customer would put out to tender. Engineered drives with
custom capabilities may still be required for applications with special loading
profiles, special environmental conditions, or where plant power supply issues
such as harmonics and phase unbalance pose a particular challenge. Most drives
have features that handle these issues out of the box for approximately 85% of all
applications (ABB Drives, 2006). All drives are available as separate devices, but
often component drives are embedded in small-scale OEM equipment solutions
requiring speed control.
Although VFDs are becoming more of a commodity item, careful engineering
following the guidelines below will help to address most of the problem areas and to
achieve the expected efficiency improvements.
VFD Selection and Sizing
The following sections provide an overview of the steps involved in dimensioning a
drive system. This overview focuses on energy efficiency aspects; for more complete
guidelines see the full ABB Technical Guide No.7 for Dimensioning a Drive (ABB
Drives 2002) upon which this section is based, or the NEMA Application Guide for
AC Adjustable Speed Drive Systems 2001, IEEE Paper No. PCIC-2001-7.
Select Drive Size & Rating
Standard drives can be selected from the catalog and with some vendor assistance,
based on inputs from the process, mechanical and electrical application engineers.
The requirements for each of the four main elements in the drivetrain system are
shown in the figure below.

Module 2 | 157

Figure 2.43 Drive dimensioning procedure, (ABB Drives 2002)

The typical dimensioning steps for a drive and motor system are listed below.
These steps apply mainly for variable torque applications, such as a pump or fan
application. Details and example calculations for each step are given in the ABB
Technical Guide for Dimensioning of a Drive System, 2002.
Step 1: Check initial requirements and conditions of network and the load

1.1 Required
1.2 Required
1.3 Required
1.4 Required
speed

voltage level (LV or MV)

quadrant control (reversing, regeneration)
power system capability (voltage/frequency/harmonics tolerance)
maximum application load (for example, fan or pump) power and

Step 2: Choose the (or evaluate an existing) motor

158 | ABB Energy Efficiency Handbook

Figure 2.44 Motor loadability curves comparing 1) 2-pole and 2) 4-pole motors

2.1 Determine the required maximum load torque at full speed - narrow
selection of motors
2.2 Check motor loadability. using torque profile curve, at the nominal speed
and then over the required speed (rpm) operating range
2.3 Check for high application load torque starting conditions
2.4 Determine motor nominal torque and power, based on number of motor
poles
2.5 Select a new (or approve an existing) motor; add a margin (from 10 to 30%,
depending on loading information certainty) so that power is available at
maximum speed.
Step 3: Choose a VFD and associated equipment
3.1 Determine type of load (cube law, constant power, constant torque,
quadrant operation)
3.2 Determine total motor continuous current (Amps) at full speed
3.3 Specify any special operating conditions and required IP (enclosure) class
Module 2 | 159

 3.4 Select a drive based on current estimation and vendor tables

3.5 Specify drive cooling requirement based on drive selection, ambient
conditions
3.6 Specify input transformer power rating
3.7 Specify length and type of cabling between drive and motor
In Step 1, the application load (for example, the pump or fan) power rating at
maximum speed can be used to determine the necessary application torque
requirement using the power torque formulas. The power supply network must
be capable of providing nominal voltage (step 1.1). If the supply voltage is lower
than nominal, the field weakening point shifts to a lower frequency and the available
maximum torque of the motor is also reduced in the field weakening range (ABB
Drives 2002).
In Step 2, the motor nominal values for power and torque are determined, based
on the application requirement (from step 2.1) and the motor model loadability data.
Then a motor selection can be made, or an existing motor is approved for a drive
retrofit.
In Step 3, the motor total current is determined based on the nominal motor values
in Step 2 and load torque in Step 1, and then a drive selection is made. A drive
should be dimensioned according to the continuous full load current requirement,
and not the horsepower requirement. The mechanical or process unit needs are
usually supplied in terms of a motor load torque characteristic, from which motor
current is derived according to the motor current approximation formulas. These
values are then compared to the converters limits to select the correct size and
model. The motors nominal current may also be used as a first approximation for
converter dimensioning. Note that when a high-efficiency motor is specified in Step
2, then a smaller drive might suffice due to the lower current requirements.
A common temptation in VFD sizing is to add a design margin to the VFD size. This
is not usually necessary because in common practice the motor has already received
a very high margin. The VFD is merely a conduit for motor power and therefore
adding a margin only for process flexibility serves no purpose. An exception to this
rule is if there is possibility for the motor to exceed its full load amp rating (beyond
service factor margin). This situation may arise due to unforeseen changes in
process flow densities, for example. In such cases, a higher drive rating is necessary
to avoid drive trips. Another exception is if the drive is to be located in warm ambient
conditions, as may be the case in small industrial boiler applications (Plantsystems.
com, 11/2008).

160 | ABB Energy Efficiency Handbook

In practice, the manual selection & sizing process outlined above is complemented
by engineering software tools as discussed in the section on VFD Sizing and
Selection Tools. Vendors normally have certain selection tables where typical motor
powers for each converter size are given; these tables are also incorporated into the
software tools.
For example: a pump has a 300 hp (224 kW) load at a speed of 2000 rpm; there is
no special starting torque requirement.
Step 1: First find the necessary load torque:
T = 300 x 5252 / 2000 = 788 lb.ft (SI: T = 9550 x 224/2000 = 1070 Nm)
Step 2: Check the loadability for a few candidate motors:
For a 2-pole motor at 2000 rpm, loadability is 95%, which means that the nominal
torque must be at least:
T n = 788 / 0.95 = 830 lb.ft (1125 Nm)
For which the nominal power must be at least:
P n = 830 * 2000 / 5252 = 316 hp, so a 350 hp motor ( 1975 rpm , 460V, 500 A, PF
0.87) is chosen.
The nominal torque of that motor is:
T n = 350 x 5252 / 1975 = 913 lb.ft (262 Nm)
The motor current at 2000 rpm (in the constant flux range) is approximately:
I M = Pload x In / Pn = Tload x In / Tn = 788 x 500 / 830 = 474 A
The continuous current used to select a VFD is then 474 A.
For a 4-pole motor, loadability at 2000 rpm is 75%
The same series of calculations reveal that the motor current is less than that for
the 2-pole motor at the operating speed, so the 4-pole motor is chosen as the most
energy efficient.

Module 2 | 161

Voltage Level: Low-Voltage (LV) vs. Medium Voltage (MV)

The selection process begins with selection of the voltage level. Low voltage AC
drives may be technically possible for certain power levels and their generally lower
price may seem attractive. However, LV drives draw higher current for a given motor
power than for MV drives. For long cable lengths between motor and inverter, the
larger required cable diameter and cost will favor an MV drive option. Power system
control and protection devices like contactors may be a limiting factor in highpower LV designs.
Converter voltage output ranges up to 4kV, which is sufficient for most standard
LV and MV motors. For HV motors, however, a specially designed step-up output
transformer is required. A standard transformer cannot be used due to variation in
frequency, the harmonic distortion and the DC component existing during transients
in the output voltage of the frequency converter.
The selection of VFD voltage level is closely related to the selection of bus voltage
levels as described in the section on Power System Design and Engineering. For a
retrofit, the availability of MV or LV busses is a decisive factor.
Quadrant Control, Converter Basic Type
The converter technology largely determines the drive losses, and hence the
requirement for cooling, the drives physical size, and reliability. The converter
selection also determines many aspects of the drive-plus-motors torque-speed
performance. Application requirements should be carefully considered in this step of
the selection process. Special requirements for 4-quadrant control will also strongly
affect the drive technology selection; see the VFD Types and Applications section
for the common application areas for various drive technologies.
Motor Capability Harmonics
Although it is usually no longer necessary to derate a motor for use with a modern
VFD, it is still good practice to check with the drive or motor suppliers as to whether
a specific motor can tolerate the drives harmonic levels. Older and/or rewound
motors may have reduced tolerance for the effects of harmonics.
A class of motors called inverter duty (NEMA MG1 Part 31) offers a higher
performance standard to ensure compatibility with VFDs. Modern VFDs ,however,
are designed to work within the tolerances of the general purpose class of motors;
this was not generally the case for older 6-step drive inverters.
Motor Capability Retrofit Situations
Modern VFD drives can be applied to many existing induction & synchronous motors
as part of a retrofit without de-rating 5-10% as was done previously. In addition to
162 | ABB Energy Efficiency Handbook

improved controllability, a VFD allows a previously oversized motor to be run at lower

speeds, consuming much less power while preserving power factor and efficiency.
However, in retrofit situations there are several additional unknowns that should be
investigated as they may lower tolerance to some of the effects discussed in the
Issues sections below:
Condition of the insulation of the existing motor.
Impedance of the motor cabling and motor, which in some cases may amplify
voltage reflections. This may be a concern in retrofit situations with very long
cable runs between motor and converter. See the Cabling and Conduit issues in
the following section for more details..
For fan applications: look for possible regions of instability at low speed/flow
conditions, especially with axial fans. Careful review of the performance curves
should precede the selection of a VFD (US DoE Sourcebook, 2006). In retrofit
situations, the VFD can be programmed to avoid these speeds.
In addition to harmonics-induced heating, there are other important issues regarding
VFD compatibility with induction type motors. The following section is based on
information from ABB and (US DoE, 2008):
Voltage stress:Motor insulation systems may deteriorate more rapidly due to the
rapid step changes in voltage output of a drive. Filters on the inverter output can
eliminate this problem by providing a purer sine wave output.
Common mode voltages are induced by the electromagnetic disturbance
from a drives modulation technique. These cause current flow in the shafts of
larger motors and may harm motor bearings. Industry sources and the US DoE
recommend the following corrective measures:
Insulated non-drive-end bearings are recommended on all motors rated over
100 kilowatt (kW)
Common mode filters may additionally be required for higher powers and voltages.
These eliminate common mode voltages and voltage reflection effects as well.
The choice of drive technology also affects the strength of common mode
voltages. For example, a 3-level VSI with an output filter arrangement can avoid
common mode voltages by grounding the star point of the output filter (ABB
Switzerland, MV Drives, 2002).
Motor Capability Cabling and Conduit Issues
A drives modulation technique creates electromagnetic disturbances, requiring
adequate electrical screening such as screened output cables (US DoE, 2008).
These EM disturbances can cause transmission line (also known as voltage
reflection or standing waves) effects in long cable runs and cause raised voltages
at the motor terminals, as shown in the figure below. Voltage reflections can also
Module 2 | 163

damage motor insulation, and are a particular concern in MV retrofit situations (ABB
Switzerland, MV Drives, 2002). Some preventive design tips for inverter-fed motors
are 1) use input and output reactive filters and 2) ensure that the grounding system
is well designed. According to one source, (Competitek 1996), PWM drives cannot
tolerate long cable lengths (longer than 500 m due to standing wave effects. It is
important to consult with drive vendors and their expertise before specifying VFDs
with long cabling to motors.

Radiated EMI

Output Filter

3-Phases, Earth

VSD

Conducted EMI

Input Filter

Radiated EMI

Conducted EMI

MOTOR

Variable cable length

Figure 2.44 EMI disturbance from VFD (shown as VSD above) cabling, (DeAlmeida, 2006)

Circulating currents can also be induced in the walls of metal conduits, even when
it contains balanced phases. A preventive design tip is to use non-metallic conduit
material, such as PVC (Competitek 1996).
Motor Capability - Resonance Issues
The following issues may arise due to complex, dynamic interactions between the
VFD drive-electric motor and pump (or fan) system. These unwanted dynamics
are usually eliminated for maintenance or reliability reasons, but they also degrade
system energy efficiency if allowed to continue at a level judged tolerable for the
equipment. This phenomenon is also called torque pulsation in some technical
sources.
Structural Resonance. Resonance is a mechanical vibration phenomenon
that occurs when the VFD output frequency matches the one of the natural
frequencies of the entire pump, piping, and mounting system. The strong
vibrations at these particular frequencies are harmful to the motor and pump
equipment couplings, bearings and support structure.
These resonances are usually designed-out of pumps and motor combinations
operating at known constant speeds. In variable speed applications however, the
wide variation in motor frequency may uncover new resonances, especially those
resulting from fluid pressure pulsations. Pumping system authorities (US Doe,
Hydraulic Institute, Europump) recommend the following techniques to predict
and avoid resonance situations (US DoE, 2008):
Simple hydraulic resonance calculations
164 | ABB Energy Efficiency Handbook

 Passing frequency analysis

Using Finite Element Analysis to reveal structural resonance
Modal testing on the actual machines, via a vibration test
Modal testing involves using an electromagnetic shaker or impulse hammer to apply
a force that is measured by an accelerometer (Plantservices.com, 2008). In retrofit
situations, where motor hardware cannot be easily re-designed, the VFD can be
programmed to avoid troublesome resonant frequencies, once they have been
identified using the methods described above.
Starting Load Torque and Speed Issues
A VFD provides many different loading options compared to the motor acting alone.
As shown previously, a VFD can provide nearly constant torque over a wide
range of speed, as shown in Curve1 in the figure below (for a 50Hz nominal input
frequency). For applications with high but temporary starting torque requirements,
then the VFD can produce torque following Curve 3 in the figure below. Vector drives
are particularly suitable for supplying high torque at low speeds.

Figure 2.45 - Motor torque performance curves possible with VFD control, (ABB Oy. Drives, 2002)

A heavier-duty VFD may be required for applications with high starting torque
requirements, or where there are high torque pulsations (Competitek 1996). The
NEMA Application Guide for AC Drives (2001) cautions that applications with
static torques above 140% of full load torque may require an oversized drive and a
motor with higher torque capacity. Vector drives are an alternative solution to this
application requirement.
Variable torque loads such as most pumps (and some fans) have low torques at
low starting speeds. Constant torque applications typically have higher starting
torque requirements than variable torque loads. High-inertia rotating machinery,
Module 2 | 165

such as very large fan, however, may require special attention to achieve startup,
as discussed in the Fan Drivetrain section. One possible solution is to bypass the
VFD during startup, allowing the motor to develop to its full breakaway torque to get
the load moving. See NEMA-MG1 and the NEMA Application Guide for AC Drives
(Bezesky 2001) for some special precautions regarding this approach.
Constant torque applications typically have higher starting torque requirements
than variable torque loads, and stricter requirements for acceleration and torque
repeatability. Although VFDs, properly sized, can satisfy these applications, they are
also good candidates for vector control drives. A vector control drive can provide
more precise torque control and much higher low-speed torque than scalar drives.
Soft Starting Torque
A common torque vs. speed curve for a VFD-equipped motor is a gentle ramp up
to maximum continuous torque at about 30% of rated speed, then a horizontal line
meaning constant torque all the way up to 100% of rated speed. Compared to a
simple soft-starter, VFDs have the advantage of being able to adjust the ramp time for
the voltages and frequencies at the motor terminals, as shown in the following figure.

Figure 2.46 - VFD adjustable startup- speed vs. startup time, (ABB Oy. Drives, 2002)

The figure below shows how VFD driving torque adjustment can be engineered to follow
the load torque for optimal energy and acceleration time performance during startup.

166 | ABB Energy Efficiency Handbook

35

120

30

100

25

80

20

60

15

40

10

20

0
0

500

1000

Driving torque

1500

2000

Load torque

2500

3000

Acceleration time

3500

Time [s]

Torque [kNm]

Expected start-up time referred to VSD start-up torque characteristic

140

0
4000
Speed [rpm]

Figure 2.47 - Load torque, run-up torque and time as function of speed, (ABB Switzerland, MV Drives,
Ormen Lange case, 2008)

A potential energy-efficiency feature of VFDs is known as flying start. The flying

start feature is useful when a motor is connected to a flywheel or a high inertia load,
and allows a startup even when the load is rotating, and without a speed feedback.
The inverter is first started with a reduced voltage and then synchronized to the
rotating rotor. Once synchronized, the voltage and the speed are increased to the
corresponding levels (ABB Motors & Drives, 2004 S. Weingarth).

In power plants, flying start capability can prevent a unit shut-down in the case
of a temporary trip of the ID or FD fan. These large fans normally take a long time
to decelerate, necessitating a boiler shut-down and a long re-start of the unit. A
flying start allows the drive to re-accelerate the rotating fan shaft and avoid a boiler
shutdown.

Motor Loadability and Cooling

Through frequency and voltage control, VFDs can make a motor run faster than its
normal full speed rating and at maximum torque over a wider speed range. This
capability greatly extends the useful operating range of a pump or fan drive system,
for example. The limiting factor in this operation is the capability of the motor to
remove excess heat, known as motor thermal loadability.
Standard induction motors are commonly totally enclosed fan-cooled (TEFC) motors.
These motors use a shaft-mounted fan to draw ambient air over cooling fins to selfcool the motor. The added heat removal capability of motors with a separate cooling
system allows those motors to sustain higher, constant torques at lower speeds
Module 2 | 167

when equipped with a VFD. The effect of extra cooling is shown on the following
figure. The following figure shows how an actual VFD can provide near-constant
torque from zero to nominal speed, if sufficient cooling is available to maintain a
constant nominal operation temperature for the motor; values with subscript n are
nominal values. Note that torque is limited in the field weakening range of operation
regardless of cooling method.

Figure 2.48 Standard induction motor loadability 1) without and 2) with separate cooling, (ABB
Drives 2002)

With VFD speed and torque overdrive, a motor may be dimensioned according
to its normal use, not for transient peak conditions, thus reducing motor size and
investment cost. Where loading peaks are expected, however, it is important that the
load, the VFD and the motor are compatible, otherwise the motor or the converter
may overheat and increase the risk of damage.

168 | ABB Energy Efficiency Handbook

Figure 2.49 - Torque-speed curves with VSI-PWM VFD and 2 types of load, (based on deAlmeida,
2006)

This figure shows torque and power for a totally-enclosed fan-cooled (TEFC)
induction motor fed by a VSI-PWM type VFD, assuming. Two typical load curves are
shown; constant and quadratic (i.e. cube-law power load) torque. These loads can
be served by a normally-sized VFD. Loads with high starting or breakdown torque
requirements require more careful sizing and selection of the VFD.
Drive Loadability and Cooling Issues
Energy losses in the VFD cubicle are a measure of the drive efficiency. For drives
averaging 98% efficiency, therefore, the heat energy is 2% of the input power. This
heat must be removed from the VFD, usually through forced cooling. It is important
to ensure sufficient drive module cooling and to include the drive fans and cooling
system in a regular maintenance program.
Generally speaking, a frequency converters short term loadability is often more
critical than the motors. The motor thermal rise times are typically from 15 minutes
(small motors) to several hours (big motors) depending on the motor size. The
frequency converters thermal rise times (typically a few minutes) are given in the
product manuals (ABB Drives 2002).
Proper application design and regular maintenance are the key to realizing drive
suppliers claims of mean-time-between-failure (MTBF) specification somewhere
between 20 and 100 years. Advances in technology however, are likely to prompt a
facility to upgrade a drive within a shorter time frame. The life expectancy of the VFD
converter is generally directly related to the temperature of the internal components,
especially the capacitors (US DoE, 2008).
Module 2 | 169

Power System Capability

A VFD and motor running at much lower than full speed have a lowered power
factor. Drives with sufficient power factor correction capability are desirable in
applications which require long periods of low speed operation. Harmonics induced
by the VFD on the power supply network are one of the issues discussed in the
Power Systems section.
Input Transformers
VFDs in the MV range require input transformers to manage the connection to the
power system. These transformers perform several functions:
They adjust power supply voltage to the levels required by the converter; most
suppliers have drives that can be connected to 3.3 6.9 kV today, but many
plants have voltages that lie outside this range.
They protect the motor and/or network from common mode voltages.
They provide isolation in case of faults; there is no physical (metallic) contact
between primary and secondary windings.
Modern VFDs have small footprints and a flexible input transformer configuration.
This configuration allows the large input transformer (See picture below) to be placed
outside the electrical room. The choice of VFD power electronics affects the flexibility
of the layout. For example, a 3-level VSI topology reduces the number of cables
between the input transformer and the converter (ABB Switzerland, MV Drives,
2002). An input transformer that can be located outside the electrical room reduces
the size and cooling requirements for that room (ABB Switzerland, MV Drives, 2002).

170 | ABB Energy Efficiency Handbook

Figure 2.50 Photo of a large input isolation transformer, (ABB Drives, 2008)

Operating Environment
Due to the sensitivity of drive electronics, in retrofit situations the VFD hardware
cannot usually be placed in the same location as previous mechanical speed
reduction equipment (US DoE, 2008). VFDs electronics are housed in an enclosure
called a cubicle. Like most electronics, the VFD cannot normally tolerate corrosive,
very humid or very hot ambient conditions. For this and other reasons related to
cooling (see the section on Drive Cooling), the VFD cubicles are usually placed in
a separate electrical room, usually together with low-voltage switchgear & motor
control centers. Typical dimensions for a large VFD cubicle are 916 ft long, 3 ft
deep and 6 ft high. VFD drives and switchgear can be housed in modular prefabricated units for easy site installation and limited civil engineering costs.

Figure 2.51 Photo of a typical MV drive cubicle ABB Drives, 2008 (ACS-5000 Medium Voltage drive)

VFD Maintenance
Availability (the inverse of failure rate) of a modern VFD is typically in the high 99+%
range. VFDs provide online diagnostic information of the status of the drive and
Module 2 | 171

motor. This information is accessible via open process industry communication

protocols and can be used by pro-active maintenance programs to increase the
reliability and the energy efficiency of the drive system. Basic values such as VFD
inverter and motor temperatures, voltage, frequency, currents, operating hours and
even total number of motor revolutions are recorded and stored at high resolution.
Derived values such as energy, torque and horsepower are also calculated and
stored for performance improvement efforts such as plant energy efficiency
programs. The VFD itself also continually performs automatic diagnostics using
this information, for early fault detection. The average MTBF in months, in a typical
industrial application such as pump flow control, is 32 months (ABB, Weingarth,
Automation World, 2004). This compares well with the MTBF of a control valve,
which is 18 months. (ABB MV drives have an available optional DriveMonitorTM
package, for use in modern asset management programs.)
VFD Cost and Technical Calculations
In the early days of VFDs a small drive cost in the region of US$500 per kW.
Technology advances and economies of scale have brought the price down in the
region of $150 per kW, and the average hardware cost per hp decreases with the
size of the drive. Small to medium drives (100 to 500 hp) range from $200 to $150
per hp, while larger drives (500 to 10,000 hp) will range from $100 to $75 per hp.
The total investment cost of a VFD are mainly hardware, engineering and installation
costs. The total installed cost of a drive is typically more than double the hardware
cost for small to medium drives, and about 40% more for larger drives. A typical cost
of a 1,000 hp drive is $100 per hp (ABB Power Systems, 2009). The base cost of
such a large system, not including engineering, is about $100kUSD. The total cost is
therefore around $185-200kUSD.
The installed cost of a VFD is small when compared to the applications energy
savings from speed control. An analysis of VSD economics by RMI in the Competitek
Drivepower Manual showed payback periods ranging from 4 years down to 1
year for initial costs ranging from $750 to $175 per hp, in an industrial pumping
application. The handbooks Case Studies section has a fully worked-out example
of a flow-control retrofit showing payback and present value cost calculations.
Many of the VFD side benefits are not quantified in lifecycle cost (LCC) calculations.
VFDs have many built-in motor protection and power quality functions that replace
costly dedicated equipment in new plant designs; these foregone costs should be
considered in LCC analyses. Some indirect benefits also reduce the investment
cost; for example, the reduced current in VFD applications means that smaller-sized
electric power system elements (breakers and cables) may be specified.

172 | ABB Energy Efficiency Handbook

VFD Calculation Tools

There are a number of sizing and selection tools that allow application engineers to
evaluate the economics of several VFD options before calling in vendor engineers.
The common input data to these tools are: Required speed range and mechanical
load (power and torque) with overloads, duty cycle, ambient conditions, supply
network characteristics, and the required IP class (enclosure) of the motor.
The common output data of these tools are: optimal motor, frequency converter and
transformer, calculated network harmonics, and drive efficiency values.
ASDMaster, an adjustable speed drive evaluation and applications software
package, is available from the Electric Power Research Institute, www.epri.com .
ABBs free DriveSize (shown in the figure below) is a PC program to help select an
optimal motor, frequency converter and transformer. DriveSize can also be used
to compute network harmonics and to create documents about the dimensioning.
The tool has current versions of the ABB motor and frequency converter
catalogues.
ABBs free FanSave and PumpSave tools calculate saved energy and money
when using VFDs instead of other means of flow control.
DriveMags DASH software tool, whose evaluation of different speed-control
methods also includes installation costs and energy cost fluctuations.
ABBs DrivePump, which is similar to PumpSave, but achieves greater accuracy
by using actual pump curve data as input, or specific speed and internal tables
based on pump handbook data. The tool can also compute motor currents and
network harmonics and energy efficiency. This tool requires more data input than
PumpSave, but its output can be used in contractual documents.

Figure 2.52 - Screenshots of DriveSize motor sizing and selection tool, showing loadability of motor in
a pump or fan application, with quadratic torque load, (ABB Motors & Drives, 2007)

Module 2 | 173

174 | ABB Energy Efficiency Handbook

Module 3
Electric Power Systems for Auxilaries

Module Summary
This module provides general design & energy impact of the most common
components of in-plant electrical power system, also known as Electrical Balance
of Plant (EBoP). Most of the material in this section is applicable to all industrial
electrical power systems. The purpose of this section is to help identify areas of
controllable losses in medium and low-voltage (MV and LV) plant power systems and
to provide some guidelines to mitigate those losses.
The information in this module may be generally applied to all industrial facilities
industries with large internal power distribution networks; industry-specific text is
shown in alternate text, such as follows:

For power plants, the scope for this module begins at the generator busbars
connection to the auxiliary transformer(s), but also includes the power path
leading through the main step-up transformer. The relationships between electric
power system balance of plant (EBoP) items are shown in the figure below.

Figure 3.1 Electrical balance of plant equipment in a fossil-fuel power station, ABB Power
Systems, 2008

Module 3 | 175

This section examines power systems from an energy efficiency perspective and
does not provide guidance on other, critical aspects of power system engineering
such as protection & control, safety, or installation. For more complete guidance on
all other aspects of power system design, see both the standards and references
sections of this handbook.

Role of Power Systems in Energy Efficiency

The energy impact of power services is growing due to increased proportion of auxiliary
electrical loads as well as the increased variability of plant loading; see the section on
Plant Efficiency Trends.
Poor design of in-plant power factor and power quality increases electrical losses,
which reduces efficiency and also leads to increased maintenance costs another good
reason to look at power and its application.
The electrical power system has an impact on the reliability of almost all equipment in
the plant. Instability in the power system has a multiplier effect that can incur energy
penalties due to unstable production and reduced reliability in many other parts of the
plant.
Need for an Integrative Design Approach
An integrative systems approach to power systems design is needed due to the
interrelated nature of auxiliary loads and the power system; drive power to pumps and
fans, energy efficiency, soft-starters, PF correctors, VFDs, harmonic mitigation and
phase unbalance are all interrelated technologies and issues.
An electrical upgrade to improve energy efficiency, such as increased use of VFDs,
premium efficiency and downsized motors, new transformers etc. should prompt a
re-evaluation of the plant power system to ensure that overall efficiency and reliability is
not compromised.
An integrative approach requires the engineer to learn as much as possible about the
plants loading or load mode, to work closely with the mechanical and process teams
towards a prediction, up to 10 years, of how that process load will vary.

176 | ABB Energy Efficiency Handbook

Power System Overview

The purpose of the in-plant power services is to supply electrical power to plant auxiliary
process loads, instruments and control systems. The criteria for delivery of this power are:
Power quality: allow only tolerable small amounts of harmonics, spikes, sags and
swells or phase voltage unbalance.
Power factor: control the power factor at all levels of the plant to reduce the
losses associated with carrying reactive power.
Power level and capacity: supply power to required capacity, at the voltage
levels needed, through efficient, right-sized transformers.
Power protection & control: allow full automatic or manual control of power
distribution to serve the needs of the loads, while protecting those loads and the
power system itself from harm.
Power distribution & layout: carry power from the source to its destination at the
load with minimal losses.
Power reliability: supply all the above with high reliability
All of the above design criteria have a direct impact on plant energy efficiency, which is
the focus of this module.

In a power plant, most of the auxiliary power demand, up to 80% of total auxiliary
load, is used by large MV electric motors that are typically connected to the medium
voltage switchgears/switchyards supplied through unit auxiliary transformers.
Between 6 to 15% of gross electrical output can go to auxiliary power, depending
on the type of prime mover for large pumps and fans, the type of fossil fuel, and
the required environmental control systems.

Power System Concepts

Electrical Power
There are three basic forms of electrical power:
Active power is the real power consumed by the electrical load, in which the electric
energy is transformed into other types like heat, light, mechanical, or chemical. Active
power is the power that can do useful work

Module 3 | 177

Reactive power is the power required to bring electrical components to the status of
operation when magnetization or induction is involved, as with generators, transformers,
and motors. Though necessary for operation, reactive power does no useful work and
simply circulates within the network.
Apparent power is the angular sum of Active and Reactive powers derived from the
following formula:
S= (P2 + Q2)1/2
Where:
S = Apparent power (volt-amps)
P = Active power (watts)
Q = Reactive power (volt-amps reactive)
Power factor is the angular relationship between the Apparent power and the Active
power; this phase angle is represented by the Greek letter , and the power factor is
defined as the ratio P/S or cos()
The following formulas describe power in 3-phase systems:
Apparent power
S=UxI
Active power
P = U x I x cos()
Reactive power
Q = U x I x sin()
Power factor (PF)
cos() = P/S

Apparent Power S
Measured in VA

Reactive Power Q
Measured in VAR

Phase angle

Active Power P
Measured in Watts
Figure 3.2 The power triangle diagram

178 | ABB Energy Efficiency Handbook

For a symmetrical 3-phase system, these same formulas can also be expressed as
follows:
= 31/2 x U x I1
S = 3 x U1 x I1
P = 3 x U1 x I1 x cos()
= 31/2 x U x I1 cos()
= 31/2 x U x I1 sin()
Q = 3 x U1 x I1 x sin()
Where:
U = rms value of the phase to phase voltage
U1 = rms value of the phase to neutral voltage
I1 = rms value of the phase current
The unit for all forms of power is the watt (W). The unit watt is also called volt-ampere
(VA) when stating electric apparent power and volt-ampere-reactive or simply Var (VAR)
when stating reactive power.
Harmonic Power, not shown in the power triangle figure, is power which is dissipated at
higher harmonic frequencies.
A harmonic is a sinusoidal component of a periodic wave having a frequency that is an
integral multiple of the fundamental frequency (i.e. 50 or 60 Hz). Harmonic Distortion
factor (DF) is defined as the ratio of the root-mean-square (RMS) of the harmonic
content to the RMS value of the fundamental wave, expressed as a percent of the
fundamental.
The distortion factor (DF) is applicable to the definition of the total harmonic distortion
(THD) for voltage harmonics and the total demand distortion (TDD) for current
harmonics.

DF =

sum of squares of amplitudes of all harmonics

* 100%

square of amplitude of fundamental

The distortion factor (DF) is applicable to the definition of the total harmonic distortion
(THD) for voltage harmonics and the total demand distortion (TDD) for current
harmonics.
Electrical Power Losses
There are two basic kinds of losses in electric power systems:
Variable losses, also referred to as copper losses, occur mainly in lines
and cables, but also in the copper parts of all electrical devices, especially
transformers and vary in proportion to the amount of current that is transmitted
through the equipment.
Module 3 | 179

 Fixed losses, also referred to as iron or core losses, occur mainly in the
generators/motors/transformer cores and do not vary according to current load,
beyond the threshold required for energizing. (Leonardo Energy, 2008).
If harmonics are present, then iron losses in transformers will vary with the current, as
discussed in the Transformer losses section, Effect of Harmonics.
It has to be noted that, not only do copper losses in electrical devices increase direct
power consumption, but they also produce heat. To keep the device within the
tolerable heat range, equipment shall be cooled either individually (e.g. fan or pump in
transformers) or centrally by introducing HVAC (Heating, Ventilation and Air Conditioning)
to the electrical enclosure or room. These additional cooling systems will further
decrease the overall net produced energy. Generated heat will affect the aging of the
electric components as well.

Power Factor
Lagging PF is due mainly to the reactive power demands of large inductive loads
such as induction motors. Reactive power does no useful work, but all plant power
system elements must nevertheless be sized to accommodate it. A high PF system is
considered to have values between 0.9 to 1.0, and low PF systems have values less
than 0.8 for in-plant power supply. The disadvantages of low power factor are:
Increased losses: the current that carries reactive power leads to losses in
electrical devices such as transmissions, distributions and in transformers. These
I2R losses are real power and reduce the overall efficiency of the system.
Reduced capacity: generators, transformers and other power system equipment
carrying reactive power have a consequently reduced capacity for carrying real
power.
Increased maintenance: The heat, which accompanies these losses, often leads
to reliability and maintenance issues and decreased component lifetimes.
Reduced voltage regulation: low PF worsens systems voltage regulation of a
transformer (RMI-Competitek,1996)
Most industrial customers, with the possible exception of utilities themselves, are
penalized by the electric utility for low plant PF. Industrial process plant PF typically
ranges from 0.87 to 0.95, but best practice calls for a 0.95 total PF (including
harmonics) and a fundamental PF greater than 0.97. Another design goal is to maintain
high PF over the entire normal operating range of the equipment.

180 | ABB Energy Efficiency Handbook

For coal-fired steam power plants the power factor of aggregated plant auxiliary
loads, at the auxiliary transformer, is typically around 0.80~0.85 (ABB EBoP
2008). Note that this PF is lower than the industry averages described above.
The power factor at the unit step-up transformer is a bit higher, typically at 0.85 to
0.90, but may vary considerably depending on the type of customer loads served.

Reactive Power Compensation Concepts

The first approach to PF correction is prevention, beginning with the selection of
high-PF, high efficiency motors that are correctly sized and operated. PF correction
can be implemented at the inductive source, centrally, or as a mix of these two
methods. Central PF correction at a distribution panel or switchboard has been
referred to as bank compensation because large rows or banks of capacitors
were used.
Reactive Power Compensation Terminology
Devices used to control power parameters (such as voltage and reactive power)
in transmission and distribution systems are generally known as Shunt Connected
Controllers, of which there are two basic types: Static Synchronous Generators
(SSG) and Static VAR Compensators (SVC):
A Static Synchronous Generator (SSG) is defined by IEEE as a self-commutated
switching power converter supplied from an appropriate electric energy source
and operated to produce a set of adjustable multiphase voltages, which may be
coupled to an ac power system for the purpose of exchanging independently
controllable real and reactive power. If capacitors are used instead of an
active energy source, then the SSG device is known as a Static Synchronous
Compensator (STATCOM). When a STATCOM is used for harmonic filtering
it is called Active Power Filter. High-power STATCOMs use the same PWM
technology as found in a VFD.
A Static VAR Compensator (SVC) is defined by the IEEE as a shunt connected
static VAR generator or absorber whose output is adjusted to exchange
capacitive or inductive current so as to maintain or control specific parameters of
the electrical power system. The term static refers to the lack of moving/rotating
equipment. An SVC does provide dynamic VAR compensation/control.

Module 3 | 181

Reactive Power Compensation

PF correction which is matched and installed at the inductive source (a motor,
a transformer or other inductive elements) has distinct advantages over central
compensation. Correction at the source generally avoids problems with overcompensation, and no special switchgear and sophisticated switching or control
devices are required. The PF benefits are enjoyed by all equipment upstream from
that point. Other considerations in approaching PF correction are listed below:
PF control strategy should include power parameter monitoring at strategic, large
equipment points in the network. Voltage transducers on all phases should be
specified for these points, as these will also provide warning of voltage phase
unbalance (See section on Phase Voltage Unbalance for details)
PF control should be considered together with harmonics, unbalance and other
power quality issues. Some compensation solutions that employ capacitor/
inductor combinations are susceptible to damaging resonance at certain harmonic
frequencies.
Modern active filtering technology offers solutions, which allow central
compensation for these issues from a single package. (See section on Power
Quality-Harmonics, for details on active filters)
The amount of extra reactive power needed to compensate for inductive loads and
their PF can be calculated from the reactive power balance formula:
Qk = P (tanntand)
Where: 
Qk
P
tann
tand

=
=
=
=

reactive power necessary for compensation; (kVAR)

the load active power (kW)
the non-compensated tangent value
the tangent value that should be achieved by the compensation.

Recall that is the phase angle and that PF = cos , so therefore = arcos (PF).
More detailed formulas and sample calculations for sizing of passive central
compensation circuit elements are from www.leonardo-energy.org, under the
subject of Centralized Reactive Power Compensation
Motor Soft-Starting
The power system is stressed by direct on-line (DOL) motor starts; large induction
motor DOL startups draw 5 to 8 times the normal operating current for a sustained
period and at low power factor. Soft-starters typically reduce individual startup
currents to only 1.5 to 2 times the operating current, improving PF during startup,
but without speed control capability during normal operation. The reduced inrush
current reduces the heat load on the motor, allowing more frequent starts between
182 | ABB Energy Efficiency Handbook

cool-down periods. Soft-starting also allow the engineer more flexibility in right-sizing
the components of electrical power system by reducing the peak loading.
See the section Motor Starting Conditions for more requirements on motor
starting, and their connections to the power system.
The term soft starter usually refers to a class of power electronics devices capable
of ramping up voltage to achieve a smooth motor startup. It is important to note that
VFDs can also provide soft-starting capability, along with the added benefit of
high and constant PF across the operating speed range. When operational speed
control is not required, however, soft-starters may be the more economical choice.
Static Synchronous Compensators (STATCOMs, described in the previous section)
also provide soft-start capability. Unlike most VFDs, however, compensators can be
serviced while the motor is running.
Synchronous Motors for PF Compensation
The IEEE standard Std. 666-2007 suggests that synchronous motors used on
continuous loads can be run with a leading power factor and thus compensate for
lagging power factors from other, smaller motor loads that are running throughout
the day. Because of their separate source of excitation, the load of synchronous
motors can be increased without requiring any additional reactive power (the unity
power factor motor), or the load can be increased and the motors will supply reactive
power as well (0.8 power factor or overexcited motor). This recommendation applies
only to continuous, low-speed and high-power applications. Also, the corrective
benefits are at the major bus level in the plant; so losses due to poor PF on lowerlevel busses are not avoided (Competitek, 1996).
VAR Compensators
Network users on the demand side of the step-up transformer pay for both real
and reactive power. Real power is billed by actual megawatt-hours consumed,
but reactive power is billed as a demand charge based on the maximum required
within the period. Statistically aggregated maximum demand will help determine
the individual units generator capacity and PF excitation level. When more reactive
power is demanded, then the excitation may deliver it (within the generator capability
curve), but the capacity for productive real power (MW) from the generator will
be reduced. Freeing the generator to supply more real power would increase the
capacity of the unit and the transmission lines to their maximum, thermal limits.
The amount of reactive power that the network demands from the generator is
not constant; these mega-VARS (MVAR) can vary considerably, in both leading
and lagging modes, throughout the day. Activation of a large industrial load on the
Module 3 | 183

network will change the VAR demand on the network, for example. To manage
changing network power factor needs, utilities may install sets of capacitors and
reactors which can be mechanically switched in or out of service. These devices are
known as mechanically switched capacitance (MSC) and reactance (MSR), and can
be operated in under a second.
Some dynamic network events, such as lightning strikes, short circuits, or other
faults, require a much faster and more accurate compensation response by
the utility. Static VAR Compensators (SVCs) use the same power electronics
technologies found in VFDs to switch in (or out) VAR-compensating elements as fast
as 2 times per cycle. The term static refers to the solid-state electronics lack of
moving parts in this device when compared to mechanical (MSC or MSR) or rotating
devices. SVCs are more expensive than the mechanical compensators, but they
are continuously controllable, offer much faster and more precise response, without
regard for hysteresis in the load pattern. In practice, these two VAR compensation
methods are complementary; mechanical devices can switch in large steps, and the
SVC can be used for fast and fine tuning of the compensation.

Figure 3.3 SVC switches for reactance (left) and capacitance (right), (ABB Grid Systems,2009)

VAR compensators can be placed at any point in the electrical power system;
near the generator source, in the grid, or near the large consumer loads. VAR
compensators can increase the net real power output of the generator, but they are
not without small losses. These small losses can be further minimized by specifying
more, smaller increments of capacitive and reactive elements, based on an LCC
analysis.
The following case material was provided by Brian Scott of ABB Grid Systems.
A generator with rated output of 695MVA is currently producing 625.5 MW. The
utility operator wishes to increase the real power output to 693 MW, an increase
of 67.5 or almost 11%. The PF requirements are from 0.9 leading to 0.95 lagging.
184 | ABB Energy Efficiency Handbook

The generator capability (P-AQ) curves in the figure below show the amount of
reactive power required for each of these limits, without (left) and with (right) SVC
compensation. Before starting an SVC design, it is recommended that power
flow and voltage stability studies be performed. As with other compensation
technologies, a harmonics analysis of the entire system is also necessary. And, as
with all large equipment in the power system, a detailed understanding of the load
pattern is important for engineering an optimal solution and for determining the
desired operation points that minimize losses.

Generator Capability Curve

Generator Capability Curve w/SVC

500

600

400
300
Reactive Power (Mvar)

Reactive Power (Mvar)

400

200

-200

200
100
0
-100
-200

-400

-300
-400

-600
0

100

200

300

400

500

Active Power (MW)

600

700

-500
685

690

695
700
Active Power (MW)

705

Figure 3.4 Generator capability curves before (left) and after (right) SVC Var compensation, (ABB
Grid Systems, 2009)

In a power plant unit, it is important to determine the combined capability of

the turbine-generator system. The target may be to increase MW output by
10% by providing SVC compensation, but this can only be achieved if the
turbine can indeed provide the extra power. If the turbine is not the bottleneck,
then the extra power can be achieved. This extra power is produced with
extra fuel, at the same heatrate as before, but the cost of increasing capacity
through SVC compensation is less than one-third of new coal plant capacity.
For example; an SVC system sized to provide +300/-170 MVA compensation
would cost over $US20M, not including installation or civil works. If the plant
unit happens to be baseloaded, then the extra power freed up by the SVC
can be sold at a rate higher than the rate earned by the generator capacity on
standby to provide MVARs

Module 3 | 185

In one case where PF was increased from 0.8 to 0.95, the efficiency of the
GSU transformer increased by 0.06% due to PF improvement alone. For stable
operation and other practical reasons, the PF at the generator cannot be
increased much past 0.95.

Active Rectifier Units on Motor Drives

VFDs with an active front end (active rectifier unit - ARUs) can play an important role
in improving industrial plant active power generation capability and leading phase
operation improvement. A VFD with active front end design gives the possibility to
supply reactive power (lead or lag) to the auxiliary power system to compensate
the reactive power needs of the remaining constant-speed motors and the reactive
power losses of auxiliary transformers.

L
Cos

M
Induction
Motor

MV BUS

ARU

DC-Link

INU

Figure 3.5 Schematic of VFD with active rectifier unit circuit, (ABB USCRC, 2008)

The reactive power compensation from ARUs is free-of-charge as long as the

converter operational point is within its P-Q circle diagram.

Figure 3.6 P-Q diagram showing ARU capability, (ABB USCRC, 2008)
186 | ABB Energy Efficiency Handbook

The benefits of ARU compensation functions are twofold 1) Full balancing the
reactive power demand of all auxiliary loads and thus gives the possibility for
the generator to produce more active power, 2~3% of rated capacity while still
maintaining the required external reactive power capability 2) Reactive power
compensation from ARUs can improve the plant leading phase operation capability
and also plant auxiliary system operation performance under various disturbances
such as suppressing transient over-voltage or under-voltage caused by generator
load rejection.

Power Quality Harmonics

Harmonics Concepts
Harmonics are voltages and currents at frequencies higher or lower than the nominal
frequency (60Hz in the US, 50Hz in Europe). These frequencies are usually integer
multiples of the nominal (fundamental) frequency and are caused by devices that
draw current in a non-linear fashion from the power source.
Typical nonlinear loads include rectifiers, Variable Frequency Drives (VFDs), and
any other loads based on solid-state conversion. VFDs are a potential source of
harmonics due to their fast current switching action at frequencies higher than the
fundamental. Transformers and reactors may also become nonlinear elements in a
power system during overvoltage/saturation conditions. Chargers for batteries (in the
UPS system), for example, may also be a source of harmonics if these do not use
the recent switch mode/chopper technology. Harmonics may also be received from
other plants nearby, such as an aluminum smelter.
Power at harmonic frequencies does no useful work and causes equipment heating,
interference and other undesirable effects. Electronics, including those onboard
some VFDs, are particularly sensitive to high levels of harmonics. The presence of
harmonics also decreases Power Factor, which is why engineers refer to true PF in
systems with harmonic distortion.

Figure 3.7- Harmonics-induced damage, (ABB Kurt Schipman ,Active Filter Savings, 2008)

Module 3 | 187

Harmonic pollution may also cause kWh meters to give faulty readings; these
devices are important for monitoring energy consumption.
Harmonics are said to distort the pure 60Hz sinusoidal waveform that carries useful
power from the source. The summary effect of these waveforms yields the Total
Harmonic Distortion (THD) measure.

Figure 3.8 Graph of high harmonic content 50 Hz waveform, (ABB Kurt Schipman)

Figure 3.9 Graph of harmonic current magnitudes of the above waveform, (ABB Kurt Schipman)

Although limits vary in different areas, the IEEE 519-1992 (USA), G5/4 (UK) standards
limit THDV 5% and limit for each harmonic component. The worldwide standard IEC
61000-2-4 also limits THD. This limit is acceptable even for very sensitive loads. These
standards also provide detailed harmonics mitigation design guidelines.
VFD-Induced Harmonics Concepts
Under ideal operating conditions, the current harmonics generated by a p-pulse linecommutated converter can be characterized by Ih=I1 / h and h=pn 1 (characteristic
harmonics) where n = 1, 2, ... and p is an integral multiple of six. In cases of nonideal conditions (e.g. unbalanced converter input voltage, unequal commutation
reactance,..), other harmonics can emerge: even, triple, odd non-characteristic and
non-integral (inter-harmonics) harmonics belong to this group.

188 | ABB Energy Efficiency Handbook

Harmonics Mitigation
It is considered best practice to reduce harmonics in the system at their point of
origin. Installing filters near the harmonic sources, such as with VFDs, can effectively
reduce harmonics. By using an individual passive filter for each VFD instead of a
large centralized filter, one can also avoid the potential problem of over-correction at
low loads. Also, the VFD with filter and motor with may then be moved elsewhere in
the plant, to different buses without any re-engineering of a central system. The next
best placement of filters is at the nearest switchboard or feeder switchgear.
Harmonics Mitigation Using Passive filters
The following section is adapted from material by ABB Kurt Schipman Active Filter
Savings, 2008, and Dr. Amory Lovins in Competitek,1997.
For large, easily identifiable sources of harmonics, conventional passive filters
designed to meet the demands of the actual application are the most cost efficient
means of eliminating harmonics. These filters consist of capacitor banks with
suitable tuning reactors and damping resistors. In addition to harmonics mitigation,
these filters also perform PF correction because they act as a capacitor at the
fundamental power frequency.
Some disadvantages of passive filters are listed below:
Offer a low impedance path to harmonics
Tuned below the first harmonic that exists in order to minimize resonance risk
Filtering efficiency depends on network parameters, hence filtering performance
cannot be guaranteed
Danger for overloading due to load increase or background distortion, difficult to
extend
Multiple branches required for filtering more than one harmonic
Multiple branches required for filtering multi-pulse arrangements
Large space requirement and weight
Always provide capacitive power: but AC drives do not require capacitive power
Generators may not cope well with leading power factor
Sizing rules not yet adapted to modern load types
In LV applications, passive filters are used less and less

Module 3 | 189

Figure 3.10 Passive filter performance vs. frequency, (ABB, Schipman Active Filter Savings, 2008)

Harmonics Mitigation With Active Filters

For small and medium size loads, active filters, based on power electronic converters
with high switching frequency, may be a more attractive solution. The basic concept
is to put a switching inverter in parallel with the load that is injecting compensation
currents at the harmonic frequencies. This approach is also known as a form of
Static Synchronous Compensation (STATCOM).
idistortion
Supply

Load
icompensation
Coupling
system
Active Filter

Figure 3.11 Active filter with load schematic, (ABB, Schipman, 2008)

The advantages of parallel active filter topology are:

Dimensioned for the compensation current only
Cannot be overloaded irrespective of the harmonic load increase over time
Does not directly affect the supply to the load
All commercial active filters on the LV market use parallel topology
Modern active filter technology is able to produce reactive power as well as mitigate,
and in some cases, eliminate problems created by power system harmonics. See
section on Power Factor and reactive power compensation for more details.
Active filters can perform the following Power Quality tasks:
Harmonic filtration up to high order
Reactive power compensation
190 | ABB Energy Efficiency Handbook

 Load imbalance compensation

Self-limiting
Built-in network monitoring
Active filters work by measuring the physical voltage and current signal, analyzing
them in real time in a high speed using digital signal processing (DSP), then creating
the balancing power inverter control signals. These components are shown on the
active filter schematic on the figure below.
The filter is programmable such that various degrees of filtering vs. reactive power
compensation can be achieved. The filters control function may be either open loop
or closed loop, but the trend is toward closed loop for these reasons (especially valid
at higher frequencies):
Directly measure and control harmonic current flowing to network
Correction for system inaccuracies
Can verify harmonics according to regulation directly
Can be used for power factor targeting
Simple CT connection using standard CTs
Easy for future harmonic load extensions
Appropriate for local & global compensation
Another trend in filter design is to have dedicated controllers for each harmonic
order. This architecture, known as frequency domain, allows more precise targeting
for each harmonic.

Figure 3.12 Active filter schematic, (ABB, Schipman, 2008)

The highest amplitude harmonics are usually the 5th and 7th harmonics; these can
be removed by using a 12-pulse uncontrolled diode bridge rectifier. A 24-pulse unit
can be used for weaker networks or where more stringent THD requirements apply.
VFD-Induced Harmonics Mitigation
There are several approaches to mitigating harmonics induced by VFDs in the power
supply system. The main methods are:
Module 3 | 191

 Increasing the resolution of the drive inverter by selecting those with a higher
pulse count .
Adding properly tuned filters on the supply line to the VFD.
Newer technology active front-ends for the drive typically reduce harmonics
induced on the supply side.
A comparison of the harmonic content between 6 and 12 pulse rectifiers is shown in
the figure below:

Figure 3.13 Harmonic distortion for 6 and 12 pulse rectifiers, (ABB Industrie AG, 2006)

Higher power applications (large MV drives) typically will use harmonics-free or highpulse (18 pulse or higher) inverters to better distribute the load internally. An ideal
18-pulse drive will eliminate the 5/7/11/13th harmonics, but not the 17/19th (harmonics
created are pulse number +-1). A harmonics analysis will reveal if these harmonics are
problematic. For very large drive systems, 15MW or larger, a common solution might
be a 12 (or 24)-pulse diode supply and passive filters on the line side or alternative a
36-pulse drive without a filter. A third approach is to specify a drive with active front end
(Active Rectifier Unit: ARU) to control harmonics on the supply-side.

192 | ABB Energy Efficiency Handbook

Case Example
Harmonics in a Pumping Cluster
The figure below shows line voltages & line currents at pumping cluster; the values
for harmonic distortion were THDV = 12%, THDI=27%
750
500

Volts

250
0
-250
-500
-750
3000
2000

Amps

1000
0
-1000
-2000
-3000
10:25:43.72

10:25:43.73
CHA Volts

10:25:43.74
CHB Volts

10:25:43.75
CHC Volts

10:25:43.76
CHA Amps

CHB Amps

10:25:43.77

10:25:43.78

CHC Amps

Waveform event at 22/11/01 10:25:43.533

Figure 3.14 Line voltages and currents before filtering, (Schipman, 2008)

The following figure shows line voltage and currents with active filter, which improved
the values for harmonic distortion to THDV = 2%, THDI=3%:
750
500

Volts

250
0
-250
-500
-750
3000
2000

Amps

1000
0
-1000
-2000
-3000
10:41:55.72

10:41:55.73
CHA Volts

10:41:55.74
CHB Volts

10:41:55.75
CHC Volts

10:41:55.76
CHA Amps

CHB Amps

10:41:55.77

10:41:55.78

CHC Amps

Waveform event at 22/11/01 10:41:55.533

Figure 3.15 Line voltages and currents after filtering, (Schipman, 2008)

Module 3 | 193

Power Quality - Voltage and Frequency Variation

Transient Effects
Most transient voltage and frequency effects do not have an immediate energy
efficiency impact, but may result from some of the PF improvement and harmonics
mitigation designs recommended in this handbook. These effects last less than 20
cycles, and may be much shorter in duration.
The list of transient effects includes: voltage sags and swells, under or overfrequency, voltage spikes, and ringing transients: high-frequency damping sinusoids
that temporarily boost voltage. The mechanical switching from PF-correcting
capacitor banks can cause ringing voltage transients that can trip electronic
equipment, even behind isolation transformers. (Competitek, 1996) VFDs themselves
may not be immune to such transients as well.
A Voltage Sag or Voltage Dip is a decrease in supply voltage of 10% to 90% that
lasts in duration from half a cycle to one minute. A Voltage Swell is an increase in
supply voltage of 10% to 80% for the same duration. Voltage sags are one of the
most commonly occurring power quality problems. They are usually generated inside
a facility but may also be a result of a momentary voltage drop in the distribution
supply. Sags can be created by sudden but brief changes in load such as
transformer and motor inrush and short circuit-type faults. A voltage sag may also be
created by a step change in load followed by a slow response of a voltage regulator.
A voltage swell may occur by the reverse of the above events.
An Interruption occurs whenever a supplys voltage drops below 10% of the rated
voltage for a period of time no longer than one minute. It differs from a voltage sag
in that the sag is not a severe power quality problem. The term sag covers voltage
drops down to 10% of nominal voltage whereas an interruption occurs at lower than
10%. A Sustained Interruption occurs when this voltage decrease remains for more
than one minute
Sustained Voltage Variations
Sustained, off-design high voltage (110%) increases the magnetizing current in an
electric motor. This extra current results in copper and stator core losses, and a
decrease in efficiency. At off-design high voltage the power factor is reduced at high
loads (IEEE, 2007).
Sustained low voltage operation (90%) leads to higher load currents and therefore
increased copper losses, and hence a reduction in efficiency of 2% to 3% at
all loads; at near full load the efficiency is relatively constant. Efficiency actually
increases when voltage drops below a threshold level for motors at partial load.
194 | ABB Energy Efficiency Handbook

VFDs and other power electronics with built-in power factor controllers will therefore
act to reduce the applied voltage under these conditions to minimize losses in the
motor.
In contrast to voltage variations, small frequency variations have little effect on motor
energy efficiencies.

Power Quality - Phase Voltage Unbalance

Sources for this section are: ABB Power Systems, Canada and (Competitek, 1996)
Phase voltage unbalance can cause excessive rotor currents and damaging
reversing torques in the motor. The combined effects of phase unbalance lead to
increased motor temperature, reduced net output torque, pulsations in speed &
torque, increased mechanical stress on motor components and reduced motor
efficiency.
Voltage Unbalance Causes and Effects
NEMA defines voltage unbalance as % of maximum deviation of the line voltage from
the average voltage.
For example, a 3-phase system with phase voltages of 466, 458, and 461:
The average voltage is
: (466+458+461)
= 461.7
The phase unbalance is therefore : (461.7-458)/461.7 = 0.8%
The main causes of sustained phase voltage imbalance are listed below:
unbalanced transformer windings
unequal impedances in distribution wiring
unbalance within the motor itself (rewound motors at higher risk)
single phase or unbalanced 3-phase loads which are unevenly distributed.
failures in VFDs or PF correction equipment
single phase-to-ground faults or disconnection failures
Although rare in industrial process plant networks, just a 3.5% imbalance can
increase total motor losses by 20 to 25 percent. In a 90%-efficient motor this is
equivalent to an increase in total power loss of 2.0 to 2.5 percentage points. The
drop in motor efficiency due to phase voltage unbalance is greater at lower motor
loadings, below 75%. At a 5% unbalance, the motor de-rating factor may be as large
as 75% of the nameplate horsepower. An unbalanced supply may have a disturbing
or even damaging effect on motors, generators, polyphase converters, and other
equipment. The foremost concern with unbalanced voltage is overheating in threephase induction motors. The percent current imbalance drawn by a motor may be
Module 3 | 195

6 to 10 times the voltage imbalance, creating an increase in losses and in turn an

increase in motor temperature.
Mitigation through Design
The US DoE recommends that unbalances greater than 1% lead to a de-rating of
the motor. Under a condition of 5% voltage unbalance, the motor de-rating factor
may be as large as 75% of the nameplate horsepower. An additional effect of voltage
unbalance is that the locked rotor and breakdown torques will be decreased, and
the motor may no longer be adequate for its intended application. The above applies
specifically to induction motors. Situations in which larger unbalanced voltages exist,
or in which synchronous motors are supplied by unbalanced voltages, should be
stated in the motor specifications (IEEE, 2007).
Downsized motors with correspondingly lower temperature ratings may be more
at risk of the overheating that follows sustained phase unbalance than a previously
highly oversized motor for the same load. The thermal margin of oversized motors
prevents motor failure but unfortunately also masks the cause of the reduced
efficiency of the affected motors.
For an existing plant, the best practice is to balance phases as closely as possible
and to ensure that power protection devices monitor continuously for phase
unbalance exceeding 1% at motor terminals. Regular thermographic and vibration
monitoring will also reveal the signature symptoms of phase unbalance. In the design
phase, the US DoE advice is to check electrical system single-line diagrams to verify
that single phase loads are evenly distributed across the phases. Designs that place
all receptacle loads on a single phase also risk phase unbalance, as this capacity
varies greatly or is seldom used.

Power System Control and Protection

The function of power system control is to selectively connect power sources with
consumers, and to provide facility operators with information on the real-time status of
the network. Power also control enables complex, automatic interlocking and energy
sequencing logic. As with DCS systems, modern power control has a distributed
architecture, with separate units for control (the brains) and actuation (the muscle).
The control units execute the logic in a microcontroller unit, then send their output
signal to contactors which perform the actual power switching. These contactors send
back status and health information to the control unit. Power control is distinct from
protection in that the contactors, relays and other switchgear in the power control
system cannot switch the very high currents during short-circuit; these situations are
handled by heavier-duty, fast acting protection devices.

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Protection systems safeguard the motors, power system equipment, and human
staff from damaging effects of short-circuits and ground faults. The equipment
typically in need of protection are: generators, busbars, lines, and transformers.
The brains of protection systems are so-called numerical relays which sense a
fault condition and then command a circuit breaker to interrupt one or all phases
of power; this is known as a trip. VFDs have many built-in protective functions to
protect the motor from abnormal power supply conditions.
Modern, microprocessor-based control and protection systems offer distinct energyefficiency advantages over older, purely electro-mechanical devices. The ability
to execute more complex control logic, in close communication with the process
controls running within the DCS, allows a higher degree of energy optimization than
possible with electromechanical switching only. Load management schemes can be
implemented which balance supply and demand across parallel plant units in a way
that that minimizes losses and enhances power quality. Power control systems
also enable complex unit-wide automatic startup and load shedding routines;
these can conserve existing capacity and avoid energy-wasting trips, and
long or wasteful re-starts. The self-supervision capabilities of modern control and
protection devices further reduces the chances for an energy-wasting trip event.

Figure 3.16 Automatic generator synchronizer device, (ABB Power Products 2006).

In power plants, the power control system can be programmed to ensure that
the GSU, the auxiliary and the distribution transformers are not energized when
not in use.
Modern power control also enables integrated allocation optimization when
there are multiple sources of power, as described in the section on Multi-Level
Real-Time Optimization.

Module 3 | 197

Much of the design reference information available under the category of substations
also applies to large industrial power supply systems.
Generator Control
In power generation, an automatic synchronization device is recommended for
parallel switching of generators with the power grid. The synchronizer brings the
rotation speed (frequency) and voltage of the generator to within the required
tolerance range, using higher and lower commands to the turbine-generator
controller and the voltage controller (ABB Power Products 2006). Voltage, phase
angle and frequency are all dynamic quantities; the synchronizer ensures that the
breaker contacts touch at the instant when the phases are matching.

In power plants, the auxiliary power supply system typically has a high-speed
transfer system to ensure a secure supply of power to boiler drivepower; i.e.
the BFW pump, circulating pump, and draft fans. In case of an interruption
in power, this switchover function provides power from an alternate, standby
network. This control function allows the unit to continue operating and avoid
the energy waste (and large opportunity cost) associated with a boiler trip.

Transformer Control
This section is adapted from the ABB Switchgear Manual, (ABB Power Products 2006):
Power control devices were once commonly used to operate the taps which change
the transformation ratio of a power transformer. This function serves to adapt the
voltage in case of load fluctuations, to distribute the load, to adjust active and
reactive currents in interconnected systems. Although most modern transformers are
equipped with automatic voltage regulation, transformers in parallel operation still
require tap change functionality to minimize the reactive current circulating between
transformers. Electric furnaces, rectifiers and other devices also rely on tap change
control for variation of their input voltage.

Efficient Power System Design and Engineering

Achieving energy efficiency improvements in power system design is challenged by
many of the non-technical barriers outlined in the section Barriers by Stakeholder.
Those barriers most relevant to the plant electrical engineering discipline are:

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 In a large power or process plant, electrical engineering (EE) is often the last
discipline to be engaged, after process, mechanical and controls. This leaves
the EE with little influence to practice efficient integrative design, since most
other aspects are now frozen. This of course, has a deleterious effect on the
energy efficiency of a plant, as virtually all of the internally consumed energy
passes through the electrical system.
The power system is also the first to be commissioned, which further restricts the
time that the EE can spend on conceptual studies described below.
The trend away from turnkey projects and toward multiple suppliers fragments the
design and communication, making integrative approaches more difficult.
The vital role of power systems to all other plant equipment is the reason why
customers often stipulate liquidated damages in contracts with their suppliers.
This threat of very large opportunity cost from downtime is a subtle deterrent
toward newer designs with potentially significantly lower lifecycle costs.
(opportunity costs are not as real as wasted energy costs, but often get the same
accounting treatment)
In a retrofit situation involving increased electrification or the introduction of VFDs, it
is good practice to re-examine the entire power system to ensure it is right-sized and
still capable of delivering high quality power at high reliability. For example, with a
change in loading previous schemes for Power Factor (PF) compensation may need
to be re-evaluated to avoid increased in-plant losses due to low PF or even for overcorrection in some cases.

Generating Station Power Systems

The most common design of in-plant power systems is termed unit
connected, in which each generating unit has a self-contained network
supplied by that units generator. The plant power system typically has its own
step up and auxiliary transformers, plus one or more startup transformers.
Large loads are served directly from the MV switchgear, and the largest motors
are usually on a separate bus, where the voltage (during motor starts) may be
permitted to drop to a much lower level, say 80% (Black & Veatch 1996, p574)
In a typical generating station the nominal voltage ratings of the auxiliary
buses are usually 2.4 kV, 4.16 kV, 6.9 kV, or 13.8 kV. All these voltage levels
are referred to as medium voltage or MV. Stations in the 10-100MW range
may have 2,400V. Most stations in the 75-500MW range use 4,160V as the
base auxiliary system voltage. For stations from 500MW to 1,000MW, it is not
uncommon to have auxiliary bus voltages of 6,900V. Occasionally, some single
dedicated loads such as BFPs in 10,000-15,000 hp (7.5 MW-11 MW) class are
supplied by a separate 13,800-V bus (Black & Veatch 1996). Bus design best
Module 3 | 199

practice is to separate redundant loads (such as pairs of ID and FD fans), on

different buses. This leads to the common double bus design illustrated in the
single-line diagram figure below. Another best practice is to distribute the loads
equally among buses.

Figure 3.17 Simplified single-line diagram for unit connected power system IEEE Std.666-2007,
Design Guide for Power Stations

Figure 3.18 Single-line diagram showing for a unit connected power system, (ABB EBoP/CRC)

200 | ABB Energy Efficiency Handbook

Power System Studies

Conceptual studies usually present the greatest opportunities to evaluate the impact
of basic efficiency improving design changes, and to seek even greater energy
efficiency improvements through rigorous analysis. The power quality conceptual
studies most relevant to energy efficiency are:
Load analysis (especially of auxiliary loads)
Power flow, voltage selection and voltage drop calculations
Motor starting analysis
Harmonic analysis
Other typical power system project studies that have only an indirect impact on
energy efficiency are:
Short-circuit analysis
Switching studies
Protection studies
Reliability analysis
Load List and Analysis
Load analysis is the single most important power engineering step towards
increasing energy efficiency. The starting point for design of the power system is
to gather data about all the loads that the system will serve. This step includes
not just the nameplate data of those loads, but also their criticality, duty cycle,
seasonal variations and startup requirements. The sources of much of this data
are the mechanical and process design teams. This data is summarized in a Load
List which becomes the main document interface between the mechanical/process
and electrical disciplines or teams. Due to fragmentation of suppliers, assembling a
complete load list is not a simple task. Data from similar past projects can provide a
guide, but only a guide, when actual load list information is lacking.
Load Analysis
Analysis of the load list should begin with quantifying the maximum operating load,
given the actual loads and load factors. Using only the nameplate values will give a
grossly inflated figure and load and lead to oversizing of the supply. A growth factor
margin is recommended by the IEEE guidelines, but this may not apply in all cases.
The load analysis steps should also quantify the number and loading associated with
VFDs. An obvious energy-saving step in load analysis is to reduce auxiliary levels
to the lowest possible realistic levels. Large or unusual loads also deserve special
attention at this stage. Medium voltage loads tend to be much better understood
and documented than low voltage (LV) loads. Attention to LV loading is important,
however, as it may comprise up to 40% of the total in a typical industrial plant, with a
wide variation between industries.

Module 3 | 201

Electrostatic precipitators (ESP) of the dry type operate by electrically charging

flue gas particles for collection on grounded plates. The charging electrodes
are energized with 55 to 86 kVDC supplied by a transformer-rectifier (TR)
supplied by a 480 VAC bus feeder. An ESP is a capacitive load. The TR is also
equipped with controls to vary the voltage depending on current conditions, to
achieve maximum voltage without arcing. (Babcock & Wilcox, 2005)

Current loads (kiloamps) can then be calculated from the loads in the load list.
The electric power formulas at the start of this chapter and may be used to
calculate current load in transformers and synchronous generators. For induction
motors direct-on-line, see the the handbooks Motors section on motor power
formulas. For VFD=equipped motors, see that sections formulas for motor current
estimation.
Power Flow and System Voltages
System voltage selection has an energy efficiency impact. Choosing a higher bus
voltage where possible (for example 6,900V vs. 4,160V for auxiliary busses) will
reduce ohmic losses due to the lower current levels relative to low voltage busses.
Selecting MV rather than LV drives and motors will reduce ohmic losses in drivepower equipment. Motors and transformers rated at the higher voltage levels
generally offer higher efficiencies as well. Commercially available circuit breakers
are limited to interrupting a maximum of 3000A of short-circuit current. This current
limitation may lead designers to split up busses and supply them from multiple,
smaller transformers. Smaller transformers have lower efficiency than larger units.
Thus, higher bus voltages will allow the designer to specify fewer, larger transformers
which will increase the overall efficiency of the system, and enjoy up front cost
savings during equipment purchase.
Power flow and short-circuit analyses are required to ensure that voltages are
correctly selected during various power flow (both active & reactive) scenarios.
Startup Analysis (Motor Starting)
Motors without soft starters draw many times their full load operating current during
their startup. High torque demands during startup will also increase the load on
the power system and may lead to over-sizing of components for these transient
conditions, at the expense of lower continuous running efficiency. The electrical
and mechanical/process engineers are encouraged to work together to find creative
solutions to make motor startup easier on the power system. For example, a
bypass valve could be opened during startup to temporarily relieve pressure, if this
is allowed by the process. Startup considerations are discussed in the Fan Startup

202 | ABB Energy Efficiency Handbook

Conditions, Pump Startup Conditions and in the Motor Starting Conditions

sections.

In power plants, very large motors such as BFW pumps or FGD booster fans
may be fed from a separate, higher voltage (13,800V) bus.

Voltage drops at motor terminals during startup may be down to as low as 80% of
the normal levels for large motors with long motor leads, far from the main auxiliary
bus. (Black & Veatch 1996). Motors which are designed for reduced voltage starting
may be specified, but these motors have lower operating energy efficiency. A better
strategy is to specify auxiliary power system with a higher capacity supply, at least
during plant start-up conditions. This will improve bus voltage regulation, but will
increase the short-circuit duty of the switchgear (Black & Veatch 1996).

For power generation stations, a startup analysis should also include a reacceleration study that investigates the consequences of a system trip
followed by a quick resumption of power. In such cases several large motors
must restart and re-accelerate at the same time.
A similar study is recommended to investigate the amount and consequences
of the in-rush power peak that occurs immediately after unit synchronization.
Another opportunity for energy saving is to alter the excitation method during
turbine startup. A static frequency converter may allow the elimination of much
energy-intensive compressed air during turbine startup.

Harmonic Analysis
A formal harmonic analysis helps to predict the harmonic content, based on the ratio
between non-linear loads (like VFDs) and linear loads (like DOL motors) revealed from
the Load List. The VFD vendor can help with a first order analysis, but some rules of
thumb are provided here, adapted from (CSELive, P.Lynch, 3/1/2008). An industry
rule of thumb is that when these loads represent more than 20% of the total loading,
then specific power solutions hardware should be considered. This assumes that the
drives to be installed have at least 3% ac line reactance or dc link reactance as a
part of their standard designs.

Module 3 | 203

If the drives dont include internal reactance, or if many of them are only 6-pulse
VFDs, then the system tolerance level drops to about 10%. If these thresholds are
exceeded, then a formal harmonic analysis is recommended. If the level of excess
harmonic content is high and many drives are involved, installation of an active filter
will likely be most appropriate; if only a small number of large drives are involved,
then installing drives with active front-ends probably is the best solution. See the
section on Harmonics Mitigation for more details on passive and active filters.
Equipment Sizing and Bus Design
Correct balancing of loads across buses will improve power quality and thus energy
efficiency. In plants with multiple power sources, a correct balancing will also lead
to optimal sizing of all power system components and reduced startup power
requirements per bus.
A proper analysis will yield the optimum breaker and cable sizing; poor sizing of
components here can have consequences for both energy efficiency and protective
functions. Undersized cables have higher losses, as discussed in the section on
Cable Selection & Sizing.
Contactors for Bypassing
Soft-starters are typically bypassed by a contactor (KB) as shown in the figure
below when the motor has completed its startup. VFDs, however, are not normally
installed with such a bypass contactor for the full load condition. For large motors,
specifying a contactor to bypass the VFD, which is not 100% efficient, may be cost
effective. The feasibility of this design depends on the motors duty factor and the
duration at continuous maximum load, and several other factors; see NEMA-MG1
and the NEMA Application Guide for AC Drives (2001) for some special precautions
regarding this approach.

Fuse
Contactor KL

Soft
starter

Contactor KB

M
3-

Figure 3.19 Schematic of motor soft-starter on power system, (ABB Motors & Drives, 2007)
204 | ABB Energy Efficiency Handbook

Short Circuit Analysis

The main purpose of a short circuit analysis is to ensure that the existing and newly
installed breakers will not be over-dutied under short circuit conditions. Breakers
must be capable of carrying normal load current and should be able to interrupt
fault currents. Hence, breakers have two ratings in ANSI / IEEE; rated current and
interrupting ratings. If breakers are called upon to interrupt currents higher than their
interrupting ratings then disastrous consequences can follow. In the IEC standard,
an additional rating is also addressed, the so-called Making Capacity; if the breaker
closes while system is shorted, or the fault is not cleared yet, then the breaker shall
be capable of closing on fault without damage and subsequently retrip.

Power Transformers
There are many different types of transformers; the focus of this section is on power
transformers, whose main function is to change the voltage levels between a power source
and a power consumer, with a minimum of losses. The relevant international standard for
power transformers is IEC 60076-1 Power Transformers (VDE 0532 Part 101).

Transformer Concepts
The basic, century-old design of a 3-phase transformer consists of two sets of
copper coils wound around the same iron core. The windings form concentric
shells of copper around a central core of laminated iron alloy plates, which forms
a closed loop for the magnetic field. The primary (input) winding induces a voltage
in a secondary (output) winding through the process of electromagnetic induction,
transmitted through lines of magnetic flux in the shared core. In principle, however,
energy can be transmitted in either direction. The magnitude of the induced voltage
on the secondary side (when the terminals are open) is proportional to the ratio
of the number of turns of the windings. A transformer tap is a connection point
along a transformer winding that allows a certain number of turns to be selected.
Transformers that have a set of variable turn ratios enable a rough mechanical form
of voltage regulation of their output. The tap selection is made via a tap changer
Module 3 | 205

mechanism. Modern power control offers other means of controlling transformer

voltage, and tap-changing can then become an infrequent operation.
The power capacity (MVA rating) of a transformer depends on the size of the
windings and iron core, and also on the method for removing heat, as described in
the section on Transformer Cooling.

Generator Step Up Transformers - GSU ( also known as Unit Transformer UT)

These transformers take the voltage form the generator busbar MV level (10kV
to 21kV) up to a higher (more economic) transmission voltage (HV) level, which
may range from 110kV up to 800 kV. Limitations on the insulation design which
can be achieved on rotating machinery prohibit the generator from producing
HV without need of a step-up transformer (Fassbinder 1997).
The GSU must be matched to the generator so that the transformer can fully
utilize the generators active and reactive power capacities. The standard
C57.116-1989 IEEE Guide for Transformers Directly Connected to Generators
describes how these characteristics must be matched to the situation:

Short-circuit impedance
Secondary (high) voltage rating
Transformer MVA rating
Primary (low) voltage rating

Unit Auxiliary Transformers (UAT)

The auxiliary power system can be supplied either from the generator bus or
from the switchyard. If supplied from the generator, then one or more station
service startup transformers might also be required.
This additional startup hardware may increase the cost and complexity of the
power system, but the reliability of the system will increase. Voltage excursions
are also lower using power supply from the generator bus, and switchyard
disturbances are eliminated. (IEEE, 2007). Typically, two UATs are used for
increased reliability and reduce load and fault currents. The IEEE design guide
also suggests an alternative configuration which may provide an improved
balance between capital costs, reliability and operating costs : a three-winding
auxiliary transformer in lieu of two separate auxiliary transformers. (IEEE, 2007)

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Station/Startup Transformers (SST)

This transformer is used during unit startup and is fed from the MV switchyard.
See the IEEE Std 666-2007 for details on the function and sizing of this
transformer.
In power plants with parallel units, the parallel units may share a single SST.

Transformer Losses & Efficiency

The largest power transformers are probably the most efficient machines devised by
man (Fassbinder 1997). Modern large GSU transformers can achieve efficiencies of
up to 99.75% at full load. Despite an impressive efficiency rating, there is still a large
incentive for improvement. The throughput of these large transformers can be up
to 1000MVA, so even small, fractional percentage gains translate into MW of saved
power. Smaller transformers are less efficient (99.0% to 99.5%), but have a smaller
throughput. The incentive to seek improvements at this lower scale comes from
the fact that most power consumers (at least in distribution networks) receive their
power after it has passed through several transformers, which means that savings of
reduced loss-transformers are compounded.
Reduced-loss transformers lose energy in their 1) iron cores and 2) copper windings.
In the core, losses occur mainly through hysteresis effects and IR eddy currents
circulating within the iron core. Hysteresis refers to the lag between magnetic
flux and the magnetizing force and these losses increase with frequency. Eddy
currents are small induced currents running perpendicular to the direction of flux.
Taken together, these losses are known as no-load losses since they occur when
the transformer is energized, and are present even when the secondary terminals
are open and under no load. These losses are sometimes referred to as core,
magnetization or iron losses.
In the windings, losses occur due to ohmic resistance (I2R losses) from the main
currents flowing through the windings; these losses vary with the load on the
transformer and are therefore known as load losses or copper losses. Some
eddy current losses also occur in the windings; so the windings are kept tall and
slim to reduce this eddy current circulation. The load loss is officially defined as
the active power consumed in a short-circuit test, where rated current of rated
frequency is fed into one winding and another winding is short-circuited. This loss
is also known as impedance loss.
Loss values are often contractually guaranteed, and are determined at a certain
reference temperature in the windings. Some typical penalties for non-compliance
with the agreed losses, as revealed during technical testing at the suppliers plant,
Module 3 | 207

are $1000 or more per kW of losses (usually iron losses only). This performance
guarantee is also sometimes known as a loss evaluation agreement.
Estimating Transformer Losses
Theoretically, a transformer has its highest efficiency at the load in which iron loss
and copper losses are equal. Therefore the load at which the efficiency is highest
can be found from the following formula:
% optimum load = ( iron loss / copper loss)1/2 x 100
This is about 57% of full load, and the curve is fairly flat for realistic core and load
loss values. Because transformer designs are conservative with respect to load, the
actual highest efficiency point is usually found closer to 80% of the rated load.
Knowing the losses, the efficiency of a transformer can be calculated from the basic
formula:
% efficiency = [ (input in Watts - total losses in watts) / (input in watts) ] x 100
In practice, the total losses are hard to measure for an existing transformer, so the
no-load efficiency of a transformer is usually calculated as shown below. This noload efficiency is useful for comparing different transformer types.
% efficiency = ( V x Aout ) / ( V x Ain )
Empirical data can be used to estimate the total percentage transformer losses (Pv),
using the graph below for typical oil-immersed two-winding distribution transformers
up to 40MVA rating, and the following formula:
P v = P o + A 2P k
Where:
A
Io
Po
Pk

=
=
=
=

loading ratio, load kVA/rated kVA (S/Sr)

percentage no-load current
percentage no-load losses
percentage impedance losses

208 | ABB Energy Efficiency Handbook

Figure 3.20 Transformer load-loss estimation curve, (ABB Power Products 2006)

The graph for the load losses Pk has an upper limit for rated high voltage 123kV and
a lower limit for rated high voltage 36kV.
For a 2.5 MVA transformer for 20/0.4 kV operating at half load (a= 0.5) and PF=0.8,
the percentage no-load losses, as shown in the graph above are P0 = 0.6%, and the
percentage impedance losses Pk =1.0%. The percentage total transformer losses Pv
are:
Pv = 0.6% + (0.25)(1) = 0.85%
In terms of real power, the total losses are = Pv x S x PF:
Total losses = 0.85% x 2500 kVA x 0.8 = 1,700 kW
Combining the formula for total % losses with the definition of efficiency leads to the
following formula for Transformer Efficiency (Eff %) :
Eff = 100% - 100% x ( P o + a2Pk) / (a x Sr x PF + Po)
Transformer losses are stated in MW, MVAR and MVA. The IEEE Std. C57.12.00 and
IEEE Std. C57.12.01 [B8] provide the tolerances associated with the transformer
losses (IEEE 2007).

Module 3 | 209

According to one power engineering industry guideline (Black & Veatch 1996),
step-up transformer MVAR losses can be estimated by applying the following
multipliers to the generator MVA rating.

kV (HV)

Multiplier

69

0.09

115

0.10

138

0.11

161

0.12

230

0.13

345

0.14

500

0.17

Figure 3.21 Multipliers (of MVA) to determine transformer MVAR losses, (Black & Veatch 1996)

The same source cites empirical data behind the following multiplier for transformer
MW losses, which suggest that power transformers are on average 99.7% efficient:
MW losses = Generator MVA rating x 0.003

In a power plant, as an example of using these multipliers, one can start with a
generator rated at 500MW real power and 0.9 network PF, and a high-voltage
side of 138kV.
Calculate the generator MVA rating : 500/0.9
= 556.0 MVA
Calculate the transformer MW losses : 556 x 0.003
= 1.7 MW
Calculate the transformer MVAR losses
: 556 x 0.11
= 61.2
MVAR

An underloaded transformer has a relatively larger core cross-section, thus

reducing iron losses. If the transformer is too lightly loaded, however, the equivalent
secondary resistance will cause the winding and core losses to be unequal and the
efficiency will be correspondingly lower (EC&M, 2000, M. Lamendola).
Power consumed by the transformers auxiliary forced-cooling system (fans and
pumps) shall also be considered as the third source of losses for any calculation of
Total Loss in the transformer. These losses are harder to calculate, but will increase
with the %load and temperature as the cooling system tries to remove excess heat.

210 | ABB Energy Efficiency Handbook

Total Transformer Losses = iron losses + core losses + auxiliary (cooling) losses
Skin effect losses, which increase with frequency, are a final, but minor source of
losses.
By increasing or decreasing the cross-section of the winding conductors or the core,
a wide range of designs with lower losses can be achieved; the quantity of materials
will be higher and therefore also the cost of the transformer. See the section on
Transformer Lifecycle Costing for more details on the trade-offs between capital and
operating costs.
For unit step up transformers, rated in hundreds of MVA, there are design
optimizations that introduce beneficial second-order effects, moving the
optimum efficiency point upwards into the 70-80% load range, and flatten the
efficiency curve even more. Realistically, a modern large step-up transformer
can be expected to be at or near peak efficiency over a range of 50-100% of
rated load, with that peak efficiency being at or near 99.7%.
Effect of Harmonics
The increased number of non-linear loads such as VFDs and switched power
supplies can lead to greater harmonic content. Harmonic distortion losses in a
transformer, mainly in the windings, are due to deformation of leakage fields. Losses
mean higher temperatures and deterioration of transformer insulation and efficiency
performance. The magnitude of losses associated with the fundamental and the
higher order harmonics are shown in the table below, for MV and HV lines and stepdown transformers in a distribution network.
The standard IEC 61378-1 describes a method to calculate losses when the current
contains harmonics. The standard ANSI/IEEE C57.110-1991 also provides an
estimation method, based on a certain load current spectrum of harmonics, which
is used to calculate the transformers K factor; its ability to withstand increased
losses due to harmonic currents on the low-voltage side(Phillips 2009). The K-factor
is used mainly for 480V step-down units and provides guidance on derating of the
transformer when high levels of harmonics are present.

Module 3 | 211

Figure 3.22 Transformer losses due to harmonics , Leonardo Energy,Network Losses 2008

Harmonics losses can be reduced using the same methods described in the
Harmonics Mitigation section.
Transformer Cooling
There are 5 basic power transformer classes, based on how they dissipate internal
heat from losses;
A for dry-type transformers, in which core and windings are embedded in cast
resin. These transformers are used up to 20MVA and a maximum of 36kV.
O for mineral (or other flammable) oil-immersed transformers, which have a
maximum temperature below the oil flame point 300 oC.
K for synthetic-oil immersed transformers, which have a higher maximum
temperature.
G for gas cooling system with fire point > 300 oC
W for water cooled systems
Note that oil-immersion serves as both insulation and coolant, and is most common
on all large (>20MVA) transformers. There are several alternatives for removing the
heat generated by losses, and these may be combined at different stages in the
transformer. For example, in oil immersed transformers, the cooling circuit collects
hot oil at the top of the tank and returns cooled oil lower down on the side. The
cooling arrangement consists of two circuits, one inner and one outer. The inner
circuit transfers heat from the hot transformer surfaces to the oil, and the outer
circuit transfers the heat to a secondary cooling medium. IEC standards provide
definitions for the different types of oil immersed transformer cooling arrangements.

212 | ABB Energy Efficiency Handbook

Code

Inner circuit

Outer circuit

ONAN

Oil Natural

Air Natural

ONAF

Oil Natural

Air Forced

OFNAN

Oil Forced

Air Natural

OFAF

Oil Forced

Air Forced

OFWF

Oil Forced

Water Forced

The transformer MVA power ratings are usually are stated to reflect different levels of
cooling. For example, the rating ONAN/ONAF1/ONAF2 may be 120/160/200. These
ratings show the maximum power rating depending on the level of cooling active.
At low loads, the ONAN circuits are sufficient; no forced cooling, hence no auxiliary
losses, are active.
Cooling has the effect of moving the operational power point lower down on the
saturation curve. The cooler the transformer, the more power and energy can be
passed through the transformer. On the other hand, power that is consumed by the
cooling devices serves to effectively increase the transformer total losses.
Oil-filled transformers with pump circulation cooling systems are common, but these
have higher losses and the higher parts count means reduced reliability compared to
fan-cooled type units. The only advantage of pump-cooled systems is the reduced
size of the unit.
Some dry-type transformers, for example, Resi-block transformers, have a design
that can withstand extremely cold temperatures. These transformer types do not
need startup heaters, as oil-filled units do in such conditions, to achieve operating
temperatures. From an energy perspective, transformers without need for startup
heating save energy, provided that full load efficiencies are not reduced.

According to IEEE Std 666-2007 An economic evaluation that considers the

initial cost of the transformer installed plus the evaluated cost of losses is
used to determine the type of cooling, e.g., ONAN, ONAN/ONAF, ONAN/OFAF
ONAN/ONAF/OFAF. These transformers supply the unit auxiliary loads and are
loaded a large portion of the time. Losses will consist mostly of load losses
and have a tendency to make an ONAN rating equal to normal load the most
economical.

The standards (IEC-3540) define the hottest-spot temperature in the winding as the
limiting factor for loading & overloading limits, and provide a method for calculating

Module 3 | 213

this temperature based on bottom or top oil temperature measurements and the
gradient.
Transformer Configuration
Some facilities specify separate power transformer units for each phase, usually
based on the assumption that separate units offer increased reliability over combined
3-phase units. Although this may have been true in the past, the reliability of 3-phase
transformers is now so high that it should no longer be the main reason to split
phases. Single phase transformers have lower energy efficiency than combined
phase units, are more expensive and require more auxiliary equipment which
combined units can share between the phases. Additional reliability can be achieved
through a bus design which includes a reserve transformer powered from another
source, for example.

In power plants, the generator step-up unit (GSU) is 5 to 6 times more prone
to failure than network transformers. This higher failure rate is due to the
much higher thermal and mechanical stresses experienced by these large
transformers. The average age of large power transformers in the US is now 39
years (as of 2008). To maintain a slight edge in efficiency, but mainly to avoid
the costs of random failures, this fleet of 130,000 aging transformers should
be carefully monitored and screened for potential problems and eventual
replacement or refurbishment. ABB, for example, offers transformer monitoring
systems (TEC), and has a formal program offering (TRES) for fleetwide
assessments of utility transformer condition, providing users with indications
where there is substiantially increased risk of failure for individual transformers.
Hartford Steam Boilers insurance division projects that the 2% annual
failure rate of the existing installed base will increase to 5% by the year
2013. Most (43%) of these failures will be due to problems with the
winding insulation.

Selection & Sizing

Transformer selection and kVA sizing is based on a thorough understanding of the
loading that it must endure, and how this loading varies over the units operating
regime during day, week, month and year; the units complete duty cycle. As with
electrical motors, knowledge of startup loading demands is required. See sources
such as IEEE Design Guide (IEEE, 2007) for details on transformer sizing.

214 | ABB Energy Efficiency Handbook

In power plants, the step-up transformer is downstream from the auxiliary

transformers, as shown in the simplified single-line diagrams from the
previous section. The MVA size of the step-up transformer can be estimated
by starting with the generator MVA size and then subtracting the auxiliary
system transformers combined MVA ratings and the step-up transformers own
losses, estimated from the multipliers in the section on Transformer Losses &
Efficiency. Industry engineering guidelines (Black & Veatch 1996) recommend
adding the MVA of one auxiliary transformer for the case when it is out of
service. This extra capacity allows a design in which the generator step-up
transformer can supply the loads of the out-of-service auxiliary transformer.
The operational cost of this extra, but seldom-used capacity may be reduced
by designs which can use some of the capacity of startup (SST) or reserve
transformers in such situations.
Sizing of the unit auxiliary transformers follows the same procedure as any
substation or industrial transformer, and is described in the sections below.

Problem of Over-sizing
In contrast to the design guidelines for motors and drives, an oversized transformer
is actually somewhat more efficient than one operating at 100% capacity
Most improper selection and sizing are due to an incomplete load analysis. Even if
the load analysis is complete and correct, there may still be a tendency to add too
many margins for electrical equipment, especially for power transformers and large
motors.
These margins may surpass 100% when the actual duty cycle is examined more
closely, using historical data. Even if significant future load expansion is anticipated,
it is generally more economical to size the transformer with the necessary additional
hardware to allow higher capacity cooling to be added later, when it may be required
(IEEE 2007).
A certain overload for a limited period of time is permissible. However, overloading
which leads to increased winding temperature above 221 F (105 C) in oil immersed
transformers increases the probability of bubbling in the cooling oil, which may lead
to dielectric breakdown in the transformer. Aging of the oil will also be accelerated by
stress due to overheating.

Module 3 | 215

According to IEEE-666-2007, some plants require much higher startup power

than others. A CCGT plant unit requires a large amount of power to bring
the GT to pull-in speed, after which the load requirements drop to a much
lower level. Coal-fired plant startup also requires more power during startup,
due to high fan load inertias. In all cases, however, the startup for auxiliaries
is relatively short and therefore the transformer can be safely loaded beyond
its rating, as per the guidelines in IEEE Std. C57.91 [B13] and NEMA TR98,
for short periods of time, instead of permanently oversizing the auxiliary
transformer.
According to the NEMA TR98 guide, an oil-filled transformer may carry 155%
of its full load rating for up to 4 hours with only a small estimated loss of life.

Sizing Procedure for Motor Load

The following simplified procedure assumes that the motor is the only load on the
transformer. Start with the rated current on the secondary side of the transformer
and make this current equal to the continuous rated current of the motor. The next
step is to determine the rated secondary voltage of the transformer. The rated
secondary voltage according to standards (IEC 60076-1) is in the no-load condition.
The process and mechanical engineers must provide data needed to determine the
voltage and current during motor start-up, continuous and intermittent operation,
and number of starts per hour. The Power Factor (PF) is also needed for the
transformer sizing, both during start-up and in continuous operation.
The short-circuit power of the source feeding the primary side of the transformer is
also a relevant parameter, especially when this value is low in relation to the power
rating of the motor. This may indicate that there will be a considerable drop in the
applied voltage from system to the primary side of the transformer during a motor
start. The transformer manufacturer might help with these issues, which are also
important in sizing a transformer for a given motor in retrofit situations.

Case Example
In one power plant, the transient high startup power demand led to a grossly
oversized unit auxiliary transformer of 10MVA. This plant was also a pumped
storage facility in which the generator was used as a motor for the water pump.
The transient high load was due to a 12,000hp (9 MW) starting motor, which
operated for only 15 minutes each day, during startup rotation of the motorgenerator when in pump mode. The transformer was sized to accommodate

216 | ABB Energy Efficiency Handbook

this very high, but short-lived load, even though the normal auxiliary load was
less than 2MVA.
An improved design was `to specify a separate dedicated startup pony
transformer which has a rating high enough for the temporary high load. After
startup was complete, this transformer could then be bypassed in favor of a
2 MVA unit auxiliary transformer. This pony transformer could safely serve the
high transient load with a rating much less than 10MVA, since the duration
period is so short.
Sizing a power plant unit auxiliary transformer is based on normal and
maximum expected auxiliary loads, but with an eye to load profile and duration.
According to IEEE Std.666-2007 Design Guide, these auxiliary loads vary for
different types of plants such as for combined-cycle and coal-fired plants. For a
combined-cycle plant, the starting load (particularly static type) to bring the gas
turbine to firing speed is considerable, when compared to normal operating
load. Since the start duration is typically less than 30 min and is infrequent for
a base load plant, temporary loading beyond nameplate per IEEE Std. C57.91
[B13] in lieu of oversizing the auxiliary transformer would be a consideration for
kilovolt ampere selection. It would be advisable to include this type of expected
loading duty in the transformers specification.

Transformer Retrofits
The benefits of new transformer design can be gained at lower capital cost by
selective replacement of certain elements, such as winding, core and cooling
system, while retaining the existing tank and mounts. These replacements can
increase energy efficiency on old transformers without the need for additional
civil and mechanical engineering needed to accommodate a new form factor. A
component retrofit may also have shorter lead times compared to a complete unit
especially for large power transformers. The decision to replace transformer internals
should be addressed in the course of a plant power systems assessment. The
greatest energy efficiency is gained by complete replacement of the old transformer,
especially if the original transformer is over 50 years old. Advances in transformer
core steel technology can substantially reduce core losses.
The following table shows the general benefits of reduced winding losses in new
transformers vs. old, and the range of capital costs involved for different transformer
capacities.

Module 3 | 217

MVA Size Range

Large

Price Range $/MVA

% Losses(old)

% Losses(new)

$5k-$10k

0.2

0.1

Medium

$6k-$12k

0.5

0.2

Small

$10k-$15k

0.6

0.3

Transformer Cost Calculations

Lifecycle costing and accounting for operational costs is particularly important for
transformers due to their exceptionally long service life. The difference between the
purchase price of a standard transformer and an energy-efficient one is paid back
several times over this lifespan.
This section is based on information from these sources: (ABB Ltd,Transformers,
2007, Loss Capitalization & Optimum Transformer Design).
The manufacturing cost, hence purchase price, of a transformer increases with
the transformer mass. However, the cost of transformer losses decreases with the
transformer mass. The optimum transformer design or model is one which has
lowest lifecycle cost (LCC) for the application.
As a first, very rough, approximation, the hardware cost alone of a new transformer
is $10,000 per MVA (based on a medium-sized step-up power transformer). The
total installed cost (TIC) of transformers is large, due to the civil and installation
costs; these vary widely, but are at least double the cost of the hardware alone in
most cases. More specific rules regarding large power transformer costs is difficult
due to to the very high degree of customization in their design.
In LCC methods, the no-load loss is assumed to be present at its measured
reference value for the whole time the transformer is energized. The evaluation of
load loss is more complicated due to the variation of the load. From the section
on losses, Transformer Losses & Efficiency, the load loss varies with the square
of the load (I2R losses). Using the formulas from the section on Lifecycle Costing
Methods, the no-load and load losses can be capitalized : the present value of the
annual energy costs can then be calculated.

In the case a power plant GSU, it is normal practice to value the load losses
higher when the transformer is operating near its rated load, which is expected
in baseloaded plants.

218 | ABB Energy Efficiency Handbook

Note that these simplified LCC methods do not take into account differences
between rated and service voltage, or the effects of any tap-changer settings.

Calculation Case
Sample comparison of two 25MVA-rated unit auxiliary transformers, at 0.85 PF,
at 99.3 and 99.7 % efficiency over 1 year:
Energy Savings = 25MVA x 0.85 x 8,000 hrs/yr x (0.997 0.993) = 680 MWh
Dollar Savings = 680 MWh x $60/MWh = $40,800/yr
Now applying LCC methods to determine the present value of the savings over
20 years at 5% RoR:
PV = $40,800 x ((1 + 0.05)20 - 1 ) / 0.05(1 + 0.05)20
PV = $508,500

Plant Power System Layout & Cabling

The physical layout of the power system components and the length and diameter of
cables can be chosen to minimize losses. This challenge is similar to that of reducing
friction in a pumping system, where power is wasted in in friction through pipes,
valves and fittings.
Waste heat from transformer and VFD cooling systems may be used in process
heating, or to seasonally augment the HVAC system, if the layout allows it and if
there is good communication between the process, piping and electrical teams.
For very large units, this recycling of heat may show a net lifecycle benefit to justify
the added hookup cost. At an early stage in plant (re)design, therefore, the process
engineers should be encouraged to include the largest power system equipment in
their heat balances.
Cable Selection & Sizing
In an electrical power system, power is wasted as losses in cables, switchgear and
other current carrying devices, including control and protective circuits. Some useful
design guidelines to reduce such losses, adapted from (IEEE, 2007):
Centrally locate the load center transformers, switchgears and LV MCCs to:
Reduce length of cable runs
Reduce losses and voltage drops
Keep buses and taps as short as possible to:
Reduce distance between aux unit transformer and generator
Module 3 | 219

 Increase cable diameter of smaller cables to one or max. two gauge higher to
achieve multiple benefits:
Lower ohmic losses
More cable of fewer different cable sizes reduces wastage during installation,
gets better terms such as Minimum Order Quantity.
Use VFDs to reduce average current to motor loads
Saves on capital costs and losses in cabling
As with pumping systems, the main equipment is often laid out before the
connections between them are determined. Also analogous to pumping systems is
the unforunate design choice of smallest allowable diameter cables to reduce initial
material costs, at the expense of much larger lifetime operating costs.
Voltage Drop and Power Loss
For cables and lines, the following formulas from ABB Switchgear Manual (2004)
may be used to calculate line voltage drop and power loss in 3-phase systems,
given the resistance of the line RL.

220 | ABB Energy Efficiency Handbook

Cable Laying Method

The cable laying method is an important aspect of cable layout and design. The
standards call for a derating factor to be applied to certain sub-optimal methods,
such as vertical (wall) mounting and duct bank designs. See the ABB Switchgear
Manual for more detailed guidelines and references on cable laying methods.
Busbar Design & Sizing
Some guidelines for copper busbar sizing: Increasing the cross section reduces
energy losses exponentially - doubling the conductor cross section area cuts the
resistance in half and reduces the losses by 50%. The first few incremental size
increases above the minimum allowable will make a big difference in the loss, but
the cost of each increment increases while the return decreases. Selecting multiple
bars in lieu of a single bus is another issue a design engineer has to consider for
achieving a lower loss system.

In power plants, the currents in bus ducts between generator and step-up
transformer are very large and may cause circulating currents in the bus ducts
themselves. These currents reduce efficiency and may lead to overheating.
Correct design of the termination of the bus duct at the transformer end can
reduce these losses and the risk of overheating. (ABB Ltd,Transformers, 2007)

To reduce busbar losses, the step-up and unit auxiliary transformers should be
located as close as possible to the generator. (IEEE 2007) . According to (Leonardo
Energy , Busbar Design, 2008), the following procedure will improve the energy
efficiency of busbar designs:
1. Select working and ambient temperatures
2. Assume initial current density of 8 amps/mm2
3. Find appropriate size in standard range
4. Calculate heat generated due to current
5. Calculate heat loss at working temperature
6. If 4>5, increase size and return to 4
7. When 4=<5, this is smallest possible size
Having calculated the size of the bar, there are three further considerations:
voltage drop
short circuit current
skin effect - increases apparent resistance by reducing effective area - important
for thick busbars, high frequencies, harmonics generated by non-linear loads
Module 3 | 221

Busbars are especially long-lived plant components, which gives their running
energy costs more weight in lifecycle calculations. The figure below shows how
these energy costs decrease as cross-section of the busbar increases.

Figure 3.23 Curves showing lifecycle cost for busbars, (Leonardo Energy , Busbar Design, 2008)

Power and Load Management

Power Management Systems continuously monitor the configuration of the network
and can respond instantly to preserve capacity and power quality. PMS is typically
used in industrial power systems to provide load-shedding, load balancing,
synchronization and generator control functions.
In power plants with multiple generators, these industrial functions may also be
applied to ensure the most economical allocation of in-house loads to generators; a
kind of load dispatch or load sharing.
Even in single generator plants, a PMS can provide automatic non-essential load
shedding at very low loads to slightly improve heat rate. An intelligent PMS would
also be a useful addition to more radical energy designs requiring optimal use of
multiple sources of auxiliary power, including renewable sources.
Suppliers of these systems, which are also referred to as Energy Management
Systems or Electrical Control Systems (EMS,ECS) will soon be adding new
capabilities as new communication standards for electrical equipment (IEC -61850)
are adopted by more equipment manufacturers and industries.

222 | ABB Energy Efficiency Handbook

Power System Design and Analysis Tools

There is a general lack of unified toolsets for modeling power systems for energy
efficiency performance and calculating energy savings from different design
alternatives. Some popular Schematic and design/drawing tools; elProCad,E3,
eTAP, Innotec Comos, SmartPlant Electrical, and Auto-CAD Electrical. Some popular
System / Network dynamic simulation tools; eTAP, MatLab/SimPower, PSSE,
SKM, and EEDSA. Tools specifically for energy efficiency design are few and nonintegrated with the big packages listed above.

Power System Maintenance

A large transformer fails on average every 5-6 years, based on statistics for power
generating plants (NERC GADS data, GAR Report 2006). The average opportunity
cost per outage is 25,4GWh; so at 60kUSD per GWh this means $1.5MUSD per
outage. These opportunity costs hide the real loss of energy associated with an
outage. These losses are estimated in this handbooks section on Efficiency &
LifeCycle Cost Calculation.
It is common practice to manually inspect the step-up, startup and auxiliary
transformers once every three years (Burns & McDonnell 2007), and even more
frequently for older equipment.
Some useful power system preventive maintenance guidelines are in NFPA 70B
Recommended Practice for Electrical Equipment Maintenance. For transformers
specifically, one can consult the ABB Service Handbook for Power Transformers.
On-Line Condition Monitoring & Control
Transformer electronic control (as in ABBs TEC) for modern transformers can
provide advance warning of degradation and eventual failure, and provide optimal
cooling control. The enhanced, real-time monitoring capability allows transformers
to be overloaded when required, reducing the need to oversize the unit for these
transient situations. Overload capability forecasts can be made, in which the
estimated thermal aging is also taken into account. The monitoring software will
calculate the extent to which the transformer can be overloaded, and provide the
financial impact of this overloading due to any extra aging of the insulation.
Modern transformers can be equipped with the monitoring and diagnostic functions
covering critical performance parameters shown in the figure below. Older
transformers, which are most in need of improved monitoring and control, can be
retrofitted with such a package.

Module 3 | 223

Figure 3.24 Transformer electronic control (TEC), ABB Transformers USA, 2006

Modern transformers use these data for hotspot calculation and for optimal control
of the cooling system. The optimal amount of cooling power will minimize lifecycle
costs. In an overloading situation, the controls will start the coolers earlier to avoid
premature ageing of the transformer. The controller also provides temperature
warning and alarms; when a lower temperature limit is exceeded, then the TEC
control will first issue a warning to operators. If temperature continues past the
higher limit, then an alarm is generated and a trip command will be sent to the
protection relay to isolate the transformer.
The extra data from a well-instrumented transformer can be used to perform an
online heat balance which can continuously calculate heat losses from different
sources, as shown in the figure below. These losses can be compared to a model
of the iron and copper losses at the current load level, providing another indicator of
performance.

224 | ABB Energy Efficiency Handbook

Figure 3.25 Heat balance monitoring in a transformer, ABB Transformers USA, 2006

Off-Line Condition Monitoring

The following off-line condition monitoring tools are also useful for uncovering wear
and damage that could lead to reduced efficiency and failure:
Transformer condition monitoring tools - oil and gas analysis.
Infra-red thermographic equipment & analysis.
Ultrasonic partial discharge (PD) detectors.
For greatest benefit, the data from these tools should form the input to a more
comprehensive power system assessment process.

Power System Assessments

An upgrade, revamp and/or replacement are conceptually different than routine
maintenance. System reliability, availability and innovative service support analysis
requires a systems approach. It starts at the network and ends at the process
equipment, and must cover all components in the system. This analysis involves an
extensive review study, plant rating evaluation, and a mechanical study including
plant layout. A budgetary cost model is developed to support the study of financial
viability. The analysis takes into account plant requirements related to regulation,
protection, controls, metering and indication. The final step in a power system
assessment is a road map which specifies the most attractive improvement targets,
and provides some medium and long-term solutions to improve plant efficiency,
system reliability and availability.

Module 3 | 225

Power System Efficiency Guidelines Summary

Design practices worth considering for improved energy efficiency in the power
system are listed below:

Select higher voltage levels for some buses (MV instead of LV).
Use 3-phase transformers instead multiple single phase.
Use large transformers instead of multiple, smaller ones; share
transformers between units.
Upgrade old transformers to achieve higher efficiency, improved
monitoring
Use PF correction, near the inductive sources where possible, to
approach 0.95 PF.
Use a generous cable laying method; avoid methods which lead to
cable derating.
Consider a plant arrangement which reduces length of cable runs &
voltage drops.
Ensure that harmonics are well within tolerance.
Understand motor duty, and size accordingly, following the guidelines
in Motor Sizing and Selection
Ensure phase loads and voltages are balanced.

226 | ABB Energy Efficiency Handbook

Module 4
Automation Systems
Module Summary
This module describes the general design and energy impact of the plant
instrumentation, controls and optimization systems. While a detailed presentation of
all relevant automation concepts is beyond the scope of this handbook, this section
examines automation from an energy efficiency perspective and does not provide
guidance on other, critical aspects of automation engineering such as interlock logic,
emergency shutdown sequencing, or fault-tolerant design. For a more complete
guide to all other aspects of automation design, see the standards and references
sections of this handbook.
The information in this module may also be generally applied to process
industries; industry-specific text is shown between rule lines.

Automation Concepts
A process plant is a hierarchy of equipment & control systems: a combination of
hardware, software, people and operating procedures interrelated as shown in the
figure below.

Figure 4.1 Levels of automation in an industrial plant

Instrumentation, control and optimization, collectively known as automation,

encompass equipment, software and methods, ranging from field devices to plant
management. The main function of plant control and automation systems is to
regulate various parts of the process, such that they operate at desired setpoints, to
initiate shutdown or trip action in case of problems, and to monitor key performance
parameters for continuous improvement. The ISA is a leading professional society
for this relatively new field of engineering. Automation is one of the youngest
Module 4 | 227

disciplines in engineering, and is growing rapidly as more sensors and intelligence

are embedded in common plant equipment.

Role of Automation in Energy Efficiency

Automation allows faster and more consistent response to changing load conditions
compared to open loop (or human in the loop) control methods. Automation also
enables the process to operate in a more stable way, and thus can be safely operated
closer to its constraints for optimum energy efficiency. When a survey (US DoE, 2004)
asked process plant professionals to identify the operational or process changes that
would realize significant energy savings, most of the responses involved one or more
automation technologies.
The responses generally fall into these broad categories:
Control and Optimization:
Improved control of boilers, and other efficiency improvements through
optimization, modeling and equipment design.
Advanced control strategies such as model predictive control, improved
measurement devices
and sensors, multivariate data processing and analysis, better scheduling
optimization strategies
Use of thermal optimization based on process integration technology (e.g., pinch
technology): use of waste heat /use of waste heat recovery technologies.
Drive Power:
Optimized pumping & fan systems based on appropriately sized/specified
equipment and often relying on variable speed drives
Use of variable speed motors rather than throttling valves to control process flow
Management & Decision Support:
Use of information tools (advisory/monitoring) to improve decision making on
thermal energy use
Improved system-wide decision-support across the whole plant and groups of
plants
Better management of power & electric loads
Regular and disciplined application of electrical and thermal energy assessment
tools
For process & industrial controls, end-users envision potential energy savings
ranging from about 2% to 25%. Vendor estimates of the savings from plant-wide

228 | ABB Energy Efficency Handbook

automation integration alone were on the order of 5% of the total energy, on average
for all process industries (US DoE, 2004).

Instruments and Actuators

Plant automation and performance monitoring & improvement functions are all
dependent on reliable plant data measurement and acquisition, and precise
controllability of processes.

Figure 4.2 Pressure transmitter (left) and process analyzer (right). (ABB,2006)

Collectively known as field devices, anything that directly senses or controls

a process typically is categorized as an instrument, an analytical sensor, or an
actuator. Instruments are sensors that obtain real-time measurements of basic
process variables such as temperature, pressure and flow rate. These are sometimes
also referred to as transmitters and are typically used as inputs to fast-acting control
loops and interlocks. Actuators are output devices such as drives, valves and
dampers that can either directly or indirectly modify measured process variables.
Process Instruments
The most common types of measuring devices (instruments) in a process or power
plant are; pressure sensors, temperature sensors, level sensors, and flow-meters.
Additionally, control may require measurements of speed, current, voltage, chemical
composition or various physical properties, such as thickness, opacity, resistivity,
etc. Accurate measurement is a requirement for process precision, as well as
energy-efficient control. Poorly chosen or located instruments will introduce lag and
instability, causing much energy-wasting corrective action or process instability.
According to the ISA, instruments should be installed as close as is practical to the
source of the measurement, with consideration being given to excessive vibration
and ambient temperature. Other common problems with process instruments are
drift, bias and lockup freezing. An instrumented that has drifted from its calibration
will lead to off-setpoint control. Bias is when an instrument under or over reports a
Module 4 | 229

measurement. Lockup, or freezing, is when an instrument continually transmits a

single value while the related process actually is varying.
These effects are particularly troubling if the instruments on-board diagnostics are
unable to detect and report them to operators. Smart transmitters have fewer
such problems due to their continual diagnostic monitoring. These transmitters tend
to be more accurate as well, and the extra signal processing allowing them to be
turned down by a factor of 10 and still provide accurate measurement (ISA 2005).
Smart transmitters should be specified as part of a broader strategy, which typically
includes an upgrade to fieldbus communication. Smart transmitters are currently
available in three widely accepted varieties HART, Profibus and Foundation
Fieldbus.
Performance monitoring, condition assessment, diagnostic tools, maintenance
management systems and asset lifecycle optimization rely on the data from smart
instruments and the automation system to provide in-depth information about the
process, as well as the condition of the process equipment itself. This information is
provided in real-time, without the need for scheduled downtime or waiting for a plant
shutdown to perform equipment inspections.
It is an energy efficiency design oversight to omit instruments altogether in certain
critical areas. The lack of accurate process data will hinder efforts at automatic
control and energy performance improvement.

In a power plant, steam flow measurements are essential to feedwater control

and in a coordinated boiler-turbine control scheme described in Coordinated
Boiler-Turbine Control. Instead of direct flow measurement, however, the
value is inferred from the HP turbine 1st stage pressure, which introduces lag
and inaccuracy in the control systems.
In feedwater control, the specification of two additional sensors enabled the
3-element control now common on sub-critical boilers. Lack of turndown in
these sensors, however, leads some units to fall back into less-stable and less
efficient single-element control at low loads. See Feedwater Flow Control for
details.
Choice of sensing technology also has an impact on power plant control
effectiveness. Level sensors that are undesirably sensitive to density variations
will introduce errors unless corrected for with additional controls. Vibration and
other effects may disturb some sensors used in condenser and de-aerator level

230 | ABB Energy Efficency Handbook

control. Levels in de-aerator are also important energy-saving steam leveling

strategies.
Improved measurement coverage allows a more accurate and complete
cycle energy balance that can be used with real-time cycle monitoring and
optimization techniques discussed in Real-Time Optimization
Steam flows are particularly challenging to measure due to their sensitivity
to changes in pressure and temperature. Flow sensors with real-time
compensation for these effects will provide more accurate data for control and
optimization. (Rosemount Instruments, 2008).

Analytical Instruments
Analytical instruments are also sensors, but they are more complex than transmitters
and perform chemical composition analysis or other procedures usually resulting in
multiple outputs. Analytics may operate at slower data update rates than process
transmitters, and are typically used for slower-acting control loops, or overall
process quality evaluation and control.

In power plants, analytical instruments are used for measuring CO, NOx, O2, pH
and conductivity. In the burner system, flame scanners are used for combustion
flame stability monitoring. Other analytics are used for measuring flue gas
composition for emissions control and monitoring. A carbon in ash analytical
instrument is for the on-line measurement of unburned carbon in fly ash.

Modern analytical instruments, like process instruments, are placed in-line in with
the process equipment and provide data in real-time, using the same communication
bus technologies as simpler instrumentation. Some analytical instruments, however,
are mounted only intermittently to perform special studies such as corrosion testing
or vibration analysis.

In power plants with fewer instruments, boiler and heat loss efficiency tests
cannot be performed continuously in real time. These older plants require the
temporary mounting of extra instrumentation, whose type and number are
given by the ASME Performance Test Code, such that the desired accuracy
may be achieved. The test codes will allow accurate measurement of efficiency,
in some cases within a range of 0.05%, such as for steam turbine efficiency.

Module 4 | 231

Process Actuators
Actuators are devices that can directly act on the process through physically
directing gas and fluid flows. Some actuators typically found in a process or power
plants are; Dampers, Louvers, Inlet Guide Vanes, Servo valve position controllers,
Variable Frequency Drives, Solenoid (on-off) valves.
Actuators with significant deadband (hysteresis) will have poor control response,
and non-linear actuators will require additional correction (linearization) to behave
well across their entire operating range. Also, a reduced range of action, such as
low turndown, can severely limit a units energy performance at low loads. Another
common problem with process actuators is stiction, in which a large force is required
to overcome static friction between two surfaces in contact.

Figure 4.3 Part-turn actuator for rotary movement of final control elements, (ABB PME120 brochure)

Control Valves
Control valves (CVs) are valves used for automatic control of fluid flow. Valve opening
is controlled by a positioner that may be driven by an electric motor, hydraulic power,
or by compressed air in response to a command from the control system.
Control valves that are oversized will operate in a nearly-closed state for most of
the time. Oversized valves are hard to control and may cause instability during rapid
changes. Control valves are oversized as a result of the oversizing of constant-speed
upstream components, pumps and motors, as described in this handbook. When
the actual flows are much smaller than these components nominal operating points,
then the CV must drop correspondingly more pressure by closing more fully. As
described in the section on pump flow Throttling, the CV wastes energy that should
not have been input to start with. Speed control is the preferred method of flow
control, and eliminates the need for energy wasting throttling control valves.
CVs are mechanical devices that often operate under great fluid pressures and are
prone to stiction in the valve stem and hysteresis. These effects will cause CV control
loops to oscillate and may lead to process instability. There are methods to measure
stiction online, and techniques for tuning PID controllers where stiction is observed
or suspected. CVs and other actuators are usually powered electrically, or from
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the plants compressed air system, which requires energy-intensive compression.

Specifying only devices with minimal air consumption or leakage, especially when
at rest, will have a significant energy efficiency benefit in a plant with hundreds or
thousands of such actuators.

In power plants, a special kind of control valve is used to throttle the steam
entering various stages within the steam turbine. Known as turbine governors,
these devices are responsible for speed and load control, and for starting
and synchronization. Turbines retrofitted with modern fast-acting hydraulic
actuators provide much improved control response for faster ramp rate and
increased energy efficiency, as described in the section on Turbine-Generator
Control.

Dampers and Louvers

Dampers are used to control the flow of air or flue gases by modifying the crosssectional area for flow within a duct. Louvers are a type of damper in which a series
of parallel blades can be rotated to control the area open for flow. Isolation dampers
are designed for on/off shutoff service (Babcock & Wilcox 2005).

In power plants, ID and FD fan control can be made more stable by installing
smart transmitters on older systems still using dampers. These final control
elements must be accurately and speedily positioned for even basic control
schemes to be effective. In some cases, damper movements within 0.25
percent of the devices full range are necessary for precise control and this
capability must be maintained over years of operation.
This section is adapted from an article in Power Engineering by Richard Vesel,
ABB (Vesel 2007):
Dampers for primary and secondary air control, as well as overfire air control,
are typically distributed around the boiler in great quantities (more than 100
in many cases). Advanced combustion control schemes will often require
precision control over most air flows, so outfitting each damper and fan with
active control elements is essential.
Outdated damper driveselectric, hydraulic or pneumaticcan suffer
from a range of problems including insufficient force/torque, slow response
time, stiction and inaccurate response due to hysteresis and other causes.
Operators can find these problems by looking through relevant operating
Module 4 | 233

trends, engaging in specific plant performance assessments or by doing a loop

performance analysis where set point, process value and control output from
a controller are analyzed over a reasonable period of time (from several shifts,
up to one month). Inaccurate or weak damper drives cause poor combustion
control response and can cost a plant in terms of poor load following, higher
heat rate, slagging, carbon-in-ash, poor emissions control and unacceptable
opacity variations.
The goal for improved damper control is to be able to remove process
deviations caused by draft-related variables (Furnace Pressure, NOX, excess
O2 and so on), enabling operating points to move closer to ideal levels.
Modern electric actuators make this possible by positioning the final control
element down to within 0.1 percent of the driving control signal. Modern
electric actuators also have other operational advantages in addition to
improved damper control. Many advanced actuators have diagnostics for
watchdog functions that alert plant personnel before a serious problem
develops, avoiding costly downtime. For example, the electric actuator can
monitor damper position, frequency of motor reversals, frequency of torque
delivered and actuator internal temperature. Monitoring these diagnostics and
associated alarms and alerts helps to ensure proactive instead of reactive
maintenance, as well as optimum air control and plant performance.
In many cases, accurate damper drives and controls alone will provide
significant improvements over legacy systems. See section Air Flow Control
for Combustion for details on airflow control and alternatives to dampers for
air flow control.

Sequential Control
Sequential control (or sequential function chart- SFC) is a series of steps (or tasks)
which bring the process through a sequence of well-defined states. This type of
control is commonly used during startup and shutdown procedures, or during
emergency (trip) action. SFC automates traditional checklists for these procedures
and is an important tool for plants with fewer experienced staff. Sequential control
has the potential to speed up these procedures within safety limits, thus saving
energy and unproductive power generation. The intermediate states in the sequence
can be automatically monitored and operators receive alarms if an expected value is
not achieved. A sample SFC program, showing states and transitions between them,
is shown in the figure below.
SFC programming, combined with the communication capabilities of intelligent
Motor Control Centers (MCCs) can turn off motors when not required by the
234 | ABB Energy Efficency Handbook

process. This may sound trivial, but many motors run uselessly because the motor
controls lack the necessary process knowledge that is given by the SFC states. The
MCC provides the necessary data to turn off motors even for very short time periods
without risk of overheating, when it is economical to do so.

Power plants being repurposed from baseload to intermediate service will be

cycled much more often and will be asked to alternate rapidly between a wider
variety of loading states. Each change of state requires a complex sequence of
events which must be performed in the correct order, and using the correct values.
SFC automaton of these tasks can improve unit turnaround and avoid costly,
energy-wasting delays due to an aborted startup or other major procedure.

Figure 4.4 SFC sample program diagram, (ABB Overview of IEC-61131 Standard, 2006)

Feedback Control
Single loop feedback control is a type of modulating control typically used for level,
flow or temperature control on a single process line or point. Traditional feedback
control typically uses one or more of the following basic regulation methods:
Proportional, Derivative, Integral. When typically combined, these are referred to as
PID control.
PID feedback control is shown in the form of a simplified block diagram in the figure
below:

PID

Plant

Figure 4.4 Basic PID controller block diagram with standard symbols
Module 4 | 235

Where, according to ISA terminology:

r = reference signal (also referred to as setpoint)
e = error signal (r-c)
u = PID controller output (also referred to as manipulated variable or control action)
c = controlled output (also referred to as controlled variable)
The PID control loop compares the controlled output of the reference signal to get
an error signal e. This signal is input to the actual controller, shown in the box
marked PID in the block diagram, which generates a corrective control signal to the
actuator in the plant. The action is designed to drive the error signal to approximately
zero, such that no further corrective control action is necessary,
A more detailed block diagram of a feedback control loop would show the additional
effects introduced by the sensor and final control elements. Such a diagram would
also show the disturbances which in most cases represent the varying load on the
process.
The reference signal is also called the setpoint of the loop. Closed loop control acts
to minimize the steady state error so that the output of the process returns to the
desired setpoint established by the operators. Unlike open-loop control, feedback
control can respond to any disturbance and return the process rapidly to setpoint,
but only if the loop is properly tuned. If the underlying process parameters change,
due to temperature or other effects, then the loop must be re-tuned.

Untuned loops may waste energy by demanding unnecessary auxiliary

drivepower and by allowing (or even causing) greater instability. According to
industry research (Matrikon, 2005), up to 75% of regulatory controls in a typical
process plant are under-performing. Many loops are incorrectly put into a fixed
or manual mode, where the PID action has been defeated completely.
Manual mode control and loop instability will generally lead operators to use
less efficient process setpoint values to avoid situations when the swinging
output variable exceeds a critical limit. Stable automatic operation allows
sustained and safe operation closer to optimal process and energy limits.

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Process Characteristics
Design and tuning of PID control loops requires an understanding of the physical
process under control. From a basic control standpoint, the process is characterized
by its gain, time constant, dead-time, and its degrees of freedom.
Process gain (K) is the amount a process output changes in response to a
change in input. Process gain can be separated into steady-state and dynamic
components. (ISA 2005). The product of process gain and controller gain is the
loop gain.
Time constant (TC) describes the rapidity of the above response. After one TC
the output variable has reached 63.2% of its final value. More complex processes
may have multiple TCs.
Dead time (DT) is the amount of time it takes for the above response to start after
the input has changed. Transportation lag or thermal inertia are common sources
of dead time.
Degrees of Freedom (n) are the number of independent variables in the process,
which is also the highest possible number of independently-acting controllers for
that process (ISA 2005). The degrees of freedom can be computed by taking the
total number of process variables and subtracting the number of relationships
(physical, chemical etc.) between them.
All the above process characteristics are important for correct loop design and
tuning, hence energy-efficient operation. Oscillations will result if the loop gain > 1.
Response will be too slow if loop gain is very low. The controller gain must therefore
be chosen to provide a total loop gain of about 0.5 to achieve rapid yet stable
performance.
Feedforward Control
Feedback control responds only after a process disturbance has already caused
a change in the output; it is blind to the original disturbance. In many cases,
this disturbance can be measured and even anticipated, as in the case of a
change in process loading. Feedforward control uses this knowledge to compute
an appropriate control response, which is then summed with the output of a
conventional PID controller as shown in the following block diagram.

Module 4 | 237

D(t)

Disturbance

Feedforward
Controller

PID

+
Plant

Figure 4.5 Feedforward controller block diagram

The feedforward response is based on a physical model of how the process

responds to the measured disturbance. The success of feedforward is dependent
on the accuracy of this model, which is difficult to obtain and maintain. Even with
an imperfect model, however, feedforward control combined with PID control
usually provides a faster and more stable response than PID method acting alone.
The feedforward controller corrects for 90% of the disturbance, while the PID
controller can rapidly and smoothly respond for the remaining 10%. (ISA 2005). The
feedforward controller model can also provide lead-lag compensation for process
dead-times, which would otherwise make a PID loop more difficult to tune.
The improved control response saves process energy and reduces waste, but
feedforward control has another energy benefit; reducing the load on the PID
controller by an order of magnitude. (ISA 2005), loops which use drivepower for
actuation will use significantly less energy.
Cascading Control
In cascading control, one PID is nested within another PID loop as shown in the
figure below. The outer (master) loop provides the setpoint for the inner (slave) loop.
For cascade control to work, the inner loop must have a shorter time constant than
the outer loop. One common example of cascading control is flow control, where the
inner loop controls valve position and the outer loop controls for output temperature.
r

PID

Flow
System

PID

Inner loop

Outer loop

Figure 4.6 Cascade feedback controller block diagram

238 | ABB Energy Efficency Handbook

Heat
Exchanger

Cascade control allows the inner loop to correct quickly for inner loop disturbances,
such as valve hysteresis, leaving the outer loop to respond more quickly to changes
in the controlled variable.
Adaptive Control
In adaptive control, also known as self-tuning or auto-tuning control, the PID
parameters themselves are automatically modified online to respond to the changing
sensitivities of the process. In effect, the parameters which are normally fixed in a
static PID controller become themselves variables in one or more feedback loops.
Some self-tuning controllers operate in static mode most of the time, but will selftune on request from an operator or after a fixed time interval.

Advanced Control and Optimization

Advanced Control encompasses many methods for controlling and optimizing larger
systems with multiple variables and with important constraints. This control level
typically operates at slower rates than single loop control, but can still operate in
real-time.
Model-Based Control
Model-based control encompasses a variety of techniques using models to
generate a control response. These models may be either mechanistic or empirical.
Mechanistic models are based on physical principles (sometimes these models
are called first principles), whereas empirical models use past data or black-box,
mathematical approximations. The most common empirical technique models the
process using a collection of step responses, each with its own coefficient(s).
The most widely used model-based technique uses a time-series model of the open
loop response of the process. This series is the models calculated response to a
series of predicted control action values and disturbance values. An optimization
function then updates the control action value series to achieve minimal deviation
from setpoint with limited control action. This sequence of control actions is referred
to as a trajectory.
Model Predictive Control, or MPC, has multiple outputs, in contrast to feedback
control methods, which output only a single control action in response to a change
in the input measurement. MPC uses a form of feedback in which the estimation
error is used by the model to improve future estimations, as shown in the simplified
block diagram.

Module 4 | 239

Figure 4.7 MPC block diagram showing model and correction blocks

MPC is valuable in process situations of multiple variables with non-linear dynamic

response, or where several control loops are interacting. The optimization function in
MPC is well-suited to handling process constraints without decomposing them into
setpoints, as is the case with PID control. MPC is also useful in process situations
where direct measurements are not possible, or cannot be made fast enough for
conventional PID control to be applied.
MPC is typically used in a hierarchy of control, providing setpoints to the lower, PID
level of control as described in the section multi-level real-time optimization. MPC
requires more engineering effort, especially during the verification and commissioning
phases, compared to conventional control methods. Access to realistic or historical
data is important for the model verification phase. Payback time for typical MPC
investments is 6-12 months (Cybernetica, NFA Days Norway 2006). Some recent
MPC projects, however, have netted impressive results, with paybacks of less than
two months.
Inferential Control
Inferential control (IC) is based on techniques such as inference engines or neural
networks. Such systems learn from experience and can be used as a guide
to operators. A properly designed and maintained IC system can absorb the
accumulated energy efficiency knowledge of experienced operators and show
the way to younger operators through complex and less frequent tasks, such as
startups/shutdowns and complex process transition procedures.
Linear Programming with Mixed Integer Programming (LP/MIP)
The optimization layer uses linear programming technology (LP). LPs are common
optimization tools used for planning and scheduling applications in many industries.
The LP minimizes an objective function (cost of fuel plus cost of purchased
electricity), while adhering to many constraints. Some of the constraints are part
of the plant model, representing mass and energy balances. Other constraints
240 | ABB Energy Efficency Handbook

represent capacity limits, such as maximum fuel flow rates to boilers, and generator
constraints (Pekka Immonen et al, Power Engineering, Nov.2008 Coordinated
Control and Optimization of a Complex Industrial Power Plant).
Multi-Level Real-Time Optimization
This section is adapted from material by Pekka Immonen, which was first published
in Power Engineering, Nov.2008 Coordinated Control and Optimization of a
Complex Industrial Power Plant.
A multi-level approach (see Figure) uses real-time optimization (RTO), connected to
advanced process control (APC). At the top level, an optimization program monitors
the current situation in the plant and gathers pricing data over the Internet to make
timely decisions about loading individual equipment in the plant. The optimization
program then dispatches these orders to an advanced control layer, which provides
coordinated, decoupled control of pressure and power generation. The base control
level modulates the actuators affecting the plant to maintain the measured process
quantities at their setpoints.

Figure 4.8 Multi-level real-time optimization, (Immonen, Coordinated Control and Optimization of a
Complex Industrial Power Plant, 2008)

In industrial boiler systems, a multi-level approach uses LP to make the

selection between the operating modes based on the fuel and power pricing
situation and the plant conditions. The selection cannot be made on pricing
information alone. The equipment limits are higher priority and they must be
honored for safety and equipment protection. The constraint set continually
updates as process conditions drift and available equipment varies with
maintenance schedules.

Module 4 | 241

The advanced control system uses technology known as model predictive

control (MPC). MPC is a multivariable control algorithm. Like the LP, MPC
uses a model, but its dynamic rather than steady-state. MPC runs at a much
higher frequency than the LP, less than 10 seconds compared to 15 minutes.
Using the model, the controller predicts the effects of moving multiple base
control setpoints: high pressure and low pressure boiler fuel setpoints, all three
extraction valves on all four turbines, all PRVs and all vent valves (a total of 28
manipulated base control setpoints).
The algorithm is capable of providing smooth transitions, whether opening
PRVs, closing vent valves or controlling the steam balance with LP boilers
when the HP boilers are maximized. In case of large process upsets, the MPC
uses all steam system components to help out, allowing temporary deviations
from their optimum targets. As the MPC is a multi-variable algorithm, all the
required operating modes are achieved with a single MPC configuration. The
overall design is greatly simplified as there is no need for alternative DCS
configurations or complex over-ride schemes at the base control layer for
boiler-follow, turbine-follow, PRV and other such modes. The most immediate
benefit from the implementation of the new strategy was the greatly improved
process stability (Immonen, Coordinated Control and Optimization of a
Complex Industrial Power Plant, 2008).

Process Model-Based Real-Time Optimization

Process-model-based algorithms and advanced signal processing functions allow
operators to quickly identify under-performing equipment and take remedial action
on controllable losses. The advantage of model-based methods is their ability to
predict plant performance for daily operations or long-term operational investments
such as retrofits or process improvements. These tools can be connected directly
to the process to run their models in real-time on actual plant data. The calculated
(expected) values can then be compared with the actual process values, as shown in
the following figure:

242 | ABB Energy Efficency Handbook

Figure 4.9 Simulation and monitoring with PowerCycle software, ( ABB Switzerland, Power Technology Systems, 2005, PowerCycle brochure)

These comparisons will reveal deviations from optimum energy efficiency, as

calculated in the process thermodynamic model. The resulting deviation data can
be used for early detection of equipment degradation of loop tuning problems. The
process thermodynamic model use by RTO is developed during the project design
phase using the methods described in section Modeling and Simulation Tools
Lifecycle Model-Based Real-Time Optimization
The LCC methods described in Efficiency and Lifecycle Cost Calculations can be
programmed to execute online and then input to one of the plant-wide optimization
engines described above.

Supervisory Control
Supervisory Control (SC) is the highest level, providing feedback for such plant
management tasks as economic optimization, decision support, performance monitoring
and load scheduling. This level of control may have a rate of 15 minutes, hours or even
days. SC relies heavily on a Human Machine Interface (HMI) that can calculate and trend
plant overall and equipment efficiencies. SC functions also allows plant management to
monitor plant performance, identify root causes and correct problems.

In power plants, load dispatch commands are a semi-automated SC function

which is at the center of plant load control and operations.

Module 4 | 243

Performance Monitoring Systems

Performance Measurement Systems do not directly control the process, as the
other systems described in this module. Performance Measurement Systems use
humans as the actuators by providing them with analysis functions and large amount
of historical data. If performance measurement is used regularly and in a pro-active
manner by plant operators, then it becomes a very effective nearly-closed-loop
system to optimize energy efficiency.
Performance Monitoring Concepts
The plant unit historical data is collected from the plants instruments and stored in
an integrated plant information management system (PIMS). Process data from all
sources throughout the plant are collected and securely stored in the data server,
where they can be analyzed further. The PIMS data repository, possibly covering
the entire operating history of a plant in its archive, is an invaluable source of
information for efficient plant operation and maintenance. PIMS can offer a wide
range of analysis and presentation tools. Among the basic tools are trend curves
from historical data on the operator station to monitor process behavior over time
and detect patterns.

In power plants the Performance Monitoring Systems (PM) will also calculate
efficiency metrics of individual components such as air heater, condenser,
turbine, combustion, and emissions control equipment.
Convective Heat Exchanger Performance
In power plant, it is important to monitor the performance of superheater,
reheater and economizer for convective heat exchange. The actual
performance value for each section is calculated by measuring water/steamside heat absorption, and performing an iterative gas-side heat balance for
each individual section. Radiation heat transfer is taken into account for the
upper heat transfer sections. The clean surface performance is calculated for
each section using design information and an iterative gas-side heat balance
for each section. The ratio of the actual operating heat transfer rate to the
predicted clean heat transfer rate determines the conditions of each section.
(ABB Switzerland, Power Technology Systems, Optimax Operations Products,
2005)
Furnace Heat Transfer Performance
An iterative heat balance calculation can also be applied to determine the
performance of furnace heat transfer areas. This calculation allows for heat
absorption in the roof and walls of the upper furnace, and the radiation heat
from the lower furnace. These heat transfer performance calculations lead to
244 | ABB Energy Efficency Handbook

a cleanliness value that can guide soot-blowing operations (See section on

soot-blowing systems).
Air Heater Performance
Similar methods are used to calculate the air heater performance and
cleanliness. The gas inlet temperatures at the air heater and other surfaces
can also be calculated. Significant deviations can be indicative of large energy
losses due to fouling or leakage.
Energy Efficiency Potential of Performance Monitoring
If the plant is properly instrumented, a PM system can be the key to a heat rate
awareness and improvement program. Such a program uses benchmarks and
key performance indicators calculated and displayed on-line in trend charts by
the PM system. The success of a heat rate improvement program depends on
an adequate assessment up-front, and management commitment throughout,
to ensure that the recommendations are actually implemented. According to
one example from EPRI, a PM system, together with a well-supported heat
rate program, improved heat rate by 1.5 percent and the net capacity factor
by 5.2 percent. Costs at that plant were also reduced by 2.3 percent. (Power
Engineering January, 2002, Douglas Smith)

A PM system is a very useful tool in plant heat rate improvement programs,

but the historical data in the system must be reliable; this means that primary
process information is acquired by properly installed, calibrated and maintained
instrumentation, as described in the section on Instruments and Actuators.

Condition Monitoring Systems

Field devices, and process actuators in particular, will degrade in performance with
accumulated operating hours, number of cycles, or due to fouling and corrosion
effects. Catastrophic failures attract attention due to the large single opportunity cost
of a trip. The slower, less-visible accumulation of wasted energy due to degraded
performance may rival these costs over the lifetime of the unit. The energy cost of
a reliability related trip is described in the section on Energy Cost of a Trip for a
discussion on the energy cost of poor reliability.
Rotating Machinery
Degradation or poor installation of the motor-coupling and bearings will reduce
drivepower energy efficiency and lead to maintenance problems. Periodic inspection
and measurement helps, but online condition monitoring of rotating machinery will
provide earlier warning of impending efficiency problems. A Condition Monitoring
Module 4 | 245

(CM) system monitors bearing vibration, eccentricity and axial rotor position on
any type of rotating machinery. These data are integrated into the DCS to leverage
the CS logging, trending and operator alarms functionality. The types of rotating
machinery deserving this form of condition monitoring are: turbines, feedpumps,
fans, pumps, motors, gearboxes and compressors.
Condition Monitoring is distinguished from process monitoring through the use
of models or other calculations to interpret the raw data and report on the actual
condition of the equipment. The large number of rotating machinery in a power plant
would make it difficult for operators to examine trends of each item. This type of
automatic analysis is especially important for vibration data, which is a distribution
of frequencies (a spectrum), which are both difficult and tedious for operators to
interpret. A CM system for vibration monitoring compares baseline spectral data
to current spectral data; any changes in the data are matched to a rules based
algorithm, which in turn determines the cause of the change. The result is actionable
information in the form of specific fault diagnosis, fault severity and maintenance
recommendation.

In power plants: for large journal bearing machines like Main Turbines and
Boiler Feed Pumps, these CM systems use Full Spectrum, Angle of the
Major Ellipse Axis and Aspect Ratio of the Ellipse for Orbit analysis plus
Shaft Centerline Position and Bearing Eccentricity. All these tools, along with
comparisons to user configured Threshold Values, combine to determine the
condition of the machine train, bearing by bearing.

Heat Exchanger Monitoring

The status of heat exchanger performance can be monitored in real-time using
measurements of flowrate and temperatures (in and out) of each stream. These
data are used to calculate the overall heat transfer co-efficient (U), using the
thermodynamic formula for heat transfer shown below.
Q = U x A x T
Where:
Q = heat transferred (kcal/hr)
A = area of heat exchanger (m)
T = temperature difference between hot & cold sides (log C)

246 | ABB Energy Efficency Handbook

All of these values are stored in a process historian database and then continuously
analyzed using a fouling factor model. This model is simply an energy balance
between the hot and cold streams within the exchanger. If the current overall
co-efficient is 5% or more less than the models prediction (Rajan 2003), then a
maintenance alert is triggered calling for proactive cleaning or problem investigation.

Control Systems
Evolution of Control Systems
Control systems have evolved from analog pneumatic controls to modern
microprocessor-based systems. There are two main branches in this evolution;
programmable logic controllers (PLCs) and Distributed Control Systems (DCS).
PLCs are the simpler of the two, and are most suitable for machinery control and
other areas of discrete manufacturing. A DCS is most suitable for processing the
large number of analog input/output (I/O) in a large power or process plant, and are
therefore often referred to as process control systems The term distributed in
DCS is meant to distinguish these from an earlier, more centralized control system
architecture centered around a process control computer. Another distinguishing
feature of DCS is their use of function blocks rather individual I/O tags for easier
programmability.
Distributed Control Systems (DCS)
A DCS provides all of the background services needed for control, operation and
monitoring:
Connections to various communication busses and networks
Controller CPUs and their associated I/O sub-systems
Human Machine Interface (HMI) for operator control, alarm and status indication
Historian services to log & store large volumes of real-time data
These DCS services can have a significant impact on plant energy efficiency. A
DCS is the only equipment type that spans all the diverse plant units. The reach
of a modern DCS allows improved coordination and plant optimization strategies.
Another source of DCS-related energy efficiency improvement comes with the
inherent tighter control of modern digital control systems, especially when compared
with legacy analog (e.g. pneumatic) control systems which may still live in the parts
of some plants. ARC Advisory Group (Dedham, Mass) estimates there is $65 billion
worth of control systems that are nearing the end of their useful life; at least a third
of these systems are installed in North America, and most of them are more than 20
years old.
Perhaps the most important benefit a DCS can provide to a plants energy efficiency
improvement program comes from this: it is the only plant system which has such a

Module 4 | 247

wide and rich interface to the operators and engineers. Thus, the DCS can leverage
the process knowledge in experienced plant personnel.

In power plants with antiquated analog control systems, a DCS upgrade

can improve unit controls to provide 2-4% greater output and heat rate
improvements (ABB Power Systems, USA, 2007).
The improved perfomance monitoring and HMI capabilities of a modern DCS
are an enabler for heat rate improvement programs which have been shown to
deliver 1.5% improvement. See Energy Efficiency Potential of Performance
Measurement.

Figure 4.10 Control room of Jnschwalde 6x500 MW plant : Before (left) and after (right) a
DCS modernization. Source: ABB Industrial IT for Power Plants.

Motor Control Centers

Motor Control Centers, or MCCs, allow more intelligent, automatic control of the LV
motors and other LV loads. An MCC provides the centralized intelligence to control
the contactors providing power to these loads. In many plants, motors may run
longer than necessary because they have only manual control in the field. MCCs
also enable improved monitoring of motor health, which leads to improved energy
efficiency of the motors through predictive maintenance. Most important of all, the
modern MCCs communication technology allows rich motor operation, performance
and diagnostics data to be shared with the process control and load scheduling
systems running in the DCS. Good communications and integration lowers the
threshold for real-time energy management and optimization schemes:
Intelligent load-shedding based on plant state, season, time of day
Feeder power allocation to most efficient or lowest CO2 power generating source

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 Optimization of duty cycle within all temperature constraints to eliminate or reduce

parallel operation
Off-line energy efficiency improvement programs can also benefit from the increased
amount and variety of data available from MCCs and integrated with process data. .

In power plant engineering, MCCs are also referred to as Combination Starter

Panels. MCC data can reveal hidden relationships between auxiliary power
consumption and fuel supply composition.
Recent advances in MCC technology allow for increased communication
between MCC and the process control systems. This integration can allows a
plant to startup and recover more quickly from a trip condition by coordinating
the many LV motors with the needs of the process control system; many
startups are aborted because of an LV motor which did not start, a condition
which is more easy to anticipate and avoid with MCCs.

Figure 4.11 Motor Control Center cabinet, and close-up of motor starter drawer (ABB Oy, 2007)

Module 4 | 249

Automation System Design and Engineering

The full energy efficiency potential of automation will not be reached unless a
systems approach is taken, which includes the entire hierarchy of control; from
the sensor to plant operating and maintenance procedures. Automation design
and engineering must go through all the familiar project phases as the other, older
disciplines. Just as PFDs form the design basis for a process concept, so does
the Control and Alarm Philosophy document guide the engineering of a process
automation system. (Shutdown strategy is also an important for of the conceptual
automation design). One of the outputs of a reevaluation of existing plant automation
systems should be a revised control strategy/philosophy document. High-level
control can be diagrammed even without the detail of P&ID drawings, using
established norms such as System Control Diagrams. In the simplest of terms, the
automation design and engineering steps are:

Develop control and alarms philosophy

Develop unit control strategy drawings
Develop P&IDs drawings
Perform instrument sizing from process requirements
Create I/O (tag) List
Develop DCS programming
Perform Factory acceptance tests (FAT), preferably using process simulators
Installation, commissioning and Site Acceptance Tests (SAT)

One of the challenges of retrofitting legacy automation systems is the lack of

documentation of the original control logic. Also, the logic source itself may be
written in a form not comprehensible to current plant staff. Understanding and
documenting the current logic may require more effort than simply starting from
scratch on a new automation platform.

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Automation System Design Guidelines Summary

Coordinated design with other engineering disciplines is a necessity for a successful
automation design. In simple terms, automation is about controlling for disturbances.
In the case of pumps and fans, the first step is to investigate the demand for flow
and to visit the process designers to see if it can be reduced. In automation, such a
process design discussion is also recommended to see if the sources of disturbance
can be reduced at relatively low cost. Most of these principles are simply good
automation design, but will lead to improved energy performance as well. Material
for this section is from ISA 77 standards, ABB and Emerson process experts.
Some general principles to guide and inspire the automation engineer who seeks the
most out of energy efficient designs:
Understand the process, then build and use models
Understand the process dynamics: degrees of freedom, gain, time constant and
especially its dead time.
Model the process to gain further understanding of its behavior and to tune your
designs, to get optimal setpoints, and to eventually train operators
Use a broad repertoire of control techniques to improve response
Use closed loop feedback instead of open loop control to keep the process at
setpoint and to correct for disturbances
Understand how the process is disturbed using data and models, then use
feedforward control to improve response to that disturbance
Use cascade control, with feedforward, to further improve control response to
rapidly changing loads, and to reduce effects of actuator non-linearity
Use model-based control to optimize multiple variable processes, especially those
processes with much non-linearity and dead-times.
Use smart, sensitive sensors to reduce dead-time, improve measurement
Use digital, smart transmitters to improve accuracy, eliminate drift and benefit
from onboard diagnostics.
Use multiple transmitters instead of only one, to increase the accuracy & reliability
of measurements.
Specify additional sensors required for the feedforward signals in your control
system strategy.
Locate sensors to decrease measurement lag, while still avoiding regions of
unstable measurement.
Specify controllers and IO systems with fast scan times to further reduce lags &
latencies

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 Specify fast, on-line analyzers rather than off-line, sample-based instruments, to

reduce loop dead-time
Use smart devices to control power input
Manage and control energy input; use VFDs for motor speed control instead of
control valves (for fluids) or dampers and vanes (for air/gas)
If control valves must be used instead of VFDs, specify CVs with low friction
packing to minimize stiction, and use a digital positioner. (ISA recommendation)
Equip dampers and louvers with smart positioners to obtain better resolution
Use signal characterization to improve linearity and response of actuators
Other guidelines:
Wait until commissioning to fine tune controllers under real operating conditions
Specify equipment with open,programmable interfaces to allow optimization
across vendors. monitor energy usage in real-time and use this data to trend &
manage energy KPIs.
Direct operations to use automation as intended without defeating it in whole or in
part by placing controls in manual mode.

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Module 5
Power Plant Automation Systems
Module Summary
This module describes the energy efficiency aspect of the plant instrumentation,
controls and optimization systems. A detailed presentation of all automation aspects
is beyond the scope of this handbook.
Gross Heat Rate and Capacity
Heat rate is the thermal energy required to produce 1kw-hour of electrical power.
Gross hear rate is the rating for gross power output from the generator terminals.
Since some of the power is used to run internal plant processes, and is thus
routed back into the plant via the unit auxiliary transformer, then the remainder
is delivered as salable power to the network. The thermal energy used to create
those deliverable kw-hours is termed net heat rate. The focus of previous handbook
sections has been on reducing in-house auxiliary loads through more efficient
electrical and mechanical design. These approaches increased net plant capacity,
and had their most direct effect on the net heat rate of the unit.
The focus of this module is on how automation can directly improve unit gross heat
rate though control action on steam cycle parameters. These gains come from
reducing controllable losses, which result from operation of the cycle equipment
away from the best efficiency points for given loads. Mitigating these controllable
losses is the main contribution of automation to improving energy efficiency.
Controllable losses tend to be higher than the cycle designers originally intended
because the plant seldom operates in steady state at its design point. Losses are
correspondingly higher at lower loads and during periods of load disturbances.
Controllable losses worsen under conditions of equipment age, and poor
implementation or tuning of boiler controls.
This section examines automation from an energy efficiency perspective and
does not provide guidance on other, critical aspects of automation engineering
such as safety interlock logic, emergency shutdown sequencing, human factors
engineering, or fault-tolerant design. For a more complete guide to all other aspects
of automation design see the standards and references sections of this handbook.

Module 5 | 253

The information in this module section is specific to power generation

industries or process plants with on-site power plants. Many sections, however,
are also broadly applicable to all industrial steam generation processes.

Power Plant Efficiency Concepts

An understanding of the basic thermodynamic principles of the steam cycle and
the basic principles of fossil-fuel combustion is essential to appreciate the actions of
plant automation systems. There are a number of ways to obtain the initial thermal
energy for the generation of steam, including the firing of oil, gas, waste & biomass.
The styles of boiler can vary, but typically there are only three main methods of firing:
pulverized fuel with multilevel wall or corner burners, fluidized bed, or stoker-fed. The
primary focus of the following discussion is the pulverized fuel boiler, as it currently
represents the single largest component of the global generation fleet.
Pulverized Coal Combustion Concepts
Pulverized fuel is mixed with preheated primary air and carried through multiple
burners, where it is injected and ignited in the lower interior of the furnace. Draft
and convection force the ignited fuel up through the active combustion zone, which
resembles a large fireball, where the vast majority of the available energy in the fuel
is released. Ultimately, the desired combustion product is CO2 and some H2O,
indicating complete fuel component combustion. Undesired products include CO
from incomplete combustion, and NOX resulting from air-related and fuel-related
nitrogen sources combining with available O2 at high temperatures. Rapid and hot
combustion reduces CO to virtually nothing, but if it is too rapid and too hot, then
thermal NOX is produced to great excess. Other undesired combustion by-products
require some form of handling or mitigation, and include SOx (SO2, SO3, etc.), ash,
carbon in ash, mercury and other heavy metal contaminants, radon, and unburned
hydrocarbons.
The rates and temperatures of combustion within the vertical combustion zone
determine the production of both desired and undesired combustion products, but
they are not constant throughout the boiler. The combustion zones inside modern
utility boilers occupy thousands of cubic yards. The size and firing rates of such large
boilers mean that fuel and air must enter the combustion zone from many locations
and at several levels within the boiler. Flows at each level need to be controlled to
both follow the load and optimally manage combustion.

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Review of Steam Generation Concepts

The figure below from IEAs Coal Online reference shows the main components in
a drum-type subcritical boiler. The boiler feedwater pump supplies water to the
drum through the economizer, which heats the feedwater to just under evaporation
temperature. The water circulates through tubes in the furnace walls, absorbing
radiant heat and evaporating to steam, which is separated from water in the
drum. The steam flows through the hanging tubes of the primary and secondary
superheaters before entering the high pressure (HP) turbine stage. The steam exiting
the HP turbine is reheated to much the same temperature before entering the low
pressure (LP) turbine stage and finally the condenser. Boiler efficiencies can be
relatively high, at up to 90-94% (LHV basis).

Figure 5.1 Simplified drum boiler diagram (IEA Coal Online - 2, 2007)

The furnace heat is transferred in these proportions, for a single-reheat subcritical

PC power-plant unit: 8% in the economizer, 3545% in the evaporator, 3040% in
the superheater elements, 15% in the reheater elements (IEA Coal Online - 2, 2007).
The air heater also recycles substantial remaining energy of the flue gas heat to
warm the intake air prior to combustion.
Parameters for Increased Thermal Efficiency
Cycle thermodynamics shows how the following basic system parameters can be
controlled to give greater thermodynamic efficiency in all power plants. Many of
these performance parameter values, including efficiency, are guaranteed by the
boiler manufacturer when the unit is fired with a specific type and quality of fuel.
Increase the average boiler steam outlet temperature and pressure up to safe
operation limit.
Decrease the average flue gas O2 of the boilers down to a level compatible with
opacity limits
Module 5 | 255

 Minimize the turbine extraction and exhaust steam pressures

Reduce flue gas exit temperature (FGET) down to a level which still prevents
condensation
The rules of thumb relating these parameters to thermal efficiency are given below,
with an assumption of linearity within typical operating ranges:
Boiler efficiency improves 1% for every 40 F (22 C) reduction in flue gas exit
temperature., whose heat is recycled by the economizer and air heater. Ref
(Babcock & Wilcox 2005)
For a supercritical unit: each 50 F (28 C) increase in main steam temperature
increases cycle efficiency by 1% (Babcock & Wilcox 2005)
For a sub-critical unit: each 50 F (28 C) increase in main steam temperature
decreases heatrate by 70 Btu (74 kJ) per kWh at full load, which corresponds to
an increase in cycle efficiency of approximately 0.7% (EPRI report CS4554)
For a sub-critical unit: each 100 psi (690 kPa) increase in main steam pressure
decreases heatrate by 35 Btu (37 kJ) per kWh (i.e. about 1/3 of a percent) at full load
(EPRI report CS-4554).
For a sub-critical unit: each 50 F (28 C) increase in reheat steam temperature
decreases heatrate by 65 Btu (68 kJ) per kWh at full load (about 2/3 of a percent).
(EPRI report CS-4554)
For a sub-critical unit: each 50 klb/hr (23 tonne/hr) reduction on reheat spray flow
decreases heatrate by 108 Btu (114 kJ) per kWh (about 1%) at full load. (EPRI
report CS-4554)
In industrial power generation situations and/or CHP plants, these additional system
parameters can be controlled for improved energy efficiency and lower operating
costs:

Minimize the use of pressure reducing valves by-passing turbine generators

Optimize (minimize) the use of the steam vent valves
Optimize the mix between purchased power and own condensing
Increase the use of low cost fuels, decrease the use of expensive fuels

Energy Efficiency Potential of Power Plant Automation

The energy efficiency potential of automation is summarized below, based on data
from ABB, IEA CoalOnline and the US DoE:
Faster plant start-up and shutdown by programming the plant-control sequences
256 | ABB Energy Efficiency Handbook

 Higher availability by detecting and indicating the causes of impending

malfunctions
Greater thermal efficiency by reducing process variability and moving variable set
points closer to the safe operating limits
Reduced emissions by controlling the combustion process and downstream
emission-control technologies
Lower maintenance costs by replacing pneumatic, electromechanical or
electronic/analogue devices
A decrease in operational costs by reducing staff requirement: todays
designers are even striving for single-operator control of coal-fired power plants
(Swanekamp, 1995)

Automation allows tighter integration between generator, turbine and boiler units,
which can give significant energy benefits. Integrated (real-time) control between
plant cycle equipment and between plant units is a particularly valuable technique
to achieve energy savings in co-generation power plants or process plants that
produce some of their own power and heat on-site (US DoE, 2004) p13. Retrofits
that include biomass co-firing can also be made more economic by means of tighter
integration with the energy consuming units.
The average life of a modern automation system varies from 10 to 15 years for
PC-based systems and 15 to 20 years for proprietary distributed control systems.
The cost of upgrading I&C in coal-fired plant is estimated to range from $1 to $6
million (Ferrer, Green Strategies for Aging Coal Plants, 2008). This cost is relatively
small when compared with some other steam plant upgrades of the power cycle
equipment, which may cost up to 5 times as much. DCS vendors (ABB, Seimens,
Emerson) claim heat rate improvements of 2-5 % can result from upgrading to a
modern DCS and advanced control technologies. The improvement could be even
higher if the energy saved from fewer trips were properly accounted for, and if
system-wide real-time optimization were included.

Module 5 | 257

Figure 5.2 Hierarchy of control in a fossil fuel plant, (ABB Solutions for Fossil Fuel Power Plants)

Power Plant Automation Standards and Best Practice

The International Society for Automation (ISA) is the source of many useful and
authoritative standards on industrial instrumentation, controls and optimization. The
ISA has formulated a collection of standards specifically for power plants: ISA SP 77
Fossil Fuel Power Plant Standards
Power Plant Automation Systems Overview
The main automation systems in a steam power plant are listed below. Protective
safety systems and most non-boiler service systems are out of scope of this
handbook.
Boiler-Turbine Control
Unit load control (Megawatt control)
Combustion/Firing rate control
Fuel Master, Fuel/Air Control

Excess Air Control

FD Fan Control, Furnace draft pressure(ID fan) control

Feedwater flow (drum level) control
Gas flow distribution (gas recirculation) control
Turbine-generator control
Turbine Control valves
Superheat & reheat temperature control
Special monitoring:

Gas analysis : O2, CO

Air flow, fuel flow

258 | ABB Energy Efficiency Handbook

Burner Management
Boiler startup / shutdown system
Fuel management systems : pulverizer, PA fan control
Furnace monitoring: Flame stability
Emissions Control
NOx control
SO2 control
Special monitoring:

Particulate count in flue gas
Condenser & Condensate Controls
Condensate controls (Water level in de-aerator tank etc.)
Coolant controls (circulating water control, cooling tower control)
Fuel Preparation Systems
Soot-Blowing Systems
Water Treatment Systems
Additional plant-wide automation systems
System-wide (multiple unit or site) optimization
Power Management System
Asset Management System
Motor Controls System
The interrelated set of boiler-turbine controls are shown in the figure below:

Figure 5.3 Utility Boiler and Turbine Control System, ABB Power Systems, Application Guide,2008

Module 5 | 259

Plant Operating Modes

A power plant is usually designed for a certain operating mode. An operating mode
is a combination of a plants duty-cycle and load response.
Duty Cycle
A duty-cycle is a units loading during a given time period. The typical unit duty
cycles are:
Base loading
:

Shift loading
:

Day/Night loading :

unit operated at constant load 24 hrs/day, 7 days week.

(nominally 8000 hrs/yr)
unit operated at constant load during each 8-hour shift,
reduced (banked) in-between
unit operated at constant load during day, then banked or
shutdown overnight

For a typical PC utility boiler, a cold restart after a complete shutdown may take
between 6 to 12 hours. A unit operating in reduced or banked mode can be hotstarted in a much shorter time. A banked unit operates at much below its capacity,
in anticipation of being dispatched to handle peak loads. This is sometimes referred
to as spinning reserve.
Load Response
Load response is usually dominated by one of the following:
Frequency response: operated at nominal load (one of above) but modulated
to compensate for network frequency disturbances. In frequency response, the
turbine governor responds immediately to the frequency drop that accompanies
an increase in end-user demand for electricity in the network.
Load-following: a unit may be asked to operate anywhere between 30% and
100% of its MCR as part of a load dispatch system, and where it may be required
to change load at a rate of as much as 5% per minute (IEA Coal Online - 2, 2007).
In most response modes, the unit load demand is established by a remote
dispatcher, part of a wide area networked load control system. Load-following is an
increasingly more common mode of operation in deregulated or liberalized markets,
as shown by average availability figures in the region of 85% for sub-critical PC
plants (IEA Coal Online - 2, 2007).
Flow Rates
The plants operation may also be expressed in terms of main steam flow rates to
the high pressure turbine. Some important main steam flow rate terms are:
Valves Wide Open (VWO) plus 5% - condition applies to units specified to run with
a 5% overpressure
260 | ABB Energy Efficiency Handbook

 Peak the maximum capacity, which is used for sizing of all other systems,
including auxiliaries. This flow is not maintained for long periods.
Maximum Continuous Rating (MCR) the steady-state maximum flow condition
Minimum flow the minimum stable flow condition

Boiler-Turbine Control
Boiler vs. Turbine Following Modes
The boiler can store energy and supply it to the turbine-generators control valve at a
certain throttle pressure. The control valve regulates steam flow for initial response
to demand. In some turbine-generators, finer control is provided by a bank of
nozzles per turbine stage; at most, only 1 such nozzle will be throttled at any given
time. See the Turbine-Generator section for more description on turbine control
actuators and position control.
The boiler responds much more slowly to demand, through changes to fuel firing
rate, due to its larger mass and thermal storage capacity. In boiler-following mode
the turbine-generator provides megawatt control and the boiler catches up to restore
throttle pressure. In turbine-following mode the boiler provides the initial demand
response by increasing firing rate and hence throttle pressure; the turbine-generator
follows by adjusting its control valves to maintain throttle pressure. Boiler-following
mode is more responsive but less stable than turbine following mode, and puts more
thermal stresses on the turbine.
Constant Pressure vs. Sliding Pressure Operation
In the modes discussed above, the boiler (hence throttle) pressure is basically fixed.
The boiler is fired at a rate that will produce enough steam for the turbine to satisfy
electrical power demand. The turbine steam valve(s) are modulated to maintain a
constant pressure at the turbine inlet. Throttling of the turbine valve at lower loads
will reduce steam pressure and temperature downstream of the turbine inlet, which
reduces turbine efficiency.
In sliding-pressure operation, boiler pressure is allowed to vary with load, the steam
turbine valves may be left open, and steam production is controlled by adjusting
boiler pressure. The boiler must still be fired to produce the required the steam flow
to satisfy demand. Sliding pressure operation is more efficient at lower loads, due
to lower first-stage turbine throttle losses (hence higher, and better controlled inlet
temperatures) and reduced boiler feedwater pump power when compared to the
higher, fixed-pressure operation. The higher first-stage temperature also increases
reheat steam temperature at low load, which further reduced heat rate. Sliding
(or variable) pressure operation, however, is slower to respond to demand - the
typical demand response rate is 50% of the rate under constant pressure operation.
Module 5 | 261

(Babcock & Wilcox, 2005). Boiler thermal stresses are also greater in slidingpressure operation, due to increased cycling of the boiler.
As a matter of practice in sliding-pressure operation, the turbine inlet valves are
generally held at a constant position between 20% and 70% load; outside of this
range, the unit is operated at constant pressure. Between 70 and 100% load, the
operating curves for the two modes are identical (ABB Inc. Plant Automation, 2006).
This level of throttling capability can provide reserve steam to meet sudden increases
from lower demand (IEA Coal Online - 2, 2007).
If rapid response to demand is required, one technique is to divert some steam from
feedwater heating so that it can be instead expanded in the turbine to generate
power; the section on Condensate Controls and the Schwarze-Pump case discuss
some of the efficiency trade-offs for this technique.
Another means of variable pressure control is by the use of large division valves in the
superheater flow links (Black&Veatch 2008) . This method keeps the boiler operating at
higher pressures and therefore does not benefit from BFW pump power reduction.
Sliding pressure method is also suitable for once-through supercritical designs, where
more rapid output changes can be achieved because of their lower thermal inertia.
Once-through boilers can increase output by 5% per minute, compared with a typical
3% per minute for drum boilers (Luby, 2003, as cited in (IEA Coal Online - 2, 2007).

Case Example
Unit C of the E.ON Scholven Power Plant, Germany

Figure 5.4 ABB AG Power Technology Systems, 2006

The power produced in the Scholven power plant covers approximately 3% of

the overall power demand in Germany, with gross output of 2,200MW.

262 | ABB Energy Efficiency Handbook

Because of the new market situation, unit C, initially intended for base-load
operation, is now being used in the medium load range. An inlet-pressure control
mode (the turbine controlling the pressure and thus supporting the boiler),
plus natural and modified sliding-pressure modes with an adjustable degree of
turbine throttling (turbine or boiler following mode) needed to be implemented.
In order to be able to follow the signal issued by the network controller, the
control concept must provide for frequent load ramps and load deltas with high
load variation rates, without any equilibrium conditions during load reversals for
secondary control purposes.
The primary grid frequency control of the unit is responsible for the balance
between the power generation and load consumption in the grid. The grid
secondary control (load-frequency control) is provided by a load dispatcher,
which regulates the agreed load exchange between the interconnected power
supply partners and the overall grid.
Due to the complexity of the primary and secondary control tasks, a modelbased unit control system (ABBs MODAN) was chosen. The model uses the
two main manipulated variables fuel flow for the boiler and the turbine control
valve in a coordinated mode. This is done by considering internal dynamic
models for live steam pressure and unit load. [If further control actions in the
condensate heating line are available, such as speed-controlled condensate
pumps or valves, the second unit control variant MODAKOND can be applied.]
This control strategy and operating mode has improved plant efficiency for
primary frequency control through reduced throttling of the turbine control
valves. An added benefit has been reduced control activity which allow for
smoother operation of main components like pulverizers, FD and ID fans,
thereby reducing plant operation costs. (This case text provided by ABB AG,
Power Technology Systems, 2006)

Module 5 | 263

Figure 5.5 Boiler automation system for Scholven unit, ABB AG Power Technology Systems, 2006

Coordinated Boiler-Turbine Control

In older plants, fuel flow control, boiler pressure and turbine steam flow control were
separate control loops to accommodate either boiler or turbine following modes.
These base control loops acted independently, making it difficult to optimize the
process, and frequent operator intervention was required. During large process
upsets it was difficult to maintain the steam conditions within acceptable limits,
especially in multi-boiler and steam header plants. When large enough, such a
process upset would result in a boiler trip.
Benefits of Coordinated Control
Boiler-turbine coordinated control combines the two control strategies by distributing
some demand responsibility to both boiler and turbine for improved overall response
and stability. The distribution of demand provides advantages similar to that of feedforward control and reduces continuous interactions between these control loops;
an advantage for precise load control in a wide-area load dispatch system (Babcock
& Wilcox, 2005). Coordinated control can be used with either constant or sliding
pressure operation.
Coordinated control is especially suited for load-following operation, where
maintaining efficiency at low loads is important for a units economic viability.
This operating mode responds well to load dispatcher signals which allocate more
generation capacity to plants with higher efficiencies. Coordinated control provides

264 | ABB Energy Efficiency Handbook

the operator with the flexibility to choose between base-loading and ramp-loading
(load following). The control technology may be either model-based or using
feedback loops. Feedback control is improved by using feedforward and adaptive
tuning techniques. The increased stability of coordinated control allows the unit to be
operated closer to its optimum at base loads, and more efficiently under low loads.
The combined effect of coordinated control is a heat rate improvement of 4% to 7%
(Ferrer, Small-Buck Change Yields Big-Bang Gain, 2007).
Pre-packaged controls in the turbine-generator equipment may not be able to
participate in a coordinated control scheme. In such cases, it is recommended to
simply remove or bypass these controls in favor of a coordinating controller. See
the Turbine-Generator section for more description on turbine controls.
Coordinated Control Demand Development
In coordinated control, a limited megawatt error signal offsets the throttle pressure
error, allowing the turbine to sustain initial megawatts until the boiler catches up.
A similar strategy provides the boiler demand signal. Adaptive tuning improves the
controllers sensitivity to different process time constants and for changes in energy
storage after large load changes (ABB Inc. Plant Automation, 2006). Dynamic
functions are used as the source of feedforward to overcome inertia in either turbine
or boiler. The boiler feedforward may be a simple model using time delays.
For a description of model-based control, see the Scholven case text in this
handbook. For details on development of the unit load demand signals, see the
references: (ABB Inc. Plant Automation, 2006; ABB Inc. Plant Automation, 2006)
and (Babcock & Wilcox, 2005).
Combustion Control
A combustion control system modulates the supply of fuel to the furnace and
also the amount of air supplied for combustion of that fuel to satisfy the demand
for energy. This fuel/air supply is also known as the firing rate, so this system is
sometimes referred to as firing rate control. The air/fuel ratio of a typical boiler is
controlled to within +/-2% of excess air (ISA 2005)
Fuel Control
A typical PC boiler combustion (or firing rate) control system receives a demand
signal from the integrated boiler-turbine control system and trims it with error signals
from main steam temperature and feedwater flow. The resulting firing-rate demand
is distributed to the subsidiary fuel flow control and air flow control via a fuel-air
master controller. The fuel flow control compares its demand signal to the total fuel

Module 5 | 265

flow for all pulverizers. The resulting command signal is sent to the pulverizers group
master controller which applies the error signal in parallel to all pulverizers, along
with a demanded air flow, which is PID-controlled on each pulverizer (Babcock &
Wilcox, 2005).
Air Flow Control for Combustion
This section is adapted from an article in Power Engineering by Richard Vesel
(Vesel, 2007):
(The drive power aspects of draft fans are discussed in the Drive Power- Fan
sections of this handbook.) Airflow control is essential to efficient and safe
combustion process. Methods of airflow control vary with the basic boiler type;
the descriptions in this section apply to a sub-critical, PC boiler design.
The basic combustion (primary and secondary) airflow control strategy is: the fuel-air
master receives a boiler firing rate demand signal from which it calculates a total air
demand based on current fuel feed rates. The air flow demand is compared with
actual flows summed from transmitters in the primary and secondary air streams.
This error signal is used by the secondary (FD) fan controller to adjust motor speed
or the damper position to modulate the flow.
These final control elements must be accurately and speedily positioned for even
basic control schemes to be effective. Inaccurate or weak damper drives cause poor
combustion control response and reduced efficiency. See the section on Process
Actuators for more details on damper actuators. An opportunity to improve airflow
control method is when a plant must upgrade the main draft air driver systems with
higher power motors to make up for additional resistance from post-combustion
flue gas processing (SCR and FGD among them) as described in the section on
Emissions Controls. A plant can realize large energy benefits by controlling main
air flow with variable speed drives such as VFDs.
Air Flow Control for Draft Control
Furnace draft pressure control is a housekeeping loop within combustion control.
The ID fans serve to regulate furnace draft backpressure so that flue gasses can be
exhausted at the correct flowrate. ID fans are controlled by a feedforward program
based on air flow demand, corrected by a furnace pressure deviation from setpoint.
Air Flow Control and Energy Efficiency
Excess O2, CO and NOx are the critical pieces of information needed to properly
manage combustion air flows. The solution that achieves and maintains essentially
complete combustion while minimizing production of NOx relies on the controlled
feeding of air into the combustion zone at various stages and in just the right
amounts. This promotes burning at temperatures high enough to consume all
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available fuel, but low enough (that is, under 2,800 deg-F or 1550 deg-C) to avoid
production of NOx in great quantities.
Other effects of this staged combustion process are: elevation of flue gas
temperatures and higher temperatures in the upper interior, as well as the backpass
of the boiler. Ash may reach fusion temperatures to form an especially tenacious slag
on boiler tube surfaces. CO-rich dark zones in the lower furnace can chemically
attack boiler tubes, so underfire air has been used to reduce this problem. With
these various competing needs, the air balancing act within the boiler becomes even
more delicate, more difficult to model and control, and harder to maintain under
dynamic load conditions. Poor air control wastes fuel and degrades heat rate, both
of which increase costs.
The problems associated with outdated damper drives are described in Process
Actuators. Plant owners can improve performance and reduce cost of ownership
by replacing traditional fan-motor-damper arrangements with fan-motor variable
frequency drive (VFD) system. A VFD provides variable speed control of a fan
in response to a signal from a controller. Response times for VFD are a bit slower
than direct damper control due to fan and motor inertia. However, if precise control
are used on trimming dampers, then optimal results can still be realized. Dampers
are also increasingly important for control adjustments at speeds less than 33% of
maximum (ISA 2005).
Automation Potential for Energy Efficient Design
Efficiency gains in combustion process have a direct impact on fuel costs (which
are 45-55% of the cost of the generated electricity- (IEA Coal Online - 2, 2007)) and
plant heat rate. The thermal efficiencies of boilers are already high (up to 94%) and,
according to the IEAs Coal Online it appears unlikely that further large gains in the
efficiency of heat recovery from state-of-the-art PC boilers can occur.
Such thermal efficiencies are calculated from steady-state mass and energy
balances, however, they do not consider the detrimental effects of unstable
operation. Unstable firing rates will deter operators from keeping the boiler operating
near its design constraints and optimum efficiency point.
Unstable boiler operation may occur after a retrofit to low NOx burners, or
after switching to different fuels. Other contributors to instability may be due to
uncorrected deadband or non-linearities in the throttle control valve(s). If the current
control system gains are too high, then the response to load demands may also lead
to swings in firing rate. One consequence of swinging between under- and over-firing
is instability in the flue gas and thermal distributions within the furnace, leading to
poor heat transfer at water wall tubing. Another disadvantage of unstable conditions
Module 5 | 267

is revealed in high carbon-in-ash losses; these contribute to a higher heat rate and
indicate incomplete burnout.
It is estimated that stabilizing firing rate, furnace draft and air flow can give 1-2%
improvement in heat rate most units (ABB). A simple approach to curing boiler
instability is to reduce the gain such that ramp rates start low, and then accelerate
if the ramp direction demand persists. (Ferrer, Small-Buck Change Yields Big-Bang
Gain, 2007). This large impact on energy efficiency should put combustion
controls at the forefront of a plant controls assessment and/or combustion
process optimization effort.
Combustion Optimization
Combustion optimization is distinct from combustion control, which is essential to
control firing rate for basic boiler functionality and safety. Optimization improves
upon basic performance. Optimization also implies the use of model-based
techniques such as MPC.

Figure 5.6 Combustion optimization system schematic, (ABB Fossil Fuel Plants, 2005)

Feedwater Flow Control

Feedwater flow control modulates pump flow to achieve the desired drum water level
and water pressure. The main boiler feedwater pumps (BFP) supply feedwater up
into the boiler at high pressure where it can begin the water/steam cycle again.
There are 3 different control methods for regulating feedwater flow and drum water
level. In single element control, a loop with proportional-integral (PI) control acts on
the input signal from drum level transmitter. In two-element control, the outgoing
steam flow is used in a feedforward loop, while drum level control continues to
correct for level disturbances. Two-element control is most common in industrial
boiler applications (Babcock & Wilcox, 2005). In three-element control, a water flow
measurement is used in a cascaded fashion. A drum-level error signal is summed
268 | ABB Energy Efficiency Handbook

with a steam flow feedforward signal to provide the feedwater demand. This demand
is then compared with the water flow measurement to provide an error signal input
to the inner PI control loop. The more accurate feedwater flow control systems
also use shrink-swell compensation to compensate for water density and volume
changes as temperature changes.
Demand for Auxiliary Drivepower
Large demand for auxiliary drive power comes from the main and booster boiler
feedwater pumps (BFPs). The drive power aspects of the BFP are discussed in the
Drivepower-Pump sections of this handbook. BFW pumping is a high-system head
application for VSD speed control; a large part of the speed control range is used in
developing pump head at low flow (ISA 2005). Benefits are therefore lower than in
high-flow, low-head systems, but VSDs are still worthwhile in this application when
compared to throttling.
The ability of VFDs to provide over-speed capacity (within the service factor of the
motor and pump) may be useful in boilers which are designed with extra margin for
overpressure operation. This extra capacity may be needed to supply peak loading
on hot summer days.
Another auxiliary load on many boiler designs comes from the relatively lower power
boiler recirculating pump, which moves water between drum and the boiler water
walls. This auxiliary load is eliminated in supercritical designs and in some HRSG
designs which use natural circulation within the boiler.
Automation Potential for Energy Efficient Design
Stable feedwater flow control allows the unit to operate closer to its design point for
main steam pressure. For a sub-critical unit: each 100 psi increase in main steam
pressure decreases heatrate by 35 Btu per kWh at full load (EPRI report CS-4554).
Steam pressure in a typical boiler is normally controlled to within +/-1% of the
desired pressure (ISA 2005).

Case Example
A feedwater pump use at a U.S. pulp and paper mill. As the peak load does
not exceed 4,000 gpm (25 l/s), and two of the pumps can produce the required
pressure at flow rates of 2,000 gpm (13 l/s) each, operating only two of the
pumps would be sufficient.
The savings achievable from shutting down an extra feedwater pump are sitespecific, depending on the pump size, the type of the drive (motor vs. turbine

Module 5 | 269

driven), price of electricity, etc. A typical range of savings is $50,000-$250,000

per year.

Case text and image from (Immonen, Assessing Industrial Power Plant
Operations & Controls, 2003)

Flue Gas Recirculation Control

Flue Gas Recirculation (FGR) is used by some units to decrease the proportion of
excess air (O2) in the furnace by partial recycling of flue gas back into the boiler
combustion zone. FGR may also have a secondary function of controlling steam
reheat temperature. The flue gas is typically extracted from some point after the
particulate control equipment and displaces fresh draft air so that the total mass
flow through the furnace remains constant.
This section is adapted from material provided by ABB Power Systems, USA:
A typical FGR system consists of one gas recirculation fan with an inlet damper
used to control the flow and two outlet dampers to divide the flow to between the
burner windbox and the boiler furnace hopper. A load based index adjusts the inlet
damper to maintain a ratio of gas recirculation and boiler air flow. A PID controller
reacts to the windbox O2 value to maintain a setpoint value of O2 in the windbox at
all times. The windbox O2 increases as the windbox damper position increases. The
hopper damper demand changes inversely to the windbox damper. The demand to
the inlet damper includes a bias from the windbox demand that is included to allow
the windbox damper to maintain the windbox O2. The resulting increased boiler
efficiency from the reduction in excess O2 is described in Parameters for Increased
Thermal Efficiency.
FGR Drivepower and Control
FGR is a useful means of controlling excess air, but the FGR fan consumes in-plant
operating power and requires maintenance. These extra costs may be higher (per

270 | ABB Energy Efficiency Handbook

hp) for FGR systems due to the higher temperature and higher particulate count in
the extracted flue gas, compared to fresh draft air fans. To avoid excessive blade
erosion under thee harsher conditions, these centrifugal fans typically have a less
efficient forward-curved blade design (as described in the section on Fan Power
and Energy Efficiency) which increases the per unit demand for auxiliary power.
A retrofit of the FGD fan motor to VFD speed control will save auxiliary power,
especially at low loads, compared to other means of flow control.
For FGR fans with inlet dampers for flow control, automation can be used to
program a smaller opening at low loads to minimize plant auxiliary load. Whether
using inlet dampers or VFD, improved flow control will also improve the ability of the
O2 and combustion controls, especially during load changes and under low load
conditions. Adaptive tuning will improve response across a wider load range, and
the distribution of recirculated flue gas may also be optimized for different loading
conditions. Another role for FGR automation is to modify the gas recirculation flow
in order to reduce the thermal stresses seen during the load changes in the lower
operating region.
Turbine-Generator Control
Where the steam flow is used to set the output at part load, there are three potential
means of control (throttle, nozzle and bypass governing) to set the flow rate to adjust
the power output as required. The turbine governor operates to maintain frequency
control during startup or big load changes. After reaching equilibrium, the turbine
then goes into load control mode.
Turbine-generator efficiency is typically 43.4% (IEA Coal Online - 2, 2007), expressed
as a ratio of output electrical power vs. thermal BTU power entering the HP steam
input. Steam turbines cannot use the latent heat of condensation, so this latter
energy is often omitted from turbine efficiency calculations. See the Coordinated
Boiler-Turbine Control section of this handbook on how sliding pressure operating
mode can reduce throttling losses across the turbine control valves compared to
constant pressure operation. Steam extracted from the turbine stages for feedwater
heating reduces unit power generation capacity, but increases thermal efficiency.
The automation potential for controlling this flow is discussed in the section on the
Condensate System.

Module 5 | 271

Figure 5.7 Turbine Generator unit photo, (ABB Solutions for Fossil Fuel Power Plants brochure, 2007)

Automation Potential for Energy Efficient Design

There are significant energy efficiency benefits in upgrading steam turbine controls
to new servo drives (mechanical-hydraulic actuation devices) for the HP and IP
control valves as part of a turbine control improvement. Older turbine valve actuation
methods suffer from hysteresis, non-linearities, and poor dynamic response. These
effects may allow for very poor maximum control accuracy of only +/-10%, and
suffer from increased maintenance needs as these older mechanical linkage facilities
and drives are more subject to wear and excessive clearance effects.

272 | ABB Energy Efficiency Handbook

Upgrading turbine valve servo drives and their controls can improve accuracy to
+/-1%. Other advantages of the improved linearity and optimized positioning
times are: improved dynamics, smoother operation, reduced throttling losses, and
enhanced stability; the following case history describes the benefits in more detail.

Figure 5.8 Upgraded turbine valve servo drive photo, (ABB Utilities GmbH, 2004)

Case Example
Upgraded Turbine Components and Unit Controls
Blnod Power Plant Units 3 &4, EDF, France
The fossil-fueled units 3 & 4 of EDFs CPT Blnod power plant are more than
30 years old located at Pont a Mousson, Lorraine, France. The maximum net
output of the plant is 265 MW.

Figure 5.9 CPT Blnod Power Plant Units 3 &4, EDF, France
Module 5 | 273

Upgrading measures were sought which could improve the maneuverability and
efficiency of the plant. The three technical upgrade requirements were:
Fast power output increase for the purpose of primary grid frequency
control; at an amplitude of up to 25 MW within 30 sec
Participation in tlrglage; the load ramps being specified by the load
dispatch center for the purpose of secondary frequency control, at an
amplitude of up to 50 MW and a gradient of 7 MW/min
Higher economic efficiency achieved by an enhanced operational efficiency
Plant measurement data and operational experience indicated that the older
electrical-hydraulic and mechanical components of the turbine would need an
upgrade to ensure the required dynamic response, in conjunction with a new
digital turbine controller.
The new digital turbine controller is of a modular and flexible design and
provides in combination with new mechanical-hydraulic activation devices
for the HP and IP control valves the basis for meeting the dynamic demands
of the process. The previous mechanical linkage facilities and drives showed
excessive clearance and effects of wear and tear. They were replaced by new
low-maintenance servo drives which were adapted to the specific needs of the
turbine.
The new model-based boiler-turbine unit control system coordinates
the operation of the boiler and the turbo-generator set. The unit control
explicitly allows for the dynamic and highly varying behavior of the two major
components, i.e. the boiler (dynamically slow) and the turbo-generator set
(dynamically very fast). Positioning interventions are done via the turbine
control valves and the fuel setpoint of the boiler. As a result, the operation can
take place both in coordinated boiler-following mode, with the turbine being
output-controlled, and in turbine-following mode, with the boiler being outputcontrolled. The output setpoint is adjusted to the level requested by the power
purchaser via an external grid controller and is additionally superimposed on
the manually-specified basic unit setpoint.
The economic efficiency of the plant has been enhanced by migrating from
constant-pressure mode to sliding-pressure mode. This way, it was possible
to reduce the auxiliary power consumption of the feedwater pumps and to
increase the overall efficiency of the units. Other benefits of the upgrade
are: reduced throttling losses of the turbine, improved control accuracy and
smoother operation. Control accuracy is improved from +-10% to +-1%.

274 | ABB Energy Efficiency Handbook

With these goals being accomplished, the plant can now demand higher
prices when selling its electricity in the power market, as the price for providing
secondary-frequency power control is determined on the basis of the maximum
possible power amplitude and by the change gradient of the load ramp. Moreover,
the plant is also able to participate in the European power market, although this is
not in-tended at present.
(Case text adapted from ABB Utilities GmbH, 2004 brochure on Upgrade of
Blnod Power Plant )

Excess Air Control

Excess air minimization is a frequently attempted efficiency improvement. The
objective is clear, and the savings are easy to quantify in terms of fuel savings.
Many successful implementations are currently in use, but significant room for
improvement exists. Note that excess air control is one of several other combustion
controls; see the handbook section on Combustion Control for more details on
other methods.
Excess Air Concepts
A primary combustion quality measure is excess oxygen in the flue gas stream. Due
to imperfect mixing, the combustion process will require more than the chemical (i.e.
stoichiometric) amounts of air for efficient combustion. For a PC drum boiler, the excess
air level at 50% load may be controlled to twice that at full load. (Black & Veatch, 1996)
Too little excess oxygen implies incomplete combustion, elevated levels of CO,
unburned carbon and volatile hydrocarbons and the potential for loss on ignition
(LOI). Too much excess oxygen means lowered efficiency due to unnecessary heating
of the unused components of the draft air stream, as well as excessive generation of
thermal NOX due to fast combustion in hot zones within the boiler. Between these
two extremes is a region of optimal performance shown in the following figure:

Module 5 | 275

Figure 5.10 Unburnt fuel and stack loss curves for combustion, (Plantservices.com, 2007)

Measurement of Excess Air

Indicators of incomplete combustion, as well as particulate contamination, used
to be available from stack gas opacity monitors. With the advent of direct oxygen
measurement sensors for harsh environments, it became possible to reliably and
continuously measure excess O2 in the flue gas stream. Measurement of excess
air is done by measuring the levels of oxygen (O2) content in the flue gas stream,
but air in-leakage also may cause an overestimation of excess air in the furnace.
Carbon monoxide (CO) monitors are often used in parallel with oxygen monitors
to verify adequate levels in the furnace. Increased CO levels indicate incomplete
combustion (Black & Veatch, 1996)
Automation Potential for Energy Efficient Design
Applying the above measurements along with thermal efficiency calculations led
to determinations that for most boilers, the best settings for excess O2 fell in
the 3 percent to 6 percent range. More detailed thermal modeling and analysis on
individual boiler configurations allows for more precise determinations.
Placing O2 under automatic control (a dedicated oxygen trim module) creates an
overall optimum level of combustion during steady state operations. The control
system calculates and adjusts overall draft air flow based on the observed variations
in excess O2, while other controls adjust fuel flow to match load requirements.
More advanced furnace designs and complex control schemes allow for individual
adjustments to FD, ID, primary, secondary and overfire air flows. Some of these
settings are under continuous and full automatic control, while others are manually
set via fixed position dampers at individual registers, such as balancing overfire
air registers, and bank functions are controlled by master automated dampers.

276 | ABB Energy Efficiency Handbook

The O2 control module should also offer automatic override of opacity; this could
promote operator confidence and lead to more time in efficient automatic mode
(Ferrer, Small-Buck Change Yields Big-Bang Gain, 2007).}
The figures below show that improvement potential still exists among industrial
power plants. The leftmost curve shows the O2 variability of boiler A, plotted
against the steam flow. The chart on the right includes a similar plot for boiler B.

Figure 5.11 Boiler excess air control (Immonen, Assessing Industrial Power Plant Operations & Controls,
2003)

Both of the steam generators are swing boilers providing industrial process power
and hence subject to large variations in steam demand. As can be seen, boiler B
controls the flue gas O2 content accurately, along the load based setpoint curve.
The O2 readings of boiler A have a lot of scatter, suggesting that the combustion air
controls could be improved significantly (Immonen, Assessing Industrial Power Plant
Operations & Controls, 2003).
Benefits of Automatic Excess Air Control
Based on findings from numerous improvement projects and assessments, the
typical potential reductions in flue gas O2 range from 0.5% to 2.0%. To estimate
the fuel savings, a rule of thumb could be used stating that one percentage-point
drop in O2 improves the boiler efficiency by 0.5 %. More accurate estimates require
boiler combustion and energy balance calculations. The actual cost reductions
depend on the boiler size and the fuel cost, and the range of savings can be wide.
The documented annual savings from recent industrial power plant projects were
between $30,000 and $200,000 per boiler.

Module 5 | 277

Reduction of furnace excess air can yield a 3% to 5% improvement in heat rate in

some older PC steam plants. These gains are typical for plants in which operators
spend much time in manual control of air flow to avoid opacity excursions. High
opacity means that the exit gas exceeds limits on the total suspended particles (TSP).
Lower excess air can also provide other benefits. The induced draft fan capacity
often limits the combustion of other fuels such as waste or biomass. With excess
air controls, the overall air demand is lower, so the waste fuel throughput may be
increased, thus decreasing expensive fossil fuel usage. The associated savings can
exceed those from the efficiency improvements.

Steam Temperature Controls

As firing rate and steam flow decrease from the design full-load conditions, the main
and reheat steam temperature tend to decrease, which results in reduced turbine
cycle efficiency (according to Carnot cycle theory at the start of this module) For an
acceptable efficiency across a wider range of loads, most boilers are designed to
maintain steam temperature over a specified load range. The control point is the
lowest point at which design temperature steam can be produced, typically 60% of
the maximum continuous rating (MCR) (Black & Veatch 1996) p.192. Some boilers
cannot achieve full superheat at lower loads, and in such cases the temperatures
may not improve through better controls. By means of more accurate boiler steam
temperature control, it may be possible to reduce temperature variations, and
thereby apply a higher temperature setpoint.
Higher steam temperatures have a significant effect on heat rate by improving the
fundamental thermodynamic efficiency of the heat engine. These improvements are
quantified in the section on Energy Efficiency Potential of Power Plant Automation.
Steam Attemperation Concepts
This section is adapted from an ABB Application Guide, (ABB Inc. Plant Automation
2006)
The primary means of controlling main steam temperature is by injecting feedwater
sprays into the superheater line, known as attemperation. The attemperation water,
which is 2-5% of the total steam flow, may come from the boiler feedwater pump
outlet, or further downstream, just before the economizer inlet. The water is typically
sprayed prior to the secondary superheater, as shown in the figure below. From an
energy efficiency standpoint, attemperation would be more effective and require
lower flows if sprayed further downstream. The risk of water damage to the turbine,
however, requires that water have time to mix and evaporate thoroughly before
entering the turbine.
278 | ABB Energy Efficiency Handbook

Figure 5.12 Steam temperature control diagram, (ABB Inc. Plant Automation, 2006)

Attemperation flow may also be tapped directly from a special outlet within the main
feedwater pump (IEA Coal Online - 2, 2007). Bypassing feedwater heating has a
negative impact on cycle efficiency. See the Pump sections for discussion on the
pump power requirements for these two alternatives.
Other means to control steam temperatures are; tilting burners away from the
superheater tubes, using bypass dampers in the back-pass or convection portion of
the unit (larger boilers that include these dampers can have 12 or more each of the
superheat and reheat dampers), or using flue gas recirculation (FGR) to moderate
combustion. These methods are typically used for longer-term adjustment (Babcock
& Wilcox 2005) compared to the quick action of spray attemperation to provide
control of transients. Attemperation flows can be eliminated on supercritical boilers
by controlling the firing rate to match the feedwater flow (IEA Coal Online - 2, 2007).
Advanced Steam Temperature Control
Steam temperature excursions are a result of an imbalance between the heat added
to the steam by the firing rate and the heat withdrawn, by the steam flow rate. An
advanced control strategy will control steam temperature for a drum boiler operating
in either constant or sliding pressure mode. Specific algorithms and techniques used
by the advanced control strategy include:
The use of enthalpy calculations to determine the different SSH inlet temperature
set points when operating in a variable pressure mode.
The use of anticipatory logic to account for changes in the boiler energy storage.
The use of an internal model controller (Smith Predictor) to accommodate for long
process time delays (dead time) and lags.
The use of adaptive tuning to provide controller sensitivity adjustment.
Advanced Model-Predictive controls can be applied, as part of an overall cycle
control optimization
Module 5 | 279

Figure 5.13 - Advanced Steam Temperature control system logic, (ABB Inc. Plant Automation, 2006)

In units with bypass dampers for heat or re-heat temperature control, the accuracy
of the control can be improved by using high-torque electric drives for positioning.
One problem inherent with these particular dampers is their constant exposure to
high-temperature corrosive gases and high levels of fly ash. In time, most of these
dampers experience increasing stiction and eventually will degrade into limited
range of motion or completely frozen states. See the section Dampers and Louvers
for more details on these actuators. Upgrading to intelligent drives with built-in
diagnostic capability can provide an early warning of damper stiction problems and
allow for proactive maintenance on the damper mechanism. Properly operating
superheat and reheat damper drives mitigate attemperator spray flows and ash build
up, in turn reducing both sootblowing and periodic maintenance in this section of
the boiler. Both produce reductions in controllable losses, which improves plant heat
rate (Vesel 2007).
Benefits of Advanced Steam Temperature Control
The benefits of advanced steam temperature control are:
Improved temperature control on process transients caused by changing load,
sootblowing, starting and stopping of mills in service
Improved steady state temperature control when operating under conditions of
reduced pressure, slagging.
Faster ramp rate
Improved steam temperature control will also reduce the need for attemperation, which
improves plant heat rate. (Ferrer, Small-Buck Change Yields Big-Bang Gain, 2007).
Provides design flexibility to control main steam temperature on drum boilers in
either a fixed or variable pressure operation.
280 | ABB Energy Efficiency Handbook

 Avoiding unscheduled outages for superheater tube failure

By means of more accurate boiler steam temperature control, it may be possible
to reduce temperature variations, and thereby apply a higher temperature setpoint.
The benefits of the higher temperature include increased generation of backpressure
power, better condensing power efficiency, and reduced steam use by the drive
turbines, all due to the higher steam expansion work available in the turbines
(Immonen, Assessing Industrial Power Plant Operations & Controls, 2003). Operating
with higher energy content steam allows specific steam consumption to be reduced,
with consequent reduction in auxiliary boiler feed pump power.

Case Example
U.S. pulp and paper mill
An example of steam temperature increase potential is shown in Figure below
(Immonen, Assessing Industrial Power Plant Operations & Controls, 2003). The
steam temperature is shown as a function of the boiler load, to reveal possible
load dependency. As load dependent behavior is not obvious in the example,
the temperature variations may be attributed to poor control. The standard
deviation of the temperature was found to be 8 F (5 C), while the average
temperature was 34 F (19 C) below the design. Therefore, the operators
tended to maintain a safety margin of 4 times the standard deviation between
the maximum and the temperature setpoint.
By means of better control, the standard deviation could drop to one half,
or 4 F (2.3 C). By using a commonly accepted safety margin of 3 times
the standard deviation, the average temperature could be increased to 913
F. At this U.S. pulp and paper mill, savings were available from increased
backpressure power generation, replacing approximately 0.8 MW of more
expensive purchased power. While the annual savings here were approximately
$130,000, the range of savings can be wide, anywhere from $20,000 to
$300,000 per year, or beyond, on relatively small power boiler systems.

Module 5 | 281

Case text and figure provided by: (Immonen, Assessing Industrial Power Plant
Operations & Controls, 2003)

The following calculation case quantifies some of the benefits of advanced steam
temperature control:
Calculation Case
Advanced Steam Temperature Control System
This calculation assumes a 500 MW unit with an initial ramp rate of 5MW/min and a
main steam temperature set point of 1000 F. The fuel savings realized from the initial
assumptions are threefold: 1) increasing the main steam temperature set point to
its design value of 1005 F thus, improving the unit heat rate 2) improving the ramp
rate to 10 MW/min thus, reducing the need to purchase power and 3) reducing the
number of unscheduled boiler outages as the result of superheater tube leaks. Total
fuel savings in excess of $600,000.00 per year is possible with the Advanced Steam
Temperature Control System. The calculation of the fuel savings is as follows;
1. Increasing main steam temperature to design;
Main Steam Temp Improvement: 5 F (2.8 C)
Unit capacity: 500 MW @ 80% capacity
Fuel Cost: $1.75/MBTU (1MBTU = 1055 MJ)
Main Steam Temp Dev Value: 1.5 BTU/(KWH F)
Annual savings = (1.5 BTU/(KWH F) x (5 F) x (1.75 $/MBTU) x (500 mw x 0.8) x
(24 HR/DAY) x (365 DAYS/YR) = $46,000/YR.

282 | ABB Energy Efficiency Handbook

The following non-energy efficiency benefits are significant and are quantified below:
2. Improving the unit ramp rate to 10 MW/min;
MWHR/ramp: 18.75 MWHR/ramp
Purchase power penalty: $20/MWHR
Number of ramps per year: 250
Annual savings = (18.75 MWHR/ramp) x (250 ramp/YR) x (20 $/MWHR) = $93,750/YR
3. Avoiding unscheduled outages for superheater tube failure;
Unit capacity: 500 MW
Purchased power penalty: $20/MWHR
Unit downtime per tube failure: 100 HR
Number of tube failure per year: 0.5
Annual savings = (500 MW) x ($20/MWHR) x (100HR) x (0.5/YR) = $500,000/YR.
Case text and values provided by: (Immonen, P., ABB Inc. Plant Automation, 2006)

Burner Management Systems

The burner management system is mainly a protective system to ensure safe
operation, startup and shutdown of the burner equipment. Emergency shutdown
occurs when high levels of unburned combustibles are detected. Monitoring of the
burner performance is by flame scanner, which measures the flame quality. These
systems are also collectively known as boiler protection systems.
Burner Controls
The goal of burner controls is maximum burnout of pulverized coal, but with
minimum NOX emissions. An advanced burner control system can initiate staged
combustion, biased firing or fuel-nozzle tilt (in tangential firing) to adjust the furnace
exit gas temperature (FEGT) with load changes, varying fuels or in relation to the
state of the furnace wall (as in dirtiness). This allows the superheater or reheater
outlet steam temperature, or NOx production in the furnace, or both, to be
controlled. Although closely related to burner management, the Pulverizer Controls
are discussed in the Fuel Handling section.
Boiler Startup and Protection
Automation systems using a nonlinear, model-based multi-variable controller can
automatically calculate optimum startup strategy for steam generators. The goal
of startup optimization is to optimize fuel consumption and time during the boiler
startup process without exceeding the maximum thermal ratings of critical system
components.

Module 5 | 283

Boiler Startup Optimization

(This section is adapted from ABB AG Power Technology brochure for E.ON
Ingolstadt plant, 2007)
Operating and monitoring are done using the regular process control facilities, as
in the figure below showing the functional principle of a startup optimizer. During a
startup procedure, the actual values which are cyclically scanned, for temperatures,
pressures and steam mass flow rates, are used for adjusting a physical unit model.
Based on this nonlinear model, the optimization program applies its predictive
optimization routines to the rest of the startup procedure. The resulting startup
curves computed on-line are then integrated into the existing unit control concept,
serving as corrective setpoint biases. The prediction horizon is 60 to 90 minutes,
thus covering the entire length of a boiler startup up to the point where the turbine
is rolled on steam. This way the most cost-efficient path overall to reach online
operation can be computed. The predicted data is updated every one to two
minutes, thus enabling an adequate response to disturbance conditions.

Figure 5.14 Boiler startup optimization model dada flow., ABB AG Power Technology, 2007

Independent of the cost savings realized, the model-based multi-variable controller

also enables a predictive integration of thermal stress data into the closed control
loop. The level of flexibility e.g. covering different unit downtimes is improved
as the physical model is continually adjusted to match the current state of the
plant. Moreover, the startup can be adapted to changing basic conditions, such as
different fuel costs or maximum permissible loads, by modifying the target function
and optimization constraints, respectively.
Benefits of Boiler Startup Optimization
With model-predictive startup optimization, it is possible to run each startup using
less fuel, while reducing the usual startup time and stress loading on critical thickwalled components. The savings realized through online optimization are generally
284 | ABB Energy Efficiency Handbook

within 10 to 20 percent of the normal costs of fuel and auxiliary power, for each
power plant startup. Startup times can generally be reduced by increasing the
loading of critical thick-walled components or by better exploiting the margins
through more homogenized thermal loading. Applying predictive startup optimization
in order to reduce the startup time is advisable if the permissible heat-up stress
margin is not fully exploited, or if the load is distributed unevenly during startup.
Energy efficiency improvements come from reduced startup fuel burned and/
or shorter startup times. Startup automation with optimization also leads to more
consistent startups and lowers the risk of an aborted startup, with the consequent
loss of input energy. Coal-fired power plants offer high additional savings potentials,
provided that it is possible to shift from startup fuel to coal at an earlier point.
Energy savings accumulate for units in cycling duty. In particular, in the case of
frequent brief standstills, when numerous startups are run under similar conditions,
the spread of startup costs is obviously reduced. On average, the use of startup
optimization results in a significant reduction of startup costs. Even in the case of
brief standstills, startup costs can be high, as a high live-steam temperature has to
be built up to approach the still high temperatures in the turbine. Taken together, the
above improvements increase efficiency by approximately 1% during startup, and
also decrease emissions values.

Case Example
Boiler Startup Optimization
The figure below shows a comparison of two startup procedures in the
Ingolstadt power plant, unit 4: with BoilerMax (bold lines) and without
BoilerMax (thin lines). The upper diagram shows the fuel quantity F_F and the
HP bypass position Y_HPB. The diagram in the middle shows the live steam
flow F_LS and the generator output P_Gen. The diagram at the bottom shows
the temperature differentials DT_SH4H and DT_SH5H occurring in HP headers
of the two last superheater levels.
The diagrams show that it was possible to run a similar boiler startup while realizing
an approximate 20% reduction of fuel consumption. Such fuel savings are possible,
since the steam flow used for starting-up can be decreased by simultaneous and
coordinated reduction of the opening of the HP bypass station. In addition, the
startup time is slightly reduced.

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Figure 5.15 Comparison of two startups with model-based startup optimization. (shown in the
heavier dashed and solid lines) and without (thinner lines) ABB AG Power Technology brochure
for E.ON Ingolstadt plant, 2007

Emissions Controls
Emissions Concepts
The flue gas contains particulates and other products of combustion which must be
cleaned to levels required by environmental regulations (in the USA, these are given
by the Clean Air Act Amendments, CAAA). Particulates are removed by electrostatic
precipitators (ESPs) or fabric filters.
Sulfur dioxide (SO2) is removed by one of the various flue gas desulphurization
(FGD) processes. The wet scrubber process using limestone as the sorbent is the
most widely used method. NOx production can be controlled in-furnace by low-NOx
burners, air staging, and the use of a re-burn fuel in the upper part of the boiler. NOx
can also be removed by injection of ammonia or an ammonia- based compound into
the combustion products, with or without the use of a catalyst, processes known as

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selective catalytic and non-catalytic reduction (SCR or SNCR) (IEA Coal Online - 2,
2007).
Flue Gas Desulfurization (FGD)
One way to limit extra auxiliary loads associated with FGD is to switch to fuels lower
in sulfur. The EPRI CQIM model described in the section on Fuel Handling Systems
provides estimates for the amount of auxiliary power required for different coal types.
Methods to improve the contact between the limestone slurry and the flue gas
improve absorption will serve to reduce the auxiliary drivepower required for
circulating pumping. Innovative methods using open-spray tower absorbers may
reduce auxiliary loads by up to 1% of total generation (Sayer, 1995).
Seawaters alkaline composition enables it to absorb SO2. Seawater FGD scrubbing
may be one of the lowest energy alternatives, where environmental agencies
grant approval. Most Recent Developments and Optimization Aspects for FGD
Technologies Dr. W. Schttenhelm et al, Power-Gen Europe, Barcelona, Spain,
May 25-27, 2004. Seawater FGD techniques eliminate the need for slurry injection
and recycle pumping. Dry FGD processes may offer lower auxiliary loads, but with
a lower SO2 removal rate (Sayer, 1995). The gypsum or sulfuric acid byproducts of
FGD processes can be sold to other industries, which may change the cost-benefit
comparisons.

Figure 5.16 Flow diagram of a typical supercritical PC plant with pollution control (cited in IEA Coal
Online - 2, 2007) Rousaki and Couch,2000)

NOx Emissions Reduction

NOx emissions reduction technologies typically involve burner modifications and
do not directly add to the plants auxiliary loads. A NOx conversion which causes
increased boiler firing rate instability under upset conditions, however, may lead to a
1-2% increase in heat rate (Ferrer, Small-Buck Change Yields Big-Bang Gain, 2007).

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In units equipped with Selective Catalytic Reduction (SCR) equipment, NOx is

absorbed by ammonia within a reactor vessel located in the flue gas stream. In
addition to reagent pumping drive-power, the pressure drop across the catalytic
reactor requires greater ID fan power, bringing the total added SCR auxiliary load
to 1% to 1.5% of total generation capacity. The SCR equipment is typically located
between the economizer and the air heater. However, in some designs the SCR
vessel is located further downstream, after the electrostatic precipitator (ESP).
This configuration requires energy to reheat the saturated flue gas to the required
reactor temperature, typically 600 F (316 C) (Babcock & Wilcox 2005). When this
energy is provided from auxiliary power, it increases the total SCR system auxiliary
consumption to values typically 2.5% of total generation (Sayer, 1995). Other
designs bypass some flue gas around the economizer to provide this energy, which
also reduces the thermal efficiency of the unit.
Particulate Emissions Control
Fuel ash and unburned carbon particles from coal and oil-fired plants are traditionally
removed by electrostatic precipitator (ESP). ESPs have low pressure drop in the
flue gas stream and use relatively low electrical power, but the size and power
requirements increase as particle size decreases, giving an average auxiliary power
consumption of 0.25% of total generation (Sayer, 1995). The alternative (and
possibly complementary) methods to ESPs, using fabric filters in baghouses, works
well at capturing fine particles but at the cost of a larger pressure drop and higher
fan power, bringing total auxiliary power to 0.35% of total generation. The fly ash
collected by these systems can be sold and used for more productive purposes than
landfill, which may change the cost-benefit comparisons.
Drivepower Potential for Energy Efficient Design
Emissions control devices add pressure drops to the flue gas stream and
significantly increase the requirement for ID fan power, often necessitating installation
of a flue gas ID booster fan. Additional drivepower is needed for limestone
slurry-feed, absorbent circulation pumps and oxidation air compressors, and the
electrostatic precipitator is also represents an auxiliary electrical load. The proportion
of plant generating capacity consumed by emissions control systems varies with the
degree of emissions reduction:
3% to 5% for reducing up to 90% of sulfur dioxide emissions from coal-fired plants
0.5% to 2.5% for reducing nitrogen oxide emissions up to 80% from all fossil-fired plants
0.5% to 1.5% for controlling particulate emissions from oil and coal-fired plants

The cumulative incremental power consumption for emissions control may be up

to 9% of gross generating output (Sayer, 1995). The increased auxiliary load also
increases plant net heat rate and the amount of CO2 emitted per generated MWh.
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Flow control through use of VFD speed control can reduce pump and fan auxiliary
power by 75% at low loads, and will correct for oversizing at full loads, reducing
power by 15%. Efficient motors and drive-trains can further reduce power by 5%.
A peaking plant that applies the suggested drivepower improvements can
substantially reduce the unit auxiliary load.
{Note that gas-fired plants, on the other hand, may only require 1% of generating
output for reducing nitrogen oxides (C.P.Robie,P.A.Ireland, for EPRI, 1991), and
newly available low NOx combustors and burner tuning methodologies can
completely eliminate post-combustion NOx treatments.}
Automation Potential for Energy Efficient Design
A low-capital cost technology to complement low-NOx burners is improved
combustion control. Using the automation techniques of co-coordinated boilerturbine control and advanced realtime control of burners, air flow and gas
recirculation can reduce NOx emissions without any increase in auxiliary power.
See the section on Excess Air Control for details on reducing NOx using control
techniques. Continuous monitoring of flue gas is vital for low-NOx burner or
combustion methods due to the risk of higher levels of unburned carbon and CO
emissions; see the section on Instruments and Actuators for more details on
analytical devices.
Automation for stabilizing firing rate after a low-NOX burner conversion can also
reduce heat rate. Combustion Optimization Solutions (COS) use model-based
predictive control techniques to reliably find the most suitable setpoints for improving
the heat rate and reducing emissions like NOx. Every ton of NOx production that
is avoided during the combustion process, is eliminated from the cost of NOx
mitigation or from offset credit purchase requirements. The value of this ranges from
$1500 to $3500 per ton at current (2009) pricing.
Automation through intelligent flow control in open-spray FGD systems is an
important criterion for the effectiveness of the system. Particle capture in baghouses
is directly related to the pressure drop; controlling this through fan speed may
increase effectiveness over a wider operating range.
More advanced powering systems may also help improve the effectiveness of ESPs
through variation of voltages and polarities. Further advantage may be gained
through coordinating ESP and fan flow control for optimum particulate removal at
lowest power consumption. Precipitators and bag filters are not required to work at
maximum capacity when the plant works at partial load.

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Automation allows these emissions control systems to be coordinated with the

boiler-turbine controls. Feedforward and adaptive tuning will make the emissions
systems respond more intelligently to loads. Integration will allow these systems
to participate in plant wide optimization using model-based techniques, The multivariable capability of model-based control allows the auxiliary ID or booster fan drive
power and steam extracted for cold-side SCR can be optimized together with the
combustion process, FD fan for any given plant load and coal quality.

Condenser Systems

Figure 5.17 Condenser cooling system towers, (ABB Ltd., Power Generation Unit, 2006)

Condenser System Concepts

Condensing steam from the exhaust of the turbine into liquid allows it to be
economically pumped to boiler pressure, at much lower energy than if it were still
in gas phase. Condensing returns the working fluid to the starting point on the
thermodynamic cycle, and lowers the turbine exit back pressure and draws steam
flow through the turbine. The coolant can be either water or air. Power generation in
the US uses 132,000-million gal/day (500 million m/day) of freshwater about 39%
of the countrys total freshwater usage. Approximately 98% of this water is for oncethrough cooling (OTC), and therefore is returned immediately to its source (Power
Magazine, R. Swanekamp, 2002).
Demand for Auxiliary Drivepower
Due to long-standing environmental regulations for thermal discharge which require
an exit temperature of the cooling water that is fairly near to the temperature of its
source, once-through cooling systems are no longer feasible. This restriction has led
to more closed-loop and air-cooled systems with forced draft towers. A revision to
US regulations is expected which may allow once-through cooling systems in some
cases, and a substantial increase in cycle efficiency. In all cases, auxiliary power is

290 | ABB Energy Efficiency Handbook

needed to drive pumps or fans to circulate the cooling media. The main auxiliary
drivepower loads are circulating water pumps and cooling tower pumps and fans.
In water-cooled systems, the amount of condenser cooling water required is approx.
0.35 to 0.75 GPM (1.3 to 2.7 l/m) per kW of generating capacity. An approximate
figure for power required to circulate this water is 10hp (7500 W) per MW of
generating capacity.
In air-cooled condenser designs, the exhaust steam flows through finned tubes
and ambient air is pushed through the fins with the help of a large fan. Air-cooled
condensers typically operate at a higher temperature than water-cooled versions,
which reduces cycle efficiency. An approximated rule of thumb is that for every ten
deg-F increase in condensor temperature, there is a 2% heat rate increase.
Drivepower Potential for Energy Efficient Design
Lowering the temperature of the coolant will directly improve the plant heat rate. The
condenser efficiency improvement potential is large, given that condensing wastes
half of the input heat energy in the cycle.
Location is an important factor in the configuration of the condenser system, as
is the design of the LP turbine and the condenser hardware. The condenser is the
plant unit most affected by seasonal temperature variations, which have an impact
on the thermal efficiency of the entire cycle according to the rules of thumb in
Parameters for Increased Thermal Efficiency.
Applying the principles from the drivepower module will result in high-efficiency,
speed-controlled cooling water pumps delivering cooling effect at a lower pumping
power over a broader range of flow. The reduced auxiliary load will lower the net
heat rate. The favorable economics of efficient circulation may prompt higher flow
designs to deliver more cooling and therefore a reduced heat rate due to improved
thermodynamics.
Drivepower demands in air-cooled systems can be further reduced through use
of high-efficiency components. Fans with aerodynamic improvements can give up
to 80% savings and may be relatively easy to retrofit. Larger cooling tower crosssections equipped with larger fans using Low Face Velocity (LFV) designs will use
much less power, according to the fan affinity laws described in Fan Power and
Energy Efficiency.
Adding a micro-mist to the inlet air can provide additional evaporative cooling
effect, up to 15 F (8 C) in some industrial scale systems (RMI, 2007) High-quality,
right-sized motors combined with VFD for flow control as described below can
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yield a combined energy saving of up to 80% of electrical power when running at

half-speed. Some of these high-efficiency technologies for air-cooled systems are
illustrated in the figure following:

Figure 5.18 Optimized fin fan schematic, Rocky Mountain Institute, 2007)

Multiple cooling towers each with one or two speed fans are usually brought online
individually to handle changes in unit load. Operating all available towers in parallel,
each equipped with VFD for fan speed control, provides much improved energy
efficiency. This latter design maximizes the surface area for heat transfer and
minimizes the fans electrical drivepower requirements (Rumsey, 2003).
Automation Potential for Energy Efficient Design
Improved and integrated control of condenser coolant systems can provide some
surprising efficiency gains. As with other power plant systems, correct and adaptive
tuning will allow the condenser coolant systems to deliver at optimum efficiency over
a wider range of ambient coolant temperatures and plant loading.
Model-based optimization techniques may also be useful to determine the most
efficient cooling water/air flow rates given the increased pumping power - see the
case description in the box text below. Automation can also be used to reduce the
auxiliary load of these large circulating systems by optimal cycling of the pumps
throughout a range of unit operating conditions. Pump system efficiency can be
further increased by using constant speed motors for primary pumps, but equipping
the secondary pumps with VFDs for trimming flow control.
For cycle designers, it may be useful to think of the LP turbine as a source of steam
heat for a combined heat and power plant, even if the heat is only to be used inplant. Using the steam productively may increase backpressure, but this again is an

292 | ABB Energy Efficiency Handbook

optimization problem that can be solved using the techniques described in previous
sections. Some applications for in-plant CHP are the HVAC system, and fuel drying or
pre-heating; these options are explored in the module on High Performance Design.

Case Example
Maasvlakte 540 MWe coal-fired plant in the Netherlands
For the Maasvlakte plant in the Netherlands, thermodynamic modeling showed
that there was a different optimum flow-rate depending on the temperature
of the cooling water (which varies at the plants location from 1C to 20C).
At 4C, the optimum flow rate was 12.2 m/s, while at 20C it was 18.8 m/s.
Results from this modeling exercise were confirmed by actual plant data. An
average reduction in the condensor cooling-water temperature from 20C to
15C at this plant reduced the heat rate by almost 1%.
(Case data from Kromhaut and others, 2001, and cited in (IEA Coal Online - 2,
2007)

Automations monitoring functionality can be used to continually check the

condensers heat exchanger performance. The most-common causes of condenser
inefficiency are: microbiological growth on the water side, scale formation on the
water side, tube pluggage by debris and air in-leakage on the steam side (Buecker,
B. of Burns and McDonnell Engineering, Chemical Engineering; Vol. 102; Issue 4,
Apr 1995). Online monitoring, combined with modeling of these fouling phenomena
can be coupled with a pro-active treatment program to keep the condenser at peak
design efficiency.

Condensate System
Condensate System Concepts
The purpose of this system is to collect the condensate (boiler feedwater) leaving the
condenser, remove non-condensable gases, raise its temperature through a series
of feedwater heaters and then deliver it to the deaerator for additional heating and
temporary storage. From the deaerator, the feedwater goes to the boiler feed pump
where it is pumped up to near boiler drum pressure at the inlet of the economizer.
Increasing the boiler feedwater temperature effectively increases the upper
temperature of the thermodynamic cycle, raising the efficiency. Heating the
feedwater using steam extracted from the turbine stages is more thermodynamically
efficient than using other nearby sources, such as fuel in the furnace. Up to 30% of
steam may be extracted for this purpose, typically at a intermediate and high turbine
Module 5 | 293

pressure stages. Designs with higher steam pressures allow a greater number of
extraction points and hence greater number of heaters in the train.
Demand for Auxiliary Drivepower
This systems main requirements for auxiliary drivepower come from the condensate
and booster pumps. The relatively low-power vacuum pumps are not considered in
this discussion. The condensate pump is a low suction head extraction pump which
must deliver sufficient discharge head to overcome pressure drops through several
feedwater heaters. A booster pump is also sometimes used after the de-aerator
to raise pressure to a level sufficient for flow through the high-pressure feedwater
heaters. The power demand and control of the main boiler feedwater pump is
discussed in the Feedwater control section.
Drivepower Potential for Energy Efficient Design
The general case for efficient condensate pump drive power is made in section on
Pump Systems.
Automation Potential for Energy Efficient Design
Although not strictly auxiliary systems, the feedwater heaters (heat exchangers) and
de-aerators energy efficiency could benefit from continuous monitoring at inlets and
outlets for early indication of plugging or fouling problems.
It is almost always more thermodynamically efficient to add another feedwater
heater; Welford and others (2002) cited a 0.15 percentage-point efficiency rise for
the whole unit through an increase of 20C (36 F) in the final feedwater temperature.
(IEA Coal Online - 2, 2007) Reliability and cost issues, however, often limit the
total number of heaters; a total of 6-8 heaters is typical. For a small increment in
cost, the feedwater heaters reliability can be increased by adding instrumentation
and continuous on-line condition monitoring. Such extra reliability may favor
an additional feedwater heater and be justified by the resulting increased cycle
efficiency. One new approach to feedwater heating involves the use of on-site solar
equipment to provide thermal energy for feedwater heating during the days peak
demand hours.
The steam bypass valves can also benefit from condition monitoring. The enthalpy
drop across these valve is large. Valve leakage can be detected by instrumentation
on the downstream side of the bypass line. Similar monitoring can be installed on
steam traps in all bypass lines. Valve functionality can be continuously monitored for
stiction and other control problems which lead to unnecessary loss of steam energy.
In a poorly maintained system of steam traps, annual energy losses can easily reach
six figure costs.

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The model-based optimization techniques developed for combined heat & power
(CHP) systems may be applied to feedwater heater train and de-aerator system to
achieve the optimal balance between use and production of steam, and allocation
to the most efficient heaters (or other users). Such a control strategy could improve
the off-design performance of the system, especially at lower-load operation. In
industrial boiler systems, the de-aerator and other components with an inventory
of steam or water may be used in a steam-leveling strategy to absorb process
load swings and increase efficiency (Immonen, Assessing Industrial Power Plant
Operations & Controls 2003).
In some units, peaking power supply is achieved by deliberately taking one or
more of the top feedwater heaters out of service (Babcock & Wilcox 2005). This
practice allows more steam to pass through the turbine, but at a significant cycle
energy efficiency penalty. According to EPRI Report CS 4554, taking one top (highpressure) feedwater out of service increases the heatrate by 94 BTU/kWh, which
corresponds to a 1% drop in efficiency in a typical PC unit.
Sometimes efficiency is temporarily sacrificed for higher ramp rates, as described in
the following case text; the control strategy for faster ramping temporarily shuts off
the flow to one or more LP feedwater heaters. Operators must be made aware that
protracted operation in this mode will significantly increase fuel cost and emissions.

Case Example
Schwarze Pumpe, Power Plant, Germany
Schwarze Pumpe in Germany provides an example of large, flexible PC units
where two 800 MWe supercritical lignite-fired boilers have been designed to
operate at sliding pressure to down to 40% output, with high rates of change,
and short hot start-up times. A dynamic control system covers the whole plant,
including firing and emissions control as well as the steam cycle. A 6% load
change per minute is achievable at Schwarze Pumpe with only minor effects
on the main steam and hot reheat steam temperatures, and without turbine
throttling or using the storage capacity of the boiler.
Very rapid ramping (for example, by 50 MWe in seconds) requires the use
of a degree of steam reserve and temporary changes in feedwater heating.
Temporarily diverting steam away from feedwater heating so that more passes
through the later turbine stages will have a very negative effect on efficiency in
the short term, but this matters less than meeting demand over these transient
periods.
(Case text provided by IEA Coal Online 2, 2007)
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Fuel Handling Systems

Figure 5.19 Coal pulverizer with motor, (ABB Motors, 2006)

Fuel Handling System Concepts

Fuel handling involves all the processes needed to prepare the raw fuel for mixing
with air and injected into the furnace through burners for combustion. There is a
great variety of fuel handling methods, depending on the type of fossil fuel being
used. Coal is the most complex fossil fuel, with many compositional and hardness
variations, and is this fuel which is the focus of most of this section. Also, because it
is a solid, mixing this fuel with air is more problematic compared to gaseous or liquid
fuels (Black & Veatch 1996, p.182). The main preparation processes for coal are
crushing, drying, and milling, also known as pulverization.
Demand for Auxiliary Drivepower
The main fuel handling demand for auxiliary power in coal plants come from crushers
and pulverizers/millers, and the primary air system which heats and conveys the fuel
to the burners. The CQIM Coal Quality Impact Model developed by Black & Veatch
for EPRI evaluates the total cost (not just delivered cost) due to alternative fuels.
One of the 5 main CQIM impact areas is Auxiliary Power Requirements. Changes in
auxiliary power are calculated for each fuel variant, and these are related to amount
of lost generation and increased fuel burn rate. Note that the CQIM model includes
draft fan and other auxiliary loads in addition to those directly involved in coal fuel
preparation.
The heating value of coal is given in BTUs per pound, or kilojoules per kilogram
(10000 Btu/lb = 23200 kJ/kg). Coal can range from 3500 Btu/lb (culm or waste
coal) to 15,000 Btu/lb for dry prime hard coal. Many auxiliary systems must still
run and consume drivepower, regardless of the energy (BTU) content of the coal.
These systems include fuel handling, ash handling, draft fans and flue gas emissions
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control equipment. Coal with lower heating values will therefore use a higher
percentage of auxiliary power for each unit of converted energy. Also, coals with
higher sulfur content will require increased auxiliary power to drive FGD processes.
Drivepower Potential for Energy Efficient Design
The flow control design guidelines described in the drivepower module showed how
speed control is most efficient at less than full rated speeds. The bypass method
for speed control still used in some coal milling operations is therefore a candidate
for design improvement by applying VFDs for speed control.

Case Example
Milling Applications: VFD drive instead of Bypass

In a boiler installation, 20 coal mills with a drive output of 710 kW each are
used. A speed-controlled drive with a control coupling or with an AC drive
is used to replace the bypass method. The possible saving with a control
coupling is about 11 GWh and with an AC drive 23 GWh as shown below. (For
a description of bypass flow control, see Pump Flow Control Methods)

Energy saving: 23,000 MWh/year

Reduction in CO2 emissions: 11,500 metric tonnes/year
Better boiler control with fewer losses
Crushing wheels of the mills last longer
Payback period 2.5 years

(Case text from ABB Drives, 2007)

Pulverizer Applications
In order to accommodate the larger range of operation asked of plants today, as
described in the section Plant Operating Modes, the designer should consider
specifying more, but smaller pulverizers rather than fewer, larger ones. The full load
fuel flow rates provided by the basic thermal balance will provide the upper limit of
combined pulverizer capacity. A pulverizers capacity loss due to wear will consume
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more power as grinding surfaces wear; this increase in power consumption should be
part of the sizing criteria for pulverizers. It is common practice to include primary air
fan power consumption together with pulverizer power. When pulverizer wear is taken
into account, one industry estimate of combined power requirement is 22 kWh/ton
(24kWh/metric ton) of coal for a load-following unit. (Babcock & Wilcox 2005).
When pulverizers operating at this capacity are in a typical older PC unit with
heatrate of 10,000 BTU/kWh, fired on coal with a heating value of 10,000 BTU/lb,
they will consume about 1% of the input fuel energy. This percentage increases with
decreasing coal heating value, increasing plant heat rate, and increasing moisture
content of the coal.
Automation Potential for Energy Efficient Design
Automation which can shut down one or more pulverizers for low load operation
should be coordinated with the combustion and steam temperature control systems
to avoid instability immediately after shutdown/startup. This simple automation
modification saves energy on units with larger boiler turndown, as is the case in
units which are being repurposed from baseload to dispatchable or load-following
duty. The automation of pulverizer operation within the combustion control
system, however, must accommodate the limited turndown capability of individual
pulverizers, which can individually operate in stable fashion only down to about 50%
of rated capacity. (Black & Veatch 1996, p.182)
Another potential improvement is to enable online monitoring of the relative flow of
coal in the pipes to individual pulverizers. This data can be used by the combustion
controls to achieve better balancing of fuel flow to burners in the boiler burner
array. Full closed loop combustion control, with coal-flow monitoring and and air/
fuel balancing of the the burner array is technically feasible and cost effective at this
time, but the industry is very slow to consider, adopt and apply this technology.

Sootblowing Systems
Sootblowing System Concepts
Accumulation of ash and other products of combustion on the heat transfer surfaces
will reduce heat transfer and increase plant heat rate. Sootblowing systems typically
use steam or compressed air cannons to remove soot from boiler tube surfaces
and structures. There are also mechanical vibration, and sonic soot remediation
systems which fall into this general category. Plants which have switched from
their design fuel to other, lower-quality fuels are particularly susceptible to more
ash-related problems. If internal boiler combustion levels or distributions are not
managed well, large fused-ash accumulations may form, which may eventually break
off and fall, damaging boiler and tubes in the process.
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Automation Potential for Energy Efficient Design

Soot-blowing automation can determine where and when to blow soot based upon
changes in heat transfer data. Precise control of soot-blowing will improve heat
transfer and heat rate of the unit. Soot-blowing also has an indirect impact on energy
efficiency in two ways: 1) Soot-blowing consumes power in the form of compressed
air or steam 2) Soot-blowing causes sudden changes in heat-transfer which may
disturb main steam and reheat steam temperature control, causing swings in control
action and increased attemperation use.
An automated soot-blowing system using closed-loop control will consume less
power than traditional, open loop control based only on time intervals. A system that
is integrated with the rest of the DCS can use online measurement data to compute
heat flux, which can then be used for feedback control. This control system could
be further improved with MPC and thermodynamic models and direct readings from
strain gauges (Whitworth, XCEL Energy, 2006)
Automation integration between soot-blowing and steam temperature control
systems can reduce temperature instability and improve efficiency. When the sootblowing system described above is ready to act, it can inform the steam temperature
control system which may then take feed-forward compensation measures.

Ash Handling Systems

Ash Handling System Concepts
Ash-handling systems must transport the solid products of combustion, mostly ash
and unburned carbon, from a hopper in the furnace floor.
Automation and Drivepower Potential for Energy Efficient Design
In PC boilers, bottom ash removal systems consume electrical drivepower, but do
not offer the potential for larger energy efficiency gains as the cube-law systems for
fluid and air flow.
Hot, yet unburned carbon in the solid combustion products (and possibly from fluegas dust collection systems as well) may be reintroduced into the furnace to achieve
more complete combustion. Further improvement can be gained by auxiliary systems
capable of separating the heavier carbon from the remaining lighter materials in the
ash mixture. A carbon reinjection system can improve the efficiency of coal-fired
boilers by 2% to 4% (Babcock & Wilcox 2005); this improvement is not in thermal
efficiency, but calculated on the cost basis of primary coal input.

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Module 6
Case Studies In Integrative Design
Module Summary
This module defines a base case plant unit and shows the cumulative effects of
drivepower, electrical power system and automation system improvements. Capital
investment costs and operating costs are also estimated, for the purpose of a
lifecycle cost calculation. This case study will attempt to quantify the benefits in
many scales: efficiency/heatrate, ROI payback, fuel amount & cost, NOx & CO2
costs, and power generated available for sale.

The information in this module section is specific to power generation industries

or process plants with on-site power houses. Many sections, however, are also
broadly applicable to all industrial steam generation processes.

Causes of Energy Inefficiency

This section reviews the energy efficiency issues relating to auxiliary systems in an
average facility.

Power plants using pulverized coal fuel are averaging 30-35% efficiency,
compared to 45% and higher for supercritical or combined cycle designs.
This very rough comparison provides some indicators as to where one should
focus energy efficiency efforts when confronted with an existing plant or when
evaluating alternatives to the standard design of a new plant.

Changes in Available Technology

In older plants; the initial auxiliary designs are now outdated by advances in
controls and materials; VFDs for flow control, power electronics for power quality
management, transformer designs with new materials, high efficiency motor
design, new materials etc.
In older plants; lack of control integration between plant units, such as turbinegenerator and the boiler control system leaves substantial opportunity for
automation improvements

ABB Energy Efficient Handbook 301

Sub-Optimal Design and Engineering

Oversized pumps and fans waste energy in throttled operation or in low efficiency
operating regimes
Oversized motors and power supply equipment all operating at low efficiency
Process design & engineering decisions which unnecessarily increase drivepower
loads
Aging
As plants age they become less reliable and generally less efficient due to
corrosion, fouling, wear and other mechanical factors. Feed-water heater heat
exchangers, cooling tower heat exchangers, and boiler tubes are all examples of
equipment prone to these mechanical factors.
Steam losses through leaks, heat loss through boiler walls, and other energy
losses through excessive attemperation, blowdown, or sootblowing.
Loss or lack of experienced plant engineering and operations staff, loss or lack of
as-is plant documentation.
Changes in Operating Conditions
Changes in fuel supply from what boilers and burner systems were originally
designed for, leading to degraded performance.
Plants designed originally for base-load operation near their rated output now
operating below this capacity due to changes brought on by a deregulated and
competitive marketplace. Efficiency and response are reduced at lower loads.
Changes due to Environmental Retrofits
Addition of emissions control equipment such as precipitators, SO2 scrubbers
that restrict stack flow and require greater in-plant electric fan drive power.
Addition of cooling water environmental protection systems that increase the
demand for cooling medium flows and thus electric auxiliary drive power.
Retrofits, environmental and otherwise, without updating of unit controls, leading
to unsuitable control behavior and greater instability, especially boiler instability.
The cumulative negative effect of these causes can be witnessed in existing plants
operation even without a benefit of any formal assessment or extensive data analysis:

302 | ABB Energy Efficency Handbook

Figure 6.1 Common indicators of an energy-inefficient plant in operation

Energy Efficiency Design Assessments

Using a systems approach known as Integrative Design, much of the plant process
and mechanical design will be considered even though the scope of the retrofit may
not extend to the boiler or steam cycle (combustion, steam or water path) primary
equipment.
This methodology is a type of design assessment, rather than the more
widely known and applied energy audit of an existing plant. The focus of this
methodology, however, is not on operating procedures or parameter adjustments:
these are usually within reach of experienced plant managers. In very simplified
terms, an energy audit seeks ways to reduce losses within the constraints of the
plant design as is, whereas a design assessment uses heat and material balances
to provide a higher upper limit to the possible gains from a retrofit.
The Integrative Design methodology does have some steps in common with an
operational energy audit: in each, there is a data gathering phase, an analysis phase,
a ranking of proposed changes, and then implementation. The ranking of proposed
design changes is based on lifecycle cost calculations, tempered by a discussion
of such important qualitative factors as compliance, availability and schedule.
The major differences between a typical energy audit and a design assessment
methodology are listed in the table below.

Module 6 | 303

Phase

Energy Audit

Design Assessment

Data gathering

Mostly operational data

Mostly design data ; P&ID drawings, flow sheets,

from historical databases,

supplier performance data and kits, backed up

Analysis

strip charts or testing

with operational data.

Efficiency calculations

Heat and material balances, and comparison

with process models. Pressure drop calculations.
Component sizing calculations using iterative
approaches.

Proposals

Procedural and small-scale

Larger-scale design & equipment changes,

investment

automation changes

Ranking

Payback based on

Payback based on longer time horizon and

short time horizon and

including other non-energy improvements

solely energy-saving

Ultimate goal is to provide a utility with capacity

improvements

improvements without having to build new plants.

For power plants, the thermal analysis is the first step in the analysis, as
this will provide the basic combustion air, fuel, flue gas and feedwater flow
requirements (Babcock & Wilcox 2005). Based on these flows, the major
pressure drops may then be calculated, followed by the remaining pipe or duct
resistance calculations.

See the section on Managing Energy Efficiency Improvement for a discussion of

managing both energy and design assessment efforts.
Integrative Design for Auxiliaries
The energy efficiency issues listed in the previous sections are complex and cut across
many plant systems. Integrative Design principles lend themselves well to improving
steam plant designs. Some of the process areas where Integrative Design has been
successfully applied are: thermal integration, power systems, designing friction out
of fluid-handling systems, superefficient passive or heat-driven (absorption) cooling,
superefficient drive systems and advanced controls. (Lovins, 2008).
Integrative Design takes advantage of the fact that efficiencies are multiplicative
and not simply additive. For a system with several components in series, such as
an electrical drive, a motor, a pump, a pipe, and a valve, the efficiency of the whole
system is the product of all the efficiencies as follows:
Esys = Edrive x Emotor x Epump x Evalve x Epipe

304 | ABB Energy Efficency Handbook

Figure 6.2 Cumulative efficiency gains in entire pumping system, (deAlmeida, 2006)

Even small gains in component efficiency can lead to very large overall efficiency
gains. For example, if each of the above components has 80% efficiency, then
overall system efficiency Esys is:
Esys = 0.8*0.8*0.8*0.8 = 41%.
But increasing individual efficiency by just 10% will have a multiplicative effect on
overall efficiency:
Esys = 0.9*0.9*0.9*0.9 = 66%
The compounding effect of a 10% increase in component efficiencies thus gives a
60% improvement overall (old 41% x 1.60 = new 66%).
For the auxiliary systems which are the subject of this handbook, an integrative
approach which considers drivepower, electric power supply, and process
automation as a whole can lead to a more balanced and energy efficient design.
The component efficiencies in the simplified example given above are seldom
static in the real world. Usually, these component efficiencies are dynamic and
will change with process flow as shown in the figure below. An integrative design
approach considers efficiency over the entire flow range, opening the door for even
greater magnification on the gains from efficient designs. For a more complete list of
Integrative Design principles, see the Appendix section.

Module 6 | 305

Figure 6.3 Typical efficiency vs. flow for drivepower components (ABB PumpSave User Manual 4.0)

Energy Efficiency Design Improvements

Base Case Unit
The base case used in this text is a 500MW (gross) single pulverized coal-fired steam
electric utility power plant unit with a single, sub-critical, drum boiler sending steam to
a single turbine. The base case plant is 25 years old and its design is representative
of the newer end of the fleet of coal plants in the US. The target unit has previously
undergone retrofits for emissions control; low NOx burners and FGD systems.
The base case plant has old equipment for flow control and drive power, which will
be replaced by modern VFD flow control methods and higher efficiency motors and
couplings. The context for the activities in this module is a small to medium-sized
retrofit project. The cases are divided into smaller scopes than would be normal in
retrofit project; this is for calculation purposes to show individual efficiency benefits.
Typically several activities would be combined in a larger retrofit project.
Change of Duty from Baseload to Intermediate
The target for this case study is a fixed-pressure unit designed for base-loading that
is converted to a variable pressure unit for intermediate (load-following) service and
for extended operation at lower loads, typically from 50% to 90% full rated load.
Efficiency Design Improvements
The table below summarizes all the design improvements suitable for a plant of
the stated type and project investment scope. The efficiency improvements are
incremental and relate only to the direct effect of auxiliary design improvements.
(For example, the effects of environmental or balanced draft conversions have an
efficiency impact that is independent of how auxiliary design is executed). The nonauxiliary conversion or upgrade costs vary greatly with plant design and are omitted
from the discussion.
306 | ABB Energy Efficency Handbook

The design methods and recommendations for auxiliary and automation systems
described in this module are largely applicable to many other fossil steam plant
designs and situations as well. The table below lists all the proposed auxiliary
designs for improved energy efficiency. The numbered proposals are singled out for
detailed description and benefits analysis in the following sections.
#

Project or Case

Scope Description & Benefits

VFDs for draft and FGD fan

Eliminate flow restricting control methods. May

flow control

be part of a balanced draft conversion. May also

include benefit of peak loading, previously limited
by fan capacity on hot days.

Upgrade sensors & actuators

Retrofit electro-hydraulic(fturbine) , smart positioners for

dampers, louvers

Balanced draft conversion

Proper furnace draft control using ID fans instead of FD

VFDs for boiler, circulating and

Eliminate flow restricting control methods; may be

condensate pump flow control

part of a feedwater heater upgrade

Motors & drive-trains upgrade

Replace existing motor and drive-trains with right-sized,

fans and speed control instead of dampers

higher efficiency equipment

DCS replacement for 20+ years

Improved automatic and operator control response

old system
4

Coordinated boiler-turbine

Coordinated boiler turbine control, use of feed-

control, sliding pressure

forward techniques for rapid response. Improved

operation

efficiency at low loads

Boiler startup optimization

Less fuel, shorter time during startup

Advanced controls for steam

Increase main steam temperature, reheat steam

temperature control

temperature, and ramp rate

Stabilizing firing rate

Improved heat rate, reduced need for attemperation.

Reduction of excess air

Decrease the average flue gas O2 of the boilers

Improved Feedwater Pressure

1-2 % improvement in heat rate

through improved airflow control.
& Level Control
9

General loop tuning

Manual and adaptive tuning techniques

Electrical power system

Power quality improvements, transformer right-sizing

upgrade

and efficiency upgrade

Plant availability improvement

Diagnostics, condition monitoring, asset management

Cooling tower retrofit

Improve drivepower & controls related to condenser

systems

Environmental upgrade

Improve drivepower & controls for FGD, precipitators,

catalytic conversion

Module 6 | 307

Project or Case

Scope Description & Benefits

Coal variability enhancements

Coal blending, improved soot blower/water canon

systems, mill replacements, fan modifications/rebuilds
to accommodate more variability in coal quality with
multiple coal sources without loss of efficiency or
reliability (Black & Veatch, 2008)

Feedwater heater upgrade

Improved efficiency with compact heat exchangers +

condition monitoring

Plant Information Management

PIMS can enable energy efficiency performance of up to

System

improvements of 1.5% through continuous monitoring

and warning of plant degradation.

Table 6.1 Suggested improvement retrofit projects; selected projects are numbered

Unit Improvement Targets

The largest heat rate improvements from the chosen retrofits occur at reduced plant
loads and during periods of rapid load ramping which is the new reality for this
previously baseloaded plant.
Performance Indicator

Target Improvement

Heat rate improvement

8%

Units

Faster ramp rate

2%

of full load rate/min

Fewer trip

20%

fewer forced outages

Reduced CO2

8%

Reduced Fuel consumption

8%

Target Excess O2 reduction

2.50

Target Main Steam Temp at Full Load

993 1000

deg-F

(+4 C)

Target Main Steam Pressure at Full Load

2,380 2430

PSI

(345 kpa)

Target Reheat Steam Temp at Full Load

975 993

deg-F

(+10 C)

Target Superheat Spray Flow At Full Load

30

klb/hr

(13.6 tonne/hr)

Target Reheat Spray Flow At Full Load

40

klb/hr

(18.1 tonne/hr)

Total Controllable Losses HR Reduction Target 251

BTU/kWh

(265 kJ/kWh)

Targeted NOx Reduction Level

lb/MMBTU (g/MJ)

15%

Table 6.2 Improvement targets of retrofit projects

Implementation Issues
Energy efficiency improvement efforts typically follow the project phases described
in the module on Managing Energy Efficiency Improvements in this handbook.
For an existing facility, measurement, prioritization and budget limitations will
ultimately decide which of the proposed improvements are implemented. There is
also a preferred technical order to the improvements proposed in the table, which
follows the levels in the hierarchy of plant automation described in the Automation
section. Higher levels of automation are generally dependent on lower levels.
308 | ABB Energy Efficency Handbook

 Upgrade sensors and actuators (especially electro-hydraulic and mechanical

components)
Upgrade motors and drives
Upgrade Distributed Control System (DCS)
Upgrade programmable control strategies
Upgrade programmable optimization routines
Upgrade plant unit operating manual & procedures
There are limitations to the possible efficiency gains in the context of auxiliary
systems redesign or retrofit. Some of the improvements discussed in the section
on High Performance Energy Design, intended mainly for greenfield plant designs,
could achieve 15% net heat rate reductions over older plant designs (from a nominal
10200 Btu/kwh (10.8 MJ/kWh) down to 8700 Btu/kwh (9.2 MJ/kWh).

Base Case Plant Design and Performance Data

As with operational energy audits, a design energy assessment starts with some
data identification and data gathering steps. Design data and documentation must
also be collected, though, along with calculations/measurements of average heat
rate at full and partial loads. Unit data was collected from the following sources:

GE Handbook, H. Rustebakke, 1983

Black & Veatch (Drbal,L et al.) Power Plant Engineering , 1995
IEA CoalOnline , citing various data sources, 2008
EPRI Field Test on VFD Retrofits, 1993
ABB: Enels Torrevaldaliga Nord : 3 x 660MW units : increased net efficiency
from 39% to 45% with emission reductions: SO2/NOx/Dust from 400/200/50 to
100/100/15 (mg/Nm3) , 2005
ABB: Unit C of the E.ON Scholven Power Plant, 2008
ABB: PC plant in China; 3 x 700 MW units. Energy performance data, before/after
VFDs, 2008

Module 6 | 309

Plant Unit Assumptions

Parameter

Value

Units

Average Unit Capacity for period

500

MWe

Assumed Annual Capacity Factor

70.0

Fuel HHV (typical)

8,895

BTU/lb

0.00890

MBTU/lb

112.423

lb/MBTU

$2.470

$/MMBTU

$0.0220

$/lb

$0.048/kg

NOx Reduction Value

$2,000

$/ton

$2200/tonne

Fuel % Carbon

48.6

CO2 Reduction Value

$5.00

$/ton

NOx (average for period)

0.210

lb/MBTU

Net Heat Rate (average for period)

10,211

BTU/kWh

Fuel Cost

SI Units

20.6 MJ/kg

$5.50/tonne

Table 6.3 Plant basic and automation parameters

Parameter

Value

Units

Operating hours per year (auxiliaries)

8000

hr

SI Units

VFD investment cost

$93

$/hp

$125/kW

Induction motor investment cost

$100

$/hp

$135/kW

Cost of electricity when sold

$0.05

$/kWh

Premium of in-plant electricity

$0.007

$/kWh

Discount rate

5.0%

Service life remaining

20

years

Oversized motor efficiency penalty

0.1

Baseline annual generated energy

3,066,000,000

kWh

Baseline heat input

31,306,926

MMBtu

Cost of saved fuel

$0.025

$/kWh

Parameter

Value

Units

Transformer investment cost

10,000

$/MVA

Average Power Output (70% of rating)

350

Mwe

Transformer Load losses

$3,000

$/kW

Transformer Core losses

$1,500

$/kW

SVC investment cost

$50,000

$/MVAR

33 1015 J

Table 6.4 Drivepower parameters

Table 6.5 Transformer & SVC parameters

310 | ABB Energy Efficency Handbook

SI Units

% Full flow

% Total

Annual hrs

Capacity factor %

100%

400

5%

90%

10

800

9%

80%

20

1600

16%

70%

25

2000

18%

60%

25

2000

15%

50%

10

800

5%

40%

400

2%

30%

0%

20%

0%

100

8000

70%

Table 6.6 Operating profile for all auxiliaries

Load Name
Boiler feedwater

ID
BFW

Rated

In

Rated

Control

Load

Operat-

hp

use

Set hp

method

factor

ing hp

%
Gross

14,000

28,000

Slip

0.81

22,680

4.8%

pump
Condensate pump

HW

2,250

2,250

Throttling

0.75

1,688

0.4%

Circulating water

CW

3,400

6,800

Throttling

0.85

5,780

1.2%

FD

2,250

4,500

Inlet vane

0.52

2,340

0.5%

pump
Forced draft fan
(blower)
Primary air fan

PA

2,250

4,500

Inlet vane

0.49

2,205

0.5%

Induced draft fan

ID

4,500

9,000

Inlet vane

0.78

7,020

1.5%

41,713

BCW

600

1,800

Throttling

0.82

1,476

0.3%

SW

400

400

Throttling

0.82

328

0.1%

SUM ALL LARGE

MV motors
Boiler circulating
water pump
Service water
pump
FGD slurry pump

FGDS

600

600

Throttling

0.82

492

0.1%

Cooling tower fan

CT

600

1,200

Inlet vane

0.82

984

0.2%

Pulverizers

PV

450

2,250

Bypass

0.66

1,485

0.3%

Air compressor

AIR

480

480

Bypass

1.66

797

0.2%

All other auxiliary

AUX

4,300

4,300

N/A

0.53

2,279

0.5%

FGD

6,500

6,500

Inlet vane

0.66

loads
FGD booster fan
TOTAL
SCR circulating

66,480
SCR

400

400

Throttling

0.82

4,290

0.9%

54,171

11.5%

328

0.1%

pump
Table 6.7 Auxiliary systems fan and pump drivepower
Module 6 | 311

Auxiliary systems fan and pump drivepower (Table 5) represent a significant

proportion of plant generating capacity in our base case example.
All pumps = 7.2% of rated generating capacity
All fans = 3.6% of rated generating capacity
This upgrade activity seeks to reduce the energy consumption of these auxiliaries
across the entire operating profile. The common operating profile (Table 4) is
approximated for all pumps and fans, and reflects the units new role in intermediate
service and longer operation at lower loads.

Fan Input Parameters (per fan)

FD

ID

FGD

Fan type

centrifugal

centrifugal

Impeller type curve

backward

forward

Nominal volume flow

cfm

450,000

600,000

centrifugal
forward
1,200,000

Total pressure increase

in water*

12

17

18

Nominal fan efficiency

80.00%

55.00%

60%

96%

Flow control method

Motor efficiency

inlet vanes

inlet vanes
96%

inlet vanes
96%

Motor supply voltage

4.1kv

4.1kv

4.1kv

Transmission efficiency

100%

100%

100%

Table 6.8a Operating parameters for fans

Pump Input Parameters (per pump)

Nominal flow

gpm

BFW

CW

HW

2800

180,000

5500

Liquid density (water: SI = 1 kg/l)

lb/cu.ft

62.4

62.4

62.4

Efficiency

85%

85%

85%

Static head

ft

10

Nominal head

ft

900/2300

55

650

Max head

ft

1000/2500

75

750

Flow control method

Motor efficiency

slip
%

95%

throttling
95%

Throttling
95%

Motor supply voltage

4.1kv

4.1kv

4.1kv

Transmission efficiency

98.50%

98.50%

98.50%

* 1 inch of water = 0.0025 bar = 0.25 kpa

Figure 6.8b Operating parameters for pumps

312 | ABB Energy Efficency Handbook

Base Case Plant Improvement

#1 Improved Fan Flow Control
In the base case plant unit there are 2 FD fans, rated at 2250 hp (1680 kW) each
and 2 ID fans rated at 4500 hp (3357 kW) each, in parallel, all of centrifugal design,
all using inlet guide vanes for flow control. On hot summer days, peak loading of the
unit was limited by the FD fan capacity. A single FGD booster was later installed,
rated at 6,500 hp (4850 kW).
Retrofit Description
In the retrofit project, all fans were equipped with VFDs for speed control and the
inlet vanes were locked in open position.

FD

ID

FGD

Number in operation

Required input motor power;

hp

1065

3190

6184

kWh

3,472,721

10,403,631

20169878

kWh

2,474,608

7,413,469

14372748

Annual energy saving kWh

kWh

998,113

2,990,162

5,797,130

Efficiency gain %

28.7%

28.7%

28.7%

Annual saved energy when sold

$2,495

$7,475

$14,493

Annual saved fuel qty

lbs

1,088,493

3,260,924

6,322,065

Annual saved fuel cost

$23,915

$71,645

$138,900

Annual saved fuel cost

$6,637

$19,885

$38,551

Annual heat input saving

MMBTU/year

9,682

29,005

56,234

Annual CO2 reduction

tons

970

2,905

5,633

Annual CO2 charge saving

$4,849

$14,527

$28,165

Improvement in heat rate

0.03%

0.10%

0.19%

Annual saving TOTAL

$37,897

$113,532

$220,108

Investment cost

$99,045

$296,670

$575,112

Payback period

years

2.4

2.4

2.4

Net Present Value

$373,234

$1,118,190

$2,167,925

rated, including 10% margin

Annual energy consumption
with existing flow control
Annual energy consumption
with VFD flow control

premium

Divide lbs by 2.2 to get kg. Multiply MMBtu by 1055 to get MJ.

Table 6.9 Main benefits analysis for fans, per fan

Module 6 | 313

#2 Improved Pump Flow Control

The boiler feedwater (BFW) pumping system in the base case plant unit has 2
multi-stage, split-casing centrifugal BFW pumps each supplying 50% of the capacity.
Each BFW pump is rated at 14,400 hp (10,740 kW). Control valve throttling was
originally used for flow control, then it was replaced by hydraulic slip-type coupling
for speed control some years ago.
The cooling water circulating water (CW) pump in the base case plant unit is a low
head, high capacity axial design. There are 2 such pumps rated at 3217 hp (2400
kW) which together consume approximately 0.8% of rated generating capacity for
the unit. The cooling system is closed loop and the pump is a vertical, wet pit type,
and control valves are used for throttling flow control.
The condensate or hotwell (HW) pump in the base case plant unit is a single pump
rated at 2144 hp (1600kW) and consumes approximately 0.1% of rated generating
capacity for the unit. This pump is a 2-stage centrifugal design. An additional HW
pump is installed for redundancy, but does not normally operate.
Retrofit Description
The pumps were equipped with VFDs for speed control and the hydraulic couplings
were removed. Previous studies (by ABB, Black & Veatch, EPRI) have indicated
that VFDs provide a 10% reduction in input electrical power compared to slip-type
couplings, even at 100% throttle flows. This advantage increases to 15% for flows
between 50% and 75% of full throttle, which more closely reflects the operating profile
of the base case plant unit. See the section on Pump Flow Control for more details
on these flow control comparisons. The benefits in the table below were calculated
using the 15% improvement factor. If throttling were used for BFW pump flow control,
then the advantage of using VFDs for flow control would vary from 10% at full throttle
to 30% at half throttle flows. Note also that most simple tools for benefits analysis are
not valid for large BFW pumps with multi-stage designs.
An alternative to retrofitting both CW pumps with VFDs is to retrofit only a single
pump and use automation to start/stop the other pump to reduce the plant auxiliary
load. The automation control logic could use the unit load and turbine back pressure
as inputs.

314 | ABB Energy Efficency Handbook

BFW

CW

HW

Number in operation

Required input motor power;

hp

11,423

3240

1170

kWh

41,109,000

15,758,502

5,216,951

kWh

34,942,500

7,372,117

2,716,618

Annual energy saving kWh

kWh

6,166,500

8,386,385

2,500,333

Efficiency gain %

15.0%

53.2%

47.9%

Annual saved energy when sold

$15,416

$20,966

$6,251

Annual saved fuel qty

lbs

6,724,882

9,145,779

2,726,740

Annual saved fuel cost

$147,750

$200,939

$59,908

Annual saved fuel cost premium

$41,007

$55,769

$16,627

Annual heat input saving

MMBTU/year

59,817

81,351

24,254

Annual CO2 reduction

tons

5,992

8,149

2,430

Annual CO2 charge saving

$29,959

$40,744

$12,148

Improvement in heat rate

0.20%

0.27%

0.08%

Annual saving TOTAL

$234,133

$318,419

$94,934

Investment cost

$1,062,293

$301,320

$108,810

rated, including 10% margin

Annual energy consumption
with existing flow control
Annual energy consumption
with VFD flow control

Payback period

years

4.5

1.0

1.2

Net Present Value

$1,855,521

$3,666,885

$1,074,277

Divide lbs by 2.2 to get kg. Multiply MMBtu by 1055 to get MJ.

Table 6.10 Main benefits analysis for pumps, per pump

#3 High-Efficiency Motors & Drive-trains

Retrofit Description
Existing motors were replaced with high efficiency, low power-factor motors. Any
applications with negative NPV (shown in red in the table below) would not be
considered as candidates for this kind of retrofit.

Module 6 | 315

Main Benefits Analysis

Motor & Drivetrain Improvement

Motor

FD

ID

FGD

Existing motor rating (per unit)

Hp

2,250

4,500

6,500

Existing motor efficiency

85.0%

85.0%

85.0%

Existing transmission efficiency

97.0%

97.0%

97.0%

New motor efficiency

96.5%

96.5%

96.5%

New transmission efficiency

99.0%

99.0%

99.0%

Oversized hp

hp

1,185

1,310

316

Oversized %

52.7%

29.1%

4.9%

Oversized motor efficiency penalty

5.3%

2.9%

0.5%

Annual energy saving kWh

kWh

651,714

1,707,351

2,820,990

Efficiency gain %

18.8%

16.4%

14.0%

Annual saved energy when sold

$1,629

$4,268

$7,052

Annual saved fuel qty

lbs

710,727

1,861,954

3,076,433

Annual saved fuel cost

$15,615

$40,908

$67,591

Annual saved fuel cost premium

$4,562

$11,951

$19,747

Annual heat input saving

MMBTU/year

6,321

16,562

27,364

Annual CO2 reduction

tons

633

1,659

2,741

Annual CO2 charge saving

$3,166

$8,295

$13,706

Improvement in heat rate

0.02%

0.06%

0.09%

Annual saving TOTAL

$24,973

$65,423

$108,096

Investment cost

$106,500

$319,000

$618,400

Payback period

years

4.3

4.9

5.7

$204,719

$496,328

$728,715

Net Present Value

Divide lbs by 2.2 to get kg. Multiply MMBtu by 1055 to get MJ.

Table 6.11 Main motor and drivetrain benefits for fans, per motor

Motor & Drivetrain Improvement

Per Unit -->

BFW

CW

HW

Existing motor rating (per unit)

hp

14,000

3,400

2,250

Existing motor efficiency

85.0%

85.0%

85.0%

Existing transmission efficiency

98.5%

97.0%

97.0%

New motor efficiency

96.5%

96.5%

96.5%

New transmission efficiency

99.0%

99.0%

99.0%

Oversized hp

hp

2,578

160

1,080

Oversized %

18.4%

4.7%

48.0%

Oversized motor efficiency penalty

1.8%

0.5%

4.8%

Annual energy saving kWh

kWh

5,689,926

2,201,555

954,702

Efficiency gain %

13.8%

14.0%

18.3%

Annual saved energy when sold

$14,225

$5,504

$2,387

Annual saved fuel qty

lbs

6,205,154

2,400,908

1,041,151

316 | ABB Energy Efficency Handbook

Per Unit -->

Annual saved fuel cost

Motor & Drivetrain Improvement

$

$136,331

$52,750

$22,875

Annual saved fuel cost premium

$39,829

$15,411

$6,683

Annual heat input saving

BTU/year

55,194,843,186

21,356,078,337

9,261,039,336

Annual CO2 reduction

tons

5,529

2,139

928

Annual CO2 charge saving

$27,644

$10,696

$4,638

Improvement in heat rate

0.19%

0.07%

0.03%

Annual saving TOTAL

$218,030

$84,360

$36,583

Investment cost

$1,142,250

$324,000

$117,000

Payback period

years

5.2

3.8

3.2

Divide lbs by 2.2 to get kg. Multiply MMBtu by 1055 to get MJ.

Table 6.12 Main motor and drivetrain benefits for pumps , per motor

#4 Boiler Turbine Coordinated Controls and Sliding Pressure Operation

This retrofit is worthwhile, but automation auxiliaries cannot claim all benefits due to
sliding pressure mode; it is therefore excluded from the summary of benefits.
#5 Advanced Steam Temperature Control
The existing control used the two parallel spray valves to control the final main
superheat (SH) steam temperature. The control strategy included two PID controllers
in a cascade configuration. The outer PID calculated a setpoint for the average of
the two attemperator outlet temperatures. A feedforward based on the unit load
demand was used as a valve demand reference. The system uses a single spray
valve to control the final reheat (RH) steam temperature. A feedforward based on the
unit load demand is used as a valve demand reference.
The sample data set, however, showed that the steam temperatures were
uncontrolled at the low or ramping loads, which degrades heatrate for the units
new role providing intermediate (load-following service. In the base case unit, the
standard deviation of the main steam temperature was found to be 8F due to unstable
operation and control action. Operators typically maintained a safety margin of 3 to
4 times the standard deviation between the maximum and the temperature setpoint
(ABB, Immonen 2006) and this was reflected in the average main steam temperature,
which was 30 F below the design point (1005F), at 975 F. Similar instability and lower
average temperatures were observed for reheat temperatures as well.
Retrofit Description
An advanced steam temperature control strategy was implemented to control steam
temperature for a drum boiler operating in either constant or sliding pressure mode:
see the section on Advanced Seam Temperature Control for design details. Using
these techniques, the standard deviation is more than halved to only 3F, which

Module 6 | 317

means the average main steam temperature can be maintained at 993F, an increase
of 18 F. Similar improvements were obtained for the reheat steam temperature.
Main Benefits Analysis
For a sub-critical unit: each 50F increase in main steam temperature decreases
heatrate by 70 Btu per kWh at full load, and which corresponds to an increase
in cycle efficiency of approximately 0.7% (Babcock & Wilcox 2005). For reheat
temperature increase of 50F the heatrate decrease is 65 Btu per kWh. The 18 F
increase in main steam temperature yielded the following benefits.
Results

Units

Baseline

Reduced Baseline

Amount of

Average Heat Input based on

BTU/h

4,248,000,000

4,227,000,000

20,218,000

Fuel Input

lbs/h

477,546

475,274

2273

Annual Fuel Cost

$/year

$76,469,102

$76,105,142

363,960

Baseline CO2 Emission

lbs/h

850,988

846,938

4,050

Baseline CO2 for 12 Months

Tons CO2/yr

3,727,327

3,709,586

17,740

Reduction
Rating x Annual Capacity Factor

Divide lbs by 2.2 to get kg. Multiply MMBtu by 1055 to get MJ.

Table 6.13 Effect on baseline performance of increased main steam temperature

Side Benefits Analysis

Reduced attemperation spray flows: these are accounted for separately in a later case
Faster unit ramp rate
Fewer outages due to tube leaks
#6 Stabilization of Firing Rate
The existing controls included the interface to the regional power system dispatcher
(ISO) that sends a unit load target. The Unit load demand was used as a setpoint
and feedforward to the boiler master and turbine load control. The unit load ramp
rate was typically 4 to 6 MW/min based on operation perception of limiting boiler
ramps to 20 psi/min.
The sample data set, however, showed, unstable firing rate and reduced heat
rate, with marked deterioration since the unit had converted to low-NOx burners.
Superheat and reheat attemperation spray flows had also reached record high levels
of 96 klb/hr and 110 klb/hr respectively.

318 | ABB Energy Efficency Handbook

Retrofit Description
In conjunction with the controls retrofit, the response was re-programmed to be
slower at start of a ramp, and greater acceleration is allowed when drum pressure is
greater than 1260 psig.
Main Benefits Analysis
These modifications, in conjunction with the upgraded advanced steam temperature
controls, reduced instability and superheat and reheat attemperation spray flows to
30 klb/hr and 40 klb/hr respectively, with the following estimated benefits:
Results

Units

Baseline

Reduced Baseline

Amount of

Average Heat Input based

BTU/h

4,247,776,000

4,178,413,824

69,362,176

Fuel Input

lbs/h

477,546

469,749

7798

Annual Fuel Cost

$/year

$76,469,102

$75,220,434

$1,248,668

Baseline CO2 Emission

lbs/h

850,988

837,092

13,896

Baseline CO2 for 12 Months

Tons CO2/yr

3,727,327

3,666,463

Improvement in heat rate

Reduction
on Rating x Annual Capacity
Factor

60,864
1.633%

Divide lbs by 2.2 to get kg. Multiply MMBtu by 1055 to get MJ.

Table 6.14 Effect on baseline performance of decreased superheat and reheat attemperation flows

#7 Improved Airflow Control - Excess O2 Reduction

Prior to all retrofits, two FD fans were used to control the boiler combustion air flow
in the base case unit. The control response was adjusted based on whether one or
two fans were in automatic service. The air flow control included the typical crosslimit by the fuel flow as described in the Combustion Control section. The sample
data set, however, showed a 0.5% variation in O2 at all loads, and worries about
opacity excursions led to much manual control.
Retrofit Description
In a control system retrofit, a dedicated oxygen trim control module was installed to
adjust the measured air flow as needed to keep the O2 at the load based setpoint.
The process variable is the lower of the two O2 analyzer inputs. The trim control
module also uses the more precise airflow control provided by VFD-equipped FD and ID
fans to achieve overall optimum levels of combustion, as described in Air Flow Control
for Combustion. Furthermore, air heater seals were inspected and worn/broken ones
were replaced, to eliminate outside air leaks from entering the flue gas stream.

Module 6 | 319

Main Benefits Analysis

Improved control and stability allowed full-time automatic control and an average
reduction in excess O2 from 3.7% to 2.5% and the following benefits. The first 0.5%
of reduction came from the air heater seal replacements, and the net reduction from
3.2% to 2.5% was obtained through the controls improvement:
Results
Average Heat Input based on

Units

Baseline

Reduced

Amount of

Baseline

Reduction

BTU/h

4,247,776,000

4,229,430,400

18,345,600

Fuel Input

lbs/h

477,546

475,484

2062

Annual Fuel Cost

$/year

$76,469,102

$76,138,842

$330,260

Baseline CO2 Emission

lbs/h

850,988

847,313

3,675

Baseline CO2 for 12 Months

Tons CO2/yr

3,727,327

3,711,229

16,098

Rating x Annual Capacity Factor

Divide lbs by 2.2 to get kg. Multiply MMBtu by 1055 to get MJ.

Table 6.15 Effect on baseline performance of decreased excess oxygen

#8 Improved Feedwater Pressure & Level Control

The base case units drum level is regulated by two motor-driven Boiler Feedwater
(BFW) pumps each with a variable speed (VFD) drive as a result of the retrofit
described in Improved Pump Flow Control. Single element-three element
control strategy is employed for drum level control as described in Feedwater
Flow Control.
The units transition to intermediate (load-following) service with higher ramp rates
and increased operation at lower loads, however, led to instability and lower average
main steam pressure 2,436 psi compared to the design point at 2,500 psi when
operating in constant pressure mode at higher loads.
Retrofit Description
The new control system uses shrink-swell compensation to maintain drum level
even at the faster unit load ramp rates. Adaptive tuning is also employed to allow
the controllers to respond most accurately across the expanded load range.
Main Benefits Analysis
The steam pressure standard deviation was reduced, allowing a higher average
pressure operation at 2,480 (an increase of 44 psi). For a sub-critical unit: each 100
psi increase in main steam pressure decreases heatrate by 35 Btu per kWh at full
load (EPRI report CS-4554).

320 | ABB Energy Efficency Handbook

Results

Units

Average Heat Input based

Baseline

Reduced

Amount of

Baseline

Reduction

BTU/h

4,247,776,000

4,241,369,600

6,406,400

Fuel Input

lbs/h

477,546

476,826

720

Annual Fuel Cost

$/year

$76,469,102

$76,353,773

$115,329

Baseline CO2 Emission

lbs/h

850,988

849,704

1,283

Baseline CO2 for 12 Months

Tons CO2/yr

3,727,327

3,721,705

5,621

on

Rating x Annual Capacity

Factor

Divide lbs by 2.2 to get kg. Multiply MMBtu by 1055 to get MJ.

Table 6.16 Effect on baseline performance of improved feedwater level & pressure control

#9 Electric Power System Improvement

Unit Transformers / Bus

Gen Step-Up

Aux 1A

Aux 1B

FGD Boost

Primary

kV

19

19

19

19

Secondary

kV

525

6.9

6.9

13.8

Rating MVA

MVA

520

40

40

10

Existing PF

N/A

0.91

0.85

0.85

0.85

Existing efficiency at oper. pt.

99.1%

97.2%

97.2%

97.2%

New PF

N/A

0.94

0.9

0.9

0.9

New efficiency

99.7%

98.0%

98.0%

98.0%

Existing Reactive Power

MVAR

159.5

21.1

21.1

5.3

(based on capcity factor)

New Active Power

MW

361.5

36.0

36.0

9.0

Change in Active Power

MW

11.5

2.0

2.0

0.5

Cable type

n/a

4x3C,

4x3C,

4x3C,

4x3C, 100mm

300mm

100mm

100mm

Cable length

ft

150.0

700.0

700.0

700.0

Existing Total Power (based

MVA

384.6

40.0

40.0

10.0

on capacity factor)
Divide lbs by 2.2 to get kg. Multiply MMBtu by 1055 to get MJ.

Table 6.17 Power system improvements

The base case units GSU and auxiliary transformers are old. The PF on the
generator and plant network sides is relatively low.

Module 6 | 321

Retrofit Description
New, right-sized transformers, active power factor correction on auxiliary network to
increase power factor.
Main Benefits Analysis
Improvements
Annual energy saving due to

Gen Step-Up

Aux 1A

Aux 1B

FGD Boost

kWh

16,800,000

1,348,564

1,348,564

337,141

kWh

84,000,000

8,428,523

8,428,523

2,107,131

kWh

100,800,000

9,777,087

9,777,087

2,444,272

transformer
Annual energy saving due to PF
increase
Annual energy saving kWh
Efficiency gain %

0.6%

0.8%

0.8%

0.8%

Annual saved energy when sold

$252,000

$24,443

$24,443

$6,111

Annual saved fuel qty

lbs

109,927,528

10,662,410

10,662,410

2,665,603

Annual saved fuel cost

$2,415,179

$234,260

$234,260

$58,565

Annual saved fuel cost premium

$670,320

$65,018

$65,018

$16,254

Annual heat input saving

MMBTU/

977,805

94,842

94,842

23,710

Annual CO2 reduction

tons

97,945

9,500

9,500

2,375

Annual CO2 charge saving

$489,727

$47,501

$47,501

$11,875

year

Improvement in heat rate

3.29%

0.32%

0.32%

0.08%

Annual saving TOTAL

$3,827,226

$371,221

$371,221

$92,805

Investment cost

$8,200,000

$400,000

$400,000

$100,000

Payback period

years

2.2

1.03

1.03

1.03

Net Present Value

$39,495,700

$4,226,240

$4,226,240

$1,056,560

Divide lbs by 2.2 to get kg. Multiply MMBtu by 1055 to get MJ.

Table 6.18 Benefit analysis results

322 | ABB Energy Efficency Handbook

Summary of Benefits
The combination of all the energy efficiency retrofit improvements, shown in the table
below, reduced the heat rate in the base case plant by 8%, with a payback of less
than 2 years.

Automation

Drivepower

Elec System

Total

Results

Improvement

Improvement

Improvement

Improvement

New
Baseline

Average Heat

BTU/h 87,960,600

71,272,115

135,981,755

295,214,470

3,278,635,530

Fuel Input Rate

lbs/h

9,889

8,013

15,287

33,189

368,593

Fuel Cost

$/year

$1,332,255

$1,079,490

$2,059,585

$4,471,330

$49,658,345

$/year

$0

$390,876

$734,337

$1,125,213

lbs/h

17,622

14,278

27,242

59,142

656,833

CO2 Emission

tons

77,183

62,540

119,321

259,044

2,876,928

Rate per year

CO2/
$

$385,917

$312,698

$596,604

$1,295,220

$14,384,640

Heat Rate

BTU/

2.46%

1.99%

3.80%

8.26%

10211

Improvement

kWh

Saved Electric

$0

$144,500

$276,067

$420,567

Input Rate

per year
Saved Electricity
Premium
CO2 Emission
Rate per hour

yr
CO2 Charge
per year
9431

Power Sales
Unit Capacity

MW

0.00

7.23

14.02

21.25

Total Annual

$1,718,172

$1,927,565

$3,666,594

$7,312,331

Investment Cost

$1,500,000

$6,516,935

$9,100,000

$17,116,935

Payback Period

years

0.87

3.4

2.5

2.4

$19,912,221

$17,504,785

$39,593,865

$74,010,872

Savings

Net Present Value $

Divide lbs by 2.2 to get kg. Multiply MMBtu by 1055 to get MJ.

Table 6.19 Effect on baseline performance of all improvements

Module 6 | 323

Conclusion and Comments

The cases were restricted to a single unit, but a true integrative design approach
would investigate possibilities for thermal and control integration with other units
and even other nearby facilities. Integrated (real-time) control between plant units
may provide a relatively low-cost way to optimize production for energy. The base
case unit is analyzed in isolation, but environmental services for cooling or pumped
storage may provide opportunities for improved auxiliary and cycle efficiency.

Software Tools for Energy Benefits Analysis

The benefits analysis performed on the base case plant was aided by the
spreadsheet tool: ABB Power Systems Valuation Tool, 2009.

Figure 6.4 Screenshot of the ABB Power Systems Valuation Tool, Version 3, 2009

324 | ABB Energy Efficency Handbook

Module 7
Managing Energy Efficiency Improvement

Module Summary
This module presents tools and methods for managing energy efficiency evaluations
and improvement efforts. This module provides methods for assessing energy
performance and for executing energy improvement design and engineering projects.
The information in this module may be generally applied to process industries;
industry-specific text is shown in a shaded box.

Indicators of Energy Inefficiency

Energy inefficient design is easier to see in an existing plant with an operating history
than in one that is still on the drawing board. The table and figure below show some
indicators of energy-inefficient design in an operating plant which may prompt
managers to take the next step toward an energy performance assessment.
Plant Characteristic

Status

Overall design type

far from current state of the art

Actual capacity

significantly less than full design capacity

Age of the plant systems

More than 17 years old

History of its major systems

multiple, minor retrofits

Regulatory/energy price conditions

in-plant power is priced at cost, and other

protective subsidies/regulations abound

Management of control, safety and pollution,

availability

no plant control strategy, patchwork

compliance, no pro-active reliability program

Number of trips

many

Length of time in which major control loops are

> 25%

in manual control
Amount of operator tweaking, length and

Much operator intervention, manual control

amount of operator intervention in startups

Exceeds pollution/emission limits

yes, often

Plant documentation

not as-built , with as is murky

Quality and documentation of control logic

not easily fathomable by anyone

Figure 7.1 Indicators of energy project management problems

Module 7 | 325

Energy Assessment Processes

Full plant performance assessments are typically $50,000 to $90,000 and loop
performance analysis packages for a full plant can be implemented and monitored
for as little as $50,000. Each can uncover costly control problems in air flows (and
elsewhere) that can reach six or even seven figures a year, depending on plant size
and the severity of the problem(s). At a 500 MW plant, for example, improving heat
rate 1 percent can result in annual fuel savings exceeding $800,000.
Motor Energy Assessment
A motor energy assessment must collect the following data from supplier and plant
documentation, equipment strip charts, or DCS logging systems:

Number of motors, their size, maintenance records

Duty cycle and load profile
Input power from 3-phase wattmeter measurements
Number and type of throttled loads
Output power from process measurements
Efficiency: nameplate less 1% for each rewind

Plant Design & Modeling Tools

Many tools exist for engineers to calculate energy performance at the component
level, but fewer tools exist which take a wider, integrative view of the plants energy
performance. An example of the former are the US DoE calculation tools for Motor,
Pump & Fan sizing and selection ; these are not for plant design, but are useful for
subsystem engineering.
Design Tools
The greatest benefit to integrative energy design would come from integrating
some of the component calculations mentioned above into the leading plant design
packages. The design tools most relevant for engineers & designers today perform
2D schematic and 3D design and some cost analysis. Engineers use design software
tools to maintain a consistent view of the evolving design data and allow project
326 | ABB Energy Efficiency Handbook

leaders to enforce some best practice workflow rules. Further benefits would be
gained if the cost-analysis functions could have built-in support for some of the most
common life cycle cost (LCC) energy calculations.
Integrated design tools make it easier to configure modeling and analysis tools
described in the next section - the effort involved in collecting data from multiple
incompatible tools can otherwise be as much effort as creating the model itself.
Modeling and Simulation Tools
Modeling tools can perform the necessary energy and mass balances to give an
integrated view of the plant performance. Configuring and running such simulations,
however, requires special training and is usually reserved for R&D or thermodynamic
engineers who may not be part of a retrofit project team. As a result, the potential of
these tools is not realized in many projects.
Ease of use is greatly increased by having a pre-built library of components which
can be assembled according to the plant PFDs. One vendor, AspenTech, claims
that their process engineering design tools can provide 5-20% energy saving due to
built-in energy pinch analysis, process simulation, and model-based cost analysis.
Other modeling tools which have pre-built components and functionality for power
plant modeling are GEs Gate Cycle and ABBs PowerCycle packages. PowerCycle
enables design of thermodynamic loops similar to a P&I scheme and to generate the
mathematical model automatically in the background. The tool has a comprehensive
library, which contains major plant components and its connections as well as
modules for control of variables and signal transmission.
Formal Energy Optimization Methods
Steam power plant modeling tools generally use one or more of the following formal
energy analysis methods:

Exergy / Available Energy Analysis

Pinch Technology / Thermal Integration
Process Integration
Data envelopment analysis (DEA)
Stochastic-frontier method
Steam pricing

A description of these methods is beyond the scope of this handbook, but details
can be found in some of the texts listed in the References section.

Module 7 | 327

Importance of Design Documentation

Good retrofit or new-plant (greenfield) design begins with good input documentation
which reflects the as-is (and as-built) state of the plant. The two most important
design documents are the PFDs (Process Flow Diagrams) and the P&IDs (Piping and
Instrumentation Drawing), examples of which are shown in the figures below.

Figure 7.2 Sample PFD on left, Sample P&ID on right, (Wikipedia / Chemical Engg World)

A P&ID is a full diagrammatic representation of a process plant. Each piece of

equipment is shown along with its connectivity to other equipment. It may be
regarded as an enhanced process flow diagram that shows, in addition to the
process itself, details such as control and instrumentation equipment, pump and
pipe sizes etc. Each instrument / piece of equipment is shown by a symbol denoting
its type (pump, sensor, valve etc.) and a unique identification number or tag for
differentiation from others (Wikipedia / Chemical Engg World)

Large Capital Project Processes

A glance at the section on Barriers to Energy Efficient Design shows that
fragmentation of disciplines and supply chain is a significant contributor to
energy deficient outcomes. The fragmentation of todays complex projects
needs integrative project methods to achieve greater unity of design and more
opportunities for plant-wide energy efficiency measures. Another, kinder word
for fragmentation is componentization and it has led to improved equipment
performance, but it has large hidden costs, especially in complex, large scale
projects with life cycle costs far greater than the initial construction expense.

328 | ABB Energy Efficiency Handbook

Project Phases and Energy Efficiency Impact

Phases in a large capital project involve many disciplines (Civil, Electrical,
Automation, Chemical or Process) in many companies and time zones. Integrated
energy design should therefore be practiced as a seamless part of the project
execution model.

The figure above shows the typical plant project phases, and the figure
below shows some pitfalls in each of these steps which can lead to an
energy-inefficient outcome.

Figure 7.3 Indicators of project management problems with energy efficiency impact

Module 7 | 329

Integrated Approach to Energy Project Management

For project, bid and plant managers, the following project guidelines were inspired in
part by successful RMI design charrette methods. A design charette is a technical
review process which originated in the field of architecture. Some important points
for project managers to consider:
Use lifecycle costing to fearlessly retire or retrofit energy-hogging assets, even
before they have been fully depreciated. Use a fair rate of return for energy
performance and re-consider the standard assumptions in your costing model.
Budget time and money for front-end energy design studies. Recruit best
in-house designers, or get outside help, to study energy balances, sitting
opportunities, renewable energy designs.
Replace low-bid contract with multiple and specific energy performance
guarantees. Low-bid projects cut energy corners, use conservative designs.
Stipulate energy performance, and agree on measurement.
Use an agile project execution model which allows iteration on the original
requirements. Avoid the big freeze on the design before all important data is in.
Use input to continuously iterate on the assumed requirements. Insist on early
submission of vendor information.
Involve energy end-users as much as possible, in all project phases. Involve plant
site operators or others to represent the energy end-users. Show the PFDs and
P&IDs to operators as early as possible.
Appoint an energy steward to enforce energy standards in your project or plant,
a senior person who will be as respected (and accountable) as safety experts are
today.
Appoint an interface manager to map & manage interfaces & ensure wholedesign consistency. The interface manager ensures that disciplines, suppliers and
operations are communicating & using a common energy philosophy and design
model of the evolving plant.
Seek a single contractor and not multiple vendors where feasible. Give project,
and responsibility, to a firm with broad, multi-disciplinary experience; do not
fracture design through divide and conquer contracting.
Be energy critical during plant retrofit work acceptance. Dont rush: ensure all
units work together under all loads this is typically the last chance to hold
suppliers to their word.
Benefits of Integrated Project Management
The up-front attention to real end-use demand will actually reduce the total number
of engineering hours, especially during the later project phases of when interfaces
(i.e.: different sub-systems) must come together and be tested.

330 | ABB Energy Efficiency Handbook

Figure 7.4 Project hours reduction with a systems approach Honours,E.C. (2004) cited in (Natural
Edge Project, 2007)

Advantage of the Main Contractor Role

The Main Automation and Main Electrical Contractor (MAC/MEC) project roles help
to tie together the design and implementation of diverse plant units to make plant
optimization interfacing easier. One function of these roles is to ensure that the
required signals and interfaces are present to allow integration and optimization
between sub-units and across the entire plant. Do not underestimate the importance
of clear and comprehensive documention, and rigorous communication and review
of these signals and interfaces as part of project execution.

Module 7 | 331

332 | ABB Energy Efficiency Handbook

Module 8
High Performance Energy Design
Module Summary
This module presents energy-efficiency designs and technical innovations which
may be above the investment and risk thresholds of a modest retrofit project. The
constraints of legacy equipment in retrofit projects also limit the potential to designin large energy efficiency gains. A new plant or unit project, however, provides a
chance for the designer to use best-in-class equipment and methods across all
systems. In new projects, the energy targets can be ambitious and should aim for
the maximum allowed by the process thermodynamics.
The information in this module section is specific to power generation industries
or process plants with on-site power generation. Many sections, however, are also
broadly applicable to all industrial steam generation processes.

Tunneling thru the Cost Barrier

Solutions that apply Integrative Design principles on greenfield or large redevelopment projects can achieve lower total-system capital costs in addition to
lower total-system energy consumption compared to non-integrated designs. An
energy effective design that has lower initial cost is much more likely to be approved.
No net or marginal loss of service or quality is suffered in such a solution.

Auxiliaries in Best-Available-Technology Plants

Supercritical and Ultra-Supercritical Boilers
Supercritical boilers operate at pressures above the top point of the water-vapor
dome. These designs eliminate the drum, and water is in continuous phase change
within the wall tubing. The higher operating steam parameters give this design higher
efficiency than sub-critical boilers, and state of the art units have reached 47% of
LHV, some examples are Nordjyllandsvrket in Denmark, and Haramachi No 2 and
Misumi No.1 in Japan.
Although metallurgical advances are the main driver in SC or USC designs,
modern, efficient auxiliaries are also key enablers. Control systems are one of the
key enablers of super-critical boilers that dominate new plant designs. By exactly
matching flow through the boiler tubing to the demands of the system, the control
system has eliminated the need for a water drum and allowed higher steam
Module 8 | 333

parameters, lower system inertia, and much greater efficiency. Greater familiarity
with the capabilities of control system technology will help engineers to push
the envelope even further to ultra-supercritical designs, achieving synergies with
developments in metallurgy.
The higher pressures of supercritical designs increase the auxiliary drive power
required by the boiler feedwater pumps. This extra power is worth the gain in
thermodynamic efficiency - for otherwise similar configurations, the move from
high subcritical to low supercritical steam conditions is said to confer an efficiency
advantage of approximately two percentage points (Weirich and Pietzonka, 1995).
Circulating Fluidized Bed (CFB) Furnaces
In CFB combustion designs, the fuel is spread over a deep wide area (the bed)
and hot air is forced through the bed to supply combustion and to lift and separate
the individual fuel particles so that they behave like a fluid, In the context of CO2
reduction, CFB can accommodate a wider variety of fuels, including biomass. CFB
furnaces can co-fire with up to 20% biomass (Ferrer, Green Strategies for Aging Coal
Plants, 2008).
Auxiliary drivepower enters the picture through the fuel preparation required for
handling and feeding a variety of fuels, and also in higher-volume ash-removal
systems. This is balanced against the reduction in power required for fine
pulverization of the fuel, which is unnecessary in CFB boilers.
Waste to Energy
A facility with CFB combustion may be equipped with recycling capacity for RefuseDerived Fuel (RDF) and therefore qualify for more environmentally sustainable energy
production. On-site processing of the RDF will require significant amounts of auxiliary
power, however.
Combined Cycle Gas Turbines
CCGT plants adds a Brayton gas turbine cycle ahead of the Rankine water-steam
cycle to achieve even higher efficiencies. The exhaust from the gas turbine is a
source of heat for the heat recovery steam generator (HRSG). Some PC steam
plants may lend themselves to conversion to CCGT by installing gas fired gas
turbines at site and use gas turbine exhaust heat to heat boiler feedwater. In such
cases both the coal fired boiler and the gas turbine are used at the same time. This
conversion design is especially useful on coal fired boilers that were de-rated due to
excessive NOx or furnace slagging (Eng-Tips Power Generating Forum, Dave Fitz,
2006).

334 | ABB Energy Efficiency Handbook

Auxiliary electric drivepower is necessary for gas turbine startup and fuel pumping
requirements, but auxiliary control can play an even larger role in energy efficient
operation of CCGT plants through optimal operation and allocation of the multiple
sources and sinks for heat and power generation and consumption.
Integrated Gasification - Combined Cycle IGCC
The IGCC process burns coal, but it begins with a low-oxygen gasification unit to
produce synthetic gas, which is then combusted in the gas turbine of a CCGT unit.
IGCC plants have lower emissions of pollutants and higher efficiencies than PC
steam plants. IGCC is key to realizing the industrys vision of clean coal, but some
challenges remain before plants can be scaled up to match the largest coal plants
today. The capital cost of an IGCC plant is estimated to be 10-16% higher than a PC
plant of similar capacity (Pew Center on Global Climate Change 2005). Recent price
volatility in natural gas are delaying the anticipated trend toward IGCC plant types,
as discussed in Trends in Steam Plant Designs and Efficiency. In one recent
project in Netherlands (ABB/Nuon), the gasifier converts coal and biomass into
syngas, which is used to fuel the combined-cycle units.
Significant new auxiliary drivepower is needed for coal slurry pumps and air/oxygen
compressors, as well as an extra pumping of economized boiler feedwater to the
syngas cooler.
Gas-Gas Reheat for Flue Gas Desulfurization (FGD)
Flue gas reheat after flue gas desulphurization (FGD) systems can scavange
additional heat from the thermodynamic cycle if they use steam heating, as
commonly applied in the USA, but newer FGD systems have feed/effluent gas/gas
heat-exchangers that avoid losses from this source (IEA Coal Online - 2 2007). See
the section on Automation Emissions Controls for details. This type FGD design,
however, requires additional auxiliary speed control and automation.
Powering and Re-Powering with Biomass
Biomass combustion is mainly carbon-neutral and should therefore be exempt from
any potential CO2 charges. Most power plants fired on PC can co-fire up to 4-5%
biomass without significant degradation and without furnace re-design (Ferrer, Green
Strategies for Aging Coal Plants, 2008). The practical upper limit to co-firing with
biomass in existing PC plants may be as high as 20% (Pew Center on Global Climate
Change 2005), but at the expense of decreased efficiency. According to Robinson
and co-authors in their Assessment Potential of CO2 Reductions due to Biomass,
2003, co-firing with 10% biomass can achieve carbon mitigation at a cost of $8-$27
per metric ton CO2.

Module 8 | 335

Wood shavings and straw have been the most common source of biomass, but
recent US energy legislation enables the use of other sources such as fresh wood
(Lahoda, Arndt, & Hanstein, 2006). The reliability of an economical supply of wood
fuel is an important requirement for continually high biomass co-firing. The definition
of biomass in the EU is limited to about 15 different materials; all else is considered
simply waste and may not be processed into energy that is considered carbonneutral.
Repowering a PC furnace to burn a higher proportion of biomass requires design
changes and possibly a complete conversion to a new furnace technology, such as
that described in the section on Circulating Fluidized Bed Furnaces. Maintaining
steam and re-heat steam temperature is another challenge when firing with larger
fractions of biomass. By increasing stability, auxiliary automation systems can help
increase the plant efficiency to levels required for economic biomass co-firing while
maintaining megawatt output.
Auxiliary fan power systems are also critical to the economic co-firing with biomass.
Drivepower must be efficient and sufficient to provide the increased excess air, which
ranges from 15% to 50% for bark, wood and most biomass fuels (Babcock & Wilcox
2005). The controllability of VFD-equipped draft fan systems allows for more efficient
operation for varying proportions of biomass. Biomass fuels have varying particle
sizes, are more volatile when dry and therefore they tend to burn more in suspension
compared to coal (Babcock & Wilcox 2005). Automatic control of VFD-equipped
draft air flows can provide a more uniform distribution, as described in Air Flow
Control for Combustion, and hence more complete and efficient combustion.
Biomass need not be co-fired in the main boiler furnace to provide its heat benefits
to the main cycle. Heat from external biomass combustion can be used to preheat air or feedwater for the main boiler. Separate biomass combustion may be an
alternative source of steam for a low-level banking of the unit.
Combined Heat and Power / Co-Generation
Also known by acronyms CHP or COGEN, this plant design puts the turbine
steam to productive use for industrial processes or for district heating. Location is
a powerful determinant of the viability of a CHP design, as is the existing turbine
design when plant conversion is being considered. A variant on CHP uses steam or
heated water for desalination purposes. The energy efficiency bonus of eliminating
condenser heat waste is illustrated in the Sankey energy flow diagram below:

336 | ABB Energy Efficiency Handbook

71

Losses

Power
Station Fuel
(106)

Condensing
Power Plant
Electricity

35

165

Boiler Fuel
(59)

CHP
Fuel

Electricity
CHP

Boiler
Plant

Heat

50

100

Heat
Losses

Losses
9

15

Figure 8.1 Sankey energy flow diagram for CHP vs. conventional steam plant, Ref : ABB

The energy balance shows that the thermal efficiency of CHP plants is high (85%+)
and approaches (and is ultimately limited by) the efficiency of the boiler itself. A
full accounting of all benefits of CHP to industrial users and society in general is
available in Small is Profitable (Lovins,A, 2006).
There is significant potential for CHP: as of 2008 only 9% of all electrical power
generation comes from co-generation plants (2008, US DoE).
Energy Storage Systems
Power plant units can operate continuously at their optimal efficiency design loads
if there is an economical way to store the produced energy for transmission at later
periods of high demand. Another advantage of energy storage is that it displaces
spinning reserve or banked plants.
Pumped Storage
Locations fortunate enough to have nearby volumes at higher elevations may use
these for energy storage. Drivepower from periods of low demand is used to pump
water to the lake at higher elevation, from which hydro power can be generated
during (peak) periods of higher demand.
Battery Storage
Battery storage and inverter technology for energy storage (see case below) is a
viable replacement for fossil fueled spinning reserve.

Module 8 | 337

Case Example
Battery Energy Storage System
Golden Valley Electric Association in Fairbanks, Alaska contracted with ABB to
construct a Battery Energy Storage System (BESS). The BESS will automatically pick
up 26 megawatts of load for 15 minutes, or 40 MW for 7 minutes. The switch from
power line to battery and back to power line is seamless and goes unnoticed by the
customers, so the prime function of the BESS is to provide spinning reserve in case
of power plant or transmission line equipment failure.
The two primary subsystems in BESS are the IGCT converter and the Ni-Cd
battery. The battery is the energy storage medium. The IGCT converter is the
interface between the DC battery voltage and the 60 Hz AC GVEA system voltage.
The converter transformers match the converter output to the 138 kV system
voltage. The BESS can be programmed for the following modes: Spinning Reserve,
Automatic Scheduling, Support for Scheduled Load Increase, Automatic Generation
Control, Var Support, Power System Stabilizer and Charging.
Carbon Capture and Storage
There are many technologies proposed for capturing then storing the CO2 released
during fossil fuels combustion. Post-combustion ammonia absorption is the nearest
to market, and will require significant additional amounts of auxiliary drivepower for
circulation pumping, CO2 liquification, and high pressure pumping into permanent
storage locations, Optimization and automation of the CCS system will also play
a key role in making this technology viable. However, current energy consumption
estimates for the new auxiliary systems required for CCS are from 25-35% of gross
plant output. This implies that for every standard PC plant of a given size, say
500MW net output, that is replace by a CCS plant, up to 40% more coal will have to
be consumed to get the same net electrical output. That is, three new SC units will
have the output of two old subcritical units.

Alternative Design Options

These design options in the table below leverage existing technologies and
approaches to improve the energy productivity of traditional fossil-fired steam plants,
but feasibility (shown as Risk vs. reward in the table) varies due to business or
technical constraints in existing plant design.

338 | ABB Energy Efficiency Handbook

Activity

Risk

Reward

Make commercial use of the byproducts of emissions control systems: Fly

LOW

MED

MED

MED

MED

LOW

LOW

MED

LOW

MED

MED

HI

MED

MED

MED

MED

HI

HI

HI

HI

ash in the flue gas is removed by existing fabric bag filters or electrostatic
precipitators, and can be used in high-quality cement production.
Install FGD systems which can process FGD by-products into fertilizer or
sulfur-based chemicals for other processing plants
Use turbo-expanders on blow-down lines to recycle blow-down steam
thermal, kinetic energies.
Buy energy efficiency as a service provided by vendors willing to stand by
their claims for their equipment and designs. Vendors and engineering service
providers could provide premium/penalty contract options for efficiency
improvement guarantees.
Draw some of the intake air for Forced Draft (FD) fans from inside the main
unit building, near the top. This recycles heat lost from much auxiliary
equipment, plus the heat losses through boiler furnace refractory linings
(which deteriorate with age). Integrate the FD fan intake with the building
HVAC system to ensure satisfactory air flows. Consider ductwork to lead
heated air from the step-up transformer fan cooling system to the FD fan
intake.
Use the low-cost waste heat from the LP turbine in an absorption chiller,
assuming there is a nearby demand for cooling. This chiller may be costeffective even if applied only to in-plant and office HVAC cooling needs.
Apply flue gas and/or condenser waste heat towards additional coal drying,
especially if lignite coal is used; lignite has a high moisture content. According
to EPRI, a CFB dryer technology which removes nearly a quarter of the coals
moisture before the coal is fed into the power plant boiler may yield a 2.8% to
5.0 % efficiency improvement. (EPRI, 2005)
Use acoustic detonation waves for cleaning ash deposits from boiler heating
surfaces, a lower energy alternative than current sootblowing practice..
Use co-generation with solar-thermal energy. Though still in the conceptual
design phase, the technologies exist to provide heat for feedwater heating
and/or steam generation from a solar-thermal plant, thus reducing fossil fuel
consumption. (EPRI, 2008)
Use engineered osmosis to recover waste heat from condenser systems.
EO uses special membranes for separation of water, driven by low amounts
of heat from condenser cooling systems. This technology could be used in
conjunction with desalination facilities.

Module 8 | 339

Smart Grid and Efficient Generation Technologies

The Smart Grid begins with Efficient Generation
Smart Grid, Smart Utility, and Efficient Generation are terms encompassing plant
improvements, renewable source power generation, load-flow management,
automation, and systems integration. The term smart grid refers to a wide range
of technologies and operating procedures that will make todays power system
into one that is largely automated, applying greater intelligence to operate,
monitor and even heal itself. The smart grid will use the same basic power delivery
infrastructure in use today, but also will draw on advanced monitoring, control and
communications technology.
Widespread adoption of the converter technology used in VFDs will allow trains
and other vehicles to re-generate power during braking and supply it to the
network. This same technology also enables battery-powered vehicles and
distributed solar or wind generators to supply the grid..
Importance of Demand Side Management
No discussion of energy efficiency is complete without acknowledging the KhazoomBrookes postulate (similar to the rebound effect for end-use power consumption)
in which a free market translates efficiency gains into a reduced price per energy
service. This then attracts increased demand for and investment in that energy
service, whichleads to a net gain in absolute energy consumption. This postulate
is counterintuitive and its implications can be disturbing to well-meaning engineers
devoted to efficiency improvements. The postulate states that energy efficiency
improvements that, on the broadest considerations, are economically justified at
the micro-level, lead to higher levels of energy consumption at the macro-level.
This discussion leads the reader beyond purely technical topics, but it may lead
progressive utility investors to also consider demand-side reduction strategies in
conjunction with the plant efficiency measures proposed in this handbook.
Several utilities have committed large sums of capital to invest in demand-side
reduction activities, to the tune of hundreds of millions of dollars per organization.
This is being facilitated in many states, led by California, which have decoupled
tariffs, such that utilities are not going to lose revenue as a consequence of their
demand-side reduction activities. This is an alternate means for a utility to avoid
disappearing reserves, while they anticipates a high cost of emitting CO2, or find it
difficult to impossible to locate and license new coal-fired generation facilities.

340 | ABB Energy Efficiency Handbook

Appendix A
Technical Symbols
The following tables of common electrotechnical symbols and SI units are from ISO
31 and IEC 60027. This ISO standard 31 is being superseded by the harmonized
ISO/IEC 80000 standard.
Mathematical Symbols for electrical quantities (general)
Symbol

Quantity

SI unit

quantity of electricity, electric charge

electric field strength

V/m

electric flux density, electric displacement

C/m

electric potential difference

electric potential

permittivity, dielectric constant,

F/m

electric field constant, o = 0.885419 10 - F/m

relative permittivity

electric capacitance

electric current intensity

electric current density

A/m

x, ,

specific electric conductivity

S/m

specific electric resistance

electric conductance

electric resistance

electromotive force

apparent power

w, (va)

active power

reactive power

W, (var)

phase displacement

rad

load angle

rad

power factor, = PIS, cos )

los angle

rad

loss factor, d = tan )

admittance

resistance

conductance

reactance

susceptance

impedance angle, = arctan X/R

impedance

F/m

rad

Table A.1 Technical symbols (ABB Switchgear Manual, 2005)

Appendix A | 341

Mathematical symbols for magnetic quantities (general)

Symbol

Quantity

SI unit

magnetic flux

Wb

magnetic flux density

magnetic field strength

A/m

magnetomotive force

permeability

H/m

absolute permeability, o = 4 10-7 H/m

H/m

inductance

L mn

mutual inductance

efficiency

slip

number of pole-pairs

w, N

number of turns

n tr (t)

transformation ratio

number of phases and conductors

overvoltage factor

ordinal number of a periodic component

fundamental wave content

relative permeability

harmonic content, distortion factor

kr

resistance factor due to skin effect

Valid only for sinusoidal voltage and current

Note: For US/English version of these symbols, see IEEE 280 Standard Letter
Symbols for Quantities Used in Electrical Science and Electrical Engineering

342 | ABB Energy Efficiency Handbook

Appendix B
Steam Plant Cycle & Equipment
Thermodynamic Cycle
The following diagrams and text are adapted from (IEA Coal Online - 2, 2007)
The proportion of the heat supplied that is converted into mechanical work is
referred to as the efficiency of the cycle. For the ideal engine, the efficiency is related
to the initial and final temperatures of the system, as follows: h = (T1T2)/T1 (1)
where h is the efficiency and T1 and T2 are the upper and lower (initial and final)
temperatures between which the engine operates, expressed in degrees Kelvin. The
lowest temperature in the steam-turbine cycle depends on the temperature of the
coolant water that cools the steam and condensate leaving the low-pressure outlet
of the turbine system. The idealized thermodynamic steam-water (Rankine) cycle,
with superheating, is illustrated on the figures below. Pressure vs. Volume (right side)
and Temperature vs. Entropy (left side)

Figure B.1 Idealized Rankine cycle P-V and T-S diagrams, (IEA Coal Online - 2, 2007)

Sites with access to cold sea water can reach lower bottom-end temperatures in the
cycle, and so achieve higher efficiencies. For an upper temperature of 600C (typical
of a state-of-the-art supercritical turbine) and lower temperature of 20C (typical for
sea-water cooling at a North European coastal location), the theoretical maximum
efficiency given by equation (1) is 66%. In practice, steam-cycle efficiencies are
much lower, in the low 40s% for sub-critical boiler units.

Appendix B | 343

Steam Cycle Equipment

The main steam power plant physical units fall into these categories, with common
terminology:

Furnace (Fire-side) , incl. coal handling, burners and stack exhaust

Boiler (Water-side) , (Steam path)
Turbine (Steam path)
Condenser (Water-path)
Plant Auxiliary Systems
Generator and electric power supply network (Electrical BoP)

Figure B.2 Steam cycle fluid flow and main equipment, (IEA Coal Online - 2, 2007)

Cycle Operation
A drum-type subcritical PC boiler takes the pressurized and preheated boiler
feedwater from around 250260C up to the evaporation point, then superheats
it to 540C or above before sending to the high- pressure turbine. In the steam
turbine, the steam is expanded while its energy is converted into mechanical work
as it passes over static and moving blades within high-pressure (HP), intermediatepressure (IP) and low-pressure (LP) turbines, which are usually compounded on to
one shaft that drives the generator. .All large steam-turbine cycles incorporate reheat
of the intermediate-pressure steam from the high-pressure turbine exit, and multiple
stages of feedwater pre-heating using steam extracted from the turbine to maximize
efficiency. Steam emerging from the LP turbines is condensed, then pumped back to
the boiler after pre-heating, thus completing the cycle
The thermal efficiency of state of-the-art PC plants is 4547%, LHV (Lower Heating
Value) basis, at cold sea-water cooling locations. Such plants use main steam
conditions well into the supercritical range, with pressures approaching 30 MPa and
temperatures around 600C Because of the degree of scope for achieving further
efficiency improvements through moving to even higher steam conditions, materialsdevelopment programs are in progress in different parts of the world to reach them.

344 | ABB Energy Efficiency Handbook

Together with cycle design advances, these are expected to realize power-plant
efficiencies well beyond 50%, LHV basis (IEA Coal Online - 2, 2007).
Boiler Operation
The figure below shows a drum-type subcritical boiler in simplified diagrammatic
form. The economizer, forming the last stage of the boilers convective section,
takes the incoming feed-waters temperature to about 60C below evaporation
temperature for sending on to a steam drum/evaporator recirculation loop. The
economizer takes the flue gases down to around 350C. Lower-temperature heat,
down to about 100150C, is recovered by transferring the heat to the incoming
combustion air using an air heater. This final stage of heat recovery is the air heater,
which generally takes the flue gas temperature down from the economizer exit
temperature of 350400C to 120150C

Figure B.3 Steam generator main equipment, (IEA Coal Online - 2, 2007)

Evaporation takes place using mainly radiant heat, which is transferred to watercarrying tubes forming the wall of the furnace zone of the boiler. The ensuing water/
steam mixture passes to a large steam drum, which allows the steam to separate,
and the water returns to the evaporator. Either forced or natural circulation is used
to send the water round the loop. Steam leaving the drum is then sent to the
primary superheater. In both subcritical and supercritical boilers, the superheat and
reheat heat-transfer surfaces are mounted above the furnace and in the convection
section of the boiler. Super-heaters and re-heaters are generally of a pendant and/or
horizontal type, each with at least two stages (for simplicity, only two for superheat
and one for reheat are shown on the figure)

Appendix B | 345

346 | ABB Energy Efficiency Handbook

Appendix C
Integrative Design Principles
Integrative Design is founded on Whole System Thinking principles. These
principles also appear in the related fields of System Engineering, Sustainability
Engineering, Industrial Ecology, and meta-design. Integrative design principles
are reminders to engineers to look in the places where people, by nature, are not
equipped to easily visualize. The four corners which may hide design problems and
opportunities are:
Hidden Quantity

Reason why

Things that add up slowly, over time

we tend to focus on the now, and less on the

far future

Things that multiply along a long path

we tend to focus on the here and less on the

route

Things at the edges

we tend to focus on the center and less on the

periphery

Things in peoples heads

we tend to focus on the objective, and less on

the subjective

Think Lifecyle: to see small things accumulating over a long time

Choose quality for reliability, over initial cost
Choose service over product
Select high-efficiency and high-quality components,
The higher initial costs will be repaid in saved energy within a short period and
in reduced downtime over a long period...
Increased reliability has an direct energy efficiency benefit via reduced unstable
or unproductive (ex: startup) operations
Get fine control of your power input
Seek controllability in pumps, fans, burners so that you provide only the power
that the process needs, and no more than necessary
Think Bottom Up: to see things multiply along a long path in space
Reduce demand first, then size supply
Reduce downstream loss first, then upstream

Appendix C | 347

Bottom-up thinking moves in the opposite direction of the process flow of fluid, heat
or even of information & signals. Start with what you need to have or deliver, then
work back to supply.
Start downstream to design systems with lower capacity requirements
Reduce and rationalize end-use demand first : gather data to estimate the
REAL end-use loading, then work backward to the power source, reducing
losses along the way, Finally, size the supply according to the now-reduced
loads
Keep capacity design margins small
It will be cheaper to add extra capacity when requirements increase. Consider
a parallel standby unit instead of oversizing the main unit.
Recover and re-use process energy
Use any means, mechanical or chemical, to retrieve what the process doesnt
want...
Compounding over Time
Efficiencies compound upward along the flow path, and, because energy is an
operating cost, these savings also compound over time.
Compounding over Capital Cost
There is third major compounding effect, and that is the capital equipment cost.
A reduction of downstream loads usually means that upstream supply equipment
can be safely downsized, which also usually means lower installed costs. Take full
advantage of this effect by doing a bottom-up energy assessment of the candidate
designs when the plant is still on the drawing board, rather than waiting for a retrofit.
Think Interfaces: to see things at the edges
Put system before components
Put application before equipment
Practice good thermal integration
Connect sources with sinks, aspire to know and use all the available energy
(exergy), including ambient energies...
Harmonize the interfaces in both project and plant
In your project - between the disciplines & between suppliers. In the plant between diverse process units & between black-boxes.
348 | ABB Energy Efficiency Handbook

 Instrument and monitor your power usage in real-time

Specify many, smart transmitters, placed so operators can see the process
eat your power across plant units: use data to trend & manage energy KPIs at
plant level.
Make models and use them to control and teach
In your project - to tune your design. In the plant - to enable real-time
advanced control to keep process stable & at constraint.
Interface busting is made more difficult in a world of highly componentized plant
equipment. Component-based engineering comes with hidden costs, namely losing
the ability to optimize the whole system to its real energy constraints. This lost
opportunity can be visualized as wasted volume when constructing a sphere of large
blocks vs. smaller ones. Integrated design guidelines insist that vendors provide
smaller, less-specialized component units with richer physical & programmatic
interfaces. Avoid big isolated non-integrated feature-bloated and often more
expensive components or systems, using this rule..
Think People & Process: to see how people think, feel and work together
Put people before procedures & hardware
Put people in charge
Put away the standard design - go for a walk
Ask for time to study alternatives, nature, and talk to operators of the last
standard design plant
Use an agile project execution model
Involve operators or others to represent the energy end-users, iterate on the
assumed requirements
Appoint an energy steward
An energy steward should be as respected as safety experts are today.
Seek a single contractor, not multiple vendors
Give project, and responsibility, to a firm with broad, multi-disciplinary
experience. Do not fracture design through divide and conquer

Appendix C | 349

350 | ABB Energy Efficiency Handbook

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352 | ABB Energy Efficiency Handbook

 IEA Coal Online - 1. Coal Combustion Technologies for a Competitive Market.

2006. http://www.coalonline.org/site/coalonline/content/viewer?LogDocId=81494
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ISA. Instrument Engineers Handbook: Vol2. Process Control and Optimization.
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iso.org/iso/hot_topics_energy.
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sustainability/working_towards_a/the_bottom-line_benefits.html.
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1984.
Lahoda, J,, A. Arndt, and W. (Siemens) Hanstein. BIOMASS LOOKING FOR
EFFICIENT UTILIZATION THE REHEAT CONCEPT. Siemens Power Generation.
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energycentral.com/centers/energybiz/detail_sourcebook.cfm?id=19.
Lovins, Amory (Rocky Mountain Institute). Advanced Energy Efficinecy : Concepts
& Practice. DVD. Stanford Univeristy, March 2007.
Lovins, Amory. 10xE Presentation to Irving Oil. Presentation, RMI, 2008.
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 Wikipedia. Fossil Fuel Power Plants. Sept 30, 2008. http://en.wikipedia.org/wiki/

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On-Line Resources
Supplier Corporate Sites:
ABB Inc., http://www.abb.com/energyefficiency
ABB Power Generation Solutions & Products has brochures, case studies
Alstom Power, http://www.power.alstom.com/home/
Info on power plant integration
Siemens Power Generation, http://www.powergeneration.siemens.com
Pages & tech papers on steam power plants
Honeywell ACS, Power Solutions, http://hpsweb.honeywell.com/Cultures/enUS/IndustrySolutions/Power
Schneider Electric, http://www.criticalpowernow.com/
White papers, efficiency calculators , but focus on low voltage
Engineering Services Corporate Sites:
Foster-Wheeler Global Power Group , http://www.fwc.com/GlobalPowerGroup/
Many good technical papers on CFB, biomass co-firing, materials
Black & Veatch Energy , http://www.bv.com/markets/energy/
Article on coal plant retrofits
www.bv.com/services/Climate_Change_Solutions/En...
GE Power, http://www.gepower.com/home/index.htm
Has design guides and handbooks, section on Clean Coal (IGCC)
Bechtel Power, http://www.bechtel.com/power.html
Has several project cases
Burns & Roe Power and Energy , http://www.roe.com/power_index.htm
Not much online
KBR (Kellogg,Brown & Root) , http://www.kbr.com/publications/coal.aspx
Articles on coal gasification
Intergraph Process,Power & Marine , http://www.intergraph.com/ppm
2D, 3D design software packages
AspenTech , http://www.aspentech.com/
Modeling and simulation software tools
CH2M Hill, http://www.ch2m.com/corporate/services/sustainable_solutions
EPC with good energy efficiency credentials

References | 355

 Arup, http://www.arup.com/
EPC with good energy efficiency credentials, mostly built environment
Rumsey Engineers, http://www.rumseyengineers.com/
Specialist in energy efficiency engineering, mostly HVAC
Southern Company, http://www.southerncompany.com/planetpower
One example of a utility with a progressive energy efficiency profile
Journals, Articles & News Sites:
Energy Central , http://www.energycentral.com/
Have a large tech white paper library
Power Engineering International, http://pepei.pennnet.com/
Good articles on steam plant efficiency, retrofits
Plant Engineering LIVE, http://www.plantengineering.com/
Many white papers, links on energy efficiency
Plant Systems, http://www.plantservices.com/
Excellent VFD articles, sustainability links
Connecting Industry, http://www.connectingindustry.com/
Section on energy management
International Journal of Energy Research
http://www3.interscience.wiley.com/journal/3343/home
Academic Sites:
The Natural Edge Project, http://www.naturaledgeproject.net
Course in whole system design, with pumping system case
Engineering News Record, Power & Industrial, http://enr.construction.com/
infrastructure/power_industrial/default.asp
Industry news
Energy Storm, http://www.energystorm.us/
Citations, abstracts only
University of Pittsburgh, Mascaro Sustainability Initiative, http://www.
mascarocenter.pitt.edu/
Mostly built environment, but some power infrastructure as well
Massachusetts Institute of Technology, Engg Systems Div. http://esd.mit.edu/
NTNU Norway , http://www.ntnu.no/
MITs Center for Engineering Systems Fundamentals , http://cesf.mit.edu/
For schools : start when they are young!

356 | ABB Energy Efficiency Handbook

Professional & Association Sites:

Motor Decisions Matter http://www.motorsmatter.org/
Public awareness, Motor Planning Kit
Pump Systems Matter, http://www.pumpsystemsmatter.org/
Great papers,tools,links
Air Movement and Control Association (AMCA) International, http://www.amca.
org/
Non-profit supplier assoc.; has Best Practices for fan systems(US DoE
Sourcebook, 2006)(US DoE Sourcebook, 2006)
Industry and Expert Sites:
Electric Power Research Institute , http://my.epri.com
Non-profit R&D and consulting organization, utility & industry funded
Eng-Tips Forums, http://www.eng-tips.com/
Peek inside the daily work of practicing engineers
A great powergen engineering forum
CR4 Engineering forum, http://cr4.globalspec.com/
Large forums with hi quality posts
Leonardo Energy, http://www.leonardo-energy.org
Global community of sustainable energy professionals
Have a slide library for energy educators, design guides on power quality
National Assoc. of Energy Service Companies, http://www.naesco.org/
Demand side programs, but some relevant recommendations
The Design Futures Council, http://www.di.net/articles/archive/the_design_
futures_council/
Mainly architectural design, but some good, general material
Pew Center on Global Climate Change, http://www.pewclimate.org/
Non-profit, non-partisan think tank
Authorities : US & International Sites:
International Energy Agency (IAE) , www.iae.org
Global data on coal applications
IEA Clean Coal Centre, http://www.iea-coal.org.uk
Unbiased info on coal tech
IEA Coal Online, www.coalonline.org
ISO, http://www.iso.org/iso/hot_topics_energy
Intl standards organization, with emerging energy mgmt. standards
World Energy Council , http://www.worldenergy.org/
Pubs on power plant efficiency, energy policies(World Energy Council, 2007)
Consortium for Energy Efficiency (CEE) , http://www.cee1.org/

References | 357

 US Dept. Of Energy, Energy Eff.& Renewable Energy, http://www1.eere.energy.

gov/industry/
Industrial Technologies Program
ISA Instruments and Automation society, http://isa.org/
Standards and industry organization
IEEE Power & Energy Society, http://ieee.org/portal/site/pes
Good links, active forums
IEEE Industry Applications Society, http://ewh.ieee.org/soc/ias/cms/
National Academy of Engineering http://www.nae.edu
Educating the Engineer of 2020: Adapting Engineering Education to the New
Century
American Assoc. of Engg Education (ASEE), http://www.asee.org/
Accreditations, Prism magazine, Journal of Engg Education
American Society of Heating, Refrigerating and Air-Conditioning Engineers
(ASHRAE), http://www.ashrae.org/
American Society of Mechanical Engineers, http://www.asme.org/
EU Intelligent Energy programme : http://www.energypath.eu/
For schools , high-schools

Revision History
Ver

Date

Author

Change Description

2.4

23.03.2009

RPM

Torque vs speed info and calculations

3.0

26.03.2009

RPM

Added Arash Baebee comments to VFD section

3.1

12.04.2009

RWV

Final Edit before layout

358 | ABB Energy Efficiency Handbook

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