AVJ Engineering Consultants - knowledgeplatform.inknowledgeplatform.in/wp-content/uploads/2016/11/Magnadrive... · Pune –411052 Telefax: 912025460104 Mobile: 919923413733 Mail ID:

AVJ Engineering ConsultantsAVJ Engineering Consultants

AVJ Engineering Consultants

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MAGNADRI.WMV


• AVJ Engineering Consultants was established in the year 2009 after I worked for 36 years and is based at:

Flat No.1, Plot No.21,

Mahabali Housing Society,

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Mahabali Housing Society,

Karve Nagar,

Pune – 411052

Telefax: 912025460104

Mobile: 919923413733

Mail ID: [email protected]

Website: www.avjengineering.com

AVJ Engineering Consultants will be known as AVJ Engineering & Marketing Pvt. Ltd.


Presentation Presentation on Reduction on Reduction in in Auxiliary Power Consumption Auxiliary Power Consumption and and Reduction in Reduction in

O&M Cost ThroughO&M Cost Through

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MagnaDrive Magnetic Couplings and Adjustable Speed Drives (ASD)

“The Next Industrial Revolution”

By

Vinod Malhotra


MagnaDrive, Seattle USA

Flownetix, UK

Electromagnetic & Ultrasonic Flow

Meters

About AVJ Engineering Consultants

AVJ is Distributor & Marketing Associates for:

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Meters

Jyoti Limited, Baroda – Pumps, Motors &

Switch Gears

Essential Power Transmission for Gear

Box.


Magnadrive Couplings and ASDMagnadrive Couplings and ASD Jyoti PumpsJyoti Pumps

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Flownetix Ultrasonic SmartFlownetix Ultrasonic Smart

Water MetersWater Meters


MagnaDrive’s Value Proposition

“MagnaDrive’s revolutionary disconnected

MagnaDrive Benefits

MagnaDrive is the Only GREEN Technology

Which Offers Dual Benefits - Saves Energy &

Reduces O&M Cost also

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torque-transfer technology reduces your total cost of ownership by lowering maintenance and operating costs, increasing process availability, and

improving system reliability.”


• Founded in 1999

• Technology of the Year by Industry Weekfor 2001

• 20 Domestic Patents and More than 200 International Patents

About MagnaDrive

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International Patents

• Installed on Over 35,000 Systems and in India 61 Systems.

• Recently Awarded $2.7 million Contract by U.S. Navy

AVJ Engineering ConsultantsAVJ Engineering Consultants About MagnaDrive

• 2004 Inc. 500 Fastest Growing Private Companies

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• 2004 Inc. 500 Fastest Growing Private Companies

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• 2004 Deloitte 500 Fastest Growing Technology Companies


• Inc. 500 Fastest Growing Private Companies

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• Deloitte 500 Fastest Growing Technology Companies


• MagnaDrive Produces Magnetic Adjustable Speed Drives and Couplings that eliminate the physical link between the motor and load and instead uses a Magnetic field to transmit torque across an air gap. It’s a simple but effective mechanical technology that is GREEN gives following advantages

– Reduces energy consumption

– Reduces motor stress at start-up

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– Reduces motor stress at start-up

– Cushions shock loads and eliminates motor seizure– FGC Demo.wmv

– Tolerates misalignment and thermal expansion

– Extends equipment life and reduces maintenance requirements through reduced vibration and cavitations

AVJ Engineering ConsultantsAVJ Engineering Consultants Principle of Operation

Magnet & Copper Penny Demo.wmv

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AVJ Engineering ConsultantsAVJ Engineering Consultants MagnaDrive Benefits

A Mechanical,A Mechanical,

ImagineOperates While Misaligned

Controls Load Speed

Cushioned Start

Cushions Shock Loads

13

A Mechanical,

Non-Electronic Device

A Mechanical,

Non-Electronic DeviceEasy to Install

Easily UnderstoodEliminates Motor Seizure

Extends Equipment Life Reduces Vibration

Compact


• Pumps

Application Types

Target Market

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• Pumps

• Fans

Application Types

Target Market

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• Pumps

• Fans

• Blowers

Application Types

Target Market

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• Blowers


• Pumps

• Fans

• Blowers

Application Types

Target Market

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• Blowers

• Centrifuges


• Pumps

• Fans

• Blowers

Application Types

Target Market

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• Blowers

• Centrifuges

• Bulk Handling


• MagnaDrive is not only a Drive but a “Total Solution”to Achieve Lower Total Cost of Ownership

A

B

S

O

L

MagnaDrive is Solution

MagnaDrive “THE” Solution Module

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MagnaDrive

Energy Zero Vibration Works in Misalignment

No Throttling Lower O&M cost No Motor Seizure

L

U

T

E

S

A

V

I

N

G

S

Lower Motor Ratings

LOWER COST OF OWNERSHIP

RESULT Lower Starting Current


• Couplings

Product Lines

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• Couplings• Adjustable Speed Drives (ASDs)

AVJ Engineering ConsultantsAVJ Engineering Consultants Coupling Range and Models

• Constant and Variable Torque

• 2 to 2500 KW Applications

• Four Models:

Magnetic Couplings

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• Four Models:

– First Generation Coupling (FGC)

– Delay (MGD)

– Torque Limiting (MGTL)

– Vortex


• FGC - First Generation Coupling

• MGD – Magnaguard Delay

Couplings:FGC

MGD

Permanent Magnet

Couplings

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• MGD – Magnaguard Delay

• MGTL- MagnaDrive Torque Limiting

• VORTEX

MGTL

AVJ Engineering ConsultantsAVJ Engineering Consultants Product Overview -Couplings

FGC Product Line

• 2 to 2500 KW @1500• Variable and Constant

Torque applications • Can deliver higher starting

torques

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torques• Cushioned start desired• Shafts: standard or

special sizes• Dist. Between Shaft ends

(DBSE): within or beyond standard range

AVJ Engineering ConsultantsAVJ Engineering Consultants FGC Coupling

CONDUCTOR STEEL

COPPER CONDUCTORCOPPER CONDUCTOR

CONDUCTOR STEEL

MAGNETS

AIR GAP SPACER

SHRINK DISC SHRINK DISC

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LOAD HUBMOTOR HUB

ALUMINUM MAGNET ROTOR

AIR CLEARANCE (GAP)


• Range 16 to 625 KW

• Air Gap Increases from 1/8 to 3/16 inch During Start Up

MGD Product Line

Product Overview -

Couplings

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3/16 inch During Start Up

• Gap Change Reduces Torque Transfer About 50% for Cushioned Smooth Start

• MGD Also Has Partial Disconnect Feature Built In


CONDUCTOR STEEL


CONDUCTOR STEEL

ALUMINUM MAGNET ROTORS

MAGNETS

AIR GAP SPACER

SHRINK DISCSHRINK DISC

Product Overview -

MGD

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LOAD HUBMOTOR HUB

AIR CLEARANCE (GAP)


• All the Features of the MGD, Plus MGTL has Complete Disconnect Feature Built In

• Complete Disconnection Results when High Torque Repelling

MGTL Product Line

Product Overview –

Couplings

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when High Torque Repelling Magnetic Force Occurs Due to Additional Slip

• Repelling Force Completely Uncouples Motor from Load for Complete Protection

• Self Resetting when Motor is Turned Off

AVJ Engineering ConsultantsAVJ Engineering ConsultantsCoupling Benefits - MGTL

CONDUCTOR STEEL


CONDUCTOR STEEL

ALUMINUM MAGNET ROTORS

MAGNETS

AIR GAP SPACER

SHRINK DISCSHRINK DISC

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LOAD HUBMOTOR HUB

AIR CLEARANCE (GAP)


• Offers Low Maintenance

• Simple Installation

• Efficient Torque Transfer

• Permits Shock Loadings (Load is Cushioned & Slips)

Coupling Benefits:FGC & MGE

MGD

Product Overview -

Couplings

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(Load is Cushioned & Slips)

• Greater Misalignment Tolerance

• Ideal for Applications Subject to:– Vibration

– Periodic Load Seizure

– Pulsating Loads

– Thermal Expansion

– Higher Starting Inertia/Torque

MGTL

AVJ Engineering ConsultantsAVJ Engineering Consultants Type of Loads

• Centrifugal Loads

• Centrifugal loads are rotating loads, such as centrifugal pumps, fans, and mixers. They closely follow the affinity laws, which dictate how flow, horsepower, and torque change as speed changes:

• New Flow = Original Flow × Δ Speed

• New Torque = Original Torque × Δ Speed2

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• New HP = Original HP × Δ Speed3

• In other words, flow varies proportionally with change in speed (Δ Speed, expressed as a percentage of the original speed), torque varies with the square of the change in speed, and horsepower varies with the cube of the change in speed.

• It is important to understand that torque is demanded by the load. Attach a 2-hp motor to a 2-hp load, then attach a 10,000-hp motor to the same load and both motors will generate 2-hp (ignoring losses).


(HP1 / HP2) = (Flow1 / Flow2)3

TechnologyTechnology

Affinity (or “Fan”) Laws

Proportion of Max

Flow Flow Reduction Power Consumed Power Saved

(Flow1/Flow2) (1-Flow1/Flow2) (HP1/HP2) (1-HP1/HP2)

99% 1% 97% 3%

98% 2% 94% 6%

• Torque Transmitted & Flow Are Reduced By Increasing the ASD Air Gap

• A 1% Reduction in

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98% 2% 94% 6%

97% 3% 91% 9%

96% 4% 88% 12%

95% 5% 86% 14%

90% 10% 73% 27%

85% 15% 61% 39%

80% 20% 51% 49%

70% 30% 34% 66%

60% 40% 22% 78%

50% 50% 13% 88%

40% 60% 6% 94%

Speed and Flow Yields a 3% Energy Savings

• A 10% Reduction in Speed and Flow Yields a 27% Energy Savings

• A 50% Reduction in Speed and Flow Yields a 88% Energy Savings

Energy Savings May be Greater

Due to Reduced Vibration and

Misalignment Tolerance of

MagnaDrive Air Gap


Why pump should not be operated at full Valve Opening?

Pump Curve:

Pump curve for 150 KW ECW pump.pdf

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• Non-Centrifugal Loads• Other loads, such as screw compressors, positive displacement pumps,

positive displacement blowers, paper roll machines, conveyor belts, punch presses, and rock crushers, do not follow the affinity laws.

• Flow varies proportionally with speed.

• Torque and horsepower may decrease, remain constant or increase—it depends on the application.

• Speed changes for non-centrifugal loads do not generate the same large energy saving as with centrifugal loads, but changes in speed may be desirable for process control reasons. In other words, you may want to control the speed

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for process control reasons. In other words, you may want to control the speed of the process, even though you are not saving any energy.


Rigid CouplingsRigid Couplings

Rigid Chain Gear Disc

Fixed Speed – Mechanical Couplings


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Flexible / Elastomeric CouplingsFlexible / Elastomeric Couplings

Flexible ShaftRubber (Tire) Jaw Pin


Misalignment

• All couplings are subject to:



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Parallel / Offset

Misalignment

Axial Misalignment


• MagnaDrive has a unique design:

Permanent Magnet

Rotor

Permanent Magnet

Rotor

Copper Conductor

Rotor

Copper Conductor

Rotor

Fixed Speed –Mechanical Couplings


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Motor Shaft Load Shaft

Air GapAir Gap


Motor Shaft Load Shaft



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MagnaDrive

can operate with

Angular Misalignment

MagnaDrive

can operate with



Motor Shaft Motor Shaft Load Shaft Motor Shaft Load Shaft



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MagnaDrive

can operate with

Parallel Misalignment

MagnaDrive

can operate with

Parallel Misalignment

MagnaDrive

can operate with

Axial Misalignment

MagnaDrive

can operate with

Axial Misalignment

MagnaDrive

can operate with


MagnaDrive

can operate with



• Lower Inrush at

Startup

Cushioned Start

Coupling Technology

Reduced starting power requirementReduced starting power requirement

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• Lowers Peak

Demand

• Immediate Restarts

Energy Savings as a resultEnergy Savings as a result

of removing system of removing system

inefficiencies inefficiencies


• Motor Characteristics– Up to 5000 HP Motors @ 1500 RPM– Up to 3000 HP Motors @ 3000 RPM

• Vibration Isolation • MagnaDrive Corp - Pump - No Vibration - Lorain,

OH, USA.wmv

Couplings

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OH, USA.wmv• Alignment Problems• ..\Misalignment Demo.wmv• Need for Cushion Start • Thermal Expansion Issues• Shaft Seizure Issues• Mechanical Seals are Present• Need to Protect Critical Equipment


Rigid & Flexible CouplingsRigid & Flexible Couplings MagnaDrive (MGE/FGC/MGD/MGTL)MagnaDrive (MGE/FGC/MGD/MGTL)

• All mechanical couplings are somehow physically connected causing:

�Misalignment

�Vibration transfer

�Premature equipment failure

�Energy waste due to misalignment

• The disconnected nature of the MagnaDrive connection (air gap) provides:

�Misalignment allowance up to 3 degrees

�No vibration transfer

�Longer equipment life (bearings, seals, etc.)

�Energy savings due to motor/load disconnection

• Installation, operation, & maintenance issues: • Installation, operation, & maintenance issues:



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• Installation, operation, & maintenance issues:

�Time and money spent on laser alignment

�Time and money spent maintaining equipment

�Production downtime costs

�No overload torque protection

�Some types require grease/oil

�“Hard” start causes extra stress on equipment and energy spikes

�No speed adjustability

• Installation, operation, & maintenance issues:

�Virtually no time and money spent on alignment

�Less time and money spent maintaining equip.

�Lower production downtime costs

�Overload protection

�MagnaDrive is a GREEN technology

� “Cushioned” and delayed start increases equipment life and provides lower peak demand and inrush (additional energy savings)

�MagnaDrive couplings can be fine tuned to save energy

Increased cost

of ownership

Lower cost

of ownership


• Fluid Couplings

• Applications:

• Bulk Material Systems Conveyors:

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• Bulk Material Systems Conveyors:

• Coal Handling

• Ash Handling

AVJ Engineering ConsultantsAVJ Engineering Consultants Fixed Speed –Fluid / Hydraulic Couplings

Fixed Speed –Fluid / Hydraulic Couplings

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Fluid Coupling Issues - OilFluid Coupling Issues - Oil



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Fluid Coupling Issues – High MaintenanceFluid Coupling Issues – High Maintenance

"Replacement parts for fluid couplings are notoriouslyexpensive. However, we had no choice but to keeppaying out as the Dryer-Pulveriser Mill is such a keyelement within the refinery process. Unfortunately wewere in a lose-lose situation, when the applicationfaltered it not only cost us money to fix it, it was alsocosting us money for the duration it was off-line.“

Fixed Speed –Fluid / Hydraulic

Couplings

Fixed Speed –Fluid / Hydraulic

Couplings

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costing us money for the duration it was off-line.“

"The coupling requires inspection every 12 weeks withfrequent oil top ups, the oil used within a fluid coupling ishighly volatile. The coupling incorporates a fusible drainplug which is designed to discharge oil if the operatingtemperature is too high. This feature was causing aconsiderable health and safety risk to operators, we hadexperienced several fires in the past caused by hot oilblowing the fusible plug and consequently igniting.”

http://www.hub-4.com/news/696/wbb-minerals-grind-down-maintenance-costs-using-siemens-soft-startersSource:


Fluid Coupling Issues - HazardousFluid Coupling Issues - Hazardous



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AVJ Engineering ConsultantsAVJ Engineering Consultants Fixed Speed –Fluid / Hydraulic Couplings



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2002 Fatality Accident with a

major brand Fluid Coupling

at Lone Star Quarry & Mill




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http://www.msha.gov/fatals/2002/ftl02m17.htm

at Lone Star Quarry & Mill

Lone Star Industries, Inc.

Cape Girardeau, MO

For Official Accident Report Go To:


“Curbing the killer Conveyors”

“Recently a steel worker was injured when an inclined conveyor ranbackwards, out of control, and the fluid coupling in the drive trainexploded like a bomb, spreading shrapnel and hot hydraulic oileverywhere. It should never have happened”.




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“The fluid coupling is sized to soft-start the conveyor and protect themotor/drive package from overloads. It is made from aluminum and isintended to run, in this case, at 1,500 to 1,800rpm. If it is run at speedsof up to 6,000rpm then the aluminum casing will be put under massivecentrifugal loads sufficient to make the whole thing explode like abomb”.

“Then, when the drive train fails and the conveyor back-drives, thefluid coupling becomes a bomb just waiting to explode”.

http://www.renold.com/Company/News/Curbing_the_killer_conveyors.aspSource:


“An undermanager and a deputy on a backshiftwere attempting to change the oil in a leaking fluidcoupling. The men were inexperienced in this task




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which resulted in the deputy receiving oil burns tohis face”.

http://www.cfmeu.com.au/storage/documents/Apr00CC.pdfSource:


Performance of Magnetic Couplings in Bulk Material Handling Systems:

MAGNADRIVE - BWE - ThyssenKrupp, Australia.wmv

MAGNADRIVE - CONVEYOR - 1400 Ton Per Hour Conveyor in Australia.wmv

MAGNADRIVE+-+CONVEYOR+-+Australia+-+SWCC+-+Thiess.wmv

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Apprehensions:

Weather Magnetic Couplings will work in dusty environment?

+Chile.wmvDust Flying MAGNADRIVE - Tura - TURKEY (1).wmv


• Comparative Study between VFD and Magnadrive on Energy Savings in Conveyor:

MAG Drive kilo Watt

30

35

Power consumption for Magnetic Drive

0

5

10

15

20

25

30

1 5 9 1317 21 2529 3337 41 4549 5357 61

60 Minute Interval

kW

MAG Drive kilo Watt

Power Consumption per hour - 1600.16 kWhAverage Power per hour - 26.23 kW


VSD Drive kilo Watt

40

50

60

Power consumption for Variable Speed Drive

0

10

20

30

40

1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61

60 Minute Interval

kW

VSD Drive kilo Watt

Power Consumption per hour - 1933.08 kWhAverage Power per hour - 31.68 kW


• Magnadrive/VSD Power Consumption Comparison Graph

MAG/VSD Comparison Graph

40

50

60

0

10

20

30

40

1 5 9 1317 21 2529 3337 41 4549 5357 61

60 Minute Interval

kWMAG Drive kilo Watt

VSD Drive kilo Watt

Energy Savings in conveyor Mooikraal Drive Recordings.xls


Fluid CouplingsFluid Couplings

• Fluid Couplings are not totally disconnected and are subject to:�Misalignment and vibration transfer

�Premature equipment failure (gear boxes, bearings, seals, etc.)

�Energy waste due to misalignment and additional fluid friction losses inside the coupling

• The disconnected nature of the connection (air gap) provides:�No misalignment and vibration issues

�Longer equipment life (bearings, seals, gear boxes, etc.)

�Energy savings due to the motor/load disconnection. Because MagnaDrive operates with a cushion of air, a 3-5% savings in power can be attained in relation to the same work done by a Fluid Coupling

• Installation, operation, & maintenance issues:�Time and money spent on laser alignment



MagnaDrive (FGC/MGD/MGTL)MagnaDrive (FGC/MGD/MGTL)

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Fluid Coupling�Time and money spent on laser alignment

�Fluid Couplings are difficult to install and maintain

�Time and money spent maintaining equipment

�Most Fluid Couplings can not operate in both directions of rotation

�Fluid Couplings are filled with oil which is a hazard for the environment and people

�The Fluid Coupling overtorque protection is provided by a fusible plug which melts and sprays oil all around. When the plug fails to melt, the Fluid Coupling literately becomes a time bomb

• Installation, operation, & maintenance issues:�Virtually no time and money spent on alignment

�MagnaDrive Couplings have no oil, are lighter, and easier to install

�Less time and money spent maintaining equip.

�MagnaDrive Couplings transmit the same torque in either direction of rotation

�MagnaDrive is a GREEN technology and does not use any oil

�MagnaDrive Couplings basically slip if there is an overtorque condition, and certain models (MGTL) also offer a complete disconnect feature

Increased cost

of ownership Lower cost

of ownership


Adjustable Speed Drive

(ASD)

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(ASD)

AVJ Engineering ConsultantsAVJ Engineering Consultants Variable Speed –Valve / Damper Systems

Variable Speed –Valve / Damper Systems

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AVJ Engineering ConsultantsAVJ Engineering Consultants Variable Speed –VFDs (Variable Frequency Drives)

Variable Speed –VFDs (Variable Frequency Drives)

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AVJ Engineering ConsultantsAVJ Engineering Consultants Variable Speed –VFDs (Variable Frequency Drives)


Principle of OperationPrinciple of Operation

9/14/2016 59

AVJ Engineering ConsultantsAVJ Engineering Consultants Variable Speed – VFDs (Variable Frequency Drives)

Variable Speed – VFDs (Variable Frequency Drives)

VFD Issues – Installation Complexity and Space RequirementVFD Issues – Installation Complexity and Space Requirement

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Building to house VFDsBuilding to house VFDs

MagnaDrive minimal space requirement and

simple installation

MagnaDrive minimal space requirement and

simple installation

AVJ Engineering ConsultantsAVJ Engineering Consultants Product Lines

• Variable Gap – For Adjustable Speed

• Air-Cooled:

– Sizes 20 to 500 Hp @ 1500 RPM

– Horizontal & Vertical Applications

• Water-Cooled

Adjustable Speed Drives

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• Water-Cooled

– 500 through 4,500 Hp @ 1500 RPM

– Horizontal & Vertical Applications


• Variable Speed Control for Energy Savings

• Low System Maintenance

• Accepts Greater Misalignment

• Eliminates Vibration Transfer Between

ASD Benefits

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• Eliminates Vibration Transfer Between Motor and Load

• Unloaded Startup, Controlled Ramp-Up

• Permits Shock Loading

• Increased Seal & Bearing Life

• Eliminates Electronic Harmonics

• Unaffected By Power Quality Issues

• Lightning Strikes


Adjustable Speed Drive (ASD)

• For Speed Control and Energy Savings

– ASD Energy Savings Demo.wmv

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– ASD energy savings New.wmv


VFDsVFDs MagnaDrive ASDsMagnaDrive ASDs



• Special issues and installation requirements:�Require inverter duty motors�Are susceptible to dirty power�Require environment control (temp, dust, hum.)�Complexity of equipment and installation�Are expensive in medium/high voltage�Rapid obsolesce (6-7 years)/throw away�Motors control space requirement

• Operation & maintenance issues:�Harmonics

• MagnaDrive ASDs:�Operates with any kind of motor�Is not affected by dirty power�Is not affected by temperature, dust, humidity and other factors in the operating environment�Are simple to install and maintain�Have a life span of 20 – 25 years, depending on operating conditions

• Operation & maintenance issues:�No issues with harmonics�No issues with bearing fluting

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• The disconnected nature of the connection (air gap) provides:�No misalignment and vibration issues�Less time and money spent aligning and maintaining equipment�Longer equipment life�Cushioned start�No load start�Energy savings due to motor / load disconnection�Overload protection

Increased cost

of ownership

Lower cost

of ownership

• Equipment connected with VFDs still has a physical connection between the motor and load shaft causing:�Misalignment and vibration transfer�Premature equipment failure�Energy waste due to misalignment�No overload protection

�Harmonics�Bearing Fluting�No rapid restart capability

�No issues with bearing fluting�Rapid restart capability


Case Study for Hindalco Muri for ID Fan and PA Fan

ID FAN Curve.pdf

PA Fan Curve -- markup.pdf

ASD Sizing for 26.5-28.5 for PA Fan for Hindalco Ranachi.xlsx

Case Study

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ASD sizing for WC-1000 for ID fan for Hindalco Ranchi.xlsx

AVJ Engineering ConsultantsAVJ Engineering Consultants Magnadrive Capability

Magnadrive has supplied 6 Nos. ASDs WH – 4000 for 3037 HP / 980 RPM

ID Fan To China Power Plant.

MagnaDrive WH-4000 in China.pdf

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AVJ Engineering ConsultantsAVJ Engineering Consultants Success Stories

List Of Customers

List of Indian Customers as on 6th June

2016.xlsx


• Pictures of Magnadrive Couplings at NALCO Damanjodi

• Installation of Magnadrive Couplings at NALCO Damanjodi.pdfNALCO Damanjodi.pdf

• Magnadrive Coupling Operating

• DSCN0276.AVI

9/14/2016 68


• Installation of Magnadrive Couplings in NTPC Plants.

• Magnadrive Coupling Pictures in NTPC Plants.pdfPlants.pdf

• Performance of Magnadrive Couplings in NTPC.pdf

9/14/2016 69


NTPC Kayamkulam: 132 KW / 1500 rpm

DMCW Pump installation on 10.07.2014

Performance Results:

Performance Results.pdf

Success Stories

9/14/2016 70

Before Installation of Magnadrive Coupling Power consumption was 135.61 KW and After Installation of Magnadrive Coupling power consumption reduced to 113.54 Savings of 22.07 KW.


• NTPC AuraiyaPerformance Data of Clarified Pump Coupled with Magnadrive Coupling:

– Pump Model: CPRG-80-40

– Flow: 60M3/Hr.

– Head: 45 Meters

Success Stories

– Rating in KW: 18.5 KW

– Speed in RPM: 1470

Before Magnadrive: 421.5 Volts, 24.6 Amps, 0.79 PF, 4 Kg/Cm2 Head, 14.1 KW

After Magnadrive: 416 Volts, 22.2 Amps, 0.77 PF, 4 Kg/Cm2 Head, 12.4 KW

Power Saving: 12.06%

71


• NTPC Tanda:

Magnadrive Coupling

Model: FGC 18.5S.

Conveyor: 2B

Motor Rating: 110 KW

Success Stories

Motor Rating: 110 KW

Speed: 1450 RPM

No Load Current with

Fluid Coupling: 57 Amps

No Load Current with

Magnadrive Coupling: 52 Amps9/14/2016 72


Vandana Global Ltd, Raipur

Application: ACW Pump

Rating: 30 KW

Energy Savings: 19.36%

Success Stories

9/14/2016 73

Energy Savings: 19.36%

Coupling Model: FGC 10.5S

Performance of FGC 10.5S at Vandana Global.pdf

AVJ Engineering ConsultantsAVJ Engineering Consultants Quantified Business Results

9/14/2016 74

Plant Head Mr. Nandi Inaugurating Magnadrive Magnetic Coupling Model FGC 18.5S on Conveyor No. 6A At Dahanu Thermal Power Station


Client: Dahanu Thermal Power StationApplication: ConveyorMotor Rating: 110 KWSpeed of Motor: 1485 RPMArea: Coal Handling PlantOriginal Drive: Fluid CouplingPower Consumed With Fluid Coupling: 39.5 KWPower Consumed with

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Magnadrive Magnetic Coupling Model FGC 18.5S At Dahanu Thermal Power Station

Power Consumed withMagnadrive : 37.36 KWEnergy Savings: 2.14KWHEnergy Savings / Yr: 18747 KWH

Energy Saving / Yr. in Rs.: 93732.00

Other Benefits

�Reduction in Vibration Level�Zero Maintenance�Increased MTBF

Performance report of FGC 18.5S on 110 KW Conveyor at Dahanu Thermal Power.pdf


�Client: Delhi Jal Board�Project: Rithal ETP�Application: Pump�Liquid: Water�Motor Power: 280 KW�Voltage: 3.3 KV�Speed of Pump: 1466 RPM�Quantities: 8 Nos.Performance Parameters:

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Performance Parameters:

Full Load Current: 63 Amps

Magnadrive Coupling: FGC 21.0S

Current Drawn with

Magnadrive Coupling: 46 Amps

Energy Savings: 78 KWH

Energy Saving in Rs. 40.80L / Yr.

Magnadrive Magnetic Coupling

Model FGC 21.0S


�Client: SAIL�Project: BSP�Application: Pump�Liquid: Hot Benzyl�Flow: 40m3/Hr�Motor Power: 45 KW�Voltage: 415 Volts�Speed of Pump: 2980 RPM�Quantities: 4 Nos.

Quantified Business Results

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�Quantities: 4 Nos.Performance Parameters:

Current before

Magnadrive: 53 Amps

Magnadrive Coupling: MGE - 11

Current Drawn with


Energy Saving in Rs. 201480 / Yr.

Reduction in CO2

Emission: 1 Ton / Day from 4 Couplings.

Magnadrive Coupling Model MGE-11 At Coke Oven Bhilai Steel PlantPerformance Certificate for MGE-11 from BSP Coke Oven.pdfE:\VKM OWN\BSP\Coke Oven\Minutes of the Meeting.pdf


�Client: SAIL�Project: BSP WMD�Application: Pump�Liquid: Water�Motor Power: 110 KW�Voltage: 415 Volts�Speed of Pump: 1480 RPM�Quantities: 6 Nos.Performance Parameters:

Current before


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Current before

Magnadrive: 163 Amps

Magnadrive Coupling: FGC – 16.5

Current Drawn with


Energy Savings: 17 KWH

Energy Saving in Rs. 438000 / Yr.

Performance_certificate_from_WMD.pdf


�Client: Tata Motors Pune�Project: ETP�Application: Pump�Liquid: Effluent �Motor Power: 15 KW�Voltage: 415 Volts�Speed of Pump: 1480 RPM�Quantities: 1 Nos.Performance Parameters:

Power before


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Power before

Magnadrive: 9.77 KW

Magnadrive Coupling: MGE-11

Power Consumed with

Magnadrive Coupling: 6.91 KWH

Energy Savings: 2.9 KWH

Energy Saving in %. 25%

Performance Report for MGE 11 from Tata Motors.pdf


�Client: Tata Steel Tata Nagar�Location: Power House - 4�Application: Pump�Liquid: Effluent �Motor Power: 75 KW�Voltage: 415 Volts�Speed of Pump: 1480 RPM�Quantities: 1 Nos.Performance Parameters:

Power before


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Power before

Magnadrive: 50.6 KW


Power Consumed with

Magnadrive Coupling: 44.27 KWH


Energy Saving in %. 12.45%

Magnadrive Magnetic Coupling Model

FGC 16.5S at Tata Steel

PERFORMANCE REPORT FOR FGC 16.5S for pump by AVJ.pdf


�Client: Tata Steel Tata Nagar�Location: Coal Plant �Application: Conveyor No. 4A�Motor Power: 75 KW�Voltage: 415 Volts�Speed of Pump: 1480 RPM�Quantities: 1 Nos.Performance Parameters:

Power Consumption Before

Magnadrive: 54.1 KW

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Magnadrive: 54.1 KW


Power Consumed with

Magnadrive Coupling: 50.1 KW


Energy Saving in %. 8%

Continue

FGC 16.5S on Conveyor No. 4AAt Tata Steel Ltd.


Study Report by Tata Steel Ltd for 75 KW Conveyor

Study Report of MAGNA Drive r1 for conveyor of Tata Steel.pdf

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Magnadrive Magnetic Adjustable Speed Drive Model ASD 26.5 for 190 KW IDFan at Jindal Steel & Power Ltd. RaigarhPerformance parameters for ASD 26.5 from JSPL.pdf


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Magnadrive Magnetic Adjustable Speed Drive Model ASD 26.5 for 190 KW 6.6 KV ID Fan at Jindal Steel & Power Ltd. Raigarh Energy Savings around 73 KWH


The starting current reduced by: 27%Power Reduction by: 2.25 KW

Quantified Business Result for MGE 07 at Infosys Hyderabad.pdf

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% Energy savings: 26%Pay Back period:

KWH saved: 2.25Hrs of operation: 18Hrs / Year: 6570Cost of Power in Rs.: 6Per Year Energy savings: 2.25X6570X6 = Rs. 88695Per Month Saving in Rs.: 88695 / 12 = Rs. 7392Cost of MGE 07: Rs. 70478.00 Pay Back Period: 9.5 Months.

AVJ Engineering ConsultantsAVJ Engineering Consultants Competitive Analysis

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Operation Mechanical Benefits

Variable Speed X X X s Non-contact Power Transfer X X s s

Process Control X X X s s Reduce Vibration X X

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Process Control X X X s s Reduce Vibration X XEnergy Efficiency X X s s Reduce Wear X X s

Overload/Failure Protection s X s Misalignment Tolerance X XConstant Load s X s X X Reduce Power In-Rush X X X X s

Hi/Medium Voltage (High HP) X X s X s Soft Start/Stop X X X X s

Increase Bearing, Seal, Eqpt Life X X

Cost Benefits Electrical/Electronics Issues

Ease of Installation X X s Complex to Install/Support XTroubleshooting Ease X X X s Extensive Infrastructure X

Lower Maintenace Costs X X s Sensitive to Power Quality XMaintained In-house X X X s Harmonic Distortion XLonger Service Life X X X s Frequent Parts Replacement X

Reliability/Reduce Downtime X X s Parts Obsolescence XLower Total Cost (1-50HP) XLower Total Cost (50HP+) X

X = Very Characteristics = Somewhat Characteristic


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Documents

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