Energy efficiency has never been as important as it is today. TPS recognise this and continuously strive to meet and exceed our customers’ targets for improved energy efficiency, in all of our products.
Electric motors to drive pumps, fans and compressors are by far the largest consumer of the 15,000 GW of average power generated across the globe.
Typically these motors run high duty and at high loads, resulting in high annual energy inputs. As is the case in power generation, but even more so here, there are huge opportunities to improve efficiency with the use of new technologies. Over the last couple of decades there has been large-scale adoption of Variable Frequency Drives (VFDs) to a vast number of these applications, typically resulting in an annual energy saving of 20%-50%. The improvements are primarily due to the use of a frequency converter allowing the operating speed of the rotating equipment to be matched with the varied load profiles that are seen.
Whilst large market potential to convert fixed-speed installations to variable-speed still exists, there is now an urgency to introduce higher efficiency motors to replace typical induction motors that are used. The technology of choice is usually a Permanent Magnet machine, particularly as they exhibit much higher part-load efficiencies than any other type of machine, whilst also being more efficient at full load as well. An example efficiency map of a TPS Permanent Magnet motor is shown below;
Turbo Power Systems have several Permanent Magnet motor products in production which are used for turbo-compressor applications up to 500 kW. Current and future developments will extend this range to several Megawatts. For all of these high-speed machine products, we design and manufacture our own power electronics equipment, ensuring an ideal match between the two parts and increasing the cost effectiveness of the system.
IN POWER GENERATION
The overall efficiency of any electrical power generation system is fundamentally important to reducing both the life cycle costs and environmental impact of operating the equipment.
Electricity accounts for around 33% of all global energy consumption and over 40% of energy related CO2 emissions. Fossil fuels account for 66% of all electricity generation, at an average of 36% efficiency. Significant potential exists to improve this efficiency with the use of new technology. Given the relatively low efficiency of the fuel to mechanical power conversion process, primarily governed by thermodynamic laws, very high electrical equipment efficiencies are needed to preserve the useful energy available.
Direct-drive oil-free motors & generators, with ratings up to 1.2MW, scalable to 10MW. Operating speeds range from 10,000rpm to 160,000rpm.
Where gas turbine engines are used for electrical generation, it is common to use a gearbox to reduce the output speed of the turbine to a ‘standard’ speed suitable for conventional electrical machines. In decreasing the working speed of any rotating machinery, there is an inversely proportional increase in the transmitted torque and an unavoidable loss of efficiency that occurs. Torque rating is a very good measure of the physical size of a piece of rotating equipment, so the net result is a much larger and heavier generator than if the machine could operate at the same speed as the gas turbine. This would of course also avoid the weight and inefficiency of the gearbox, so the net result is a much smaller and more efficient engine/generator combination. At this point it is necessary to consider that the characteristics of the high-speed generator do not allow direct connection to the grid, so a power converter is required, essentially meaning we have replaced the mechanical gearbox with an electrical one.