VFD Technologies Of Today Saving You Money For Tomorrow PRESSURE - - PowerPoint PPT Presentation

VFD Technologies Of Today Saving You Money For Tomorrow

PRESSURE

North America Power Usage

Pumps represent the largest single use of power in industry and is shown below in the breakdown of energy usage by motor driven equipment:

• Pumps - 31%
• Fans - 23%
• Air Compressors - 8%
• Other Compressors - 14%
• Conveyors - 8%
• Others - 16%

Basic Functions of a VFD

• Varies the speed of an AC motor, hence the ability

to allow the pump to work at the best efficiency point on the curve for changing systems and well depth.

• Inherently soft starting. No inrush current

therefore no peak demand charges.

• Reduce water hammer and provides for a

controlled pipe fill without slamming check valves.

• Provides protection to the motor.

– Ground Fault, Phase Loss, Motor Overload

Basic Functions of a Pump VFD

• Provides pump system protection

– Thrust Bearing Protection on start – No Flow / Dead Head Protection – Loss of Prime – Well Dry Run – High & Low Pressure – Mainline broken pipe – Pump Over cycling – Suction Control Monitoring – Sensing a Jam in a Submersible Turbine

VFDs Improve Pump Efficiency

• Pump efficiency provides an

essential cost advantage, keeping the operating efficiency as high as possible across variations in flow demand.

• Majority of energy

savings derived from the reduction in frictional or bypass flow losses.

Can I Save in Power Cost?

Question: Does a pump always need to run at full speed to meet flow and PSI requirements based on system demands and well depth? If No, then install a Pump VFD to start saving you money.

VFD Energy Savings

Energy consumption follows the affinity laws, which means that flow is proportional to speed, pressure is proportional to the square of speed, and horsepower is proportional to the cube of speed. Example: Application

• Required 80 percent flow
• Pump runs at 80 percent of rated

speed

• Motor requires 50 percent of rated

power

Result: Reducing speed by 20 percent requires only 50 percent of the power.

VFD Discharge / Throttling Valve

Typical Pump Usage

• Examples

– 10-75HP – Submersible Pumps – 200-300 Feet Well Depth – Hours and Months Running

• 24/7
• 100 days
• It costs about $2 per day per horsepower to operate a

motor continuously at $.10 kWh after all fees assessed

Energy Savings 10HP

• $2 x 9.7hp x 30.4 days = $ 589.76
• $2 x 7.1hp x 30.4 days =

$ 430.52

• Monthly Savings:

$ 159.24

• Savings Based on 100 days:

$523.80

Energy Savings 40HP

• $2 x 39.5hp x 30.4 days = $ 2,401.6
• $2 x 29hp x 30.4 days =

$ 1,753.17

• Monthly Savings:

$ 648.43

• Savings based on 100 days:

$2,133.00

Energy Savings 75HP

• $2 x 74hp x 30.4 days =

$ 4,499.20

• $2 x 54hp x 30.4 days =

$ 3284.41

• Monthly Savings:

$ 1214.79

• Savings based on 100 days:

$3,996.00

Why Do Utilities Offer Rebates?

• Reduced line surges from soft starting over across the

line motor starting.

• Reduced power consumption due to variable motor

speed, users only uses the power they need.

• Utilities know that the majority of pumps are oversized

and over pump.

• Reduced overall impact on power grid reducing

capacity required.

Things to Look For in a VFD

• Dedicated to pumping applications.
• Easy to install, setup, and maintain.
• Easy to program using common pump terminology and

pumping units.

• High reliability and aftermarket service.
• Purchase from a distributor who can assist you in

selection and setup.

Intelligence to the Pump System Controls

• Beyond using basic VFDs, adding Pump

intelligence to the control solutions provides additional benefits which include:

– The intelligence could monitor pump operating parameters and conditions—such as vibration, leak detection, increased pressure, current draw and temperatures, and predictive maintenance. – Enhanced pump protection, resulting in longer life, increased operational efficiency and high reliability. – Reduce downtime

Basic Simplex Pump Application

• Quick Start pump menus makes single pump

system setups easy

– Select unit of measure for set point PSI, GPM, etc. – Calibrate Feedback Level Transducer – Set Pressure Set point – Set Draw Down Level

Network with Multiple Drives each controlling

• ne Pump

Create your own Pump Control Network with up to:

Setup system in under 15 minutes!

• Set Pump Control Mode
• Set Network Address for each drive
• Set Feedback Range
• Set Low and High Feedback Limits
• Set Level to Stage and De-stage Pumps
• Press Auto

Check out Example Application

Drive to Drive Multiplexing

Drive to Drive Multiplexing

Smart Pump VFDS’s Helps Reduces Cost!

Reduce Size of Large Pressure Tanks Jockey Pumps Bypass Valves Mechanical Control Panels

Pump Specific Operator Keypad

• Onboard English read out reduces field start up and

troubleshooting time with intuitive pump related terminology.

• Keypad provides real time alarms, status and operating conditions

in an easy-to-read format.

Typical Operator Keypad Messages

• No Costly External HMI to

convert VFD parameters to pump terminology

Flexible Keypad Display Modes

Transducer Feedback

Main Monitor Screen Should be Easy to Read and Understand

Pump Start Level

Start Pump when pressure drops below a preset start level for a specified start delay time.

PRESSURE

Start / Draw Down Level

Start Level (PSI)

VFD monitors feedback signal to start pump system when needed.

Motor Speed

60 Hz

5 4 3 2 1

Motor Speed

Pump starts running after start delay has expired (example with Thrust Bearing function enabled).

Start Delay Timer

Timer starts when pressure drops below preset start level.

Sec

Click to start demo Demo Running

Auto Setpoint (PSI)

Pre-Charge Level

Pump runs at pre-charge speed until feedback reaches the pre-charge level or the pre-charge time.

PRESSURE

Pre-Charge

Pre-Charge Level (PSI)

VFD pre-charges system before starting level or pressure regulation.

Motor Speed

60 Hz

Motor Speed

Pre-charge speed 30Hz.

Status

When pre-charge is completed the system will regulate automatically.

Auto Setpoint (PSI)

Pre-Charge Active Pre-Charge Completed Regulation

Click to start demo Demo Running

Feedback Loss Detection

Example shows feedback transducer loss detection.

PRESSURE

Feedback Loss Detection

VFD detects transducer loss

Transducer

Click to start demo Demo Running

High Feedback Detection

Drive trips on high feedback fault when pressure rises above high feedback level for high feedback delay time (Example: 5 sec.)

PRESSURE

High Feedback Detection

VFD detects high feedback

High Feedback Detected

5 4 3 2 1

High Feedback Fault High Feedback Fault Delay Timer

Pump Ok!

Click to start demo Demo Running

Auto Setpoint (PSI)

Low Feedback Detection

Drive trips on low feedback fault when pressure falls below low feedback level for low feedback delay time (Example: 5 sec.)

PRESSURE

Low Feedback Detection

Low Feedback Detected

5 4 3 2 1

Low Feedback Fault Low Feedback Fault Delay Timer

Pump Ok!

VFD detects low feedback Click to start demo Demo Running

Auto Setpoint (PSI)

Setpoint Not Met

When the setpoint can’t be maintained for a specified time due to Blocked Impeller, Over-Cycling or Broken Pipe (Example: 5 sec.)

PRESSURE

Setpoint Not Met

Setpoint Not Met Detected

5 4 3 2 1

Setpoint Not Met Fault Setpoint Not Met Delay Timer

Pump Ok!

Click to start demo Demo Running

Auto Setpoint (PSI)

Motor Amps

Motor amps decrease in a loss of prime condition (Example: dry well)

Output Frequency

Drive tries to maintain pressure by increasing motor speed.

Loss of Prime (Dry Well)

Monitors:

• Output speed
• Output current
• Output power
• Output torque

A

100

Prime loss current level

60

Hz

Pressure Drop

Pressure drops in a loss of prime condition (Example: dry well)

PRESSURE

Pressure Feedback Loss or Prime Detected

5 4 3 2 1

Loss of Prime Fault Loss or Prime Delay Timer

Pump Ok!

Prime loss frequency

Click to start demo Demo Running This function can be used to detect if there is no water in the system (air) or a dry well condition.

Motor Amps

Drive automatically limits motor amps by regulating the motor speed.

Motor Speed

Motor speed automatically reduced to prevent motor overload.

Hard Current Limit Control

Pump efficiency changes over time due to pump impeller wear, resulting in increased in pump speed and motor amps to maintain a constant pressure or flow. The increased motor amps may cause the drive to trip on a motor overload. A hard current limit prevents the drive from tripping by reducing the output speed to keep the system running smoothly.

A

100

Hard Current Limit

3600

rpm

Pump speed is increasing Motor amps are increasing Reducing pump speed Current Limit Reached

Click to start demo Demo Running

Impeller Anti-Jam Automatic Control

Anti-Jam Automatic Control

• Provides a method for the user to select the VFD to detect high

current and attempt to expel corrosion or solids which is keeping the pump impeller from operating efficiently.

• VFD will perform a quick reversal to try and dislodge jam over a

programmable cycle count.

• If unable to clear jam, VFD will fault and display “Anti-Jam Fault” on

keypad.

Advanced Well Monitoring

• Constant Pressure with Well Draw

Down Control:

– Function allows the drive to control constant pressure when there is adequate water in the well, while monitoring a second down hole transducer for water level. – If the water level drops below user settings then the drive will reduce pump speed to maximize well

• utput. System will return

automatically to normal operation when well water is recharged to an adequate level

Constant Pressure + Well Draw Down Control

• Water Level Regulation
• IF

– the well does not recharge fast enough, then the water level will drop below the Minimum Water Level and the Drive goes to sleep and waits for the well to recharge to the Wake-up Level

• OR

– the well does recharge fast enough and the output of the Water Level PI loop exceeds the output of the Pressure Regulation, and the VFD returns back to pressure regulation

Constant Pressure with Suction Control Support

• Works like Well Draw Down control except suction pressure at inlet is

measured and becomes the setpoint instead of water level.

– Suction pressure transducer is required – Low and High suction pressure alarms/faults can be set – System can shutdown if suction pressure falls to low or becomes to high

Flow Meter Data Logging

Flow Meter Data Logging

• Flow meter feedback signal can be connected to read and

accumulate total flow for system reporting to authorities.

• System can be configured to detect “No Flow”, Low & High

Flow demands.

• Units of Flow Measurement
• Gallons Per Minute, Gallons Per Hour, Cubic Feet / min (CFM)
• Cubic Meters / hr (CMH), Acre-Feet / Yr (AFY)

22,000,000 156,000 722 0.7762 Total = 22,156,722.7762

MATRIX DRIVE ATTRIBUTES

Low Current Harmonics Near Unity Power Factor

True PF: 0.98 or higher

Greater Efficiency Power Regeneration Compact Size Permanent Magnet Control

Matrix Drive Vs Conventional Drive Overview

• Conventional Drives

– Large amounts of capacitance – Pre-charge contactor

• Matrix Drives

– AC to AC = No large capacitors – No Large Caps = No Pre-charge circuit

L1

IM

T3 T1 T2 L2 L3

IM

E R E S E T

U tility grid

IR IS IT R S T Cf U V W V U V V V W IU IV IW Motor S1 1 S2 1 S3 1 S1 2 S2 2 S3 2 S1 3 S2 3 S3 3 ＝

～ Conventional Drive Matrix Drive

35

HARMONIC CURRENT PERFORMANCE SUMMARY

Configuration Current Waveform Current Spectrum

iTHD AC drive without reactor

Total Harmonic Distortion (Current)

100％

50％

0％ Harmonics 5 7 11 13 17 19 23 25

~ 80%

AC drive with DC reactor

Total Harmonic Distortion (Current)

100％ 50％ 0％ Harmonics 5 7 11 13 17 19 23 25

~ 40%

AC drive with multi-pulse

Total Harmonic Distortion (Current)

100％

50％

0％ Harmonics 5 7 11 13 17 19 23 25

6 - 12%

Total Harmonic Distortion (Current)

100％ 50％ 0％ 5 7 11 13 17 19 23 25 Harmonics

AC drive with AFE

≤ 5%

Total Harmonic Distortion (Current)

100％ 50％ 0％ 5 7 11 13 17 19 23 25 Harmonics

0.0% 2.0% 4.0% 6.0% 8.0% 10.0% 12.0% 14.0% 16.0% 25.0% 50.0% 75.0% 100.0%

iTHD Load

iTHD-U1000 iTHD-18p

10+% 5+%

Excellent low harmonic performance is possible over a wider load range compared to Multi-pulse configurations.

Harmonic Performance – U1000 vs. 18-pulse

2+%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 80.00 82.00 84.00 86.00 88.00 90.00 92.00 94.00 96.00 98.00 100.00 40% 50% 60% 70% 80% 90% 100% Efficiency (%) % Speed

System Efficiency (Excluding Motor)

Matrix 18 Pulse Load

Efficiency – Matrix vs. 18-pulse

3.5+% Increase $100’s in added yearly Energy Savings 12+% Increase

System Size Reduction – Matrix vs. 18 Pulse

Eliminate Components:

• 18P Transformer
• Diode Rectifiers
• Phase Circuits
• Reactors
• Fusing

Benefits:

• Saves Space
• Less Wiring
• Reduced Costs

Example: 480V 40HP

18 Pulse Drive U1000 Matrix Drive

Power Supply Motor AC drive Motor

39

U1000

Sizing a Drive

• Why is it important to correctly size a drive?
• Its simple, under-size a drive and it won’t work
• properly. Over-sizing a drive is less of an issue,

but is a waste of money.

Needed Information for Sizing a Drive

• Full Load Amps
• Motor Voltage
• Single-Phase Power or Three-Phase Power
• Type of pump
• Distance from drive to pump

Full Load Amps (FLA) vs. Horse Power (PW)

• Not all motors share the same efficiency.
• So the FLA can differ from one motor to

another, even though the HP rating is the same.

• Although all VFDs have a rated HP value, go

with the FLA

Datasheet or Name Plate

• Most of the drive

information can be found

• n the name plate or on

the datasheet.

Distance Is A Factor

• Voltage spikes amplify over long distances.
• Motor protection may be needed

– 150’ and less = No Problem – 150’ to 300’ = Load Reactor – 300’ to 1000’ = dV/dt Filter – 1000’+ = Sine Wave Filter

Submersible Pumps

• When sizing a submersible pump

always add the service factor to the FLA.

• Example: 40A FLA x 1.15 = 46A
• At a minimum you would also want to add a load

reactor to protect the submersible pump from voltage spikes. Longer runs could require a dV/dt filter or a sine wave filter.

NEMA 3R

• If you are installing a drive
• utdoors be sure to consider

the worst case ambient

• perating temperature.
• For example NEMA 3R

enclosures can go to 40°C (104°F) standard and 50°C (122°F) optionally.

VARIABLE speed pump operation will improve the EFFICIENCY of your

pumping systems, save money, and reduce overall cost of ownership.

Summary

FIXED speed pump systems although the industry norm are inherently inefficient , use more power, and prone to reliability problems.

Thank You!! Mike Weber 262-899-5266 mike_weber@yaskawa.com