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 VFD power Discharge / Throttling Valve Result: Reducing speed by 20 percent requires only 50 percent of the power.

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

Drive to Drive Multiplexing Create your own Pump Control Network with up to: Setup system in under 15 minutes! Network with  Set Pump Control Mode  Multiple Drives Set Network Address for each drive  Set Feedback Range each controlling  Set Low and High Feedback Limits one Pump  Set Level to Stage and De-stage Pumps  Press Auto Check out Example Application

Drive to Drive Multiplexing

Smart Pump VFDS’s Helps Reduces Cost! Jockey Pumps Reduce Size of Large Pressure Tanks Mechanical Bypass Valves 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

Flexible Keypad Display Modes Main Monitor Screen Should be Easy to Read and Understand Transducer Feedback  No Costly External HMI to convert VFD parameters to pump terminology

Start / Draw Down Level VFD monitors feedback signal to start pump system when needed. Click to start demo Demo Running Start Level Auto Setpoint Motor Speed (PSI) (PSI) 5 2 4 1 3 Hz PRESSURE 60 0 Sec Pump Start Level Motor Speed Start Delay Timer Start Pump when pressure drops Pump starts running after start delay Timer starts when pressure drops below a preset start level for a has expired (example with Thrust below preset start level. specified start delay time. Bearing function enabled).

Pre-Charge VFD pre-charges system before starting level or pressure regulation. Click to start demo Demo Running Pre-Charge Auto Setpoint Motor Speed Level (PSI) (PSI) Regulation Pre-Charge Completed Pre-Charge Active Hz PRESSURE 60 0 Pre-Charge Level Motor Speed Status When pre-charge is completed the system will regulate automatically. Pump runs at pre-charge speed until Pre-charge speed 30Hz. feedback reaches the pre-charge level or the pre-charge time.

Feedback Loss Detection VFD detects transducer loss Click to start demo Demo Running PRESSURE Feedback Loss Detection Example shows feedback Transducer transducer loss detection.

High Feedback Detection VFD detects high feedback Demo Running Click to start demo High Feedback High Feedback Pump Ok! Fault Detected Auto Setpoint (PSI) High Feedback Fault Delay Timer 3 1 2 4 5 PRESSURE High Feedback Detection Drive trips on high feedback fault when pressure rises above high feedback level for high feedback delay time (Example: 5 sec.)

Low Feedback Detection VFD detects low feedback Demo Running Click to start demo Low Feedback Low Feedback Pump Ok! Detected Fault Auto Setpoint (PSI) Low Feedback Fault Delay Timer 2 1 3 4 5 PRESSURE Low Feedback Detection Drive trips on low feedback fault when pressure falls below low feedback level for low feedback delay time (Example: 5 sec.)

Setpoint Not Met Auto Setpoint Demo Running Click to start demo (PSI) Setpoint Not Setpoint Not Pump Ok! Met Detected Met Fault Setpoint Not Met PRESSURE Delay Timer 3 1 2 4 5 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.)

Loss of Prime (Dry Well) Monitors: • Output speed This function can be used to detect if • Output current there is no water in the system (air) or • Output power a dry well condition. • Output torque Click to start demo Demo Running Pressure Feedback Prime loss frequency Prime loss current level Loss or Prime Loss of Prime Pump Ok! Detected Fault 0 60 PRESSURE 0 100 Hz A Loss or Prime Delay Timer Pressure Drop Output Frequency Motor Amps Pressure drops in a loss of prime Drive tries to maintain pressure by Motor amps decrease in a loss of 2 1 3 4 5 condition (Example: dry well) increasing motor speed. prime condition (Example: dry well)

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. Hard Current Demo Running Click to start demo Limit Pump speed is increasing Reducing pump speed 0 3600 0 100 rpm A Motor amps are increasing Current Limit Reached Motor Amps Motor Speed Drive automatically limits motor Motor speed automatically reduced amps by regulating the motor speed. to prevent motor overload.

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.