Energy Savings on Fans and Pumps

8/9/2019 Energy Savings on Fans and Pumps

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Energy Saving on Fans & Pumps

An overview of the Options Available

Mike Carman May 1 !


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Overview of to"ay#s presentation

$ntro"u%tion ypes of flow %ontrol 'hy %hange the spee"( what happens ) Common metho"s of flow %ontrol use" Energy saving %ase stu"ies

Engineering %onsi"erations Con%lusions *uestions


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$ntro"u%tionhis presentation will look at +

fan an" pump appli%ations, the various metho"s of flow %ontrol

use" on Fans & Pumps, the merits of these systems( to see

whi%h offers the best %ontrol & energysavings


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Fan ypesCentrifugal A-ial

Cross FlowPropeller


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Pumps

Centrifugal .ane ype


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ypes of %ontrol

S/ Motor 0is% hrottle .ariable Pit%h

Parallel

0ampersOppose"0ampers

$nletui"e

.anes


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Changing spee" why ) o %ontrol the flow of air or li2ui" For pro%ess appli%ations( su%h as 0airy

pro"u%ts( petro%hemi%al( & waste watertreatment plants

For "omesti% re2uirements su%h as air%on"itioning & %omfort %ontrols


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'hat are the metho"s to%ontrol flow )

Most are me%hani%al 3early all are fi-e" %ontrol Some offer %ru"e fee"ba%k Most offer no energy saving All re2uire e-tra maintenan%e The bi product of changing speed

with VSD is reduced energy costs


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Changing Spee" by using.S0 saves energy why )

Centrifugal fans & pumps

Flow is proportional to spee" Power 4k'5 is proportional to spee" %ube" or2ue is proportional to spee" s2uare"


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Power & or2ue e-ample 1667 flow with 18 k' motor 9 pole 9 16 /PM86:; Full loa" tor2ue k' - ,88 < motor spee"

= 3M > ,99

'ith flow re"u%e" by 167( 967( 867 3ew spee"9?1 rpm( 9@9 ( 1>88 3ew power re2uire"( 11kw( !,?kw( 1, !8kw

3ew tor2ue re2uire" @ 3M( @13M( 19,983M


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6

16

96

@6

>6

86

?6

!6

A6

6

166

8 16 18 96 98 @6 @8 >6 >8 86

'hat is A S2uare an" Cube" Baw

D

y=x 3

Power

y=x 2

Torque

15kW Motor @ 1450 RPM 99Nm

% P

o w e r

/ T o r q u e

% Motor Spee


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.S0 regulating a pump 1Pressure

Flow

System running

at set flow

3ew flow re2uire"using flow valve

3ew flow "elivere" byslowing motor with .S0

y using .S0( new flow is pro"u%e" withoutusing flow valve( therby saving energy,


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.S0 regulating a pump 9Pressure

Flow

Pumps have steep %urvesor shallow %urves

'ith .S0( a saving of energy is possible on all typesof pressure < flow operations,,


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heoreti%al E-ample of energy saving

Motor si;e !8 k' at 86:; spee" Average ele%tri%ity rate 6,6?> S0G /unning time >@ 6 hours

Flow 1667 at 86:; spee" Customer re2uires to re"u%e flow to !874 @!,8 :; 5 3ew absorbe" power

@!,8


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heoreti%al E-ample of energy saving

3ew power at !87 spee"( @1,?> k' ariff rate G6,6?> - @1,?> - >@ 6 =

S0 G ? Energy savings G91(69> H ? =

G19188 Capital %ost of .S0 & panel G1@(?66 Payback 13,600/1 1!! " 1#11yrs

$13%&


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Effi%ien%ies of Fan 0rivemetho"s

6 16 96 @6 >6 86 ?6 !6 6 6 1666

1696@6

>686?6!6

66

166

7 $nputPower

7 Flow/ate

$"eal Fan %ontrol

P'M $nverter

.ariable pit%h fan

E""y Current %oupling

$nlet ui"e vanes


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ypes of %ontrol 1 Flu- .e%tor %ontrol

Fee"ba%k normally re2uire"I,a""s to%ompli%ation an" wiring,

0rive an" motor have to be mat%he" tosome e-tent,

A""itional %ost for the %ompli%ation 3ot Justifie" for normal appli%ation, Must be use" for positive "ispla%ement

pumps where starting tor2ue is nee"e",


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ypes of %ontrol 9 Swit%he" /elu%tan%e 0rives

Spe%ial motor nee"e" More stator poles so more wiring, Motor output is 0C pulses, Spee" & or2ue is %ontrolle" via P'M

te%hni2ues,

S/0 %ontroller must be mat%he" to thespe%ial motor 4 $n%urring e-tra %ost 5, 3o bypass operation possible,


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ypes of %ontrol @ Multi Spee" motors

se" for lower power appli%ations 6H1k', 9 or @ spee"s only, @ spee" is %ommon in pumps, @666 rpm to !86 rpm is an pole

%onfiguration,

Steps in spee" %hange is large, Poor power fa%tor at low spee"s


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ypes of %ontrol > 0is% throttle

3o harmoni%s generate" 3o "rives re2uire", Flow turn"own is very goo", Consi"erable pressure loss, Maintenan%e is nee"e",


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ypes of %ontrol 8 0C 0rives

Commonly use" in in"ustrial appli%ations, oo" spee" %ontrol Superb starting tor2ue,4not nee"e" )5 ,>7 effi%ient "rive Maintenan%e of brushes is a""itional %ost,

Slave motors must have a fiel" applie" an"armature loa"e" with resistor to "raw%urrent whi%h keeps brushes in operatingstate,


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ypes of %ontrol ? .ariable pit%h fans

3ormally "rive by 0OB AC motor, 3o harmoni%s generate", 3o "rive re2uire", Parallel or series %onfigurations possible, oo" volume %ontrol possible,

Pneumati%s are use" for %ontrolHunreliable Poor a%%ura%y an" high hysterisis, Comple- fan hub an" prone to stallingK


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ypes of %ontrol ! $nlet gui"e .anes

3o harmoni%s or /F$ pro"u%e", 3o "rive nee"e", Poor reliability Flow turn"own limite" an" pressure loss

a%ross the vanes,

/egular maintenan%e of vanes is nee"e", 9 sets are usually nee"e",


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ypes of %ontrol /egulating .alves

Flow is re"u%e" by re"u%ing the pressure, Proportional balan%ing is nee"e" on

bran%he" %ir%uits, /egulation is ineffi%ient %ompare" with

re"u%e" pump spee", Pumps are "esigne" for an output

pressure for a parti%ular spee" an"re"u%ing the pressure re"u%es the effe%tive%ontrol,

/egular maintenan%e re2uire",


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ypes of %ontrol P'M $nverters

$n"ustry stan"ar" Current waveform %lose to motor *uieter operation 4at higher swit%hing fre2uen%ies5

Motor overHsi;ing not ne%essary, oo" power fa%tor at all loa"s, uiltH$n Softstart %apability or2ue mat%he" to fan or pump loa" 40


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ypes of Fan an" ControlFan Appli%ation Control CommentCentrifugal A: P'M $nverter Most %ommon

For%e" "raft Sw /el 0rive Spe%ial motor re2"%ooling tower E""y Current 3o harmoni%s:igh pressure< M


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ypes of Fan an" ControlFan Appli%ation Control CommentPropeller 3on "u%te" M


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Maintenan%e 1 Monitoring

he operation an" performan%e of systemsshoul" be monitore" %ontinuously,

MS will "o this task, he spe%ifi%ation of the MS is the key to

effe%tive monitoring an" lowering ofmaintenan%e %osts,

Bots of e2uipment nee" maintenan%eI,,


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Maintenan%e 9 0ust Filters

hese must be inspe%te" regularly an"%leane" or %hange" in a%%or"an%e with the

manufa%turers instru%tions, .S0#s

3ee" very little maintenan%e,

Parameters or settings may nee" %he%kingo%%asionally,


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Maintenan%e @ Multi Spee" Motors

3ot a lot of maintenan%e ne%essary e-%eptfor bearings every 9 years,

Swit%hgear for MSM#s nee" %he%king for"amage" %onta%ts on the %onta%tors, $nlet ui"e .anes( hrottles & 0ampers

3ee" regular %leaning an" lubri%ation Operation %he%ke" for me%hani%alhysterisis an" other wear,


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Maintenan%e > .ariable pit%h fans

3ee" most maintenan%e, 'eekly inspe%tions are re%ommen"e", /egular %leaning an" lubri%ation is part of

the normal life of a .P fan, E-treme %are is nee"e" when near .P

fans, la"es %an part %ompany with therotor an" thus en"angering human life,


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'hat is the est Solution ) Substantial savings %an be ma"e using

one of the more effi%ient metho"s, P'M $nverters have high effi%ien%y, Swit%he" /elu%tan%e "rives are very

effi%ient but motors are spe%ial KK P'M $nverters H 3o Maintenan%e, P'M $nverters work with stan"ar" motors,


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Bets Book at Some Pump &

Fan Energy Saving E-amples


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.ariable flow energy savings0.BA

6 1 9 @ > 8 ? ! 166

1696@6

>686?6!6

66

166

:our

7

Energy

Flow

'eating pu(p energy sa)ing


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.ariable flow energy savings0.BA

raph on last page shows a typi%al flow againsttime( in bar graph form,

Full flow is normally only re2uire" as a boost, Average flow is 8@7 49?,8:;5 an" average

energy is 9,9@ 4saving ?75, Energy %ost G6,6?>( total energy %osts G >6 (

!?6 hours 3ew energy %osts G1986( total savings G!18 Payback, capita* costs +3 00/ 1!- " 0#..yrs


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.ariable flow energy savings

6 1 9 @ > 8 ? !6

81618

9698@6@8

>6>886

7 oo*ing pu(p energy sa)ing %anchester irport

:our

Flowrate 7

Energyuse" 7


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.ariable flow energy savings

3e-t graph shows typi%al operation of%hille" water pump in an airport terminalbuil"ing,

Average flow is @ 7 with averageenergy1@, 7, Energy save" is ?,97,

On 18kw rating saving woul" beG1>>6 an" payba%k over 9, years,

Payba%k is longer be%ause it runs for hours per "ay


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ase Study 1

owerton 2 e*sh ater


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Case Stu"y 1 owerton Company 'elsh 'ater Air pumps for sewage works Motors si;e 11 k' 91,8 amps Continues operation @?8 "ays >66 units on sites looking for energy savings & improve"

pro"u%t, 'oul" like to use %lose" loop %ontrol

from "issolve" o-ygen meter


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Appli%ation Case Stu"y 1

owerton Sewage Treat(ent orks

> AC Motors0ire%t on Bine

9 $"enti%al Sets of Pumping E2uipment operatingon > Po%kets

> AC Motorswith .S 0rive


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Case Stu"y 1 H owerton owerton S#T# # 4o 1 Pocket#16

?

>

9

6

k

66+66 6?+66 19+66 9>+661 +66>th Mar%h 1 !

0,O,BMotors

.S 0rive

L Motors


43/61

owerton Costs H Po%ket 1 0ire%t on line motor( kwh S0 G

6,6?>( G6,819 per hour( - 9> G19,9 -@?8 "ays = G>> 8,

Motors fitte" with . C "rive(yearlyenergy %osts( S0 G 9816,

otally energy savings for year S0

G1 !8, 5)era** sa)ings ..


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Case Stu"y 1 H owerton owerton S#T# # 4o Pocket#

16

?

>

96

k

66+66 6?+66 19+66 9>+661 +66

>th Mar%h 1 !

0,O,BMotors

.S 0riveL Motors


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owerton Costs H Po%ket 9 0ire%t on line motor 8 kwh S0 G

6,6?>( G6,@9 per hour( - 9> G!,? - @?8"ays = G9 6@,

Motor fitte" with . C "rive( yearlyenergy %osts 0S G 18? ,

otal energy savings for the year S0 G

19@>, 5)era** sa)ings ..

C S i &


46/61

owerton Cost Savings &Payba%k

otal yearly energy %osts "ire%t on linemotors S0 G !9

otal yearly energy %osts motors fitte"

with . C S0 G >6! otal energy savings S0 G @96 Overall savings >>7 Payba%k( 0rive & installation %osts S0

G > 66, G> 66


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owerton roup Savings

>66 Air pumps( fi-e" spee" running%osts S0 G 1(>8?(?66 Estimate" energy %osts with . C fitte"

S0 G 18( 66 Savings in energy S0 G ?>1(?66 otal investment S0 G ?6(666

fter 17 (onths sa)ings each (onthwi** be 8SD + !3,.66


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ase Study

S(urfit Townsend 'ook

See notes


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Case Stu"y 9 Motor si;e 116kw( 1 6 amps F,B,C,

3ominal 166amps /unning time !?6 hours Flow %ontrol via throttle & re %ir%ulation valve(

flow about 867 Energy %osts with valve %ontrol G6,6?>

average kwh of 6,8! per hour = G>81!6 'ith .S0 %ontrol set to 67 spee" 48675

flow( new k' power of >1,981 3ew energy %osts G9@19? Savings G996>> apita* costs + ! 0., Payback 1#16yrs


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.S0 in Control Systems


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Stan" Alone 0rive

@ phase supply& "is%onne%t P'M $nverter

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Energy Savings on Fans and Pumps

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