| confidential/property of danfoss power electronics| thursday, 16 july 2015 | 1 presenting power...
TRANSCRIPT
| Confidential/Property of Danfoss Power Electronics| Wednesday 19 April 2023 | 1Presenting Power Electronics
Energy Savings in Water and Wastewater Segment
Danfoss Industries Pvt. Ltd.
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Presentation Overview:
Introduction to Danfoss
Danfoss Core Business
Energy savings & other benefits with VFD control VFD applications in water and wastewater segment
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Danfoss in brief
78 years of experience within energy-efficient technologies
Solutions ready to combat climate challenge
Global competence center for energy efficiency – rooted in Southern Denmark
The Bitten and Mads Clausen Foundation holds the majority of shares in Danfoss
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Danfoss’ core businesses focus on Climate & Energy
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Danfoss = First company to mass produce a.c. variable frequency drives (VFD)
VFD evolution
2003 2007 1998199319881983197819731968
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Water & energy --- precious resources
Climate change is increasing pressure on
global fresh water resources
At the same time demand for energy is rising
Both are contributing to increased concern
for the environment
VFD can provide significant energy savings,
reduce water loss, and provide other benefits
in water, wastewater & irrigation systems
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Pump life cycle costs
~ 20% of the world’s energy is consumed by pumps #
Initial capital and whole of life maintenance costs = ~ 5% of the total life cycle cost
Energy costs = ~ 95%
~ 95% of pumps installed are over sized (Selected for worst case condition + safety margin)
Methods of flow control to meet average (lower) flow or varying demand include e.g.:
- Impeller trimming- Throttling valve- Bypass valve (3-way)- Variable Frequency Drive (VFD)
- # British Pump Manufacturers Association
5%
95%
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VLTAC 3Ø
Electronic unit that varies the fixed mains Electronic unit that varies the fixed mains voltagevoltage & & frequencyfrequency to to control the speed of standard a.c. electric motorscontrol the speed of standard a.c. electric motors
Infinite speed control from 0-50Hz +over-speed operation with some limitationsInfinite speed control from 0-50Hz +over-speed operation with some limitations
VFD (Variable Frequency Drive)VFD (Variable Frequency Drive)
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Typical energy savings with VFD on centrifugal pumps
Flow is proportional to speed
Power varies to the cube of the speed change
20% reduction in speed
= 50% reduction in energy
50% reduction in speed
= 80% reduction in energy
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Throttling Valve compared to VFD
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Throttling valve compared to VFD
Control with valves Control with VSD
VFD gives ~35% energy savings compared to throttling valve (On typical variable flow applications)
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Energy consumption of single & multiple pump systems
Single VFD Single VFD controlled pumpcontrolled pump
Standard cascade Standard cascade control with 1 x VFD control with 1 x VFD pump & multiple pump & multiple fixed speed pumps fixed speed pumps
Master – follower Master – follower with 1 x VFD per with 1 x VFD per pump pump
Master follower = best energy efficiency
100%100%
Note: kWh figures are approximate relative %, based on sample test
53%53% 48%48%
43%43%
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Other benefit – reduced water loss
Smooth starting & stopping with VFD
reduces mechanical stress
Less damage to piping & valves
Lower possible system operating
pressure also reduces water loss
(Non – revenue water, which in
developing countries is ~ 30% of water
supply)
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Application examples
Ground water abstraction
Reverse Osmosis
Water distribution
Wastewater treatment
Irrigation
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Groundwater – abstraction
VFD allow control of draw down on deep well submersible pumps
- Constant level, flow or pressure
Benefits (e.g.:) Energy savings
Reduced mechanical stress & leakage
Chemical dosing to match flow
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Application examples
Ground water abstraction
Reverse Osmosis
Water distribution
Wastewater treatment
Irrigation
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Reverse Osmosis Membranes are used to filter salt & other impurities from water Variables are Flow, Temperature and Salinity Brackish water requires less pressure than sea water
Benefits (E.g.:) VFD can maintain constant output flow as filters block Elimination of pressure surges extends the membrane life. Longer time between backwash cycles. Less energy consumption - lower speed with clean filters.
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Application examples
Ground water abstraction
Reverse Osmosis
Water distribution
Wastewater treatment
Irrigation
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Constant pressure with water tower/ elevated storage tank
Water Towers maintain constant pressure in the water distribution system and provide a certain capacity Pumps are used to fill the water tower, normally based on level control
Pum ping stationwithHigh serv ice pum p
Sim plif iedwellwith pum p
Source fromsurface water
Sim plif iedtreatm ent plant
Source fromgroundwater
House BX
House B1
Consum er Network B
BoosterStation
Basem ent
Industrialconsum erConsum er Network A
House A1
House AX
House A2
Elevated Storage Tank
Landscape
Booster
Treatment p lant
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Pressure Set point
From The Source
The VFD adjusts the pump speed based on a feedback signal from the pressure transmitter to maintain a constant pressure with changes in flow
Note: Booster pumps may also be utilised to overcome pressure loss in networks with e.g. significant elevation in the field.
Alternative system - pressure control with VFD
Water reservoir
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Water – Distribution
PRESSURE Benefits: Constant pressure with changing flow Elimination of water hammer Reduced water leakage Less energy consumption Less maintenance / lower whole of life
cycle cost
VFD controlled pumps replace water tower to maintain constant pressure, irrespective of demand
Flow
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Application examples
Ground water abstraction
Reverse Osmosis
Water distribution
Wastewater treatment
Irrigation
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Typical modern Wastewater treatment plant
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Typical Wastewater treatment plant (WWTP) process
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Typical energy distribution at WWTP
55%
10%
8%
8%
4%
15%
Activated Sludge
Primary P.S. Clarifier
Heating
Solids Dewatering
Raw Water P.S.
Other
28%
46%
12%
7%3% 4%
Energy
Staffing
Solids Disposal
Other
Maintenance Materials
Chemicals
Typical cost distribution at WWTP
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Benefits Exact air flow to match demand Energy savings (20% reduction in speed gives ~ 50% saving in energy) Constant pressure or temperature etc. Less wear (EG: Extends belt life) Reduced audible noise Parallel fan operation possible
Fans
Applications (E.g.)
Odour control
Ventilation
Cooling towers
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Application examples
Ground water abstraction
Reverse Osmosis
Water distribution
Wastewater treatment
Irrigation
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Irrigation
Applications
Lift station pumps (Level control)
Deep well submersible pumps
Transfer pumps
Benefits
Constant level with changing flow
Less water hammer / mechanical stress
Lower risk of pipe breakage
Potential energy savings
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Summary of benefits of VFD control
Energy savings (E.g. ~35% when compared to throttling valve)
Low in rush current / low torque surges = less mechanical stress (E.g.: prevent water hammer, gearbox damage, belt breakage)
Less water leakage due to lower possible operating pressure (I.e.: extend life of aging infrastructure)
Increased flexibility /improved system performance (E.g.: control to match actual demand & not design demand)
Advanced control & diagnostic interface possibilities (E.g.: SCADA)
Less maintenance / lower whole of life cycle costs
Environmentally friendly solution!
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•Dedicated VFD for all applications in Water, wastewater & irrigation
0.35kW – 1.4MW power range
Suit both constant & variable torque loads
Automatic Energy optimiser
Built-in pump control & protection
functions
Optimum ingress protection
High efficiency ( 98%)
Lowest cost of ownership
VLT® AQUA Drive
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Global focus
Our vision is to be recognized as the most dedicated supplier of Drives solutions in the Water & Wastewater & Irrigation sector world wide
Sales & service in ~100 countries, including India
~ 40 year track record
Dedicated product & organisation
Water Wastewater Irrigation Power generation Steam, hot water & gas supply Waste processing & recovery
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1000’s of Drives & Soft Starters in service
Water supply & treatment
RO / Desalination & recycling
Wastewater treatment
Pumping Stations
Irrigation
Power generation
District heating
Waste processing & recycling
Over 25 year track record globally & in Asia Pacific
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Danfoss can accept no responsibility for possible errors in printed material.
Please consult equipment design guides / manuals for specific details / verify data.
All images contained in this presentation are the property of Danfoss A/S or other parties where relevant & must not be copied. VLT ® is a registered trademark of Danfoss Drives)
Global References
Bisalpur Water Supply Project: Project aims to reduce dependence of Jaipur city on ground water resources. Under this project 400 MLD of raw water is pumped from Bisalpur Dam to Clear Water treatment plant at Surajpura.
Yamuna Interceptor project: Delhi Jal board.
Yen So Park is one of Vietnam’s most important development projects, Yen So Park entrails the development of a sewage treatment plant capable of treating 200,000m3 or half of Hanoi’s waste water per day. Energy saving using back channel cooling and installation space saving.
Pressurized system for Booster pumping stations in Bulgaria.
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Please consider the environment & use VFD for your next application
Thank you!
Danfoss can accept no responsibility for possible errors in printed material.
Please consult equipment design guides / manuals for specific details / verify data.
All images contained in this presentation are the property of Danfoss A/S or other parties where relevant & must not be copied. VLT ® is a registered trademark of Danfoss Drives)