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The use of mass of tonnes of carbon is an irrelevant criteria when it comes to our
customers. This may be the populist criteria that our politicians have latched onto
however it is not as flexible an approach as other considerations. Our customers
measure performance in terms of costs, i.e. dollars. The more we save the end user by
improving efficiency then the more dividends can be distributed to the shareholders.
This presentation is aimed at mechanical engineers and their responsibility to deliver
the most efficient plant at the least cost. Many government departments pay lip service
to Whole of Life costs. Although tender documents may require such analysis , this
rarely happens. The low cost tender is accepted and thus the most efficient plant is not
always installed. This leads to many problems in the cost of operation of a pumped
system.
1
Why Are VFDs Specified for Pumps
Process conditions are not Electrical supply restraint-
fully developed Soft starting
Variable process conditions Braking- Dynamic or hold
Poor pump selection Unlimited number of starts
Future process upgrades and stops
Energy efficiency-Reduced Waterhammer mitigation-
operating cost Fatigue
Prior art-Industry practice Ignorance -Engineer having
Over-speeding a pump to no understanding of other
reduce pump frame size process control solutions
This slide presents some of the common criteria used in determining why a pump
should be fitted with a VFD. It behoves the mechanical engineer to spend time and
effort to determine accurately the process conditions , electrical criteria and any other
matters that impact on the need for a VFD in terms of varying the speed of a pump.
When you have completed this presentation you perhaps should revisit the reasons why
you may have selected a VFD. It is all too easy to change the fixed speed drive to a
variable speed drive. A simple change on the P&ID has significant short and long term
effects.
It should be considered that statistical evidence here and in the USA is that the prime
cost of a pump is approximately 12‐15% of its Whole of Life costs. The remainder goes
in maintenance and energy costs. The energy costs are the largest proportion. Where a
contractor has the year and a day mentality the Capex will outweigh any considerations
for efficiency. That is why modern contracts impose penalties for exceeding predicted
energy requirements.
This presentation will show you that VFDs do not save energy in many cases. In fact they
consume more energy than other solutions. All analysis should be on the basis of wire to
water. i.e. The kW‐hrs to move x m3 of fluid. Not the energy shown on a pump curve or
predicted by the Laws of Affinity.
2
Pump Speed Control Solutions
Mechanical Electrical
Cone & disc variator Variable Frequency Drive
Cyclic variator Eddy current drive
Vee belt & pulleys Two speed motor
Gearbox Direct Current drives
Internal combustion engine Slip ring motors
Scoop control fluid Multiple pole motors
couplings Relay pulsed motors
Hydraulic drive
Varying the speed of a pump can easily be achieved by means other than a VFD. This
slide gives you some indication of those alternatives.
Soft starters or VFDs are often used to overcome the inadequacies of a power supply.
The voltage drop where the pumps are long distance from the sub station is a case in
point. Once such an installation has to have a VFD then that VFD can be used for other
demands. However it is often more efficient to have a parallel contactor in the SCA.
Once the pump has started then the parallel contacted can be closed and the losses
associated with a VFD will be avoided.
Some of the mechanical options provide as good if not better variable speed solutions
to the VFD.
3
Process Solutions-Alternatives
Pressure, temperature Change pump impellor
or flow control valves diameter
Bypass valves Alternate pump type
Larger suction tanks or Multiple pumps
sumps Different sized pumps
Holding tank
Pump for longer
periods
Stop/start controls
As an alternative to varying the speed of a pump there are other process solutions
described in this slide. Have you as the designer considered these solutions?
A control valve or bypass can in certain circumstances use less or an equal amount of
energy than an inefficient VFD. The Capex will certainly be lower when you consider not
only the cost of a VFD but the real estate (switchroom), screened cables, impact on
motor design and life, harmonics etc. A reduced size impeller and a pump operating at
100% BEP is far more efficient than a VFD solution.
The larger suction tanks will enable the pump to operate over a varied range. As the
head in the suction tank increases the pump naturally delivers more flow as the
operating point drops down the HQ curve. Look at the following graphs and note the
system curves. If the system curve was lower on the graph because the suction tank is
at a higher level you can see the increase in flow.
A larger holding tank can allow a pump to operate in a stop/start regime where it
operates at 100% of best efficiency point (BEP). This can be combined with pumping for
longer periods at a more modest flow rate.
The pump impeller can be reduced in diameter and thus draw less power. Such a change
can keep the performance at 100% of BEP and thus not use the energy required to
operate a VFD.
An alternate pump type may be beneficial. A progressive cavity pump or positive
displacement pump can be far more efficient than a centrifugal pump for viscous fluids.
Constant flow rate at relatively high head can be delivered by a positive displacement
pump.
4
Th f diff i d li h f fl id h di l fl
Pump Considerations
This section of the presentation will talk of the pumps needs.
5
Pump Selection-The Issues
Duty point(s) Casing pressure rating
Static head (Hs) Efficiency
Friction loss (Hf) Specific speed
Dead head Moment of inertia
Transients Curve shape
Design factors Stability over range
- head Best efficiency point
- flow 1st Critical speed
- NPSHa
These criteria are typical of the points that need to be considered by the designer.
Software is available to model all the scenarios to be expected in a system. The data
sheets provided by the Hydraulics Institute or API 610 can be used to specify a pump.
They also act as a memory jogger for the specifying engineer.
Modern pumps and motors have been designed using FEA to minimise the costs to the
manufacturers. One of the downsides is that the moment of inertia has been reduced.
An impact is that to mitigate a pressure transient it is often necessary to increase the
MOI. To do this flywheels are added. Such is the irony of modern design.
The curve shape needs to be considered when it comes to parallel pumping. The
specifying engineer needs to consider that the HQ curve should be constantly rising to
shut off. If the curves is drooping or more complex instability in parallel operations may
occur. The software mentioned above allows this evaluation.
When it comes to selecting a pump there exists tools on the Internet offered by
different pump manufacturers. www.sulzerpumps.com has a very professional offering
that can be used to determine the cost of a pump over the life of the pump. Other
manufacturers such as Goulds, ITT Flygt, Flowserve, ABS also provide such software.
There is often the case where is motor is operated at a greater speed than the nominal
design speed based on the number of poles. One industry does this as the pumps are
made in super duplex stainless steel alloy. The cost of the pump itself is very high and
thus operating at a higher speed means that a selection may be made of a lower cost
efficient pump. The moment of inertia is not greatly affected as the motor represents
90% of this criteria. There is a concern that the pump may finish operating at the 1st
critical speed and vibration may be a concern. There is also a limit o the speed such a
motor can operate. Some designers have resorted to using 60Hz motors. This of course 6
l i i l h di A li d SE A i ll 50H
System Design-Issues
Software allows the Motor/VFD Efficiency
analysis of systems Wire to Water kW
Excessive design The original Affinity
factors used Laws are based on
Pump suppliers design systems with no static
factors head
New vs. Old pipe Affinity Laws overstate
friction losses energy savings
Pipe wall /lining Revise the 2nd Affinity
tolerances Law for Minimum Flow
Refer to www.pumpsystemsmatter.org and download PSIM. This software is a cut down
version of AFT’s Fathom. If this software proves valuable then invest in Fathom at
www.aft.com. For transient analysis look at AFT’s Impulse.
It has been a common mistake where excessive design factors are added to a pump’s
performance specification. How often does a junior engineer do the calculations and the
checker or senior engineer add a factor for safety? This results in oversized pumps and
motors. This impacts on the efficiency of the whole unit. It is one of the major causes of
the retrofit of a VFD. Two wrongs do not make a right, The pump body and /or impeller
should be revised. Adding a VFD ensures even more energy is wasted in such cases.
Whatever factors you believe are necessary rest assured that the manufacturer of the
pump also has some factors that may result in the pump over performing. These lead to
inefficiency as the performance does not lie on the 100% BEP point. The manufacturer's
tolerance can be specified by use of Hydraulics Institute criteria, API 610, ISO 9906 or AS
2417 criteria. The mechanical engineer must understand what these criteria mean when
specifying the pump.
Often pumps are selected for systems where the design life may be 25 or 50 years. As
pipe materials such as those lined with cement may deteriorate over this period, the
worst casse scenario is used. One of the problems is that the system friction loss will be
lower when the pumps are commissioned. Thus the system curve at the start will be
less steep. The pump will operate at a different flow rate and will be at a different pint
on the HQ curve. It may be that in the early years a reduced diameter impeller should
be fitted to keep the performance at the BEP. The pipe wall may not deteriorate to the
extent predicted by the codes and standards. Not all systems are the same. The
boundaries of a system should be investigated to ensure the pump selected meets the
criteria. Only then should a VFD be considered.
7
Pipe wall thickness and lining thickness can impact on the design criteria for head loss
Pump Curve #1
In the pump performance graph above a system with a high static head is shown. The
red dotted lines are set at 60 and 85% of BEP. The powers represented are the shaft
powers of the pump. This selection of a pump is not the best as the duty point is not on
the BEP.
If the suction tank went to a high level the system curve would be lowered. The flow
would increase and the motor power would increase but the efficiency would improve.
If the flow rate under these circumstances was to remain the same then by reducing the
speed would achieve this efficiently compared to a flow control valve. This graph is used
to illustrate the point that if the duty point is controlled in the range of 60 to 855 of BEP
the use of a VFD can be justified.
When the duty point is greater than 85% of BEP it can be seen that the slope of the
power curve becomes closer, in terms of being parallel, to the HQ curve. This point is
made as it explains the rule of thumb presented later that where the operating pint is
greater than 85% of BEP a VFD does not provide the speed control effciently comapred
to other forms of control.
8
Pump Curve #2
This HQ graphs builds on the point made in the system Pump Curve #1 previously
shown. It illustrates an operating point above 85% of BEP. The shape of the pump curve
is near parallel to the pump power curve. Hence where the duty point follows the pump
curve there is little power change and so a VFD will not deliver energy savings of
significance. In fact the energy overall will increase.
9
Existing Pump Oversize?
This is a common pump dilemma that VFDs are used
to solve but the VFD does NOT save the energy! The
credit goes to the reduced head/flow requirements.
VFD suppliers offer the retro-fit of a VFD to change
pump speed to meet reduced process conditions
Change of pump or impellor reduced diameter
achieves the necessary reduced flow, hence power
A flow control valve achieves the necessary reduced
flow and maintain the best efficiency point (BEP)
A multiple small pumps and motor could be cost
effective
The reduced energy requirements of a system result from reducing the kW‐hrs to move
a certain mass of fluid in time. The VFD in itself does not save energy.
Retro fitting of a VFD may appear to save energy at the ammeter. However all the
energy used has to be taken into account and this includes the embedded energy in the
VFD cubicle, screened cable and other devices. With today’s engineer having to focus on
sustainability the criteria need to be included in the analysis.
A change of pump impeller or even the pump can result in a selection that is close to
100% of BEP. No VFD can better such a selection.
A flow control valve can achieve a process solution for less Capex and Opex than a VFD
for systems with moderate static head and where the speed is only reduced to an
equivalent duty point at 85% of BEP. When an existing pump is oversized it is relatively
easy to bring the operating point back to this level of Bep with a control valve.
The installation of multiple pumps or different size pumps can be effective in providing a
solution to meet variable process conditions. The engineer should remember that the
pump curve for a parallel operating pump should be constantly rising to shut off.
Drooping or irregular curves are not suitable for parallel pumping in most applications.
10
Pump Curve #3
This curve shows a system with no static head as for a chiller recirculation system for
instance. The pump was incorrectly selected and delivers 1000m3/hr instead of
800m3/hr. Follow the system curve down to 800m3/hr and it can be seen that a 291mm
impeller will deliver the correct flow. If the process duty should be 800m3/hr instead of
that shown as 1000m3/hr then a reduced impeller size will give the same process result
as adding a VFD drive but will be far less costly.
Both a VFD and a reduce impeller will save pump motor energy. It is only when there is
a large change of demand that may take the flow rate down to below 85% of BEP that a
VFD becomes justified. Each system is different and should be thoroughly modelled and
analysed to determine Whole of Life costs.
11
Pumps using VFDs- Considerations
Energy savings with a VFD occurs for duties
reduced to between 60% to 85% of the BEP.
Where duty is reduced to only 85% of BEP, a
control valve energy demand is less than that for
the combined VFD installation inefficiencies
Wire to water energy kW-hr per m3 delivered
should be the criteria used in assessing a VFD
application
VFDs offer little benefit for systems with more than
50% static head
VFDs are ideal for closed systems with varying
process duties-no static head
The points made in this slide emphasise what has been discussed in the previous slides.
For closed head systems, with no static head, the VFD provides a beneficial method of
modulating the flow over a wide range. This type of application is often found in the
building services industry such as chiller recirculation pumps. Diurnal and hot/cold days
demand varies considerably. Thus, the variable speed pump can be used. Multiple
pumps with only some using a VFD are sometimes used to save even more energy.
Whatever is being considered the wire to water energy usage in pumping each m3 of
fluid should be considered for the life of the plant.
12
Electrical Design Considerations
Although this presentation is aimed at mechanical engineers there is a need to
understand the electrical engineer’s criteria when a VFD is considered for an
application. You will see from these matters that a VFD is not a simple device and there
are a number of important criteria that affect the plant design. The mechanical engineer
may consider that design costs have been reduced by using the flexibility of a VFD.
However the increased electrical design costs will far outweigh these savings.
Believing that leaving it to the commissioning engineer with the flexibility to change
flows does not deliver to the end user the most efficient cost effective solution. It also
burdens the commissioning engineer with a crisis to be resolved at the time the plant is
being debugged and brought on line.
13
What is a Variable Frequency Drive?
Legacy- < 600Hz Today >20kHz
BJTs (Bipolar Junction IGBT (Insulated Gate
Transistor) Bipolar Transistor)- these
SCRs (Silicon Controlled offer the benefits of higher
Rectifier) frequencies and increased
GTO (Gate Turn Off
efficiencies
Thyristor)
This slide shows the devices that comprise a VFD. On the left are the legacy devices.
Improvement in technology has resulted in the use of IGBTs. These may be more
efficient but they introduce challenges to older types of motor. Discussed later in this
presentation are the impacts on motors and electrical supply resulting from these high
frequency devices.
The VFD converts the A.C. supply to D.C. Then the IGBTs fires pulses at high frequency
that replicate the sign wave of an A.C. supply. The shape and frequency of these waves
result in the variable speed of the motor.
14
Electrical Factors to be Considered
Voltage (LV, MV or HV) Overspeed capability
Power Braking requirements
Line & load side harmonics Power loss
Load torque Ride through time
Speed range Audible noise
Speed regulation Length/type of cable
Failure mode Power factor correction
Acceleration/deceleration Altitude
times Motor, insulation and VFD
Efficiency life
These are the factors that the electrical engineer has to consider when a VFD is
deployed for a pump application. In specifying a pump the mechanical engineer needs
to understand these requirements. Communication with electrical and process
engineers is required so that all parties understand the issues. Further the supplier of
the pump, motor and VFD must have a common understand of the criteria.
The engineering team has to provide a full functional description so that the PLC
programmer and system integrator can determine the software code. Further this
document is used by the hydraulics engineer to undertake the final transient analysis to
cover all the scenarios the system is expected to operate under.
Negotiations with supply authorities is required to ensure line side harmonics are
acceptable.
15
Cable
The cable used for a VFD application is important.
Firstly, the length of cable is important. As the length increases above 25m it provides
an inductive load in parallel with the motor. This can contribute to the peak voltages
and is detrimental to the life of the motor.
Secondly, the cable needs to be screened to avoid the electrical interference with
instruments and other drives. If the VFD is being retro‐fitted to an existing motor then
the cost of removing an existing cable, and replacing same with a new screened cable,
needs to be taken into account. Removal of old cables in cable ladder or buried either
directly or in conduits is a challenge. Copper, as it ages, hardens and even small cables
cannot be readily removed and are often abandoned.
Refer to WEG motors website www.weg.co.nz The Unseen Truth Behind Motors fed by
Inverters and technical papers on the Toshiba website toshont.com/vfdapp.htm for
more details on these electrical subjects.
16
Motor Considerations
Now we will consider the motor, whether new or existing, that needs consideration. It
may be that a special motor is necessary to be compatible with a VFD. It may be that an
increase in motor size is required to handle the new duty.
17
Bearing Damage –Induced Shaft Voltage
Induced Shaft Current Types
1.Conductive mode bearing
current-low speed , good
conductivity.
2.Discharge mode bearing
current-higher inverter
output frequencies-The
capacitive voltage builds up
until it is able to break down
the dielectric resistance of the
grease.
Since the 1920’s the generation of eddy currents in shafts has been known. The advent
of the VFD has resulted in motors suffering damage to their bearings in the event that
the non drive end bearing is not insulated. By insulating this bearing the eddy current
loop is interrupted. Shaft brush bearings are also used to dissipate the current.
The graph in this slide shows the voltage spikes that can occur when there is induced
current but no insulated bearing or shaft brushes.
Refer to WEG motors website www.weg.co.nz The Unseen Truth Behind Motors fed by
Inverters and technical papers on the Toshiba website toshont.com/vfdapp.htm for
more details on these electrical subjects.
18
Motor Cooling
Below 25hz motor fan speed will not cool motor
Supplementary fan required
Added cost of drive, cable, SCA, controls, access
and maintenance
Reduced reliability
An electric motor has a mechanical fan for cooling. When the pump is slowed using the
VFD there is a practical limit where the fan can no longer provide the cooling air
required. In Australia our average temperatures are generally higher than Europe and
Japan where motors have been designed. Therefore, there may be a need for a
secondary fan to provide the cooling.
Certainly, below 25Hz a secondary fan is a near certainty. A secondary fan not only adds
to the Capex but needs cable and an SCA in the switch board. The energy use needs to
be added to the Whole of Life cost of the installation.
Where a fan cannot provide the cooling a water cooling systems is often provided
especially for large motors. Water cooling may also be used for the VFd themselves.
This adds complexity to the system in both Capex and Opex terms.
19
Efficiency
Published motor efficiency
data is based on a pure
sinusoidal voltage
The high frequency
harmonics created by VFDs
increase copper and core
losses decreasing the
efficiency of the motor
Materials behave differently
under these operating
conditions resulting in a
higher efficiency drop when
fed by VFDs.
Published motor efficiency data is based on a pure sinusoidal wave form. Even modern
VFDs do not produce perfect sine waves. The motor operates less efficiently as a result.
As the motor manufacturer does not know what form of sine wave the VFD provides
they do not publish data on their motors for VFD applications. In addition the study of
motor data at reduced load will show that the motor efficiency decreases as the motor
is run at a lower speed. This does not occur when other variable speed or process
solutions are selected.
Harmonics are generated by the VFD, not only in the cable to the motor, but also on the
supply side. The 3rd, 5th, 7th and 9th harmonic affect the wave form. This affects the
efficiency of the motor. Refer to
www.toshont.com/ag/vfdapplication/ag_14_harmonics.pdf
On the supply side the authority cannot define the harmonics that exist or their range.
Thus the electrical designer is in a difficult position to design devices to eliminate or
balance out the harmonic interference. However the authority will have in place
regulations as to the stability of supply.
It should be remembered that the materials that make up the motor will behave
differently under these conditions. Therefore the motor efficiency is going to be
affected.
20
Current
A higher r.m.s. current to supply the same
output (about 10% higher)
Increase in motor operating temperature
On average, VFD fed motors will have a
temperature increase of about 15°C, at rated
speed and load
A higher r.m.s. Current is provided to the motor using a VFD. This increases the motor
temperature. The increase in motor temperature affects the design life of a motor. This
is particular so for a conventional motor not designed for use with a VFD. Thus if fitting a
VFD to an existing pump set to correct a poor selection may involve the cost of a new
motor that may be of a special design.
21
Noise Level
Due to the harmonics, the motor noise level will
increase when it is operated using a VFD
Experience shows that the sound pressure level at A
scale at motor rated speed is increase by anything
between 2 and 15dBA with a VFD
This “ extra ” noise level depends mainly on the
inverter switching frequency and harmonic
content.
Noise mitigation costs increase
Noise level in a motor driven by a VFD is impacted. This noise may not be in the audible
range but will contribute to the overall sound power. Statistics on VFD drives indicate
that the increase in noise is in the range of 2dBAto 15 dB A. When considered that to
double sound power a 3dBA occurs.
This increase in noise may result in a need for a noise enclosure which not only impacts
on the Capex. It also may impact on the pump room design and the increase in
maintenance time to remove the enclosure or for additional hours to work in cramped
conditions.
22
Motor Design Life
Standards Damage
IEC 34-17 and DIN VDE 530 Repeated voltage peaks
VFD voltage peaks (Vp) < 1,000V breakdown die-electric
and dV/dT <500 V/μs but VFD strength of insulation
motors are subjected to 5000V/μs Die electric strength reduced
and 1,500V by humidity & temperature
Voltage peaks depend on carrier Corona & partial discharge
frequency destroy motors
dV/dT affects the insulation Standard motors design life
between turns, the high voltage reduced by up to 75%
spikes affect the insulation between Standard insulation varnish is
phases and phase to ground NOT acceptable
It has been seen that there are a number of factors that impact on the motor . These all
go to reducing the design life of a motor. In particular if the motor is not specifically
designed for VFD use the design life may be substantially reduced. Even with soft
starters this has proved to be an issue worthy of consideration.
Conventional varnishes used in electric motors cannot withstand the high peak voltages
that occur in VFD driven motors.
Refer to WEG motors website www.weg.co.nz The Unseen Truth Behind Motors fed by
Inverters and technical papers on the Toshiba website toshont.com/vfdapp.htm for
more details on these electrical subjects.
23
Commercial Considerations
As outlined in the introduction, apart from the ethical duty to the common good ,the
mechanical engineer has an obligation to their customer. This may be the contractor
who has engaged the consultant but overriding that is obligation to the law, the
authority or end user. The common denominator is the commercial issues involved.
These may be competing with quality and time. The mechanical engineer is obliged to
provide a safe and inefficient pump installation. To do this an understanding of matters
electrical and process need to be considered with the mechanical.
It is easy for an experienced engineer who has paid off the mortgage, owns the family
home and is looking forward to retirement to be ethical. That person is not threatened
on a day to day basis. However the younger engineer has to be respected by their peers
and should always hold their technical acumen above commercial affairs when they feel
compromised. After all, the project manage invariably knows far less than you and you
should not be made to accept a situation you believe is wrong. You may need to
withdraw from a project. In the long run you will be more respected for your stand. The
returns from the court case as an expert witness will certainly make up for any short
term loss.
24
Costs of a Pump/VFD Installation
Capex Opex
VFD componenets with a VFD inefficiency ≤ 95%
design life < 10years Inefficiency of motor
Larger switchroom Supplementary fans
Increased air conditioning Special motor spares
Screened cable Air conditioning energy
Harmonic protection Reduced life of motor
Special motors Spares for VFD
Supplementary fans Spares costs oversize pump
Increase in noise mitigation Risk & reliability (FMECA)
Increased design costs Increase in noise
The criteria listed in the presentation are detailed below:‐
Capex
The components in a VFD cubicle generally have a design life of 10 years. When it comes
time to maintain a VFD the components may not be available. Technology in this sphere
is fast developing. Manufacturers do not continue to manufacture components forever.
Other speed control or process solutions have longer design periods. This particularly so
for legacy proven technologies such as control valves.
The VFD cubicle can be sizeable and will occupy room in a switchroom. There is a cost
for this real estate. There have been cases where the switch room has proved
inadequate in size during the design phase and a new location has had to be provided.
This has increased the length of cable runs and thus the impact of other parameters
previously discussed that lead to inefficiencies and reduced life of components. Just
increasing the size of a switchroom increases the length of all the conduits, cable
ladders, mass of concrete, building materials and air conditioning for such a building.
Increases in switch room size and the heat generated by VFD cubicles leads to increases
in the size of any switch room air conditioning system. Many outback or even sea board
plants have air conditioning to cater for the extremes of temperatures in Australia.
Water cooling of a VFD adds to cost particularly if secondary heat exchangers are
required with a whole reticulation network. Remember that electronic components
generally have a temperature limit based on northern hemisphere conditions. These
may be as low as 40°C. This is not appropriate for our environment.
Previously we have discussed the need for screened cables. This imposes a cost burden
on the use of VFDs. It is amplified if the old cable needs to be removed.
25
Commercial-Other
Engineers who use suppliers to select pumps or process
solutions lose engineering control of the procurement
process
Pump suppliers do not necessarily know, or care, about
the process vs. electrical requirements of the
VFD/motor interface-divided responsibility
String testing motor/pump/VFD is difficult during the
contract period because of :-
-time
-manufacture location of components
-responsibility of the other parties equipment
-packing/unpacking/re-packing
There is growing tendency for consulting engineers to avoid risk by providing
specifications that require the pump supplier, motor supplier or variable speed drive or
process control solution supplier to take increased responsibility. The design of pump,
motor & VFD combination is complex and cannot be subcontracted to one supplier. The
engineer is responsible for system design and cannot abrogate those responsibilities.
It is unsure if this trend is fuelled by a risk aversion on the part of the designer or purely
that our universities are not producing engineers with the practical knowledge to
understand complex systems such as variable process conditions, Whole of Life costs
and total energy requirements. Certainly the VFD as a solution to varying process
conditions has been oversold to the market. There are even credits to companies for
installing VFDs without too much analysis. It is all too easy to leave the final process
determination to the field during the commissioning time. All this does is delay the
commissioning at a time when practical completion is required and time is of the
essence.
Individual suppliers that are cost driven have their own risk aversion agendas. The low
cost selected supplier even more so. That is when problems arise at the interfaces
between motor, pump and VFD. The supplier will stand behind the limited information
given to them and will not have any particular cares about your problems, the other side
of the fence. Certainly they will not be concerned about any perceived energy savings or
embedded energy that may be considered. Certainly, the VFD salesman will be hard to
find in the event of a dispute.
To demonstrate this dilemma, consider the testing of motor, pump and VFD. Many
authorities, particular those in the water industry, want the whole assembly tested as a
string. Now the pump may be made in Brazil, the motor Japan and the VFD in Brisbane.,
Australia Who is going to be responsible for shipping to the place of testing, unpacking ,
operating, repacking and re‐shipping the components to site. Who fixes any failures
when under time pressure a failure occurs on the test bed? Who is then responsible 26
f i i ll i h i d f ? Thi ll i h h diffi l f if i
Conclusions
Engineers need to specify all operating & electrical conditions to
pump, motor & VFD supplier
Invest in the mechanical engineering and specify correctly
Future operating conditions may not occur. If they do they can be
met with alternate solutions
VFDs do not always save energy, Capex or Opex
VFDs do not avoid transients from power loss
VFDs provide a suitable solution to some pump operating
conditions but should not be considered a panacea
“You just can't ever beat the energy efficiency of running a
properly sized pump at 100% BEP rated flow”.
Mechanical engineers have a poor understanding of electric motors
& VFDs and fail to communicate with process or electrical
engineers
A mechanical engineer has to fully understand the design process in order to specify
correctly to all parties the needs of a VFD driven pump. A responsibility matrix is a first
start so that all parties know who is the responsible party. The interfaces need to be
understood and even the other engineering discipline’s criteria need to be considered.
Thus, there is a need to invest in the time and effort in upfront engineering before
blithely changing a fixed speed pump to a VFD driven unit. Have you over specified the
pump? Do you know the range of conditions resulting from all the variables? Are you
using boiler plate templates from the Hydraulic Institute or API 610 to communicate the
pump details to the supplier? Have you checked the selection using the pump suppliers
software? Have you considered Whole of Life costs and satisfied the operator? Is this
the best solution for the long term design life of a facility?
Pumps may be oversized or fitted with a VFD because of some perceived future process
condition(s). These invariably never eventuate. In fact it is better to not allow anything
but the space for future needs on this basis alone. The worst solution is to use a VFD
and expose the operator to significant energy costs for something that may run for
longer than expected or never happen. Additional pumps or different sized pump
operating at fixed speed may be the ultimate solution that delivers efficient energy
usage.
VFDs are the not the panacea made out by this VFD industry in providing lowest wire to
water energy requirements for all pump applications. They almost always cost more in
energy terms to operate compared to other solutions. The long term effect on design
life of other components needs to be considered.
A common myth promoted by one VFD manufacturer was that a VFD will avoid
transients. Well a VFD does not operate when there is a loss of power. This is when the
most challenging hydraulic transients occur. There is a point though that the VFD will 27
stop damaging fatigue from stopping and starting when there are transients in a system
Questions
Questions asked:‐
1.Does a system in building services need a VFd and pressure regulators downstream of
the pump where there is little static head. The answer is no and it would appear the
system in question has been designed by someone who does not fully understand the
total system.
2.In a sewage pumping system where the flow rate may change and the surface
condition of the pipe may vary is a VFD justified? Sewage pumping stations are a special
case as slime build up and blockages can impact on the system losses. In addition there
are diurnal flow rate changes. Sewage pumping stations are generally remote from the
sub station and VFDs are provided to stop in rush currents and voltage drop on the
supply side. Therefore when a station is equipped already with a VFD it makes sense to
use it to stop fatigue, overcome slimes build up and cater for diurnal fluctuations.
3.Is a multiple system with integral gas accumulator a better solution for variable flow
rates than a VFD. This type of installation is common in water supply systems for plant
water. The diurnal flow rates change and there is a need to balance flows efficiently.
Those system are usually skid mounted and are available from Grundfos, Lowra and
other multistage pump suppliers.
4.It is common for a specification to require a high level of technical understanding
however all to common the bids received have a high level of departures. What can the
engineer do about such things when under pressure to accept the lowest bid? The
engineer has an ethical duty to serve the end user with a technical solution that meets
the Whole of Life cost criteria. Therefore ,in the event of such conflict the engineer
should withdraw from the project.
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Useful links
This presentation was by
sulzerpumps.com
Geoff Stone
geoffrey.stone@yahoo.co.uk mcnallyinstitute.com
eng-tips.com
Tel 0402 35 2313
Or nidi.org
02 8850 2313 pumpsystemsmatter.org
aft.com
toshont.com/vfdapp.htm
virtualpipeline.spaces.live.com
canterburyengineeringassociates.com
The links above offer a multitude of good material in respect of pump applications.
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