Project Title

Conversion of DOL (Direct Online) run Process Water Motors to Variable Speed Control - (2010-IT5af)

Industrial Supervisor Mr. Kanagasabai Ravichandran - E&I Manager Company Name Merck Sharp & Dohme (MSD), Singapore Academic Supervisor Dr. Mark Ho, Prof. Andrew Nafalski Project Member Sundaram Suresh Kumar (110011324)
1

CONTENTS

Introduction Necessity of the Project Background of the Project Goals & Objectives Design Analysis Results Project Milestones Project Achievements Conclusion Question and Answers
2

Introduction
This Project aims to Convert Two Process Water

Pump Motors (110kW) from Direct Online (DOL)

Motor Control to Variable Speed Drive (VSD-PID) Control, to operate on an Efficient, Duty & Standby (Lead Lag Control), and Automate the operation of System.

Necessity of the Project

The Existing system was not an Energy Efficient in Design -Two Process Water Pumps was operating

continuously
When the load demand decreases or increases, the system cannot automatically sense the changes in process Conditions. Not Continuous Process Control system

Necessity of the Project

Not Reliable Control System - Frequent Operator Input / Interference was required

Remote Monitoring of Process conditions was not

available at Control Room The Operation of entire system was not Automatic Starting of Pumps and Opening of Suction, Discharge valves. No Lead (Duty) & Lag (Standby) Sequencer for the Pumps was available.
5

Background of the Project

Each of the Two Process Water Pumps/ Motors (110 kW 1500 m3/h) shall be operated by respective Variable

Speed Drive in Duty (Lead) Standby (Lag) Concept.

The System shall be Automatic Continuous Process

Control system
The Suction and Discharge Valve of respective pumps, shall automatically open before start of respective pump, and close when Pump is Stopped.
6

Background of the Project

The Variable Speed Drive modulates the Speed of Motor in accordance to load changes, maintaining a smoother

and Precise control of Pressure and Flow.

Pumps shall be started and stopped Automatically. Connected to Remote Monitoring Panel at Control Room for remote monitoring of Process conditions. Sequencer to alternate the Duty of Lead and Lag Pump to ensure equal tear and wear of both the Pumps.
7

Block Diagram of the System :

Pump Controller Unit

HMI

PID Controller

Variable Speed Drive (Pump A)

Variable Speed Drive (Pump B)

Pressure Transmitter Repeat Signal & Alarm Contact at Control Room

Suction & Discharge Valve On/Off Signal & Open Feedback Status Signal

Suction & Discharge Valve On/Off Signal & Open Feedback Status Signal

Flow Pressure Transmitter Transmitter (Vortex) Process (Process Water)

Motor-Pump A

Motor-Pump B

Goals & Objectives

Continuous Process Control System : Pressure Transmitter shall be used to measure Pressure of

Process, and forms input element of Closed Loop System.

The Variable Speed Drive (Output element) shall modulate the Speed of Motor in accordance to Pressure Setpoint Value at the PID Controller (VSD), maintaining a smoother and precise control of Pressure and Flow.

Faster Response Time : The System shall respond faster,

when the load demand varies, the PID Controller shall ramp up or down the Speed of the Motor, as determined by Setpoint.9

Goals & Objectives

Automatic operation of System : The new improved system shall automate the operation of

two pumps together with Suction and Discharge Valves.

Lead Lag Sequencer : The system shall alternate the duty selection of the Pump, ensuring equal tear and wear for the both the pumps. Remote Monitoring of Alarm : Any failure of critical components in system shall be indicated at Remote Annunciator Panel (Control Room), as an Alarm.
10

Goals & Objectives

Fail

Safe Design incorporated into design of System :

i) Variable Speed Drive / Pump Failure - The functioning Standby Variable Speed Drive Pump will start and ramp to meet the Setpoint (Pressure) to avoid Process upset. ii) Suction & Discharge valves Failure The affected

Pump will stop, and Start the Standby Pump/Motor. The

Valves are Fail-close type. iii) An alarm will be activated, at the Remote Annunciator Panel (Control Room), to notify the Operator.
11

Design Piping & Instrumentation (PID) Drawing :

12

Design Components of the System :

Variable Speed Drive (VSD) with PID (Proportional Integral Derivative) Controller Pressure Transmitter Motor (VSD Rated) Suction On/Off valves with Open Feedback Switch Discharge On/Off Valves with Open Feedback Switch Flow Transmitter (Vortex) for Indicating & Totaliser purpose
13

Design Components of the System :

Variable Speed Drive-ACS800 (ABB) The Variable Speed Drive Rectifier, DC Bus, and Inverter. consists of

Three phase current is fed to the Rectifier, which converts it to direct current (DC).

Input Voltage 3 Phase 415V AC Input Frequency 50 Hz Output Voltage 3 Phase 415 V

The DC voltage is fed into the DC Bus, which filters the pulsating voltage. The Inverter unit then connects each motor phase either to the negative or the positive DC bus according to a certain order.
14

Design Components of the System :

Pressure Transmitter- Emerson 3051C
The Differential Pressure Transmitter measures pressure using Capacitive (Cell) Sensor, any change in pressure at Sensing Diaphragm is sensed by change in capacitance between two capacitor plates.
Electronic Unit

Capacitor Plates

The microprocessor detects change in signal at the capacitor plates, and transmits 4-20mA DC Current Signal to the VSD.
Pressure 0-12 Barg Output mA 4-20mA Operating Voltage 24VDC Accuracy 0.075 % Span

Sensing Diaphragm

Fill Fluid Cell Sensor

15

Design Components of New System :

On/Off Valve - Automax Valve assembly consists of Valve Actuator, Solenoid valve, and Limit switches. The Valve Actuator is Rack & Pinion, Spring return type actuator.

Operating Voltage 24 V DC Suuply Pressure 6 Barg Fail Safe Close

The VSD-PID Controller energises a 24 V DC Voltage to open the Suction & Discharge Valve.

16

Design Components of the System :

Vortex Flowmeter Yokogawa YF102

Meas Flow Output mA Operating Voltage Accuracy

0-3000 m3/h 4-20mA 24 VDC 1 % Span

Vortex flowmeter consists of Shedder bar embedded with Piezo-electric crystals (Bluff body) intruded at pipe, which creates vortices to be shed alternately.
Electronic Unit

Piezoelectric Crystal

Vortices generate an ac voltage at Piezoelectric transducer, whose frequency is proportional to fluid velocity. The electronics microprocessor transmit 4-20mA dc Current Signal to the VSD.

Flow

Pipe Flow Element (Bluff body) Vortices

17

Analysis Operation of System :

Variable Speed Drive & Process Water Pumps in Operation

Video

Video
18

Analysis
Comparison Direct Online (DOL) Control vs. VSD Operation :
A

1500 1000
m3/h

Ampere 390

Flow 1500 m3/h

Ampere 198
Flow

500 0 Ampere Flow

DOL 390 1500

Ampere

VSD 198 1500

19

Flow 1500

m3/h

Analysis
Process Water System Variable Speed Drive
Pressure Setpoint at 6 Barg Pressure Setpoint at 5 Barg

Speed 2500 rpm

Flow 1250 m3/h

Flow 1500m3/h

Flow Ampere Speed

1250 165 2500

Flow Ampere Speed

1500 198 3000

20

Speed 3000 rpm

Ampere 165 A

Ampere 198 A

Analysis Challenges :
During Tie-in / Integration of the New System to the

Existing Process partial tie-in (with One VSD and

One DOL Pump) was done initially, and later

Completely Upgraded to two VSD run Pumps.

Project Budget Constraints

21

Results
Pump Sequencer-Runtime Projected Statistics :
5000
hrs hrs

Pump A 4896

1000 0
Pump A Pump B

DOL Runtime hrs 4896 3864

Pump A

Pump B 3864

VSD Runtime hrs 4381 4383

Pump A 4381

Pump B 4383

H 4000 O U 3000 R 2000 S

hrs

hrs

Pump B

22

Results
Process Water System Reliability :

DOL 65 %

Reliability % / Year DOL VSD

DOL

65 84
VSD
23

VSD 84 %

Results
Projected Energy Cost Saving :
Total Saving VSD

DOL
DOL AMOUNT (SGD) KWH/YEAR 468643 2130193
KWH/YEAR

VSD 237926 1081483

AMOUNT (SGD)

Total Saving 122916 1048711

24

Results
Man-hours (Operator Interference) to Operate the System

DOL 286 hrs

H O U R S

Manual / Operator Interference hours / YEAR DOL VSD 286 92

25

DOL

VSD

VSD 92 hrs

Project Milestones

26

Project Achievements
Operate in an Energy Efficient, Reliable and Fail-Safe Design environment. Equal Duty & Running time hours ensuring equal tear and wear of parts for each of the Pump. Automatic Operation of Suction and Discharge On/Off valves and Total System. Load variable PID controller enables smoother and faster control of the process water pumps. Implementation of the project in timely manner and as per project schedule Total Cost Saving of SGD 122916 / YEAR
27

Conclusion
The conversion of DOL to VSD-PID-Lead Lag Controlled run Process Water pumps was completed as per project schedule and specifications.

28

QUESTIONS & ANSWERS

29

THANK YOU

30