Energy efficiency in Water pumping

systems:
Variable Frequency Drives (VFDs) and
Efficient Electric Motors

Energy Efficiency
 Index

1 What is EnergyLab?

2 Introduction

3 Control Methods

4 Analysis

5 Conclusions

6 Applications

2
1 What is EnergyLab?
What is EnergyLab?

EnergyLab is a research centre specialized in Energy

Efficiency and Sustainability
We have top private and public partners warranting our
stability and strategic growing prospects
We look forward to build up a leading team of professionals
interested in helping us to carry out this project and benefit
from belonging to a cutting-edge centre

3
1 What is EnergyLab?
Our mission and vision

Mission Vision

Identify, develop, promote and A Centre with international

disseminate technologies, reputation specialized in boosting
processes, products and Energy Efficiency and
consumption behaviors that Sustainability, with the ability to
enhance Energy Efficiency and guide, coordinate and lead
Sustainability among industry, innovative initiatives and project
transport, building industry and impacting on the society, the
among society overall economy and the environment.

WHAT WHERE HOW WHAT FOR

IDENTIFY
INDUSTRY
SECTORIAL APPROACH ENHANCE
DEVELOP TECHNOLOGIES ENERGY
BUILDING
PROCESSES INDUSTRY Energy Textile ind. EFFICIENCY AND
PRODUCTS Automotive Wood ind. SUSTAINABILITY
Building Food ind.
PROMOTE HABITS SOCIETY Fishing ind. Other industries

DISSEMINATE TRANSPORT

4
 What is EnergyLab?
1 Our goals and services

Goals
Goals Services
Services
What for

Stimulate the continuous market penetration
of new products, processes and technologies ENERGYLABS VALUE CHAIN
in the field of Energy Efficiency and
Sustainability
CERTIFICATION

Identify, stimulate and develop business
opportunities in the field of Energy Efficiency
and Sustainability
EDUCATION

TECHNOLOGY APPLIED DEMONS-

WATCH R&D TRATION

Build up and coordinate a wide network of
clients comprising top companies and
DISSEMI-
research institutes of excellence in Spain and NATION
worldwide

Raise multiple sources of income and STUDIES

financial sources from public and private
funds, that assure economical stability and
sustainability in the mid term

Why

5
 What is EnergyLab?
1 EnergyLab's technological strategy is committed to the
penetration of advanced technologies ...

feedback

GOAL:
MORE ENERGY
Applied Research & Technology Validation and EFFICIENT AND
Development Market Penetration SUSTAINABLE
TECHNOLOGIES
AND PROCESSES

Analysis and Definition of Standards

Define ++ Develop
Define Validate ++ Exploit & Transfer
Develop ++ Validate

6
 Who sets up EnergyLabs project
1 EnergyLab is developing from its private and
institutional trustees ...

Private
Companies

Public
Institutions

Universities

EnergyLab
EnergyLab was
was founded
founded on
on September 12thth 2008
September 12 2008

7
 Who sets up EnergyLabs project

1 ... into and Open Centre coordinating several

collaboration frameworks with an international scope

Other collaborators
Developing an International Network Fostering an Internal Network

Network of Strategic
Collaborators

ERC
UIC / Energy
E.ON Energy
ECW LTE Hydro-
360 Saving

EEC
EGQubec
BRC CEER
Trust
Research
Center
Energy
Efficiency
EnergyLabs
patronos XXX
SCE ORN
L/
E
ENERGY Center
Partners
EPRI
LAB

EnergyLab
EnergyLab manages
manages an
an all-round
all-round collaboration
collaboration

8
1 Concrete projects
Projects carried out with commpanies

Demonstrative project of Geothermal Heat Pump in housings single families

PROYECTOS DE BOMBA DE
CALOR GEOTRMICA

Installation and monitoring of systems of GHP in houses in Spain, in order to obtain indicators that describe fully

the technology characteristic of the Spanish geography .

Development of a Business Plan of GHP also carrying out, a valuation of the viability of the different technologies.

Demonstrative plan for the use of Geothermal Heat Pump in Galicia.

Installation and monitoring of pilot facilities of GHP in buildings of houses and buildings of the services sector in
Galicia in order to characterizing the technology with a bigger depth.

Pilot Project of Speed Drives

Technology validation through installations of these systems in various industrial processes and measuring
results.

Technology watch in energy efficiency technologies

Making Technology Watch reports on various energy efficient technologies, both the lighting area, and the area

of industry and construction .

9
1 Concrete projects

Lignum Facile: Wood, energy efficiency and sustainability. Construction systems

Modelling of energy efficiency standards in building systems that allow the comparison of energy efficiency of
wood versus other materials

Metrics between Gas&Electricity

Determine the metrics and indicators to establish energy efficiency and sustainability, technical and economic, of
various industrial processes which may be powered by gas or electricity

Energy Studies in Galician councils

Conducting a study of energy saving in public facilities of several Galician councils

Study of removers of parasite consumptions through Stand-by in domestic equipment

Analysis of consumption of own equipment and check the use of them to estimate the simplicity and convenience
of use, efficiency, and final determination of the pros and cons of such.

10
1 Concrete projects

Energy Study on Aggregates Industry

Mobility and Energy Study Process in an Aggregates Industry Plant.

Energy viability study in building

Feasibility Study of Geothermal Heat Pump and use of waste heat from a supercomputing center.

R & D Projects funded by public notice

Advanced System Project Showcases Lighting

Project in collaboration with the company Inditex, based on the study of an advanced system of lighting in shop
windows to improve energy efficiency

Optimization Project of a Geothermal Heat Pump for DHW and Heating or Cooling

Project in collaboration with the University of Vigo, which studies the experimental energy optimization of a
geothermal heat pump for simultaneous production of ACS with air conditioning

11
 Index

1 What is EnergyLab?

2 Introduction

3 Control Methods

4 Analysis

5 Conclusions

6 Applications

12
2 Introduction
Variable Frequency Drives and Energy Efficiency

 A Variable Frequency Drive (VFD) is a system for controlling the rotational

speed of an alternating current (AC) electric motor by controlling the
frequency of the electrical power supplied to the motor.

 Adding a variable frequency drive (VFD) to a motor-driven system can offer

potential energy savings in a system in which the loads vary with time.

 VFDs belong to a group of equipment called adjustable speed drives or

variable speed drives. (Variable speed drives can be electrical or mechanical,
whereas VFDs are electrical)

 The operating speed of a motor connected to a VFD is varied by changing the

frequency of the motor supply voltage. This allows continuous process speed
control.

 Fans, pumps and compressors are the most typical applications for speed
regulation.

13
2 Introduction
Variable Frequency Drives Project

 VFDs technology validation through installations of these systems in various

industrial processes and measuring results.

 Applications were selected from various industrial sectors :(Sewage water

treatment plants, feeding industries, paper industries, irrigation communities, ).

 Energy consumption were measured with the control system installed previously.

 It oversaw the installation of speed control equipment.

 Were monitored new energy consumption and realize energy savings analysis.

 Conclusions were drawn.

14
2 Introduction
Variable Frequency Drives and Energy Efficiency
Variable Frequency Drive
Pumping Systems

15
2 Introduction
Approaching curves and hydraulic pumps

Pump ideal curve

H Q1 H1
n0

Q
H2

H If the height increases, decreases flow
H1 (and vice versa)

n0
The pump has a
pressure value
equal to H
H2
Q2
Q2 Q1 Q
n0

16
2 Introduction
Approaching curves and hydraulic pumps

H Ideal curve Pump

Q1 H1
n0
H2

Q
H1 If the speed decreases, decreases flow
(and vice versa)
n0
n1
Q2 H1

Q2 Q1 Q
n1

17
2 Introduction
Approaching curves and hydraulic pumps

If for a system of pipelines and hydraulic

restrictions (valves, etc..) pressure is
System curve determined, it is possible the circulation
H of a certain flow.

If the pressure increases, it will increase

Q the flow rate.
H2

H
H1

H
Q

Q2 Q1 Q

18
2 Introduction
Approaching curves and hydraulic pumps

H

Q1

Q2
For a given
H,
H2 if by some means restriction increases the resistance,

H the flow will decrease.
H1

R1
H
Q

R2 > R1
R2

Q2 Q1 Q

19
2 Introduction
Approaching curves and hydraulic pumps

R0
H Pu
mp m
ys te
S
Operating point
Hst + Hdin 100

Hdin
50
n0

Hst

0
0 100
Q Q0
Q0

System
Hst
R0
M Pump Hst + Hdin Hst
n0 Q0

20
2 Introduction
Real curves, operating point

H n0 = 1490 R0
rpm
Operating point
Hst + Hdin 100

Hdin
50

Hst

0 Q0
0

100
Q
Q System
0
Hst
R0
M Pump Hst + Hdin Hst
n0 Q
0

21
2 Introduction
Formulas, laws of affinity

Flow = Q1 / Q0 = n1 / n2
H n0 = 1490 R0
rpm
Height = H1 / H0 = (n1 / n2)2

Hst + Hdin 100

Power = P1 / P0 = (n1 / n2)3
Area Q x H
Hdin = k.Q2
50
 H = Hst + Hdin = Hst + k.Q2
Hst

0
0 100
Q l/s
Q
0 xg
Power = QxH


Power is proportional to the area: Q (flow) x H (height)

22
 Index

1 What is EnergyLab?

2 Introduction

3 Control Methods

4 Analysis

5 Conclusions

6 Applications

23
3 Control Methods
Flow Control  ON-OFF

Objective: Flow Q = 70 l/s

H n0 = 1490 R0
rpm Method:
Operating 70% of the time  ON
100
point 30% of the time  OFF

50
Power:
0,7 x 100 kW + 0,3 x 0 kW
Hst
P = 70 kW
0 Q
0 70 100 Q1
Q1 Q0 (promedio)

Hst
ON R0
OFF M
Hst + Hdin Hst
n0 Q1 (promedio)

24
3 Control Methods
Flow Control  Throttling

Objective: Flow Q = 70 l/s

New Operating Point
Method:
H n0 = 1490 R1 R0 Increased restriction of the
rpm
system, R0 to R1, by throttling the
118
valve.
100 Q decreases but increases H
Power (proportional to the area)
H x Q  1,18 x 70
50

Hst P = 82,6 kW
0 Q Q1
0 70 100
Q Q
1 0

Hst
R1
M
Hst + Hdin Hst
n0 Q
1
25
3 Control Methods
Flow Control  Throttling
Throttle valve

Q1

Pressure meter

Hst
R1
M
Hst + Hdin Hst
n0 Q
1
26
3 Control Methods
Flow Control  By-pass

New Objective: Flow Q = 70 l/s

H Operating
n0 = 1490
rpm R0 Method: reduce system
Point
restriction of R0 to R2, through
100 R2 relief by-pass valve.
H decreases applied to the
valve R0 and hence reduces
60 Q to exit.
50

Hst Power (proportional to the area)

 0,6 x 135
0
0 70 100 135 Q P = 81 kW
Q1 Q0 Qt Q1

R

Q Hst
R0
M
Hst + Hdin Hst
n0 Qt Q1
R2 total restriction seen from the pump
27
3 Control Methods
Flow Control  ASD
Objective: Flow Q = 70 l/s

Method:
H n0 = 1490 R0
rpm Decrease the speed of the pump until
reaching that point of operation
which imposes our objective
100 New
n2 = 11 R0 = 70 l/s
16 rpm Operating Simultaneously reduces H and Q.
60
Point
50
Power: (proportional to the area)
Hst  0,6 x 70
P = 42 kW
0
0 70 100
Q
Savings Q1
Q1 Q0

Hst
R0
ASD M
Hst + Hdin Hst
n2 Q
1

28
 Index

1 What is EnergyLab?

2 Introduction

3 Control Methods

4 Analysis

5 Conclusions

6 Applications

29
4 Analysis
Example: Comparison Power Consumption Throttling vs. Adjustable Speed Drive

Power Consumption: Throttle Valve versus Adjustable Speed Drive

40
38
36
34
Power (kW)

32
Throttle valve
30
Adjustable Speed Drive - ASD
28
26
24
22
20
0 200 400 600 800 1000
Time (s)

30
 4 Analysis
Comparison table (I)
Time Flow Control Method
On-Off Throttling By-pass ASD
1 hs % l/s kW MWh kW MWh kW MWh rpm kW MWh
2
3260 92 276 92 299,92 17995 96,6 314,916 18895 99,68 324,96 19497 1393 81,88 266,93 16016
3
3000 70 210 70 210 12600 82,6 247,8 14868 81 243 14580 1116 42 126 7560
2500 54 162 54 135 8100 68,04 170,1 10206 65,8 164,5 9870 943 25,38 63,45 3807

8760 644,92 38695 247,24 732,816 43969 246,48 732,46 43947 149,26 456,38 27383
SAVINGS 189 11312 276 16586 276 16565 0 0

H n0 = 1490 R0
rpm
126 n1 = 139
3 rpm 3
2
Savings:
118
105 100 1
n2 = 11
89 16 rpm 1 1 ASD vs. On/Off  189 MWh  11.312
n3 =
943 r
pm
60 2 2 ASD vs. Throttling  276 MWh  16.565
47 50 3 3

Hst ASD vs. By-pass  276 MWh  16.565

0
0 70 100 140
Q
54 70 92 112 135

31
 4 Analysis
Comparison table (II)
On/Off Throttling By-pass ASD
hs % l/s kW MWh kW MWh kW MWh rpm kW MWh
1 2.000 92 276 92 184 11.040 97 193 11.592 100 199 11.962 1.393 82 164 9.826
2 4.000 70 210 70 280 16.800 83 330 19.824 81 324 19.440 1.116 42 168 10.080
3
2.760 54 162 54 149 8.942 68 188 11.267 66 182 10.896 943 25 70 4.203

8.760 613 36.782 247 711 42.683 246 705 42.298 149 402 24.109
SAVINGS 211 12.674 309 18.575 303 18.190 0

H n0 = 1490 R0
rpm
n1 = 139
126
118
3 rpm 3
2 Savings:
105 100 1
n2 = 11
89 16 rpm 1 1 ASD vs. On/Off  211 MWh  12.674
n3 =
943 r
60
pm
2 2
ASD vs. Throttling  309 MWh  18.575
47 50 3 3
ASD vs. By-pass  303 MWh  18.190
Hst

0
0 70 100 140
Q The time distribution affects the final
54 70 92 112 135 energy cost.
Q

32
4 Analysis
Economic Analysis

Estimated cost of installing a frequency inverter for driving a 100 kW centrifugal

pump:

 Estimated cost of the drive and installation  9.000

ROI
(Return on investment)

 ASD (Adjustable Speed Drive) vs. On/Off  12.674  < 1 year

 ASD vs. Throttling  18.575  < year

 ASD vs. By-pass  18.190  < year

33
1 What is EnergyLab?

2 Introduction

3 Control Methods

4 Analysis

5 Conclusions

6 Applications

34
5 Conclusions
Principal findings

 VFDs makes the process reliable and the output variable is easily controlled.

 VFDs increase energy savings in a system in which the loads vary with time.

 You can use the existing electric motor.

 Soft start with low current.

 Prevents water hammer.

 Reduce system wear and equipment.

 Reduce ambient noise.

Additional advantages:

The drive improves the Power Factor (with VFDs cos Fi 1 versus usual 0.86)

35
1 What is EnergyLab?

2 Introduction

3 Control Methods

4 Analysis

5 Conclusions

6 Applications

36
6 Applications

 Purification, pumping and water supply.

 Irrigation systems.

 Regulation of blowing air and ventilation systems.

 Compressors, air conditioning and industrial cooling, and pressure

groups for hydraulic systems.

 Jet fans for ventilation in tunnels.

37
Csar Barreira Pazos
cesar.barreira@energylab.es

Edificio Isaac Newton.

Lagoas Marcosende, s/n. 36310, Vigo.
T_986 81 86 66 F_986 81 86 65
cesar.barreira@energylab.es
www.energylab.es

38