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Optimized VF Drive System for Descale Pumps

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Efficiency is IMPORTANT

In fact up to 97% of motor lifetime operating cost is attributed to electric energy charges.

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Descale Pumps
Constant Speed Descale Pumps waste energy and water, and require heavy maintenance of Motors, Bypass Valves and Pumps

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Operation with Variable Speed Pump Drives


Bypass Valves activated at lower speed and pressure Pumps stopped for Roll Change Pump speed can be reduced for mill delays Pump speed can be lowered between bars

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Pump Laws
Fluid Flow varies with the Speed Q = K1N Fluid Pressure varies with the square of the Speed P = K2N2 Pump Power varies with the cube of the Speed kW = K3N3

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Benefits of Variable Speed Pump Drives


Reduce Water Waste (Q=K1N)
Clean water that will not clog up the descale nozzles is a valuable commodity in HSMs Constant speed pumps running continuously use up a large amount of treated water Reducing the flow when descale is not in use will economize up to 40% of the water used in constant speed systems

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Benefits of Variable Speed Pump Drives


Reduce Pump & Valve Maintenance (P=K2N2)
Reducing the speed to 70%, reduces the pressure to 49% Valves can be moved to Bypass after speed is reduced, and back to Descale before top speed is attained At lower pressure, the pump/valve life is dramatically increased Vibration Detectors on pump, motor and gearbox bearings warn of impending problems

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Benefits of Variable Speed Pump Drives


Reduce Electrical Energy Waste (kW=K3N3)
Pump consumes 80% energy even when nozzles are bypassed Reducing the pump speed to 70%, reduces the power to 35% Pump Speed reduced when bar exits descale zone Decel controlled to a rate that avoids cavitation Decel continues to 20% speed or until next bar arrives in descale zone Pump can accelerate rapidly with no cavitation

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Benefits of Optimized Variable Speed Pump Drives


Reduce Voltage Fluctuations
Starting constant speed motors on-line create large voltage fluctuations affecting other sensitive equipment Motors suffer 500%-600% overloads during on-line starting Motor and switchgear maintenance greatly reduced

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Optimization Recommendations
4-Pole motor with speed Multiplier recommended to avoid resonance Separate the RM & FM Systems One of the Pumps should feed either system Any Pump can be on Standby

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Optimization Requirements
MAIN

TM MV Inverter

TM MV Inverter

TM MV Inverter

4- Pole 3.3 kV or 6.6 kV Motors

GEAR MULTIPLIER

GEAR MULTIPLIER

GEAR MULTIPLIER

HI-SPEED PUMP

HI-SPEED PUMP

HI-SPEED PUMP

RM DESCALE SYSTEM

FM DESCALE SYSTEM

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Motor/Drive Operation
Decel starts when bar leaves descale zone & next bar not scheduled within 10 seconds Accel starts when bar within 5 seconds of descale zone Bar transport and tracking system predicts accel/decel for both RM & FM Pump top speed is permissive for bar to enter descale zone