Transcript Priya_Danfoss

Energy Savings in Water and Wastewater
Segment
Danfoss Industries Pvt. Ltd.
Presenting Power Electronics
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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
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78 years of experience within energyefficient 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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VFD evolution
Danfoss = First company to mass produce a.c. variable frequency drives (VFD)
1968
1973
1978
1983
1988
1993
1998
2003
2007
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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
5%
 ~ 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)
95%
 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
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VFD (Variable Frequency Drive)
Electronic unit that varies the fixed mains voltage & frequency to
control the speed of standard a.c. electric motors
AC 3Ø
VLT
 Infinite speed control from 0-50Hz +over-speed operation with some limitations
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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
controlled pump
100%
Standard cascade
control with 1 x VFD
pump & multiple
fixed speed pumps
Master – follower
with 1 x VFD per
pump
43%
48%
53%
Note: kWh figures are approximate relative %, based on sample test
 Master follower = best energy efficiency
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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
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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
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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
Consumer Network B
Treatment plant
House BX
Simplified
well
with pump
Elevated Storage Tank
House B1
Pumping station
with
High service pump
Source from
ground
water
Booster
Station
Simplified
treatment plant
House A2
House A1
Source from
surface water
Basement
House AX
Landscape
Consumer Network A
Industrial
consumer
Booster
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Alternative system - pressure control with VFD
Pressure
Set point
From The Source
Water
reservoir
 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.
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Water – Distribution

VFD controlled pumps replace
water tower to maintain constant
pressure, irrespective of demand
Flow
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
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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
cost distribution at WWTP
Typical
energy distribution at WWTP
3% 4%
15%
7%
28%
Energy
Staffing
2%
Solids Disposal
4%
8%
Other
Maintenance Materials
55%
8%
Activated Sludge
Primary P.S. Clarifier
Heating
Solids Dewatering
Raw Water P.S.
Other
Chemicals
10%
46%
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Fans
Applications (E.g.)
 Odour control
 Ventilation
 Cooling towers
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
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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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VLT® AQUA Drive
•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
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Global focus
 Water
 Wastewater
 Irrigation
 Power generation
 Steam, hot water & gas supply
 Waste processing & recovery
 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
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Over 25 year track record globally & in
Asia Pacific
 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
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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.
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)
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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)
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