Reducing Pump TCO Using New Variable Speed Drive Functions · 4/8/2019 1 1 Reducing Pump TCO Using...
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4/8/2019 1 1 Reducing Pump TCO Using New Variable Speed Drive Functions Who is Graybar? Graybar is a leading distributor of electrical, communications, data networking and security products. We help customers power, network and secure facilities with speed, intelligence and efficiency. 2
Transcript of Reducing Pump TCO Using New Variable Speed Drive Functions · 4/8/2019 1 1 Reducing Pump TCO Using...
4/8/2019
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Reducing Pump TCO Using New Variable Speed Drive Functions
Who is Graybar?
Graybar is a leading distributor of electrical, communications, data networking and security products.
We help customers power, network and secure facilities with speed, intelligence and efficiency.
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Our Customers
Graybar serves the Construction, Commercial, Utility, Industrial and Government industries. Our customers include:
• Contractors
• Industrial companies
• Commercial organizations
• Telecommunication service providers
• Utilities
• Federal, state and local governments
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Our Story
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Enos Barton and inventor Elisha Gray started Gray & Barton in 1869 to manufacture telegraph equipment. Little did they know their company would become one of the most admired in business history.
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Graybar Technical Specialists - Nathan Schiavo and Roger Kozera
• Technology appraisal
• Training
• Technology interpretation in layman’s terms
• Joint calls and walk-throughs
• Standards development
• Technology take-offs
• Integration suggestions
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Major Electrical Brand Names
●Belden
● Belden
● Hirschmann
● GarrettCom
● LAPP USA
● Panduit
● Phoenix Contact
● Pepperl Fuchs
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Major Electrical Brand Names
●Schneider Electric
● Square D
● Telemecanique
● MODICON
● Merlin Gerin
● APC
● Pelco
● Eaton
● Cooper Power Systems
● Bussmann
● Crouse-Hinds
● Cooper Lighting
● B-Line
● Pentair
● Hoffman Engineering
● McClean● Hubbell Incorporated
● Hubbell Wiring Devices
● Burndy
● Killark
● RACO
● Bell
● Leviton
● Leviton Wiring Devices
● American Insulated Wire
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Schneider Electric Brands● Additional Brands
●Berger Lahr
●Elau
●Magnecraft
●ECP Tech
Services
●TAC
●Lee Technologies
●Nu-Lec Industries
●Power
Measurement
●Crouzet
●SCADAPak
●ProFace
● Additional Brands
●Citect
●EFI Electronics
●Hyde Park
●Accusine
●Juno Lighting
●Electrical South
●Veris Industries
●Clipsal
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Schneider Electric Brands
● Additional Brands
●Xantrex
●Areva T & D
●Invensys
●Foxboro
●Triconex
●Wonderware
●Simsci
●Avantis
●Eurotherm
●Robertshaw
Variable Frequency Drives
Confidential Property of Schneider Electric |
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Confidential Property of Schneider Electric
Where are Variable Frequency Drives used?
> Variable Frequency Drives (VFD’s) are mainly used to
control 3-phase asynchronous AC electric motors.
> They are used in many types of applications:
> Pumping
> Ventilation
> Conveyors
> Hoists and Cranes
> Packaging machines
> Automatic doors
> Industrial machines
Confidential Property of Schneider Electric
What does a Variable Frequency Drive do?
> A VFD controls the operation of a motor allowing:
> Control of acceleration of the motor
> Control (and change) of speed of the motor
> Control of deceleration of the motor
0 % Speed
100 % Speed
Time
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Confidential Property of Schneider Electric
How does a Variable Frequency Drive do this?
> A VFD controls the
operation of a motor
by regulating:
> Voltage supply to
the motor
> Current supply to
the motor
> Frequency of the
AC current to the
motor
Diode
Bridge
Converter
Transistor
Inverter
_
+
“AC”
Output
AC
Line
Input
DC
Bus
Link
DC Voltage
(non-inverted)
Confidential Property of Schneider Electric
Why are VFD’s used?
> Using a VFD to control the operation of a motor
can significantly reduce the electrical
consumption in some common applications:
> Pumps
> Fans
> These are commonly found in:
> Building Automation (HVAC)
> Water Utilities
> Wastewater Treatment
• Energy Savings
• Application Performance
• Mechanical Requirements
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Confidential Property of Schneider Electric
Why are VFD’s used?
> Using a VFD to control the operation of a motor
allows direct control of:
> Acceleration
> Deceleration
> Speed
> This is important in almost every application:
> Conveyors
> Consumer appliances
> Industrial machines
> Pumping
> HVAC
• Energy Savings
• Application Performance
• Mechanical Requirements
Pag
e 16
Schneider Electric Drives and Soft Starters Ranges
Building Machines ProcessSoft Starter
Altistart
Soft starters
Altivar
Machine
Altivar
Process
Altivar
Building
0-600HP 0-100HP0-100HP 0-900HP
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Enclosed 22
Altistart™ 22
Altistart™ 48
Functionality
Performance
Duty Rating
20 100010 400
Enclosed 48
Altistart ™ 01 N1
Altistart ™ 01 N2
7.5
Soft Starters - Altistart Family
Industrial &Utility
WWW, O&G, Mining
OEMs and Panel builders
pump, fan, & conveying
End User Irrigation pumping
Buildings system pumping
OEMs and Panel builders
pump, fan, compressor
& conveying
Target buyers
Target applications
Altistart 48 Soft Starters
• 17-1200 Amps
ATS48 Controller
• Type 1, 12, 3R
• Service entrance rated
ATS48 System Package
Open EnclosedRemote display
terminal
SoMove
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Our HVAC Buildings DriveOptimized for Fans & Pumps
1210 Standards
Compliant Nema 1
Nema 12
Nema 3R
Altivar Building - 212 & S-Flex
Embedded communications:
• Modbus
• Apogee P1
• Metasys N2
• BacNet
Communication option :• LonWorks
Daisy
Chain
Daisy
Chain
capable
Open communication with BMS
Altivar Building – Communications
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Page 21Confidential Property of Schneider Electric |
Machine
• High level Safety functions embedded
• Printed circuit boards have class 3C3 conformal coating
• The only drive to introduce nominal torque at 0 for synchronous motors in open-
loop.
• Advanced connectivity via numerous Ethernet and serial based networks
• Integrated programmable logic functions
• More than 150 ready to use functions
• Application oriented
• Compact and Book form factors
• Replaces both the Altivar 312 and Altivar 32 ranges
• From ¼ Hp up to 20 Hp
• 1 phase : 240V
• 3 phases : 240V,480V, 600V
• Synchronous and Asynchronous motors
The Range
Solution
Safety & Performances
More Communication
Altivar Machine ATV320 Make Your Machines Even Smarter
Machine
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• High level Safety functions embedded and with option card
• Printed circuit boards have class 3C3 conformal coating
• Uses same communication cards as ATV320.
• Advanced connectivity via numerous Ethernet and serial based networks
• Two versions: Embedded Ethernet & Modular
• Control motors in open loop and closed loop
• Embedded Encoder
• Easy to integrate
• Can replace low hp ATV71
• Stocked and available
• From 1 Hp up to 100 Hp Heavy Duty Rated
• 3 phases : 480V
• Synchronous, Asynchronous and Reluctance motors
The Range
Solution
Safety & Performances
More Communication
Altivar Machine ATV340 Stay on the Top of the Smart Machine Era!
Machine
Page 24Confidential Property of Schneider Electric |
The Altivar Process Family
ATV9xx
Solid & Mechanical Movement
Industrial
Processes
Utility
Processes
Fluid & Gas Movement
ATV6xx
Multi Pump management
Sensorless Flow Estimation
Torque control
Braking and Regen
Safety Modules
Dual Ethernet IP ports
DC bus sharing
110/150% over-load
Closed loop
120/150% over-load
EtherNet TCP
Dynamic QR
Codes
Load Sharing
Pump Anti-Jam Function
Energy saving
motor control
Torque performance
motor control
Embedded
WebserverEasy User
Interface
Type 1 / 12
Enclosures
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Altivar Process 6xx
Helping you decrease your
pump’s Total Cost of
Ownership
Page 25Confidential Property of Schneider Electric |
Source: Courtesy of Barringer & Associates- “Pump practices & life”
> Inherent in the pump’s
mechanical design
> Should be considered as a
factor affecting system TCO
> Equipment life,
maintenance costs
impacted by operation away
from BEP
> The BEP is achieved with
the correct balance
between head and flow
> SE Drives can be set to
operate pump at or near
BEP ALL THE TIME
“Best Efficiency Point” (BEP) is Where You Want to Operate a Pump
Schneider Electric | Variable Frequency Motor Controllers ~ 30 Years of Lessons Learned Page 26
Asset Management
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Monitor pump operation state and efficiency
Page 27Confidential Property of Schneider Electric |
Pump curves embedded:
• Easy to set
• Embed 5 points from pump curve and assess efficiency
Advantages:
• Monitor [Head vs Flow], [Power vs Flow], [Efficiency vs
Flow] and [Power vs speed]
• Sensor-less Flow Estimation with Head Vs Flow curve or
Power Vs Flow curve
• Monitor outlet pressure, inlet pressure, water level,
• Raise alarms according to actual status
Process optimization
How to insert the pump curves into the drive
Process Asset Protection Functions
Pump Protection Functions
• Cavitation Protection by inlet pressure monitoring,
• Dry running protection,
• Hydraulic network protection by outlet pressure monitoring,
• Pipe burst prevention by high flow monitoring,
• Pump overheating prevention by low flow monitoring,
• Pump cylic start function to protect the pump against too many restarts,
Pump Lifecycle Extension
• Pump service lifetime extension by pump
efficiency monitoring with the accuracy of pump
datasheet,
• Sleep-wake up and multi-pump management to
manage staging/destaging of pumps
Asset management
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Anti Jam Function
Clogged intake pump due to rags, wipes, and other
fibrous or elastic materials in wastewater pumps
Page 29Confidential Property of Schneider Electric |
Perfect fit for waste water applications
• This function allows manually or automatically executing
forward & reverse pump rotations.
• Alarm or fault appears if a predefined threshold is reached
• Trigger by torque, start, time
Advantages:
• Usually applied in waste water lift station, avoid clogging
substances damaging the pump impeller
• Save from recurring maintenance cost
Asset management
Level Control
Designed to be flexible:
• Emptying or filling of tanks/towers in water and waste water
applications with centrifugal pumps and submersible pumps
run by single or multi-drive systems with multidrive link
• Integration of different kinds of sensors (Switch, pressure,
level sensors)
• Energy Optimized : Automatic calculation of the number of
pumps to be started and the optimal speed according to the
estimated Disturbance flow
Advantages:
• Prevent sedimentation acumulation : Random level factor
will change liquid level in tank
• Running at the System Best Efficiency Point during the
entire filling or emptying process to reduce energy consumed
Process optimization
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Booster Control
Page 31Confidential Property of Schneider Electric |
Decentralized Application Expertise:
• Booster control function is used to maintain the desired
pressure or flow at the outlet of the pumps according to
the demand
• Single and Multi Drive architectures with Multidrive link
that allow different staging/destaging and speed control
mechanisms
Advantages:
• Installation cost decrease : Use of one drive to control
several motors without any additional controller
• Reduce energy consumption : Optimize the system
consumption with Energy Optimized strategy
• Decrease pump aging : Monitor pump operation time
and run them in turns to decrease wear
Process optimization
Application Notes
Real Time Data from Field
Page 32Confidential Property of Schneider Electric |
Monitoring with real information:
• Provides dashboards to monitor process data and the
energy consumed.
• Provide insights for predictive maintenance, asset
management, energy monitoring thanks to
• Native Ethernet : RSTP capability allowing continued
service
• Embedded Webserver : Easy access from anywhere
Advantages:
• Providing the necessary level of determinism for most
process applications
• Obtain the real information at the real time
• Using this data has a performance indicator
• Increasing the productivity of the systems
Process optimization
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Confidential Property of Schneider Electric
Embedded Ethernet,
Webserver & Wireless
> Access via open standard
> HTML5
> Achilles Level 2 cyber
security
> Local or Remote Programming
and Monitoring
Operational
Intelligence
Confidential Property of Schneider Electric
Customized Home Screens
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> Altivar Process x30
• 240V, 1-100HP, Type 1
• 480V, 1-500HP, Type 1
• 575V, 3-100HP, Type 1
• 690V, 3-125HP, IP00
> Altivar Process x50
• 460V, 1-125HP, Type 12
• Optional disconnect
switch 1-75HP
> System Drives x60 / x80
• 460V 1HP-900HP
• 230V 1HP – 60HP
• Enclosed Process Drives
Page 35Confidential Property of Schneider Electric |
Altivar Process FamilyEnclosure Types
Cabinet & Wall Mounting Offer - ATV630
300 x1155290 x 922226 x 673211 x 549168 x 395143 x 334
Up to 5,5kW Up to 11kW Up to 22kW Up to 45kW Up to 90kW Up to 160kW
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Range for Harsh Environment - ATV650
250 x 678 290 x 910 345 x 1250
Up to 22kW Up to 45kW Up to 90kW
with
or
w/o
switch !
Confidential Property of Schneider Electric
Altivar Process Drives Systems A Complete Offer
• Lightly Engineered Drives
• Control Options
• Bypass Contactors
• High/Low Temperature Options
• Passive Filters
• Engineered to Order Drives
• Special Wiring
• Custom Paint
• Remote Monitoring
• Active Front End LH Drives
• Regenerative Drive Systems
• Custom Engineered Drives
• Non-Ventilated Enclosures
• Extreme Environmental Designs
• Multi-pulse designs
• Application Enabled
Proven designs customized to each client’s specific needs
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Page 39Confidential Property of Schneider Electric |
> Enclosed Drives 60HP and above Built in Seneca, South Carolina ( FS5 Velocity
and MCE)
Quick Introduction to Altivar Enclosed Drives IDSDS
Altivar 680/980 Drive Systems150HP-900HP
Altivar 660/960 Drive Systems
The future of Harmonic MitigationExample: 600HP for WWW customer
18-Pulse Harmonic filter New low harmonic
120” Wide 80” Wide 63” Wide
As the Harmonic Solutions are becoming more innovative,
the solution is optimized with better performance.
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Page 41Confidential Property of Schneider Electric |
> Custom Drive Systems to meet various
application requirements. Some Options would
Include:
• NEMA 4x Enclosures with AC Units
• Custom Bypass Configurations
• Unique Enclosure Designs
• NEMA 3R Vented and Non-Vented Designs
• Integration with PLCs and HMIs
• HP Range up to 900HP | 480V
• Multi Drive Panels
• Custom 18 Configurations
>Email [email protected] with
RFQ!
Custom Drive Solutions to Meet ANY Customer Needs
Example 400HP N4X SS Drive Solution w/ AC
Useful Links
● AltivarDrives.com
● Altivar and Altistart Documentation and Tool Links
● SoMove Software
● HarmCalc
● ECO2 Energy Savings Software
● Spares Online
● FAQ
● CAD Drawings
● Swivel Shots (ATV12, ATV32, ATV212)
● Calculators and Visual Product Configurators
● Drives and Soft Starts webpage
● Schneider Electric Customer Learning Center
● Schneider Electric Demo Request
● Digest Online
● Schneider Electric YouTube Channel
● Product Cross Reference
● Drives Classic Technical Library
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