Energy Saving Analysis of Frequency Control Technology in Fans and Pumps

Abstract: In industrial production and product processing and manufacturing industries, fan and pump equipment have a wide range of applications. Their energy consumption is not a small overhead expense. With the continuous deepening of economic reform and increasing market competition, energy conservation and consumption reduction have become one of the important measures to reduce production costs and improve product quality. Keywords: frequency conversion fan pump energy efficiency I. INTRODUCTION  In the industrial production and product processing manufacturing, fan, pump equipment, a wide range of applications; its power consumption and such as valves, baffle-related equipment, the loss of the throttle and maintenance, Maintenance costs accounted for 7% to 25% of production costs, is not a small overhead costs. With the continuous deepening of economic reform and increasing market competition, energy conservation and consumption reduction have become one of the important measures to reduce production costs and improve product quality. In the early 1980s, the frequency control technology developed in response to the requirements of industrial automation development created a new era of intelligent motors. A change of ordinary motor can only run at a fixed speed of the old model, making the motor and its drag load without any changes in the case that can be adjusted according to the requirements of the production speed, thus reducing the motor power to achieve the purpose of efficient operation of the system . In the late 1980s, the technology was introduced into our country and was promoted. Now in electric power, metallurgy, petroleum, chemical, paper, food, textile and other industries in the motor drive equipment has been practical application. At present, the frequency control technology has become a major development direction of modern electric drive technology. Excellent speed performance, significant energy-saving effect, to improve the operating conditions of existing equipment, improve system safety and reliability and equipment utilization, extend the life of the equipment, etc. With the continuous expansion of applications are fully reflected .     Second, an overview   Usually in industrial production, product processing and manufacturing fan equipment is mainly used for boiler combustion system, drying system, cooling system, ventilation systems and other occasions, according to the production needs of the furnace pressure, wind speed, , Temperature and other indicators to control and adjust to meet the process requirements and operating conditions. The most commonly used control method is to adjust the damper, baffle opening size to adjust the controlled object. In this way, regardless of the size of the demand for production, the fan must be running at full speed, and changes in operating conditions make energy throttling loss of throttle, baffle consumed. In the production process, not only control accuracy is limited, but also caused a lot of energy waste and equipment loss. Resulting in increased production costs, shortened equipment life, equipment maintenance, high maintenance costs.   pump equipment in the field of production also has a vast application space, to pump stations, tank storage tank system, industrial water (oil) recycling systems, heat exchange systems are used centrifugal pumps, axial pumps, gear pumps, Piston pumps and other equipment. Moreover, according to different production needs are often used to adjust the valve, return valve, cut-off valve throttling equipment such as flow, pressure, water level signal control. This will not only cause a lot of energy waste, piping, valves and other sealing performance damage; also accelerated pump chamber, valve body wear and cavitation, serious damage to equipment, affecting production, endangering product quality.   fans, pumps most of the equipment used asynchronous motor direct drive mode of operation, there is a large start-up current, mechanical shock, poor electrical protection and other shortcomings. Not only affect the service life of the equipment, but also when the load appears mechanical failure can not be instantaneous action to protect the equipment, pump damage often occurs at the same time the motor is also burned phenomenon. In recent years, out of the urgent need for energy saving and the continuous improvement of product quality requirements, combined with the use of frequency converter (inverter) easy operation, maintenance-free, high control accuracy, and can be achieved high-functional features; thus using Drive-driven program began to gradually replace the damper, baffle, valve control program.   frequency conversion speed control technology is based on the basic principle of the motor speed and the power input frequency is proportional to the relationship: n = 60f (1-s) / p, (where n, f, s, p, respectively, , Motor slip, motor pole pairs); by changing the motor operating frequency to achieve the purpose of changing the motor speed. Inverter is based on the above principles using AC - DC - AC power conversion technology, power electronics, microcomputer control technology in a comprehensive electrical products.     Third, energy-saving analysis Through the basic laws of fluid mechanics we can see: fans, pumps equipment are square torque load, the speed n and flow Q, pressure H and shaft power P has the following relationship: Qαn, H Αn2, Pαn3; that is, the flow rate is proportional to the rotational speed, the pressure is proportional to the square of the rotational speed, and the shaft power is proportional to the rotational speed of the cube.   To a pump, for example, its export pressure head for the H0 (outlet pressure that is, the pump inlet and outlet pipe static pressure difference), the rated speed of n0, the valve is fully open when the pipe resistance characteristics r0, rated The pressure corresponding to the condition is H1 and the outlet flow is Q1. Flow - speed - pressure curve as shown below.     control in the scene, the pump is usually used to run the outlet valve speed control flow. When the flow rate decreases from Q1 to Q2, the valve opening decreases and the resistance of the pipe network changes from r0 to r1. The system operating point moves from point A to point B along the direction I. By the throttle effect pressure H1 becomes H2. Pump shaft power actual value (kW) can be obtained by the formula: P = Q · H / (ηc · ηb) × 10-3. Among them, P, Q, H, ηc, ηb, respectively, power, flow, pressure, pump efficiency, transmission efficiency, direct drive to 1. Assuming that the total efficiency (ηc · ηb) is 1, when the pump moves from point A to point B, the power consumption saved by the motor is the area difference between AQ1OH1 and BQ2OH2. If the governor is used to change the pump speed n, when the flow rate is reduced by 50% from Q1 to Q2, then the pipe network resistance characteristic is the same curve r0. The system operating point will move along the direction II from point A to point C, Pump operation is more reasonable. In the valve is fully open, only the case of pipe network resistance, the system to meet the flow requirements of the scene, energy consumption is bound to reduce. In this case, the motor consumes less power than the area of ​​AQ1OH1 and CQ2OH3. Compared with the valve opening adjustment and pump speed control, it is clear that the use of pump speed control more effective and reasonable, with significant energy savings. In addition, it can also be seen from the figure that when the valve is adjusted, the system pressure H will be increased, which will threaten and destroy the sealing performance of the pipeline and the valve. When the speed is adjusted, the system pressure H will vary with the pump speed n lower and lower, so there will be no adverse effects on the system.   comparison from the above is not difficult to come to that: when the demand for the pump flow from the scene down to 50% from 100%, the use of speed regulation than the original valve to save the corresponding power BCH3H2 size, energy saving rate of 75%. Similarly, if the use of frequency control technology to change the pump, fan speed to control the scene pressure, temperature, water level and other process control parameters, the same can be based on the system control characteristics of the relationship drawn from the curve drawn above Comparing results. That is, using frequency control technology to change the motor speed than the use of valves, baffles more economical and economical regulation, equipment operating conditions will also be significantly improved.     Fourth, the energy-saving computing  Fan, pump equipment with frequency control after the energy-saving effect, usually using the following two ways to calculate:   1, according to the known fans, pumps in different control modes Flow - load curve and the scene of the load changes in operating conditions were calculated.   To an IS150-125-400 centrifugal pump, for example, the rated flow 200.16m3 / h, lift 50m; equipped with Y225M-4-type motor, rated power 45kW. Pump in the valve adjustment and speed adjustment flow - load curve as shown below. According to operational requirements, the pump runs continuously for 24 hours, of which 11 hours a day runs at 90% load and 13 hours runs at 50% load; the annual running time is 300 days. The annual power saving amount is: W1 = 45 × 11 × (100% -69%) × 300 = 46035kW · h =  W2 = 45 × 13 × (95% -20%) × 300 = 131625kW · h  W = W1 + W2 = 46035 +131625 = 177660kW · h   0.5 yuan per kilowatt-hour calculation, the annual electricity savings of 88,830 yuan.  & nbsp

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