Professional Documents
Culture Documents
Pump Control KSB PDF
Pump Control KSB PDF
P u m p C o n t r o l / Sy s t e m Au t o m a t i o n
Pump Control / System Automation
August 2006 Edition
Subject to technical changes.
Technical Data Technical Data Technical Data Technical Data Technical Data
1
Contents
2
Contents
3
1 Principles
1 H [%]
nmin nmax
Principles
120
1.1
100
Hydraulic Principles
80
1.1.1
Pump head
Pump Principles 60
H [%]
Positive-displacement pumps
120
These pumps are primarily used
it min
p du
• Reciprocating piston pump Fig. 2 Typical working range of a centrifugal pump with pump
• Positive-displacement pump characteristic curves for different pump speeds
• Diaphragm pump
• Gear pump pumps must be protected
against impermissibly high pres-
• Screw pump
sures. A change in the flow rate
• Vane pump is only possible as a result of a
• Hose pump, etc. change in the rotational or
stroke speed, or due to add-
itional devices (bypass). The
Their main common features pump characteristic curve shows
are: the relationship between flow
rate and head (pump pressure)
The flow rate varies with the ro-
at a constant speed.
tational or stroke speed. The
head, on the other hand, is inde- If the speed changes there is a
pendent of this. Due to this be- proportional change in the flow
haviour, positive-displacement rate.
4
Principles 1
Centrifugal pumps:
Centrifugal pumps are used for
most technical applications. This
is due in particular to the fol-
lowing properties:
• Robust construction
• Simple design
• Cost-effective manufacture
• “Good natured” operating
behaviour
• Good adjustability
The working principle of the
centrifugal pump is based upon
energy transfer by flow diver-
sion as well as an additional
centrifugal force effect in radial
impellers. In contrast to posi-
tive-displacement pumps the
maximum pump pressure is limit-
ed by the operating principle.
Special devices to protect against
overpressure are seldom neces-
sary. Based upon the assumption
that the drive speed is constant,
different flow rates can simply
be achieved by means of a throt-
tling valve. The permissible
working range is shown in the
pump characteristic curve.
5
1 Principles
1.1.2 H [%]
Pump characteristic System characteristic curve
Flow Rate Adjustment 160 curve (part load)
B2
Throttled operation
Flow Rate Adjustment by 140 System characteristic
Throttling curve (full load)
120
100 B1
Excess
80 pump head
60
40
20
Required pump head
0
Fig. 3 Throttling configuration 20 40 60 80 100 120 Q [%]
P W [%]
120
P W1
The purpose of increasing the 100
Power saving
system resistances – the fitting of 80
P W2
a restriction (throttling) – is to
60
make the resulting system char-
acteristic curve steeper. At a con- 40
Evaluation
+ Lower control cost – Pump pressure too high, par- – Mechanical load on the throt-
ticularly where the pump char- tle valve
+ Advantageous at mainly full
acteristic curve is steep
load operation – Danger of flow noise at high
– Poor pump efficiency in part levels of throttling (e.g. in
+ Suitable for applications with
load operation thermostat valves).
short operating periods
– Low power saving in part load
+ Well suited for flat pump char-
operation
acteristic curves
– Unfavourable control behav-
iour when the excess head is
high
– Throttle valve necessary
6
Principles 1
Flow Rate Adjustment
H [%] System characeteristic curve
Using a Bypass Pump characteristic curve
(part load)
160
System
140 characteristic curve
(full load)
120
Useful flow rate Bypass flow rate
100 B1
B2
80
Excess
60 pump head
40
Fig. 5 Bypass configuration
20
Required pump head
The bypass line is arranged in 0
20 40 60 80 100 120 Q [%]
parallel to the pump. The pump P [%]
flow is thus divided into the use- 120
ful flow, which flows into the P W1
Constant shaft power
100
system, and the bypass flow, (No saving)
ied. The pump itself runs at al- Fig. 6 Pump and power characteristic curves
most the same operating point,
i.e. at the system’s design point,
in full load operation.
Evaluation
7
1 Principles
60
40
Required pump head
20
0
20 40 60 80 100 120 Q [%]
operation also lies at this higher Fig. 8 Pump, power and efficiency characteristic curves for one,
pressure level. As a result, the two and three pumps in parallel operation
increase in the flow rate is less
than originally expected.
Evaluation
+ Very well suited to flat system + High operating reliability due – High switching frequency in
characteristic curves with a to several pumps (redundancy) unfavourable system designs
high static head component
– In the event of flat pump/sys-
+ Good adaptation to part loads tem characteristic curves pump
operation is flow-dependent
+ High system efficiency
– Increased construction cost
– Problematic in the event of
+ Low control cost for pressure- (piping, valves, pumps, space
high inlet pressure fluctuations
dependent pump operation requirement)
8
Principles 1
Flow Rate Adjustment by H [%]
Speed Adjustment 160
System characteristic
Relationships in the 140 curve
continuous speed adjustment (full load)
120
of centrifugal pumps B1
100
Unlike the procedures for flow
rate adjustment mentioned in the 80 n = 100 %
9
1 Principles
Pump head
several pumps is used in all ap-
plications where demand fluctu-
ates substantially and where the
following requirements must be
met: Pump flow rate
Grid
Evaluation of one variable speed pump
+ Broad flow rate adjustment + Low drive energy costs
FI range (with limited head
+ Swapping of the variable speed
range)
pump possible
+ High control quality
+ Redundancy on the pump side
– Limited use in the event of
+ Reduced switching frequency inlet pressure fluctuations
+ Reduced mechanical load – Limited working range in
variable speed operation
+ Reduced hydraulic feedback
effects – Medium purchase costs
Fig. 12 One variable speed
pump
10
Principles 1
1.1.3 The aim of the following calcu- This equation allows us to cal-
Characteristic Curve Conver- lation processes is to create a culate a second order parabola
sion at Variable Pump Speed pump performance chart which from the origin (Q = 0, H = 0)
includes all important character- through a point B2 (H2, Q2) in
If the pump and pumped fluid
istic curves. the H/Q diagram. The values of
are the same, the performance
H2 and Q2 are known, since the
data for a centrifugal pump in • Piping characteristic curve
parabola is to cut through this
variable speed operation vary (system characteristic curve)
point.
according to the following mod- • Controlled-operation curve
elling / affinity laws: H1 and Q1 are unknown and
• Pump characteristic curve will therefore be denoted as Hx
(nominal speed) and Qx in what follows.
Q1 n
= 1
Q2 n2 • Affinity parabolas The flow rate Qx will, depend-
Equation 1 • Pump characteristic curves ing upon the necessary accuracy,
(for reduced speeds) be assumed for several points on
the parabola and Hx then calcu-
H1 n1 2 • Pump characteristic curves for
= lated according to the derived
H2 n2 parallel operation
formula.
Equation 2 • Power characteristic curves,
The value pairs Qx and Hx are
(fixed speed / variable speed)
shown in table form in what fol-
P1 n1 3 for single pump operation and
= lows for the sake of a better
P2 n2 parallel operation
overview.
Equation 3 These results form the basis of
any economic calculation to be
In what follows, the pump char- performed.
acteristic curves will be calcu-
For the further calculation
lated for an example in which
process it is helpful to derive an
two pumps are operated in par-
equation that creates a relation-
allel (one pump continuously
ship between head and flow Key:
speed controlled, the second op-
rate. To this end, equation 1 is
erated at a fixed speed). B: Operating point
squared and inserted into equa-
H: Head
For simplification, we make the tion 2 (equation 4).
Q: Flow rate
assumption of a closed circuit
n: Pump speed
without static counterpressure. H1 Q1 2 n 2
= = 1 P: Power input at the
Using the calculation methods H2 Q2 n2
pump shaft
represented the user can also Equation 4 x: Sought quantity
solve cases with single pumps or
even multi-pump systems. For a
deeper understanding of the hy- Indices:
draulic interplay between pump
N: Nominal
characteristic curve and system
Rearranging once again gives 0: At zero flow
characteristic curve, we recom-
equation 5. 1; 2: Pump 1; Pump 1 + 2 in
mend that you work through a
parallel
few systems yourself, following
Q1 2 ...’: In fixed speed operation
the pattern given. For daily H1 = H2 ·
Q2 W: Leading value
work IT programs conveniently
Z: Intermediate points
support the calculation. Equation 5
11
1 Principles
Note:
The piping / system characteris-
tic curve for open systems with
static counterpressure is ex-
plained in Chapter 1.2.5.
The controlled-operation char- head available to cover the pip- • Operating behaviour of the
acteristic curve is a theoretical ing pressure losses and the use- consumer installation
curve along which the operating ful pressure at the consumer in- • Similar load behaviour over
time or time-independent
point should move. stallation.
load behaviour
It ensures that from the min- The value HW is dependent • System dimensioning
imum to the nominal flow rate upon the following influencing
there is always sufficient pump factors:
12
Principles 1
Pump Selection
H [%] System characteristic curve
A pump is selected that achieves 120 (full load)
40
found using the equation below.
ra
pa
i
ty
Given Sought
Qx Hx
15 9
25 25
35 56
13
1 Principles
la
abo
In many cases it is worthwhile
par
40
ity
selecting the point B1 at half the
fin
20
Af
pump flow rate.
0
2
Hx = H'B1 · (Qx / Q'B1 ) 0 20 40 60 80 100 Q [%]
2 Q’B1 QN
Hx = 115 % ·(Qx / 25 %)
Fig. 18
Given Sought
Qx Hx
10 18,4
15 41,4
20 73.6
25 115.0
2
H0.2 = H0 · (n2 / nN)
In the second step the head at H0.2 = 120 % ·(84 % / 100 %) = 85 %
2
14
Principles 1
Pump Characteristic Curve
H [%]
through B1 at Speed n1 B’0 B’1
H0 120
H’B1
The pump characteristic curve
100
through the operating point B1 Pump
80 characteristic
is calculated using the same cal- curve B1 nN
H0.1
culation process as before. HB1 n1
60
Speed at B1: 40
(Q1 = 19 %, H1 = 66 %)
20
0
HB1
n1 = nN · 0 20 40 60 80 100 Q [%]
H'B1 QN
65 %
n1 = 100 · = 76 % Fig. 20
115 %
Head at Q = 0 and n = n1
2
H0.1 = H0 · (n1 / nN)
2
H0.1 = 120 % ·(76 % / 100 %) = 69 %
Addition of the
H [%]
Pump Characteristic Curves
H0 120 Pump
1
The parallel operation charac-
100
teristic curve is found by adding B 0.2 B’4 B4
H0.2
the flow rates of the two indi- H4 80 Z’4
vidual characteristic curves: n2 Z4 B 4
60 Z’4 B 4
Q0 Z’4
Pump 1, fixed speed, 40
with nominal speed nN
20
Pump 2, variable speed,
0
with speed n2 0 20 40 60 80 100 Q [%]
QN
Starting from shut-off head H0
up to head H0.2 the flow rate is Fig. 21
generated by pump 1 alone.
Pump 2 cuts in at the point B’4
as counterpressure decreases.
The summed characteristic curve
of the two pumps intersects with
the controlled-operation curve
at B4 and head H4.
At this pressure level pump 1
provides the flow from Q0 to
Z’4 and pump 2 provides the
flow from Z’4 to B4.
15
1 Principles
Determination of Auxiliary
H [%]
Points and Intermediate
120
Characteristic Curves
BN
100
a) Operating point B3 with Z3 Z’3 B3
HZ3
auxiliary point Z3 80
B’4
Since the operating points BN 60
B 3Z’3
and B’4 are quite a long way 40
apart an additional operating
20 B 3Z’3
point B3 is placed in between.
The point QB3 = 85 % was se- 0
0 20 40 60 80 100 Q [%]
lected with the associated head QB3 QN
HZ3. At operating point B3 the
Fig. 22
pump delivers a flow at reduced
speed, which is represented by
characteristic curve for reduced We read off:
the distance between the points
speed this distance is moved left Distance Z3B3 = 26 %.
Z3 and B3.
to the origin at head HZ3. The
For the construction of a pump end point is Z3.
HZ3 n3 2
n3 = nN · H0.3 = H0 ·
H'B3 nN
90 % 89 % 2
n3 = 100 · = 89 % H0.3 = 120 % · = 95 %
113 % 100 %
16
Principles 1
Addition of the Characteristic
H [%]
Curves of Equally Sized Pumps L2 L2
120
1 and 2 at Nominal Speed
100
At a head of 100 %, for ex- Pump
s 1+
80 2
ample, the distance to the inter-
section with the characteristic 60
curve of pump 1 is measured
40 L1 L1
and the same distance marked
off to the right of the intersec- 20
tion. 0
0 20 40 60 80 100 Q [%]
Using this procedure, depending QN
upon the accuracy requirement,
further points for the summed Fig. 24
characteristic curve of the two
equally sized pumps 1 and 2 are
found.
20
0
0 20 40 60 80 100 Q [%]
Fig. 25
17
1 Principles
Fig. 26
20
0
0 20 40 60 80 100 Q [%]
Fig. 27
18
Principles 1
The further points are deter-
mined in the same way
n3 3
P3 = P'3 + P'3,n ·
N nN
3
89 %
P3 = 108 % + 80 % ·
100 %
P3 = 164.4 %
P4 = P'4 + P'4,n
2
n4 3
P4 = P'4 + P'4,n ·
N nN
3
84 %
P4 = 112 % + 52 % ·
100 %
P4 = 143 %
P5 = 2 · PN = 2 · 100 % = 200 %
HN - Hl,max 20
HW,min = HN - ·QN2
QN2 - Ql,max2
0
0 20 40 60 80 100 Q [%]
100% - 80% QI,max QN
HW,min =100% - ·100%2
100%2 - 65%2
Fig. 28
HW,min = 65 %
Notes: Input power in the event If the speed is reduced by less power of 3 as the speed falls, the
of a speed change than 20 % of nominal speed the slight worsening of efficiency is
If the speed is changed the efficiencies remain almost con- not important. In the worked
points of a throttled-operation stant. In the event of greater de- example no efficiency correction
curve move along second order viations the efficiency worsens was made.
parabolas to the other throttled- slightly. Since the power require-
operation curve. ment of the pump reduces by a
19
1 Principles
Influences Due to the Design upon the flow rate. It always teristic curve has no static com-
of the System contains dynamic components ponents and thus begins at the
that increase quadratically with origin (H = 0). In practice, to
The operating point of a cen-
the flow rate due to the flow re- prevent consumer installations
trifugal pump is always the
sistances – for example in circu- being undersupplied, the neces-
point of intersection between the
latory systems (heating). sary pressure graph lies above
system characteristic curve and
the system characteristic curve.
the pump characteristic curve. However, it may also incorpo-
Its precise path is dependent
All control methods thus change rate additional static compo-
upon the system in question.
either the pump or the system nents, such as differences in geo-
characteristic curve. detic head or pressure differ- The controlled-operation curve,
ences caused by other factors – along which the operating point
The system characteristic curve
for example in transport systems should move, must consequently
denotes the pressure require-
(pressure boosting). In circula- lie on or above the necessary
ment of the system depending
tory systems the system charac- pressure line.
al
ua
dd
ur
ad
on
cu
ra
II cu
n
20
Principles 1
Influences of the Pump pends upon the gradient of the vestment to motor size (€/kW)
head and the graph of pump ef- falls as the power increases.
The pump can influence the ex-
ficiency. In general: The steeper
tent of possible savings realized In multi-pump systems (as in
the pump characteristic curve,
by pump control in different our example with 2 operating
the flatter the power characteris-
ways: by the path of its charac- pumps) the economy calculation
tic curve.
teristic curve, by the different is performed according to the
motor sizes required and by the The motor size of a pump unit same way as described in the
design of the pump. The graph has an influence, since experi- following sections.
of the pump input power de- ence tells us that the ratio of in-
120
Chapter 1.1.3 only addressed
the different pump input power
requirements of the pumps 80 P E,u
(shaft power). However, if we P E
want to precisely determine the P W,u
electric drive power saved, the 40 P E,g
21
1 Principles
A Comparison of Three Sys- • In the H/Q diagram circulation systems. The consid-
tems With and Without Speed erations and predictions can eas-
• In the pump input power
Control ily be applied to open transport
curve
systems, such as water supply
On the following pages we will • In the savings diagram systems or waste water systems,
compare systems with and with-
The systems shown are closed for example.
out speed control:
1) Throttling configuration
with/without pump speed
control
Fig. 31
e
curv
drawn for several speeds in in- n = 70 %
p eration e
d-o ur v
Controlle u re c
crements of 10 % from the n = 60 % e ss
e d pr
40 n = 50 % R e q u ir
nominal speed down. The sys-
it
tem characteristic curve begins n = 40 % lim
ty
p du
at the origin of the H/Q dia- Pu m
0
gram, since it is a closed system, 0 20 40 60 80 100 Q [%] 120
and its path is parabolic. The
gradient of the system parabola Fig. 32
is dependent upon the losses in
the pipe network and thus also
upon the throttling processes of
However, for hydraulic and en-
the consumer installation. The
ergy reasons the pump pressure
fluctuation of the system charac-
should lie very close to this
teristic curve permitted by the
boundary. This means that the
pump is limited by the minimum
controlled-operation curve,
and maximum flow rate.
along which the operating point
In practice the required pressure (intersection of the system char-
curve lies above the system char- acteristic curve with the pump
acteristic curve. To prevent characteristic curve at the speed
undersupply at any consumer in question) moves, should lie as
installation, the pump pressure little as possible above the re-
must always lie above this curve. quired pressure curve.
22
Principles 1
Diagram: Pump input power
P W [%]
As for the H/Q diagram, at 120
(shaft power)
speed the pump input power is 80 thr
r in
powe
marked at 100 %. Like the input
Pump
pump characteristic curves, the Power saving
40
input powers are also drawn at Pump input power in
variable speed operation
speed increments of 10 %.
0
0 20 40 60 80 100 Q [%] 120
As the operating point moves
along the controlled-operation
Fig. 33
curve away from the design
point to a lower flow rate, the
associated shaft power of the
with the speed is intersected in shaft power requirements for
pump can easily be determined.
the input power diagram. The variable speed adjustment. The
The intersection of the con-
same procedure is followed for shaft power saved by the speed
trolled-operation curve with the
all intersection points. adjustment lies between this
pump characteristic curve in
curve and the input power in
question in the H/Q diagram is The intersection points can then
throttled operation and at con-
extended downwards until the be joined together in the pump
stant speed.
power curve that corresponds input power diagram, giving the
Diagram: Saving
∆P E [%]
The saving found from the 120
pump input power diagram is
now transferred. The motor effi-
electrical power
80
ciencies in fixed and variable
Saving in
23
1 Principles
2)Throttling configuration
with overflow valve and
with/without pump speed
control
Fig. 35
Pump head
-o p eratio e rv
e
Controlled u rv cu
drawn for several speeds in in- n = 60 % ss u re c ic
e t
ed p r ris
crements of 10 % down from 40 n = 50 % R e q u ir te
rac
a t
the nominal speed. The system ch mi
n = 40 %
s t em u t y li
characteristic curve begins at the Sy pd
Pum
origin of the H/Q diagram since 0
0 20 40 60 80 100 Q [%] 120
this is a closed system. Its path is
parabolic and should pass Fig. 36
through the design point (100
%) for fully opened consumer that is not required to be dis- acteristic curve is limited by the
installations. If the flow through charged. This means that the overflow valve – with the great
the consumer installations is re- pump almost always works at disadvantage that there is an al-
stricted, the overflow valve almost full power. Without most continuous wastage of
opens and allows the flow rate speed adjustment the possible drive energy.
pressure rise on the pump char-
24
Principles 1
Diagram: Saving
∆P E [%]
This power saving can again be 120
shown in its own diagram. This
electric power
clearly shows that the power 80
Saving in
saving potential resulting from
variable speed operation in a 40
system with an overflow valve is Electric power saving
significantly greater than is the 0
case for pure throttling. 0 20 40 60 80 100 Q [%] 120
Fig. 38
3) Bypass configuration
with/without pump speed
control
Fig. 39
era
drawn for several speeds in in- op
n = 60 % d-
lle
crements of 10 % down from tro
40 n = 50 % n
Co it
the nominal speed. The system lim
n = 40 % u ty
characteristic curve begins at the pd
Pum
origin of the H/Q diagram since 0
0 20 40 60 80 100 Q [%] 120
this is a closed system. Its path is
parabolic. The flow rate of the Fig. 40
pump is divided into a useful
and a bypass flow rate. Note:
Both flow rates can vary from In this hydraulic system the (dif-
0 – 100 % and always add up to ferential) pressure cannot be
100 %. This means that the sys- used as the sole controlled quan-
tem characteristic curve is always tity. In this case, pump oper-
constant for the pump and that ation is controlled, for example,
the pump operating point always as a function of the temperature
lies at the design point. If the difference.
pump speed is adjusted to the
system requirement, the operat-
ing point moves downwards
along the system characteristic
curve in part load operation.
25
1 Principles
Saving diagram
∆P E [%]
The saving between the fixed 120
speed and the variable speed
shaft power characteristic curve
electric power
80
can be clearly seen in the saving
Saving in
Fig. 42
Economy Calculation
H [%]
n = 100 % System characteristic curve (full load)
Comparison: Throttling config- 120
opt
uration with and without infi-
100 n = 90 % BN
nitely variable speed adjust- Qmax
n = 80 %
80
ment n = 70 % n cu
rve
ratio
Pump head
-op e e
Controlle
d c urv
This is based upon the H/Q dia- n = 60 %
p r e ssure
ed
gram (Fig. 43), the power dia- 40 n = 50 % Requir
it
lim
gram (Fig. 44) for the input n = 40 %
u ty
pd
power at the pump shaft, the Pum
0
diagram relating to the saving of 0 20 40 60 80 100 Q [%] 120
26
Principles 1
approximately 50 % of the flow
P W [%]
rate is permanently required 120
over 1000 hours; the associated
100
(shaft power)
80 rottling co
38 %. Multiplying the saved r in th
powe
input
electric power with the propor- Pump
Power saving
40
tional operating hours and the
Pump input power for
price of electricity yields the sav- speed adjustment
ing for the time period in ques- 0
0 20 40 60 80 100 Q [%] 120
tion. Now we must only add up
the proportional savings. The re- Fig. 44
sult obtained is a saving of ap-
prox. € 232 per year (based
∆PE [%]
upon 1 kW consumed nominal 120
power).
electric power
non-dimensionally to improve
40
comparability. Following the
Electrical power saving
same pattern, however, effective
0
figures can also be used in the 0 20 40 60 80 100 Q [%] 120
calculation for each specific ap-
plication. For example, if the Fig. 45
shaft power required at nominal
load is 10 kW, approx. € 2320 8760 [h][∆h]
per year can be saved.
1000 1000 1000 1000 1000 1000 1000 1000 760
Standstill
6400
Economy consideration
Operating hours
27
1 Principles
28
Principles 1
1.2.3
Control Terminology Based
upon the Example of Pump
Control
X
4 - 20 mA
Measurement
location
Y1 :0-10 V
Controller Z1 Z2
(Xs ) W Feedback
transmitter
Y2 for differential
5 - 50 Hz pressure
Consumer
1 installation 2
(variable load
Frequency behavior =
inverter Signal
interference
quantity)
Heat
exchanger
Controlled system
Fig. 48
1.2.4
Controlled Quantities for
Closed Hydraulic Circuits
p
Differential Pressure Depend-
Pump Consumer
ent Control installation
29
1 Principles
30
Principles 1
In differential pressure control
for heating pumps we currently H
differentiate primarily between
the control methods ∆p constant
and ∆p variable. Hmax
∆p-c
Hs
Control method ∆P constant 1/2 Hs ∆p-v
The electronics holds the differ-
ential pressure generated by the Hmin
pump constant over the permis-
sible flow rate range at the set Q
differential pressure value HS.
Fig. 50 Control methods ∆p-constant and ∆p-variable
Applications:
Optimal control method:
In two-pipe heating / cooling
Constant differential pressure at
systems with thermostatic valves
the point of lowest differential
that have high load authority
pressure (not easily realizable).
(previously gravity systems),
generously dimensioned systems
(resistance of piping small com- Simple alternative:
pared to the resistance of the
thermostatic valves). Constant differential pressure
∆p-c at the pump.
Floor heating with individual
room temperature control.
Problem:
31
1 Principles
ectly. era
op
n = 60 % d-
olle
r
40 n = 50 % nt
Co it
The following applies: n = 40 % li m
u ty
pd
Pu m
• Full load output of the pump 0
0 20 40 60 80 100 Q [%] 120
only at max. heat consump-
tion.
Fig. 51
• Automatic speed and flow rate
reduction in the event of
falling temperature difference Applications: Note:
and at the same time a reduc-
Use in circuits with a largely Do not use in circulation sys-
tion in pump input power.
constant flow rate and constant tems (e.g. in heating systems)
or variable supply temperature, with a variable flow rate.
e.g.
Due to the transport times of the Since during throttling the heat-
conveyed fluid long idle times • On the primary side ing medium in the heating unit
may occur, which can impair – Changeover cools off more quickly as a re-
fault-free control. The use of – Injection circuit sult of the longer transit time.
additional measures, such as – Low differential pressure The higher temperature differen-
secondary differential pressure manifold tial leads to higher speed, which
control, allows such systems to • On the secondary side however leads to the reversal of
be controlled. – Return mixing circuit and the desired effect, since throt-
injection circuit (without tling means that less heating
consumer-side throttling) power is required and therefore
a lower flow rate, less discharge
head and reduced speed.
32
Principles 1
Return Temperature (TR) The following applies to pump
Dependent Control output control in heating sys-
tems:
The return temperature depend-
ent control of pumps is generally
Low external temperatures High external temperatures
used in heating/cooling systems
왔 왔
with heat exchangers that do high heat demand low heat demand
not use throttling and have a 왔 왔
constant supply temperature. low return temperature high return temperture
The prerequisite is a load-de- 왔 왔
high pump speed low pump speed
pendent, variable return temper-
왔 왔
ature.
high mass flow rate low mass flow rate
왔
low power consumption
Applications: Note:
Well suited for systems without • A minimum circulatory flow
throttle units and with a con- rate must always be guaran-
stant supply temperature. teed for reliable function (see
Fig. 2).
• The operating limits for the
cold/heat generator must be
adhered to.
33
1 Principles
Supply Temperature (Tv) flow and it can be used in al- flow temperature is thus
Dependent Open / Closed most any such system. The pre- matched to the system load. The
Loop Control requisite is a supply temperature pump speed and thus the flow
controlled by atmospheric con- rate are adjusted according to
The supply temperature depend-
ditions based upon an automatic the supply temperature:
ent open-loop control of pumps
mixing configuration or a low-
is primarily used in heating sys-
temperature boiler with tempera-
tems with a constant volumetric
ture adjustment option. The nmax
Pump speed
Low external temperatures High external temperatures
왔 왔
high supply temperature low supply temperature Control line
왔 왔
high consumption low consumption nmin
왔 왔
high pump speed low pump speed
왔 T min Supply temperature T max
low pump power consumption
Fig. 53
Apart from the supply tempera-
ture dependent open-loop con-
trol described above there is also
supply temperature dependent p
closed-loop control, in which Pump Consumer
installation
the supply temperature should
TV
be held constant. This is the case
TA TV Heat/
in heat recovery systems, for ex- Controller cold
generator
ample. In such systems the sup-
ply temperature is to remain
constant despite the varying in-
H [%]
coming heat. This means, at 120
n = 100 % System characteristic curve
era
op
n = 60 % d-
o lle
r
40 n = 50 % nt
Co it
n = 40 % y li m
t
du
Pu mp
0
0 20 40 60 80 100 Q [%] 120
Fig. 54
34
Principles 1
1.2.5
Controlled Quantities for Open
Circuits
Pressure Dependent Control
Pressure dependent control is p
Min.
particularly suitable for open
systems with variable volumetric
flow. This is brought about by
various withdrawal rates (throt-
tling) at the consumption points. Nominal operating point
Nominal head BN
The task of the variable speed HN Controlled-operation curve A
pump is to supply sufficient Controlled-
operation curve B Hdyn
pressure (flow pressure) to the urve
istic c
consumption points. Due to the System character
Applications: Note:
• Water supply systems The influences of any variable
Drinking water inlet pressure and difference in
Pressure boosting geodetic head or counterpres-
Fire extinguishing systems sures must also be taken into
account in the design of pumps
• Industrial processes
and control systems.
• Cooling systems
35
1 Principles
Applications: Note:
e.g. in In addition to the signal trans- If there is a danger of blockages
mitter required for system con- or operating errors it is recom-
• Waste water treatment
trol, devices that protect the mended that the pump flow rate
• Cooling water systems tank against overflowing and is also monitored.
• Process technology stop the level from falling below
If the total flow rate is split be-
the minimum level must also be
tween several pumps (peak load
provided in the tank.
pumps), particular attention
In the design of the pump/trans-
These protective devices should should be paid to the operating
port concept attention should be
always be independent of the method of the control system.
paid to the combined effects of,
control system’s signal transmit-
and interaction between, the fol-
ter (in the simplest case by
lowing variables:
means of separate float
Supply, discharge, tank switch- switches).
ing volume, pump size, control
speed.
36
Principles 1
Flow Rate Dependent Control
The objective of this is to hold
the flow rate at a desired value.
Interference factors, such as
fluctuating inlet pressure or re-
sistance (e.g. due to dirty filters) Treatment
system
must be compensated. The H/Q Q
Winter water level
curve / controlled-operation
curve should be a vertical line Summer water level
H [%]
n = 100 % Controlled-operation curve
120
n = 90 % e
ic curv
100 r s ystem ch aracterist
Summe
n = 80 %
80
n = 70 %
n = 60 %
40 n = 50 %
curve
acteristic
Winter system char
Hstat
0
0 20 40 60 Qset 100 Q [%] 120
Applications: Note:
• Water treatment systems The influences of any inlet pres- Flow (rate) transmitters shall be
sure variations, geodetic head selected in accordance with the
• Cooling processes
differences or counterpressures requirements of the fluid and the
• Mixing tasks must also be taken into account external operating conditions.
• Waste water treatment in the design of pumps and con-
trol systems.
37
1 Principles
1.2.6 To this end the effects of the ference factor. The variable vol-
Compensation of Additional main interference factors must umetric flow results in different
Interference Factors be offset. In the following two pipe friction quantities. Two
examples the throttling behav- possibilities for offsetting this
The task of the control system is iour of the consumer installa- additional interference factor are
to manage the process optimally. tions represents the main inter- described below.
Compensation by the Q1 = 50 %
HV,1= 20 %
Selection of the Correct 1
Measurement Location Q2 = 50 %
HV,2= 20 %
2
We will now highlight the influ- QN = 100 %
HN = 100 % HV,P - V = 40 %
ence of the measurement loca- P
Feed manifold Return manifold
38
Principles 1
System characteristic curve
Development:
1 2
Pressure losses in the pipeline
sections are plotted over the 1 2
flow rate. If the flow rate in-
creases linearly the pressure loss
increases quadratically. Para- H H
consumers. H 1
The required pressure curve If both consumer installations sure between feed and return
are closed (Q/QN = 0) there is manifold is constant and in-
Measurement location II
no flow, and thus no flow losses. creases continuously over the
There must always be a suffi- The pump works at such a low length of the main pipelines to
cient pressure difference be- speed that the set value (Hset) is the pump depending upon the
tween feed and return manifold, just maintained. If a consumer flow rate (up to the nominal
so that the consumer installa- installation is opened there is a flow rate at nominal heads).
tions are always adequately sup- flow in the main pipelines ac- Pump control (pressure / differ-
plied. Depending upon the con- companied by pressure losses. ential pressure control) is opti-
sumer installation in question, However, in order to be able to mal if the controlled-operation
various load states can exist. For maintain the set value, the pump curve lies on or only slightly
example, each consumer instal- must increase its speed and gen- above the required pressure
lation could be loaded at be- erate more pressure. Since the path.
tween 0 - 100 % independently pressure loss increases quadrat-
of one another. ically in relation to the flow
To ensure that the consumer in- rate, the controlled-operation
stallations are adequately sup- curve II takes on a parabolic
plied at all times, in the example shape. The pump generates only
shown the required pressure as much additional pressure as is
path is assumed to be such that necessary to compensate for the
at least the nominal pressure re- dynamic pressure losses that
quirement of the consumer (here arise.
Hset) exists between feed and re- This is also particularly clear in
turn manifold. the pressure diagram. The pres-
39
1 Principles
Measurement location I at the We see that, particularly in low We see clearly here that despite
pump part load operation, the gener- speed control the pressure is too
ated pump pressure lies above high at the feed manifold in part
If the differential pressure is
the required pressure path. load operation. This excessive
measured at the pump, the tar-
pressure can have an un-
get value must be set at the In the pressure diagram the pres-
favourable effect upon the con-
nominal head. In the H/Q dia- sure is constant at the pump and
sumer behaviour. In any case,
gram this means that the pump decreases along the main
however, too much pump energy
pressure is constant over the en- pipelines depending upon the
is expended.
tire flow rate range (horizontal flow rate.
controlled-operation curve I).
Compensation by means of
Additional Measured Variable
(Flow Rate)
Feed
For various reasons it is not al-
ways possible to measure a long
Flow rate
way from the pump and near to measurement Controller
the least favourably situated (4 ... 20 mA)
consumer installation. This ap-
plies to district heating systems, Differential
pressure
p sensor
where very long distances have
to be bridged or, for example,
Frequency inverter
systems that are constructed ac-
cording to the plan in Figs. 61
and 62.
Heat/
Return
40
Principles 1
Controller
Frequency
inverter
Flow Pressure
rate
Applications: Note:
• In building restoration with Modern control systems are cap- • Pressure requirement of the
insufficient system data able of calculating the optimal consumer installation.
controlled-operation curve auto-
• In the event of undersupply in This is also possible without
matically.
various load states (by vari- flow rate measurement.
able controlled-operation This requires the following oper-
curve) ating data
• In the event of long signal • Nominal head
transfer distances
• Nominal flow rate
41
1 Principles
42
Principles 1
1.3.4
Further
Pump-specific Functions drives
Slave drive
In addition to open and closed
loop control, other important
functions for integrated pump
drives include dynamic pressure
compensation, a memory func-
tion, minimum flow tripping,
dry-running protection, inertia-
p+
secure start function and real Master drive
time clock functions.
• Due to dynamic pressure com-
pensation in variable speed
operation, pipe friction losses Set value Consumer
(internal / external) installation
can be compensated when a
Heat generator Differential p -
pressure sensor near the pump pressure sensor
is used, so that pressure re-
mains constant at the con-
sumer installations.
Fig. 64 Pumps with integral drive in a master/slave configuration
• A memory function records
the power input curve with a • An inertia-secure start func- An integrated pump drive can
closed pump discharge side tion is provided for shaking a generally be used as a variable /
throttle. This data is required blocked shaft loose by gener- fixed speed single drive or in
to activate the “minimum ating an alternating torque. Master/Slave mode.
flow tripping” and “dry-run-
ning protection” functions. • The internal real time clock of In Master/Slave mode several
the drive means that time- drives can be operated in paral-
• Minimum flow tripping (en- dependent functions, such as lel. In the event of a fault the
ergy saving function) ensures time-of-day and day-of-week master function can be assigned
that in closed loop control programming, pump change- to another drive. The necessary
mode the drive is switched off over and night-time setback data exchange takes place via an
as soon as the flow rate falls can be selected. internal bus system. No addi-
below a preset minimum tional external control equip-
value. This is to avoid wearing ment is required for this applica-
out the pump. When demand tion.
rises again, the pump is
switched back on automatic- Fig. 64 shows a differential pres-
ally. sure control setup in a heat sup-
ply system in which several
• If the dry-running protection drives can work in master/slave
function is activated, the mode.
motor is stopped if the power /
speed ratio falls below a
stored value due to dry-run-
ning to protect the pump
(mechanical seal) and the
system goes into fault mode.
43
1 Principles
1.3.5
Economy / Reduction of Life
Cycle Costs
The extra costs for an integral
pump drive are, as is the case for
other speed-controlled pump
drives, recouped after just a few
years due to the power saving.
Moreover, an integral drive for
pumps offers further savings po-
tential.
The following important points
can be mentioned:
• Very low installation and com-
missioning cost
• Low space requirement
• Further power savings possi-
ble by minimum flow tripping,
time-programming, night set-
back
• No downtime due to parallel
operation of pumps
Due to these potential savings
and possibilities offered by a
modern integral drive, the inte-
gral drive offers clear advan-
tages over conventional solu-
tions with regard to life-cycle
costs.
44
Principles 1
1.4 The technical building equip- This results in tasks including
Principles of Communication ment comprises various systems the following:
Technology (HVAC = Heating Ventilation
• Operations management
Air Conditioning), e.g.
• Modern building management • Operations monitoring
systems are used in large • Heating
buildings • System automation
• Sanitary (supply and disposal)
• Building management systems • Energy management
• Air conditioning / ventilation
provide “intelligent” input to • Maintenance management
the operating systems and • Electric
• Data archiving
technical building equipment • Measurement, open and
closed loop control technology • Operational analysis
• Building management systems
create open communication
between the automation and Only by planning that covers all
control systems. systems can neutral building
management systems be created
which fulfil the expectations of
the operator.
Serial
data transfer
S R
(new)
S: Sender R: Recipient
45
1 Principles
Vertical communication
via LON interface
Open/closed-loop control, monitoring
46
System Automation Terminology and Planning Notes 2
2 If a pumping task is to be Regarding b)
System Automation solved, various operating condi-
If technical requirements are
Terminology and tions have to be taken into ac-
such that the task cannot rea-
Planning Notes count, e.g. acquisition and oper-
sonably be handled by one fre-
ating costs, operating reliability
The planning of circuits of all quency inverter alone, there is
(stand-by equipment), process
voltage levels covers the collec- the option of using several duty
conditions, desired operating be-
tion of operating conditions and pumps with several frequency
haviour, etc.
the specification of the system inverters. This makes it possible
concept and the planning prin- We can proceed with project to manage difficult system con-
ciples to be used for implemen- planning in the following order: ditions (e.g. greatly fluctuating
tation. The project planning inlet pressures, frequent part-
a) Flow rate to be split between
phase represents a period of load operation) reliably and eco-
one or more pumps
intensive co-operation between nomically in addition to achiev-
the principal, his engineering b) One or more frequency ing increased operating reliabil-
consultant, and the contractor. inverters ity.
47
2 System Automation Terminology and Planning Notes
2.1
General Electrical Notes
Power Supply System Types
TN-C system
L1
The neutral point of the voltage L2
generator is directly earthed. L3
PEN
The housing of the connected
operational equipment (control
cabinets, motors, etc.) is con-
nected to the neutral point via RB
the combined neutral and pro-
tective conductor (PEN). Fig. 68 TN-C system
TN-S system L1
L2
As above, but protective con-
L3
ductor PE and neutral conductor N
N are laid separately. PE
RB
Fig. 70 TT system
48
System Automation Terminology and Planning Notes 2
Earth Leakage Circuit Breakers Ambient Temperature the value for delta operation.
(ELCB) This is the most common start-
In compliance with the relevant
ing method. (It is less well suited
Earth leakage circuit breakers DIN and VDI provisions the fol-
in the event of a high load mo-
disconnect all poles of operating lowing simplified system classifi-
ment of inertia and small motor
equipment within 0.2 s as soon cation can be made:
moment of inertia due to a
as an electric shock hazard
• Ventilation devices and sys- marked speed reduction in the
occurs due to an insulation fault.
tems for aeration and deaera- switchover pause).
ELCBs are designed for different tion, e.g. if the permissible
nominal leakage currents. ambient temperature is higher
than the (maximum) external Soft starting
Designs with tripping currents
temperature. It is possible to soft start three-
of 30 mA also act as personnel
protection. At greater tripping • Cooling devices and systems phase asynchronous motors us-
currents protection against fires for pure heat removal, e.g. if ing fully electronic soft start de-
ignited by earth leakage currents the permissible ambient tem- vices. In this process the start-up
dominates. perature is less than or equal current, and thus the start-up
to the (maximum) external torque, is deliberately influenced
Devices with rectifier circuits
temperature. by the voltage dosing (phase
(e.g. frequency inverters), in
angle control).
which direct leakage currents • Air conditioning devices and
can occur in the event of a fault, systems for the air condition-
may not be operated behind ing of rooms if certain room We can differentiate between:
ELCBs. In these cases so-called climatic conditions must be
universal ELCBs (for all types of adhered to in addition to heat • Soft starters with adjustable
current) with a higher tripping removal (temperature, mois- run-up period (current limit-
current are used. ture, air quality, etc.) ing only possible by increasing
the run-up period)
• Soft starters with adjustable
Power System Dependent Pro- Starting Method (Starting maximum start-up current
tective Measures Process) for Squirrel-Cage (the start-up time is auto-
Motors matically adjusted via the
Power system dependent pro-
tective measures are protective Squirrel-cage motors (asyn- moment balance between
measures using protective con- chronous three-phase motors) motor moment and load
ductors. The protective conduct- have high starting currents. In moment).
or (PE) is connected to the in- order to prevent disruptive volt- • Soft starters with combined
active bodies of the electrical age fluctuations, power supply adjustment of run-up period
operating equipment. Protective companies prescribe certain and max. start-up current.
conductors and PEN conductors starting methods for high power
are marked in green/yellow. motors. For motor powers
above 4 kW certain starting pro-
In power system dependent pro-
cedures are necessary for three-
tective measures, line-side over-
phase motors.
current protective devices switch
the power off and a fault mes- Star delta starting
sage is generated in the IT sys-
When starting using a star delta
tem.
circuit the starting current and
starting torque of three-phase
motors are reduced to a third of
49
2 System Automation Terminology and Planning Notes
50
System Automation Terminology and Planning Notes 2
Selection of controlled
quantity Specify controlled
quantity Possible controlled quantities
Temperature
The objective of the following
Level
considerations is to find a con- Closed no
.............
pipe system
trolled quantity that permits the (open)
51
2 System Automation Terminology and Planning Notes
Set Value /
Set Value Switching n = 100 % Quadratic
120
n = 90 % opt Linear
In systems that do not impose
52
System Automation Terminology and Planning Notes 2
Monitoring the Pumps and the Thermistor type motor protec- Flow monitoring
Hydraulic System in the Auto- tion
Flow monitors are used to pro-
matic Operating Mode
Greatly increased protection is tect the pumps against overheat-
Even in the planning phase it is offered by temperature measure- ing due to zero delivery. Flow
important to provide a suitable ment in the motor to be pro- rates that fall below the limit
reliability concept for the entire tected. value briefly are unproblematic
system. The objective of this is for the pumps and are not taken
PTC thermistor detectors fitted
to limit faults and, as far as pos- into account (e.g. during run-
in the motor winding directly
sible, to maintain the function of ning up and running down
monitor the temperature of the
the system. Impaired functional processes).
motor winding. When the nom-
groups are switched off and,
inal response temperature of the In accordance with the main
where available, replaced by
PTC thermistor is reached its re- goal of the reliability concept –
stand-by groups or emergency
sistance increases sharply, and maintaining the operation of the
functions. The most important
the motor is switched off. Indi- system where possible – differ-
monitoring functions for electric
vidually, klixon or other tem- ent reaction modes can be se-
and hydraulic limit values are
perature monitors based upon lected depending upon require-
explained in what follows.
bimetallic technology are also ments. The requirement to pro-
used for motor protection. If tect people takes precedence
continuous temperature meas- over all protective and emer-
Excess current monitoring
urement is also desired, PT 100 gency functions.
Basic protective function for an sensors can also be used.
electric motor against thermal
overload in direct operation on
the power supply system. Cur- Dry-running protection
rent-dependent protective de-
To protect the pumps, monitor-
vices that monitor the tempera-
ing takes place to establish
ture of the motor winding indir-
whether sufficient pumping
ectly by means of the current
medium is present. This can be
flowing in the supply line. This
determined by various measur-
generates a current-dependent
ing procedures. If the value falls
picture of the heat buildup in
below the set limit value the sys-
the motor. Over-current relays
tem is completely shut down
(bimetal) with a protective and
and the corresponding message
back-up fuse or an over-current
provided. The system can be re-
trip in a motor protection switch
started manually or automatic-
are used. An over-current trip
ally, depending upon the safety
behind a frequency inverter (FI)
requirements. In any case, the
remains inactive since the FI
fault message should be saved
limits the output current to a
for the operating personnel.
value below the tripping current.
Therefore, in the worst case a
blocked motor is supplied at
nominal current and overheats
due to lack of cooling.
53
2 System Automation Terminology and Planning Notes
54
System Automation Terminology and Planning Notes 2
Flow monitors Temperature sensors: Installation
Common measurement prin- Measurement Principle: • Assembly (electrical and
ciples: mechanical) of the set up
Temperature-dependent resist-
control cabinet modules takes
• Calorimetric ance change
place in-situ.
• Flow paddle Note:
• The laying and routing of
Note: Submersion sensors have rela- cables and lines for the power
tively long response times (slow supply, motors, detectors and
Flow monitoring devices are pri-
reaction to temperature centralized instrumentation
marily used as limit signal trans-
changes). and control connections takes
mitters for monitoring and con-
trol purposes (dry-running pro- The design should be based place on-site.
tection, minimum flow detec- upon the planned insulation of
tion). the pipe (sensor length).
The assembly of all components
The simple flow paddle is more into a functional system must be
sensitive to contamination and carefully planned due to the nu-
Documentation
pressure surges in the pumped merous interfaces. The following
fluid. The costs and level of complex-
summary includes the most im-
ity of the system are of decisive
portant electrical tasks.
importance to the content and
Level detectors scope of the documentation. For Assembly (electrical and mech-
smaller systems or manufac- anical) of the set up control
Common measurement prin-
turer’s standard systems, mass cabinet fields in-situ takes place:
ciples:
produced documentation is nor- Site-supplied – by the bidder
• Capacitive mally sufficient. – see separate
• Hydrostatic pressure For customized systems or large quotation
55
2 System Automation Terminology and Planning Notes
56
Project Planning Examples 3
3
Project Planning Examples
3.1
System Description
The system is a district heating
network. It comprises 26 heat Boiler
transfer stations with a differen-
tial pressure requirement of
18 m at the transfer points. The
heat transfer stations are con-
nected via heat exchangers. The Fig. 73 System diagram
primary side output is adjusted
by atmospheric conditions via a At this flow rate the piping sys-
throttle fitting. The district heat- tem calculation results in a pres-
ing system is designed for a sup- sure loss of 24 m to the most re-
ply temperature of 130 °C with mote heat transfer station.
a return temperature of 80 °C.
Due to the differential pressure
The planned new construction is
requirement of the heat transfer
based upon a maximum heat
stations of Hw = 18 m and the
output of 47 MW. The flow rate
maximum line losses of HT =
of 861 m3/h is calculated from
24 m a pump head of HN = 42 m
the maximum values of heat
must be met (provided).
output and temperature differ-
ential.
3.2
H [m]
Calculation of the
Piping Characteristic Curve 50
HN = 42
(see also page 12 Fig. 14) 40
30
Once the nominal flow rate 25
(QN) and line losses (HT) have Hw = 18 Piping characteristic curve
been determined the piping (full load)
10
characteristic curve can be con- 5
structed.
250 500 750 1000 Q [m3/h]
QN/2 = 430.5 QN = 861
2
Hx = HT · (Qx / QN)
2
Hx = 100 % · (Qx / 861 m3/h) Fig. 74 Piping characteristic
Given Sought
Qx [m3/h] Hx [m]
250 2
500 8.1
750 18.2
861 24
57
3 Project Planning Examples
3.3
Further Steps in Accordance
With the “Project Planning Se-
quence Plan”
(please refer to page 71)
Possible controlled quantities Since the consumer behaviour determines the system resistance, the
– differential pressure
differential pressure is the correct controlled quantity.
– ..................
H [m]
Calculation of the controlled-
operation curve (see 1.1.3) 50
HN = 42 ath
ep
40
essur
pr
ired
30 r requ
urve o
25 ration c
Controlled-ope
Hw = 18
10
5
Fig. 75
58
Project Planning Examples 1
왔 The next step is to determine the Hw ≅ 18 m must be maintained.
required differential pressure As the flow rate increases the
curve. piping losses are added to this
value (see also piping character-
To prevent undersupply at any
istic curve).
of the heat transfer stations the
minimum differential pressure The origin of the parabola is
must be 18 m. This means that moved to the level of the set
even at minimum consumption value by a small expansion of
≅ 0 m3/h this minimum pressure the formula.
Due to the output data and the typical load behaviour (frequent op-
Flow rate split between one or eration at part load), the total flow rate should be split between two
more pumps
pumps.
59
3 Project Planning Examples
H [%]
Pu m p 1
120
B I,N
HN 100
BN
B I,max
80
n curve
HW Controlled-operatio
60
40
20
0
0 20 40 60 80 100 Q [%]
QN/2 QI,max QN
From the relationships described for part load operation it is clear that
Determine shaft power the individually operated base-load pump requires its maximum shaft
power (Pw, max) at the point B1, max. This value can be read off the
pump diagram in question or calculated using the power formula.
Caution! The maximum shaft power of the base-load pump is
greater than is the case for QN2.
60
Project Planning Examples 3
왔 H [m] H/Hopt
n ~ 100 %
1.2
Controlled-operation curve
HN = 42 n ~ 90 % opt
1.0
40 P1(n N)
0.8 n ~ 80 %
30 Qmax
n ~ 70 % Parallel operation P1 + 2(n N)
25 0.6
Hw = 18 0.4 n ~ 60 %
10 0.2
5
0
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 Q/Qopt
1.3
250 500 750 1000 Q [m3/h]
P [kW] P/P opt QN/2 = 430.5 QN = 861
2.2
140
130 2.0 P1 + 2
120 1.8 ti on
p era
110 do
1.6 o ttle
100 Thr
90 1.4
80 1.2 n Power consumption in
tio
70 pera variable speed operation
1.0 le do P W,max
60
hr ott
50 0.8 P1 T
Saving
40 0.6
30
0.4
20
0.2
10
0
0 0.2 0.4 0.6 0.8 1.0 1.21.31.4 1.6 1.8 2.0 2.2 2.4 2.6 Q/Qopt
61
3 Project Planning Examples
62
Project Planning Examples 3
왔 H [m]
n ~ 100 %
Controlled-operation curve
HN = 42 n ~ 90 % opt
40 P1(n N)
n ~ 80 %
30 Qmax
n ~ 70 % Parallel operation P1 + 2(n N)
25
Hw = 18
n ~ 60 %
10
5
0
250 500 750 1000 Q [m3/h]
P [kW] QN/2 = 430.5 QN = 861
140
130 P1 + 2
120 on
ti
pera
110 do
ot tle
100 Thr
90
80 Power consumption in
on
70 er ati variable speed operation
op
led P W,max
60
hr ott
50 P1 T
Saving
40
30
20
10
0
250 500 750 1000 Q [m3/h]
QN/2 = 430.5 QN = 861
8760 h [∆h]
1000 1000 1000 1000 1000 1000 1000 1000 760
Standstill
6400 h
Operating hours
63
3 Project Planning Examples
Economy calculation
∆PE B S ∆EE
kW h/a Euro/kWh Euro/a
19 1000 0.10 1,900.--
15 1000 0.10 1,500.--
21 1000 0.10 2,100.--
26 1000 0.10 2,600.--
26 1000 0.10 2,600.--
28 1000 0.10 2,800.--
25.5 400 0.10 1,020.--
Result: Σ 14,520.--
Under the assumed
conditions, annual electricity
cost savings of Key:
approx. € 14,500 can be
∆PE : Saved electrical power
expected for the circulating
pumps. B : Operating hours
h/a : Hours per year
Depending upon the
S : Electricity costs
influencing factors a payback
period between 1.8 and 2.9 ∆EE : Saving on electricity costs
years can be expected. ∆EE = ∆PE · B · S
64
Reasons for Pump Automation and Control 4 4
4
Reasons for Pump Automation
and Control
4.1
Operational Reliability
4.2
Improving Operating Behaviour
a) Holding process data constant e.g. •Differential pressure in dis- Benefits:
trict heating systems • Process optimization ensures
•Pressure in pressure boosting uniformly high quality
systems
•Level in sewage works
•Flow rate in water treatment
65
4 Reasons for Pump Automation and Control
4.3
Increasing Product Quality
a) In machine tools e.g. •Constant pressures in cooling lu- Benefits:
bricant systems • More accurately dimensioned
•Lower transfer of heat from the workpieces
pump into the cooling lubricant
4.4
Reducing Operating Cost / Life-Cycle Cost
a) Effective requirement e.g. •Adaptation of the pump output to Benefits:
optimization the requirement profile of the sys- • Reduced investment cost
tem • Saving in electricity costs
d) Reduced energy loss of e.g. •In district heating the overflow Benefits:
the system valve seldom trips in, therefore less • Saving in fuel costs
heat is lost into the earth
e) Modified flow rates for •Water shortage by reduction of the Benefits:
set value characteristic curve • Protection of water reserves
4.5
Improving System Information
a) Pump operating data e.g. •Capture Benefits:
•Summarization • Determining weak points
•Assignment • Information on operating se-
•Evaluation quences
•Display • Optimization of the system
• New findings that feed into plan-
ning of new systems
b) Process information e.g. •Evaluation of sensors Benefits:
•Storing of measured values, fault • Reduction of the inspection and
data, etc. servicing cost
•Operating statistics • Early detection of damage
•Fault detection and diagnosis
•Trend recognition
66
An Overview of Automation Concepts 5
5 Fixed speed Variable speed
An Overview of Automation 1 2 Several
Concepts Frequency Frequency frequency
inverter inverters inverters
Depending upon the pumping
task requirement and the operat-
ing conditions to be observed,
various electrical and hydraulic
circuit concepts may be the most
favourable solution. These range
from one variable speed pump
to several equally or differently
sized pumps with one or more
frequency inverters. Hydraulic-
ally, the options range from
pumps connected in parallel
through pumps connected in
series to a combination of both.
Figs. 79 and 80 show an
overview of the most common
circuit options. Some parallel
configurations are briefly de-
scribed on the following pages. Fig. 79 System diagram “Parallel connection of centrifugal pumps”
P1,2
P1,2
Qmax,2
P2 H1,2
Qmax,1
P1 H1,2
Qmax,1,2
P2 H2
Qmax,1,2
P1 H1
67
5 An Overview of Automation Concepts
5.1
Parallel Connection of Identical Process
Pumps with One Frequency
Inverter
(one pump in variable speed
operation on an alternate
basis)
The flow rate is split between Set value Pressure
Transmitter
several equally sized pumps, re- transmitter
sulting in:
Automation
• Good adaptation to demand devices
180 ion
rat
If the pump output is reduced – ope
160 ot tled
by reducing the speed – only a Thr
140
greatly reduced shaft power is 120
ion Variable speed operation
rat
required. This effect is also 100 d ope
ottle
80 Thr
achieved after peak load pumps Saving P1
60
have cut in.
40
20
0
0 0.2 0.4 0.6 0.8 1.0 1.21.31.4 1.6 1.8 2.0 2.2 2,4 2.6 Q/Qopt
68
An Overview of Automation Concepts 5
5.2
Process
Parallel Connection of Identical
Pumps with Two Frequency
Inverters
(2 pumps in variable speed op-
eration on an alternate basis)
The flow rate is split between
Set value Pressure
several equally sized pumps. Transmitter
transmitter
Each pump unit can be operated
on each of the two frequency in- Open-loop control
verters and on the 50 Hz grid. Closed-loop control
pressures 0.4
0.2
• Better part load efficiency 0
with more than two operating 0 0.2 0.4 0.6 0.8 1.0 1.21.31.4 1.6 1.8 2.0 2.2 2.4 2.6 Q/Qopt
pumps.
Fig. 84 Power diagram for the “parallel connection of centrifugal pumps”
69
5 An Overview of Automation Concepts
P1(n N)
by a small pump. As a result, the 80
n ~ 80 %
Base load pump
following should be achieved: Qmax
60 Parallel operation P1 + 2(n N)
20
• Minimum flow rate to the
0
main pumps ensured 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4
1.3
1.6 1.8 2.0 2.2 2.4 2.6 Q/Qopt
P [%]
• Reduction in switching fre- 240
quency at low load 220
200 P1 + 2
180 ion
rat
ope
160 ot tled
Fixed speed base load pump
Thr
140
120
ion Variable speed operation
rat
100 d ope
ottle
hr
80 Saving P1 T
60
40
20
Variable speed base load pump
0
0 0.2 0.4 0.6 0.8 1.0 1.21.31.4 1.6 1.8 2.0 2.2 2.4 2.6 Q/Qopt
70
An Overview of Automation Concepts 5
5.4
Further Electric Configuration Grid
Concepts from the KSB Prod-
uct Range
FIs
The optimal solution, from a
control point of view, is one in
which each pump/motor is as-
signed a frequency inverter. The
disadvantage of this is the higher M1 M3 M2 M4
equipment costs and a greater
space requirement. For certain
P1 P3 P2 P4
applications (e.g. district heating
with two supply and return
pumps each) this is the best so-
Fig. 87 Each pump is assigned a frequency inverter
lution.
71
Overview of Project Planning
Sequence
Determine controlled quantity
Closed
yes piping system no (open)
yes yes
Possible controlled quantities Possible controlled quantities Possible controlled quantities Possible controlled quantities
Temperature Differential pressure Pressure Temperature
– Supply temperature ................. ................. Level
– Return temperature ................
– Differential temperature
–................
................... .
Pump selection
System description
Tender texts
Economy calculation
72
Fax order form “KSB know-how” series
At your request, we will be pleased to send you all “KSB know-how” brochures previously published as
well as any volumes to be published in the future. All we need is your address and confirmation below.
Company:
Attn.:
Street address:
Post or ZIP code / City / Country:
KSB Aktiengesellschaft
Johann-Klein-Straße 9
67227 Frankenthal
www.ksb.com
Subject to technical modification without prior notice
We look forward to hearing from you.