Fierce competition reigns in the chemical industry, with companies under pressure to continuously improve the efficiency and effectiveness of their plant and equipment. Energy-intensive secondary processes such as pump applications offer significant cost-cutting potential and are increasingly in the focus of attention today. The ABB Industrial Drive ACQ810 is a new AC drive boasting very high energy efficiency for use in the water and waste water treatment industry.
The ABB Industrial Drive ACQ810 provides special pump control functions for single pumps and multi-pump systems as a contribution to trouble-free operation in water and waste water processes. In addition to cutting the lifecycle costs for the pumping system, these integrated, pump-specific functions save time and operating expenses, increase energy efficiency and reduce CO2 emissions. The ACQ810 is available from 1.1 to 400 kW (380 to 480 V).
One of the biggest advantages of the ACQ810 is its ability to realise energy savings compared to constant-speed technologies or conventional flow control meth-ods. Instead of allowing the motor to run permanently at full speed, the new drive module adjusts the speed of the motor according to the specific requirements of the application. A motor speed reduction of just 20 % is often sufficient to halve the normal energy consumption. Another 10 to 20 % can be saved by leveraging the ACQ810’s integrated intelligent functionality. An investment in the ABB Industrial Drive ACQ810 is typically recovered within two years based on the achievable energy saving alone.
Intelligent pump functions
Integrated energy saving functions like the energy optimiser significantly improve the energy efficiency of pump systems. The energy optimiser is a software based algorithm that is generated by a highly advanced motor model developed by ABB. The system consequently operates more efficiently. The energy optimiser reduces the motor magnetising current when the pump system is operating at partial load, thus lowering the losses of both the motor and the ACQ810. The overall efficiency of the drive system is maximised as a result, and this has a direct impact on the costs for energy.
The integrated energy counter displays the energy consumption as well as the energy savings in kWh or local currency. Energy consumption is compared to previous time frames defined by the user and if an increase is detected by the ACQ810, an alarm is generated. The automatic energy optimisation function of the AC drives enhances the efficiency of the drive.
Pump priority, sleep & boost and multi-pump control are among several other intelligent pump functions of the ACQ810 that help save energy.
Pump priority targets systems where the output at a given time is determined by actual consumption. The drive can be programmed, for example, in such a way that pumps with a higher output are used in the daytime and pumps with a lower output at night. This allows better maintenance planning and boosts energy efficiency by operating pumps closer to their best efficiency points; a smaller pump works more efficiently at a lower flow rate than a large pump, which has to be throttled.
Sleep & boost is suitable for pumping systems in which water consumption falls during the night. This function detects slow rotation during low-consumption periods and runs the pump to boost pressure prior to shutdown. The pump is prevented from switching off and then starting up again straight away because of fluctuations in the demand for pressure. The pressure is continuously monitored and pumping restarts as soon as it falls below a minimum level. The pump switch-off time is delayed as an effective way to save energy.
Multi-pump control is designed for applications where several parallel pumps are operated together and the required flow rate is variable. This function provides process stability, controls the variable flow rate precisely and optimises the pump speed as well as the number of pumps required. It represents the most energy efficient way to operate a system of parallel pumps.
The ACQ810 additionally integrate all the most popular functions for pump applications in water and waste water treatment processes. Some of these functions also help save energy. Pump priority is intended for systems where the consumption rate varies based on demand. The pumps can be operated so that the mean time between repairs is flexible. Optimised pump control not only means more effective maintenance planning but also more efficient use of energy because the pumps work closer to their best efficiency points.
To prevent sediment build-up on the tank walls, the surface level is randomly varied within a range preset by the user using the level control function. The flushing effect obtained by starting up with short ramp times results in cleaner pipes. An efficiency speed for the best operating point can be specified for each pump to reduce overall consumption to a minimum.
Plant components protected
In addition to significantly lowering energy consumption, the ACQ810 also extends the life of the plant and its components by avoiding wear, improving process control and eliminating, or at least reducing, starting and load impulses – and all this for an extra investment that is paid back in less than two years thanks to the massive energy saving. From year three onwards, the owner begins to make a profit while simultaneously helping to protect natural resources.
Online-Info www.cpp-net.com/2310447
Share:
