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In real-life engineering applications, pumps will usually not be replaced once they have been selected and installed. In other words, in a pipeing system, the models of the pumps are fixed and unchangeable, while the operating point of the pipeline system is determined by the load (flow) demand, which varies under different conditions. Therefore, in order to meet the demand, the pumps are usually selected according to the maximum load demand, which gives rise to a mismatch between the actual loads and the capacity of the pumps, resulting in low energy efficiency of the pumps.
ENERGYWIN’s pumping efficiency technology can solve the problem of mismatch between the pumps and the pipeline system. Our independently developed automatic control software (Patent application number: 200910131127.6) enables the pumps to automatically recognize and adapt to the changing process demand and conditions within a certain flow range. The software will control the pumps to always operate in the optimal energy efficiency range, resulting in minimum electricity consumption.
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ENERGYWIN’s energy-saving control system includes the following hardware modules: IPC/Microprocessor/PLC, parameter-setting module, touch screen, input module, output module, communication module, data storage module, data conversion module and measurement sensors, etc. The control process of the system is shown below:
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With PID closed-loop control, the system is stable, reliable, easy to adjust, and provides complete fault diagnosis. With PID closed-loop control, the system is stable, reliable, easy to adjust, and provides complete fault diagnosis and protection. It protects against overvoltage, overcurrent, overload, phase failure and hardware failure, providing the motors of the pumps with the best protection. The specific control process is described below:
- The controller samples real-time parameter data from the facility at fixed intervals and stores historical data. It uses the software to make judgment about the trend of movement of the load demand and guide the operation.
- The feedback signals to be sampled include the fluid level of water tank, pressure at the intake and outlet of the pump and fluid flow rate; the monitoring signals to be sampled include fluid temperature, current, voltage and operating frequency, etc.
- After being analyzed, the sampled signals are compared on a logic basis with the pre-set parameters of the controller and processed. Then the parameters of the controller are calibrated according to the particular conditions of the facility. Multiple closed-loop controls can be used.
- Next, the optimal control solution is decided for various conditions according to the requirement of the process of the system. The frequency converter will be controlled to conduct variable frequency adjustment and operating combination of the pumps, ensuring that the system always operates in the most energy-saving way.
- Meanwhile, the start/stop of and switching between the duty pumps and the standby pumps can be achieved to ensure that the system can operate safely and effectively even under extraordinary conditions. Thus the optimal control of the system for energy-saving is achieved.
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- Automatic logic control that optimizes the operating conditions of the pumps to ensure the system always operates within the optimal range for energy efficiency;
- Smooth stepless speed regulation of the pump motor;
- Local and remote control. With high-luminance and high-contrast touch screen, the local control provides a user-friendly interface;
- Support for RS232/RS485/RS422 serial communication and the ProfiBus system, realizing data sharing between the SCADA system and the DCS system;
- All-round and complete fault diagnosis and protection that protect against overvoltage, overcurrent, overload, phase failure and hardware failure, providing the motors of the pumps with all-round protection. Once the protection is triggered, the duty pump will be turn off and the system will automatically switch to the standby pump and simultaneously issues a fault alarm signal;
- Shift rotation between pumps. Automatic shift rotation between the duty pump and standby pump according to pre-set procedure and schedule can be realized. When the duty pump fails due to a fault or its running time is up, the standby pump will be automatically actuated; when there is a fault, the system will immediately issue a fault alarm signal. Thus the reliability of the pump system is greatly enhanced;
- Detection and display. The touch screen provides for parameter configuration and display of operating status and fault alarm of the system. The main content includes:
- Instantaneous energy efficiency monitoring and analysis: display the instantaneous energy consumption and efficiency;
- Display of instantaneous operating parameters: including input voltage/current, output voltage/current, operating frequency, motor RPM and continuous running time, etc.;
- Display of operating status of the system: on/off, open-loop/closed-loop, remote/local, etc.;
- Protective action and fault indication; and
- Display of calibrated parameters for automatic control of the equipment and protection of the relay.
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| We adopt a “system approach” instead of an “individual equipment approach” to the assessment of the energy-saving potential of motor-driven systems to achieve the maximization of their energy-saving effect. With our technology, more than 90% of the motor-driven systems in the world can have their energy efficiency improved by 10% at least and 20% on average. |
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