General presentation Intelligent Pump

May 2006 Control IPC

© ABB Group - 1 -
30-Nov-11
 IPC
Content IPC general presentation

1. Business backround
2. Marketing
3. Technology
4. Savings
5. References
© ABB Group - 2 -
30-Nov-11
 IPC
Backround VSDs with pumps, big picture

 Consultants help customers

to define specification for
pump station
 Pump system integrators
(SI) deliver turnkey
automation solution to
customer
 Customers enjoy the results
 Component suppliers
(pumps, motors, VSDs) sing
along
© ABB Group - 3 -
30-Nov-11
 IPC
Backround Business backroud: Sulzer references

 Planning by
global SIs
 Consultants
also in the
game
 Very
attractive
size of
parallell
pumps
© ABB Group - 4 -
30-Nov-11
 IPC
Backround Big picture, ABB’s VSDs for pumps

ACS550 ACS800 MV DRIVES

Simple drive, for most With pump control for For high power pump
common pump application demanding single and applications
parallel pumps
P < 355 kW P < 5,6 MW P > 1 MW
Tough competition Limited competition Limited competition
© ABB Group - 5 -
30-Nov-11
 IPC
Backround Big picture, marketing approach

 Having 3 different VSD products for pumps, we have 3

different approaches to market
 IPC applications are demanding - support by SIs is
needed. Volume is lower, but margins are more
attractive. Some cases there is very limited competition
(low harmonic drives with IPC features)
 With ACS550 are volume is the key issue, margins are
lower because of tough competition
 With MV Drives a swiss approach
© ABB Group - 6 -
30-Nov-11
 IPC
Backround Big picture, marketing

 Need to know all 3 players

(consultants, SIs and
customers) country by
country, do we?
 For demanding applications
SIs needed, have we?
 SI/partner support & training
available from FIDRI
 Those delivering just AC
drives without added value
have only limited market to
sell and limited margin to gain
© ABB Group - 7 -
30-Nov-11
 IPC
Backround W&W TOP6 volumes in Europe

 Based on ARC focus Russia 9,5

study, power range
<200kW, in MUSD UK 7,3
 This gives us an idea
Germany 7,3
where the big fish are
 Agressive approach in all Italy 4,7
key players in these
countries France 4,1

Turkey 3,5
© ABB Group - 8 -
30-Nov-11
 IPC
Backround ACS800 IPC focus

 Single and parallel

pump applications
for demanding
clean and waste
water applications
 State of the art AC
drive solution for
pumps
© ABB Group - 9 -
30-Nov-11
 IPC
Backround ACS800 IPC results

A. A totally new level of

energy savings available
limiting life cycle costs
B. 100% redundancy for
trouble free operation
C. Tailor made features for
both clean water and
waste water application
© ABB Group - 10 -
30-Nov-11
 IPC
Backround IPC core team

 Tero Nousiainen - Head of

SW development, 10 years
experience of SW
 Jukka Tolvanen - Product
Manager, 10 years
experience of various ABB
positions
 Mikael Holmberg - Pump
Specialist, 10 years
experience of pump industry
 Heikki Kervinen - Market
Manager, 10 years
experience of ABB sales in From left: Tero, Jukka, Mikael and Heikki
© ABB Group - 11 -

Europe and in Asia

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 IPC
Backround IPC extended team
 Simo Hammo
 University co-operation,
Laboratory manager,
Lappeenranta University of
Technology (LUT)
 Juha Viholainen and Hanna
Värri Left: Simo Hammo, Hanna Värri and Juha Viholainen

 LUT, Recearchers
 Vassili Jung
 EEABB, Programmer,
Commissioning help
 Akseli Savolainen
© ABB Group - 12 -

 FIDRI, Energy saving specialist

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 IPC
Marketing Marketing material in intranet

 For the latest updates visit

inside.abb.com/
salessupportdrives -> PUMPS
 Material consists in general
 Product and case notes
 Technical articles
 Success stories
 Animations
 Pictures
 SW manual
 Energy saving tool PumpSave
 AP library (Adaptive programs)
 Fair demo
© ABB Group - 13 -

 Giveaways
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 IPC
Marketing Marketing material for partners
 Partner pages:
Products ->
Industries ->
Pumps
 Latest news,
success stories,
documents,
marketing
material,
animations,
links…
© ABB Group - 14 -
30-Nov-11
 IPC
Marketing Marketing material in CD
 Cubicle with CD and
give-away material
inside
 Updated twice per
year
 Contains all IPC
material ~ 100MB
 Orders -> Jukka
Tolvanen
© ABB Group - 15 -
30-Nov-11
 IPC
Marketing Fact files

 Product notes tell about

IPC features
 Case notes inform live
applications
 5 ready (May 2006)
 Technical notes inform
theory
 Available also in ABB
Library
 Easy to attach to IPC
quotations
© ABB Group - 16 -
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 IPC
Marketing Case Notes, Rainwater
 Solved problem
 Flooding in town center due to inadequate
capacity of stormwater removal system.
 Solution
 Increase capacity of system with holding
tank and pumping station.
 Pumps operated by ABB industrial drives
with intelligent pump control.
 Benefits
 Parallel drives and pumps provide system
redundancy.
 IPC puts intelligence into the pumping
station for independent, energy-efficient
operation.
 With IPC pumps operate reliably without
jamming or blocking even when dirt, gravel,
litter and other debris are present.
© ABB Group - 17 -

 IPC eliminates need for PLC, contactors and

other external equipment.
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 Industrial drives are designed for reliable

operation in harsh environments.
 IPC
Marketing Case note, Pressure boosting
 Solved problem
 Need for pressure boosting station to
maintain constant pressure in water
distribution system.
 Solution
 ABB industrial drives with intelligent
pump control software installed to
operate the pumps at the station.
 Benefits
 Parallel drives and pumps provide
system redundancy.
 IPC eliminates need for PLC,
contactors and other external
equipment.
 IPC operates the pumps in an energy-
© ABB Group - 18 -

efficient way.
 Pressure is very stable, reducing
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system maintenance needs and

increasing customer satisfaction.
 IPC
Marketing Case note, Flow calculation
 Solved problem
 Need to check flow in return
pipeline from biological treatment
plant to ensure that pump is
operating correctly and cleaned
water is being recycled into the
process.
 Solution
 ABB industrial drive with IPC
software calculates flow data
without the need for sensors in the
pipeline.
 Benefits
 Cost-effective solution compared
to expensive flow meter.
 Eliminates need for additional
© ABB Group - 19 -

equipment (measuring device,

power unit) in harsh operating
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environment.
 IPC
Marketing Case note, Waste water
 Solved problem
 Above-ground wastewater storage and
old pumping station required
modernization.Need to eliminate
odors.
 Solution
 Underground storage tank with four
submersible pumps.Pumps operated
by ABB industrial drives with intelligent
pump control (IPC).
 Benefits
 Four pumps provide unprecedented
level of fail-safety, as two can handle
maximum load.
 Anti-jam feature performs preventive
maintenance on pumps. No restriction
© ABB Group - 20 -

to flow in the pipeline, so less risk of

clogging and blockages.
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 IPC boosts energy efficiency.

 IPC
Marketing Pumpstation at Mallorca in Spain

 PI ctrl of wastewater
pumpstation, always
empty station = no
smell for tourists
 Parameter 60.07
NUM PUMPS
ALLOWED = 2
© ABB Group - 21 -
30-Nov-11
 IPC
Marketing 4pcs submersible pumps
© ABB Group - 22 -
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Hidrostal, 60kW, 400V

 IPC
Marketing Pump motor protection

klixon +
3*PT100
© ABB Group - 23 -
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 IPC
Marketing Ultrasonic level sensor for actual signal
© ABB Group - 24 -
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 IPC
Marketing 4pcs ACS800 IPC Master-Follower
© ABB Group - 25 -
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 IPC
Marketing 100% Redundancy

STAR
connection
of optofiber
with
branching
unit NDBU-
95
© ABB Group - 26 -
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 IPC
Marketing Case note, Water hammer
 Solved problem
 Potential problem of water
hammer causing damage to
pipes and possible injury to
staff.
 Solution
 Installation of eight ABB drives
to smooth out demand.
 Benefit
 Sudden stops that lead to water
hammer are reduced.
 Harmonic filters limit distortion
© ABB Group - 27 -

to the
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 IPC
Marketing Technical articles
 4 articles ready (May 2006),
some more to come
 Energy savings in waste water
applications (2 articles)
 Flow measurement
 Energy savings in clean water
applications, parallel pumps
 Easy to present in seminars
and technical magazines in
local market
 FIDRI is focusing to World
Pumps (www.worldpumps. com).
© ABB Group - 28 -

Many ABB articles already

30-Nov-11

printed there
 IPC
Marketing Success stories

 Normally printed in AC
Drives news
 Informs globally about local
IPC breakthroughs
 Good idea to think if you
can share the same IPC
success locally
 Please inform Maarit
Savinen if you have a good
story to tell
© ABB Group - 29 -
30-Nov-11
 IPC
Marketing Animations
 Animated IPC features:
 Level control
 Anti-jam
 Redundancy
 Multipump ref sync (May. 2006)
 Easier to understand and
show basic IPC features
 ABB Water related fly & slide
animations CD
 Ask Heikki Kervinen
© ABB Group - 30 -
30-Nov-11
 IPC
Marketing Images

 3D images to
support LABB and
SIs with local IPC
marketing material
 A lot of pump
photographs
available in ABB
Library
© ABB Group - 31 -
30-Nov-11
 IPC
Marketing Fair demo

 Demonstrates redundancy
of 3 parallel pumps and anti-
jam cleaning
 Fibre optic connection for
laptop
 1 phase 230VAC needed
 Further info in ABB Library
 One for Europe, one for Asia
 In Europe - contact Ms Erjo
Koponen (Helsinki)
 In Asia – contact Mr Ere
© ABB Group - 32 -

Jääskeläinen (Kuala Lumpur)

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 IPC
Marketing Local tasks

 LABBs have limited engineering power for turnkey

solutions in pump applications
 Focusing to IPC marketing activities is LABBs cup of tea
 Having trained network of SIs and consultans supports
marketing, sales and service
 Factory team ready to help in local training activities
 This network also helps in after sales problems, calls go
to SIs, not to LABB
© ABB Group - 33 -
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 IPC
Marketing Local tasks, ABC steps

 Get familiar with marketing

material, takes ½ day
 Arrange 1...2 days training
session for potential SIs,
consultants and customers
locally, takes 5 days. Ask factory
support if needed.
 Report about pilots, use those as
a reference later, 1day
 Participate local pump fairs &
seminars, 2 days. Ask factory
© ABB Group - 34 -

support if needed
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 Marketing
in action Fairs & seminars 2006

 7th international water supply & drainage &

water treatment expo, 28-30 April 2006,
Shanghai
 Achema 2006, 15-19 May, Frankfurt, Germany
 ECWATEC 2006 + seminar, 30 May-2 June
2006, Moscow
 Singapore Pumps & Systems, 4-7 July 2006,
Singapore
 Aquatech Amsterdam 2006, 26-29 September,
Holland
 WEFTEC 06, 21-25 October 2006, Texas
 Water Pipeline Systems, 22-24 November,
© ABB Group - 35 -

Liverpool, UK
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 How about your country?

 IPC
Marketing Marketing in action

 Introduction to customers,
½...1 day
 Regional meeting
 Motors, intrumentation,
partners together
 Factory support if needed
 Pictures from Sweden
© ABB Group - 36 -
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 IPC
Marketing Marketing in action

 Technical training to
specialists, 1...2 days
 Detailed training with
multiple hands-on training
 Focus to partners,
customers and ABB sales
 Factory support if needed
 Pictures from Turkey
© ABB Group - 37 -
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 IPC
Marketing Easy approach.... 2 steps

 In general IPC is a
powerfull SW tool to solve
the most demanding pump
automation solutions
 Focusing only to 1 or 2
simple features of IPC is a
good start
 With ”2 simple IPC steps”
SELLING IPC IS DEAD
EASY
© ABB Group - 38 -
30-Nov-11
 IPC
Marketing Step 1 – ACS800 with the flow meter

 Flow meters are separate

components to measure flow
and detect leagake
 ACS800 IPC has easy
sensorless flow calculation
function included – flow meter
inside
 PQ-curve of the pump data
needed
© ABB Group - 39 -
30-Nov-11
 IPC
Marketing Step 2 – ACS800 with the anti-jam

 Anti-jam function
cleans the pump
 Preventive maintenance
 High efficiency
 Easy set-up
 Excellent in waste
water applications
© ABB Group - 40 -
30-Nov-11
 IPC
Training G171 Course - ABB University

 Course Goal: The goal of this course is to teach students to

calculate energy saving of a pump applications, read pump curves,
programming and modify multipump applications.
 Student Profile: This course is intended for electricians, technicians,
and engineers, who commission, install, operate and service
© ABB Group - 41 -

ACS800 multipump systems.

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 IPC
Training Factory support - Pump academy

 Twice a month FIDRI

team of pump specialists
meet to solve questions
by ABB sales network
 Teleconference and
Sametime meeting
support active
information sharing
 Team of 30 pump
specialist from both
APAN and EU gather
© ABB Group - 42 -

and share experiences

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 IPC
Savings Basics

 All drives can achieve

20...50% energy savings
compared to throttling
 Energy makes 50...90% of
the life cycle costs (LCC) of
the pump station
 Savings creates pure
economical benefit for
customer
 With IPC higher level of LCC
savings available compared
© ABB Group - 43 -

to competitors
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 IPC
Savings Life cycle costs (LCC) elements

 Energy makes the biggest

stake in LCC, 50...90%
 Elements of LCC
 Cic Initial cost
 Cin Installation cost
 Ce Energy cost
Life-cycle costs of a pump (Gylling 2005)
 Co Operation cost
 Cm Maintenance cost
 Cs Down time cost
 Cenv Environmental cost
© ABB Group - 44 -

 Cd Decommissioning cost
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 IPC
Savings LCC in marketing
 In everyday business, customers
are focusing to investment cost
(Cic)
 When selling drives only with
price, competition is hard
 With IPC marketing approach
LCC is optimized to create huge
benefit for customer
 Convincing customer with LCC,
less competition and higher
margins available
© ABB Group - 45 -
30-Nov-11
 IPC
Savings IPC Energy savings

 AC drive control versus other

control methods save energy
about 10...50%
 Waste water control method in
IPC easily boost savings
10...30% vs traditional control
 With parallel pumps 5...20%
additional energy saving
possible with ”Multipump ref
sync” vs traditional VSD control
© ABB Group - 46 -
30-Nov-11
 IPC
Savings IPC reduces LCC

 It is estimated that
50...90% of LCC are
energy
 Having 10...20%
additional savings by
IPC in energy bill, this
amount in LCC is
same as whole
investement
 Customer gets free HW
with ACS800 IPC
© ABB Group - 47 -
30-Nov-11
 IPC
Savings Savings, pump efficiency

 Pump efficiency (n) varies a

lot, much more than efficiency
of the motor or VSD
 Efficiency as a function of flow
on left
 Normally the nMAX is around
80%
 In normal pump operating area
efficiency of the pump might
vary between 40%...80%
 IPC is focusing to these facts
when controlling the speed of
the pumps
© ABB Group - 48 -
30-Nov-11
 IPC
Savings Savings, Specific energy

 Specific energy = Energy used / Pumped volume

 With A and B system curves lower speed creates energy savings
 With low static head the biggest energy saving potential in VSD
control
© ABB Group - 49 -

 Efficiency speed in IPC Level control

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 Smart start of parallel pumps in IPC Multipump

 IPC
Savings Tools, PumpSave

 ABB supports PumpSave

to calculate energy savings
with ABB Drives
 PumpSave is easy to use
Excell based tool
 VSD control is compared to
other flow control methods
 Payback time of
investement and annual
CO2 reduction calculated
 Available in ABB Library
© ABB Group - 50 -
30-Nov-11
 IPC
Savings PumpSave, Efficiency speed example
 With PumpSave it is
easy to demonstrate
efficiency speed savings
 In waste water systems
static head is quite low
 Tradiotional control
method in waste water
systems is ON/OFF
 PumpSave calculates
motor, this time 110kW is
OK
© ABB Group - 51 -
30-Nov-11
 IPC
Savings PumpSave, Efficiency speed example

 Operating profile: We
focus to efficiency speed
which is 80% of nominal
speed/flow
 95% of time system is
running with eff. speed
 5% of time tank is so full
that max speed is
required
 ABB industrial drives
selected
© ABB Group - 52 -

 Energy 0,05€/kWh
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 IPC
Savings PumpSave, Efficiency speed example

 As a result IPC with efficiency

speed saves almost 20% of
annual energy costs
 Annual saving almost 4 000€
 Compared to the price of a
120kVA ACS800-01 drive the
payback time is short
© ABB Group - 53 -
30-Nov-11
 IPC
Savings LCC, Maintenance cost Cm
 VSD marketing with pumps is
focusing to Energy savings Ce
 IPC also generates saving in
maintenance Cm
 Priority of pumps balances the tear and
wear of pumps -> routine maintenance
for parallel pumps in same time
 Anti-jam cleans the pump to avoid
unpredicted service
 Level control uses flush effect to keep
pipelines open
 Level control runs pump close to nominal
© ABB Group - 54 -

speed to longer the lifetime of the pump

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 IPC
Savings Example - higher savings with VSD
© ABB Group - 55 -
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 IPC
Savings Example: Throttling vs. VSD
© ABB Group - 56 -
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© ABB Group - 57 -
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 Technology
Basics Centrifugal Pump
Discharge
 A pump is a
machine that
transfers
liquids.
 80 per cent of Impeller
all pumps are
centrifugal
pums.

Inlet
Volute
© ABB Group - 58 -
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 Technology
Basics Centrifugal Pump and AC Motor
© ABB Group - 59 -
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 Technology
Basics The Pump causes the Liquid to Flow

Flow Q

Dynamic head Hdyn Static head Hst

H = Hdyn + Hst
© ABB Group - 60 -
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 Technology
Basics Pump Formula

r *Q * H * g
P
h

P = shaft power

r = density

Q = flow [Q] = 1 m3/s = 3600 m3/h = 1000 l/s

H = head [H] = 10 m = 9,81 * 104 Pa = 1 atm

h = efficiency g = 9,81 m/s2

© ABB Group - 61 -
30-Nov-11
 Technology
Basics Head/Volume Characteristics

Head
H
Q=0
H = Hmax
Pump Curve

Pump
HN duty point

System Curve
H=0
Q = Qmax
QN
© ABB Group - 62 -

Volume Flow Q
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 Technology
Basics System Curve, Static Head
 Static Head > 0  Increasing Static Head
© ABB Group - 63 -
30-Nov-11
 Technology
Basics Affinity Laws

Q n
1 1
Flow
Q n
2 2

2
H  n1 
Head 1
 
 
H 2  n2 

3
P  n1 
Power 1
 
 
P 2  n2 
© ABB Group - 64 -
30-Nov-11
 Technology
Basics Pump Efficiency in VSD Control

 Without Drive
control, efficiency
changes along
pump curve (blue
line)
 With Drive control
efficiency
changes along
system curve
(yellow line)
 With Drive control
efficiency is much
© ABB Group - 65 -

higher
30-Nov-11
 Technology
Basics Example of Pump Efficiency vs. Flow

Efficiency h
(%)

80

60

40

20

0
0 50 100 150 200 250 300 350 400
Q (l/s)
© ABB Group - 66 -
30-Nov-11
 Technology
Basics Power Curve of a Pump
© ABB Group - 67 -
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 Technology
Basics Reading the Curves
© ABB Group - 68 -
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 Technology
Basics Pump curves, efficiency approach

 Focus to pump efficiency

 1800rpm, eff 83%
 1200rpm, eff 70%
 Pump curves,specially
efficiency curves, are
important when
optimazing pump system
© ABB Group - 69 -
30-Nov-11

AHLSTAR™ A_P44-200 pump curves

 Technology
Basics Pump curves, efficiency approach

 Focus to system efficiency

 Pump curves are essential
in all optimizations
 Lets play with curvers!
 1800rmp, 240l/s, 200kW,
n=83%
 900rpm, 120l/s, 30kW,
n=83%
 For 240l volume we need
either 200kWs or 60kWs
 Lower speed -> energy
© ABB Group - 70 -

saving
30-Nov-11
 Technology
Basics Static head vs Energy efficiency

 System curves on right hand side. On left hand

side equivalent energy curves
 With low static head the biggest energy saving
potential in VSD control -> efficiency speed of
IPC Level control
© ABB Group - 71 -

 Please check Savings slides

30-Nov-11
 Technology
Basics Flow Control is Needed

Example: Water consumption at home

Midnight Morning Afternoon

A glass of water Shower Watering the garden

0,1 litre per second 1 litre per second 10 litres per second
© ABB Group - 72 -
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 Technology
Basics Flow Control Methods
© ABB Group - 73 -
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 Technology
Basics Throttle Control
© ABB Group - 74 -
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© ABB Group - 75 -
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Basics
Technology
By-Passing
 Technology
Basics On-Off Control
© ABB Group - 76 -
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 Technology
Basics Variable Speed Control
© ABB Group - 77 -
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 Technology
Basics Pumps in Parallel

Pumps
1 and 2
© ABB Group - 78 -
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 Technology
Basics Pumps in Series

Pumps
1 and 2
© ABB Group - 79 -
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 Technology
Basics Variable Speed Control of Pumps pays
© ABB Group - 80 -
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 Technology
Basics Consider VSD Control when...
the pump is a part of the control system. the pump output varies.
© ABB Group - 81 -
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 Technology
Basics Power Consumption of a Pump

r *Q * H * g
P
h

when h is constant P  k *Q * H
© ABB Group - 82 -
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 Technology
Basics Relative Power Consumption
© ABB Group - 83 -
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 Technology
Basics Energy Consumption of a Pump (W)

 W = Power Consumption multiplied by the Time

P
© ABB Group - 84 -
30-Nov-11

t
 Technology
Basics Duty Cycle Curve

1 2 1
Median Flow Q  Q  Q  Q
m 6 max 3 50 6 min
© ABB Group - 85 -
30-Nov-11
 Technology
Basics Energy Consumption

 Calculated by the Median Flow Method = Energy

Consumption in Variable Speed Control

Qmax = 300 l/s

Q50 = 250 l/s
Qmin = 81 l/s
300 2  210 81
Q    l/s  204 l/s
m 6 3 6
and the equivalent power is 42 kW.

The total energy is

W = 42 kW*5000 h = 210 MWh
© ABB Group - 86 -
30-Nov-11
 Technology
Basics Reading the Pump power curve

Duty point of a pump:

Nominal
x Throttle control
x Variable speed control

Power consumption of
the pump in variable speed
control
© ABB Group - 87 -
30-Nov-11
 Technology
Basics Segmented Duty Cycle
© ABB Group - 88 -
30-Nov-11
 Technology
Basics Comparison in MWh
Time Flow Throttle Variable Speed
Control Control
1480 rpm

% h % l/s kW MWh rpm kW MWh

40 2000 90 270 75 150 1400 64 128

30 1500 62 186 71 107 1180 35 53

30 1500 32 96 65 98 920 24 36

Compared to throttle control variable speed control

© ABB Group - 89 -

saves energy 355 - 217 MWh = 138 MWh

30-Nov-11
 Technology
Basics Result

 Variable Speed Control Saves Energy, which means

More Money for You!

Cost saving =
saved energy*energy price
137 MWh * USD 50/MWh = USD 6850/year

For VSD
the Payback Period would be
© ABB Group - 90 -

less than Two Years

30-Nov-11
 Technology
General ACS800 Pump Control features
Control method (pick 1) Features (pick 0…5)
 Multipump Control  Anti-jam Function
 Traditional PFC  Flow Calculation Function
 Multipump auto
 Pump Priority Control
 Multipump sync
 Sleep Boost Function
 Multipump ref sync
 Shared IO
 Level Control
 Adaptive programming
 Huge amount of different combinations (some examples
above)
 The Intelligent Pump control SW is functionally backward
© ABB Group - 91 -

compatible with Traditional PFC.

30-Nov-11
 Technology
General IPC benefits in general

 Boosts energy savings

 Replace additional HW & SW
 Flowmeter
 External communication modules (Profibus, Ethernet)
 PLC (SW & HW) -> IPC + Adaptive programming
 Additional I/O modules
 Control panel with clear application and signal texts
 Includes helpful W&WW segment features
 Multipump control for clean water pumps
 Level control for waste water pumps
 Pump priority for parallel pumps
© ABB Group - 92 -

 Anti-jam to clean pump

 Flush effect to pipeline clean
30-Nov-11
 B. Redundancy
 Parallel pump set-up
guarantee trouble-free
operation and limits downtime
 Fibre optic link controls
parallel drives. Defected part
of the system is isolated in
500ms. Other parts of the
system continue like nothing
had happened.
© ABB Group - 93 -
30-Nov-11
 B2. Redundancy in practice

 If drive is lost, whole system is

down

 In redundant system loosing

one drive causes only
performance limitation
 Redundant wiring supports
sensor failures
© ABB Group - 94 -
30-Nov-11
 C1. Tailor made features, clean water

 Smooth control to limit

hammer effect and leakage
 Easy to have different size of
pumps in parallel
 Large amount of safety
functions
 Drying of well
 Prevention of cavitation
© ABB Group - 95 -
30-Nov-11
 C2. Tailor made features, waste water

 AC drives has a bad reputation in

this segment. Traditional PI control
means catastrophy in waste water
stations.
 ACS800 IPC can easily handle the
most difficult waste water
applications and quarantee trouble-
free operation
 Automatical cleaning of pumps as
preventive maintenance
 Flush effect to keep pipeline clean
© ABB Group - 96 -

 Less sediment formation to tank walls

 Energy saving with efficiency speed
30-Nov-11
 C3. Flow measurement

 ACS800 IPC is cabable of

measuring the flow of single
and parallel pumps without a
flow meter
 Accuracy is good for normal
applications
 Patent pending, university
study of results
© ABB Group - 97 -
30-Nov-11
 C4. Priority of parallel pumps

 ACS800 IPC is cabable of

running parallel pumps in
predefined way
 Different flow conditions
covered with a right pump.
Bigger pumps taking care of
high load, smaller pump for low
load
 Tear and wear according
customer wish – either stable
with all pumps or focused to
© ABB Group - 98 -

one. Works as preventive

maintenance
30-Nov-11
 IPC
References General
 Next slides show first 100
factory deliveries of IPC
 Case notes are presented
separately
 In 2004, FIDRI delivered
560MW of industrial drive
power for pump
applications
 With this amount of power
we can make 32 m
fountain out of river Nile
 Nile discharge at mounth
is 1584 m3/s
© ABB Group - 99 -
30-Nov-11
© ABB Group - 100 -
30-Nov-11 IPC
References
References 1/3
© ABB Group - 101 -
30-Nov-11 IPC
References
References 2/3
© ABB Group - 102 -
30-Nov-11 IPC
References
References 3/3
 IPC
References Pilot sites in Finland

 Waste water sites

have been very
reliable
 Booster station
with flow
calculation & PSA
remote control
 Happy customer
© ABB Group - 103 -
30-Nov-11
 IPC
References Flow calculation in Sweden

 Updated ACS800
drive
 6 moths trial – 2%
gap with real flow
meter
 Happy customer
© ABB Group - 104 -
30-Nov-11
 IPC results

A. A totally new level of

energy savings available
limiting life cycle costs
B. 100% redundancy for
trouble free operation
C. Tailor made features for
both clean water and
waste water application
© ABB Group - 105 -
30-Nov-11
 B. Redundancy
 Parallel pump set-up
guarantee trouble-free
operation and limits downtime
 Fibre optic link controls
parallel drives. Defected part
of the system is isolated in
500ms. Other parts of the
system continue like nothing
had happened.
© ABB Group - 106 -
30-Nov-11
 C1. Tailor made features, clean water

 Smooth control to limit

hammer effect and leakage
 Easy to have different size of
pumps in parallel
 Large amount of safety
functions
 Drying of well
 Prevention of cavitation
© ABB Group - 107 -
30-Nov-11
 C2. Multipump Control

 4 different programs to
control parallel pumps
 With Traditional PFC 1 VSD
+ DOLs (not recommended)
 With Multipump control each
pump has VSD. 3 different
control methods to meet
customer requirements in all
pump application.
 Multipump auto
 Multipump sync
 Multipump ref sync (patent
© ABB Group - 108 -

pending)
30-Nov-11
 C3. Multipump Control
rpm
 Multipump auto
 Master jumps to next
PI min freq (par 20.07)
starting pump
pump 1 pump 2 pump 3
rpm
 Multipump sync Master
 One master, same Follower
speed

pump 1, 2 and 3
 Multipump ref sync rpm
 One Master, same
speed, optimal
number of pumps
© ABB Group - 109 -
30-Nov-11

pump 1 pump 2 pump 3

 C4. Multipump Control parameters

 Left column creates a 1 pump system

© ABB Group - 110 -

 Multipump parameters in group 60 (right column)

30-Nov-11
 C5. Sleep Boost Function

 Before shutting
down, pump is
boosting pressure
or water level to
extend sleep time
 Saves energy and
mechanical stress
by preventing
unnecessary starts
and stops
© ABB Group - 111 -
30-Nov-11
 C6. Sleep Boost Function parameters

 Group 43 for Sleep Boost

 Parameter 43.08
important for safety to
limit the boost time. All
competitors do not have
this safety feature
© ABB Group - 112 -
30-Nov-11
 C7. Multipump Connections, example

 2 pumps, ring connection

AI2 DI1 DI6 Ch2 AI2 DI1 DI6 Ch2

PUMP 1 HAND / AUTO

PUMP 2 HAND / AUTO

© ABB Group - 113 -
30-Nov-11
 C8. Multipump Connections, example

 2 pumps, ring connection, level feedback

© ABB Group - 114 -
30-Nov-11
 C9. Tailor made features, waste water

 AC drives are not commonly used in

waste water applications.
 ACS800 IPC can easily handle the
most difficult waste water
applications and quarantee trouble-
free operation
 Automatical cleaning of pumps as
preventive maintenance
 Flush effect to keep pipeline clean
 Less sediment formation to tank walls
 Energy saving with efficiency speed
© ABB Group - 115 -
30-Nov-11
 C10. Level Control (Patent pending)

 Designed for waste water

applications
 Integrated level control logic
in the drive
 Each motor is controlled by
AC drive, no contactors
 Water level is the controlled H
variable by level transmitter
 Can be used for emptying or
fill in control in storage tanks
© ABB Group - 116 -

Q
30-Nov-11
 C11. Level Control, Example
 3 Preset levels
 Pumping out from
the tank / free
flow into tank
 Common stop
mode / stable
stop mode
© ABB Group - 117 -
30-Nov-11
 C12. Level Control parameters
 System set-up
 Group 47 for Level
control
 Group 60 defines the
parallel pumps if any
 This parameter list
creates a 1 pump level
control system.
© ABB Group - 118 -
30-Nov-11
 C13. Anti-jam Function
 Prevention of jam in pump,
preventive maintenance
Speed
 Cleaning up the pump in
congested status
 Different triggering
conditions:
1. Starts if current level rises over
the set limit, so then there
might be something jamming < one anti-jam step >
the pump
2. Run-on-time sequence Time

3. Service switch connected to DI

© ABB Group - 119 -

signal
30-Nov-11

4. Every start
 C14. Anti-jam Function parameters

 Negative speed not

acceptable for all
pumps, par 20.01-02
 Acc and Dec. times fast
enough, par 22.04-05
 Anti-jam cycles listed in
fault logger
© ABB Group - 120 -
30-Nov-11
 C15. Flow measurement

 ACS800 IPC is cabable of

measuring the flow of single
and parallel pumps without a
flow meter
 Accuracy is good for normal
applications
 Patent pending
 University study of results,
article in World Pumps Dec.
2005
© ABB Group - 121 -
30-Nov-11
 C16. Flow Calculation Function
parameters

 Calculation based on
Bernoulli’s equation
 There are 34
parameters in Flow
calculation, mainly
pump curve points
© ABB Group - 122 -

 Group 5 there are

parameters for actual
30-Nov-11

and total flow.

© ABB Group - 123 -
30-Nov-11

C17. World Pumps Dec. 2005

 Pump curves, why?

 Pump curves show everything,

specially the technical behaviour of
pump
 Pump curves are essential
 to be able to discuss with pump
customers,
 to understand IPC benefits in
efficiency and in parallel connection
 Pump curves, and IPC are fun
© ABB Group - 124 -
30-Nov-11
 Pump and system curve

 Pump curve (downward) links

Head (H) and Flow (Q)
 Hmax when Q=0
 Qmax when H=0
 System curve (upward) tells
Static head (Hstat) and the
resistance of the system
 Shape of the curve describes
the pipeline
 Operating point in junction
© ABB Group - 125 -
30-Nov-11
 VSD (variable speed drive) control

 Pump speed & flow is

controlled with VSD
 Operating point follows the
system curve, pump curve
shrinks (dash line)
 HV and QV are both smaller
compared to HN and QN
 Efficiency of the VSD control is
optimal
© ABB Group - 126 -
30-Nov-11
 Throttling control

 Throttling is one flow control

method based on valves
 Throttling creates taller system
curve (dash line)
 When HT is higher, QT is
smaller
© ABB Group - 127 -
30-Nov-11
 By-passing control

 By-passing is one flow control

method
 Part of the flow is rotating
round the pump, depending on
valve position
 System curve is lower
 HB is lower, QP is bigger but
because of flow rotetion
QP,REAL is smaller
© ABB Group - 128 -
30-Nov-11
 On-off control

 On-off control is based on

starting and stopping the
pumps with contactor or soft
starter
 Operation follows the basic
HQ curve – pump runs in
operating point or sleeps
© ABB Group - 129 -
30-Nov-11
 Efficiency curves 1/2

 Pump efficiency (n) varies a

lot, much more than efficiency
of the motor or VSD
 Efficiency as a function of flow
on left
 Normally the nMAX is around
80%
 In normal pump operating area
efficiency of the pump might
vary between 40%...80%
© ABB Group - 130 -
30-Nov-11
 Efficiency curves 2/2

 Efficiency curves (dash lines)

added to pump and system
curve presentation
 Optimal efficiency follows the
system curve when Hstat = 0
 With VSD control operating
point follows system curve
 If Hstat is big and pump is
running with low speed ->
efficiency is poor
© ABB Group - 131 -
30-Nov-11
 Parallel pumps

 When pumps are connected

parallel, more flow is
generated.
 Head stays the same
 QTOT is not directly the sum of
separate flows – parallel
pumps generate pressure
others need to win to be able
to make more flow.
 New operating point of a single
pump on dash line. Q1,par and
Q2,par are smaller compared to
single set-up
© ABB Group - 132 -
30-Nov-11
 Serial pumps

 When pumps are in series,

more head is generated
 Flow stays the same
© ABB Group - 133 -
30-Nov-11
 Flow profile, one day

 In most of the pump

applications the flow
required varies
 Example, water
consumption in
residental area
during one day
© ABB Group - 134 -
30-Nov-11
 Duration curve, one year

 Duration curve
describes the
dimensioning data
for pump system
 Annual operating
time, normally
5000h/a (curve
meets X-axis)
© ABB Group - 135 -
30-Nov-11
 IPC Level control, control in HQ curves

 System with 3
pumps
 All started one by
one to efficiency
speed (eff1, eff2...)
 HTOT when all
pumps run in full
speed
 Optimal energy
savings
© ABB Group - 136 -
30-Nov-11
 IPC Multipump control, HQ curves

 Pressure boosting
station with 3 pumps
 HN nominal pump
curve
 H1, H2 and H3
describes pump
curves in single or
parallel connection
 All pumps enable run
with same speed
© ABB Group - 137 -
30-Nov-11
 Affinity laws of pumps

 Affinity laws decribes the link

between speed (n), flow (Q),
head (H) and power (P) of the
pump.
 Specially the link between P
and n is essential in when
optimazing the energy
consumption of the pump
 The power (P) needed is
proportional to the cube of the
speed (n) or flow (Q)
© ABB Group - 138 -
30-Nov-11
 Specific energy

 Specific energy = Energy used / Pumped volume

 With low static head the biggest energy saving potential in VSD
control -> efficiency speed of IPC Level control
© ABB Group - 139 -
30-Nov-11