Guidelines for the Use of Variable Frequency Drive (VFDs)/Single Phase Generator Combinations For Short-Term Operation of Small

Water and Wastewater Pumping Installations Introduction The use of Variable Frequency Drives for converting single phase to three phase power has generated a great deal of interest. This paper provides guidelines for using variable speed controllers for operating small motors and pumps that require less than 15 Horsepower. In a VFD/Single Phase Generator application, the VFD is used to convert single phase to three phase power fed by a single phase generator and to efficiently match a motor/pump combination at a lift station or a well to the conditions at the site. The use of a VFD allows water or wastewater service to be restored to minimum acceptable levels in a most timely, efficient and economical manner. This paper will examine the centrifugal pump, electric motor, VFD and single phase generator relationships that are important in optimal selection equipment for this purpose. Centrifugal Pump Relationships Centrifugal pumps are widely used in water and wastewater treatment and exhibit characteristics that make them very adaptable to variable frequency control. Generally centrifugal pumps are driven by electric motors that operate at synchronous speeds of 1200, 1800 and 3600 RPM. The synchronous speed of a motor is based on a rotation that is in perfect balance for a given voltage at a frequency of 60 Hertz. When a motor is placed under load, such as when it is connected to a pump, there will be some slip in the motor. Standard motor nameplate ratings are stated as 1140, 1725 and 3450 RPM. When the motor is connected to a centrifugal pump, the speed or the rotation in revolutions per minute (RPM) where the pump operates, will provide a specific flow rate at a specific head condition. This unique condition, is called the centrifugal pumps specific speed. It may be calculated as shown below. From this relationship, a pump curve can be developed which will indicate how the pump will operate for various flow and head conditions.

Specific Speed (Ns) for a Centrifugal Pump Ns = rpm X (gpm)1/2 H3/4 Ns rpm gpm H Specific Speed Speed in rpm Gallons per Min. Head in feet

When the flow (gpm) and head (feet) of water are known. The theoretical horsepower for operating the pump can be easily determined using the following formula. Since the specific gravity of water is equal to one (1), it is often neglected. Brake horsepower requirements gpm s gr. H Bhp Flow in gpm Specific Gravity for water Total Dynamic Head in feet Horsepower required to drive pump

Bhp = gpm X H(ft) X s gr. 3960 X Pump Efficiency

Pumping equipment in water and wastewater operation will be operated at a constant speed, or that speed provided by the motor. The variable frequency motor controller, is a device that changes the frequency of the voltage applied to the motor, which in turn changes the speed of the motor. When the speed of the motor changes, the applied horsepower and the pumping characteristics also change. With a centrifugal pump, these relationships are governed the Affinity Laws. A brief review of these relationships is provided below. Affinity Laws for a Centrifugal Pump Application The operating conditions for a centrifugal pump may be estimated by using the Affinity Laws. The Affinity Laws are a group of relationships that may be used for estimating Flow, Head Condition and Horsepower requirements of a centrifugal pump when the speed of the pump is changed from a known speed or the specific speed, to some other value. The plot that follows governs the operating relationships for all centrifugal pumps.

Affinity Laws for Centrifugal Pumps: Q1 = N1 Q2 N2 H1 = H2

( N1 )
N2

Q N H Bhp

Bhp1 = Bhp2

( N1)
N2

Flow in gpm Speed in rpm Head in feet Break Horsepower or The Horsepower needed to drive the pump

By using these relationships a plot for all centrifugal pumps for all pumping conditions can be developed. These relationships will be used in controlling motor speed to provide the pumping characteristics needed in a variable speed control situation.

Plot of Affinity Laws for Any Centrifugal Pump Condition

100 80 70 60 50 40 30 20 10 0

% Q, Head, or Bhp

Capacity

Head Brake HP

10 20 30 40 50 60 70 80 90 100 Rated Speed - %

The VFD will be used to change the motors operating characteristics from a constant speed to a variable speed. Under different speed conditions, the pump will operate at a different capacity, different head or pressure output, and at a different horsepower. In this application, the VFD operates the motor at a reduced horsepower. Motor and Generator Sizing Relationships: The Horsepower and Kilowatt requirements for supplying power to a motor can be calculated using the following formulas. Motor HP and KW Requirements for a Pumping Condition: HP = Bhp Motor Efficiency X Power Factor

KW = .746 X HP Note that the KW required for sizing a motor, is based on the brake horsepower needed to operate the pump and calculated for a specific pumping condition. In the VFD application, the motor is already in place and sized to operate the pump. Since the VFD will be used in an emergency situation where power must be supplied by a generator, what we need to know is the kilowatt rating of the generator needed to supply this horsepower. Since there are efficiency losses by the motor and the power factor will be

less than unity, a close approximation to the kilowatt rating of the generator needed to operate the motor is the HP of the motor multiplied by 1000. However, because starting current will be considerably higher than the full load current requirements it will be necessary to provide a larger generator than under these steady state conditions. This is discussed in more detail in the following sections. Adjustable Frequency Motor Control Motors that drive pumps, must have sufficient horsepower to meet the requirements imposed by the pumping unit. The horsepower that is required is the amount of force that the motor will have to move against. This force is described as torque. Torque is a standard measure for all electric motors and 1 ft-lb of torque is the turning force required to move a 1 lb. object at a distance of 1 foot away. Torque may also be described as the pounds of water that can be lifted by the pump/motor combination over a measured distance and elevation. Motors that are used in the water wastewater industry are classified as class B motors. They are designed to operate with standard, torque, horsepower, voltage and frequency requirements. It is these characteristics of class B motors that can be optimized by the use of a VFD. As a motor starts it must overcome the inertia for the force at rest. This is known as starting torque. As the motor is started there is a brief amount of time before the motor turns. At this instance a motor develops about 150% of its full-load torque. As the motor accelerates the load, the torque will momentarily decrease then until it reaches a maximum of about 200% of its full-load torque. This is the accelerating or pull-up torque. If the motor is overloaded beyond its capability, the motor will stall or abruptly slow down. This is referred to as breakdown torque. Torque will decrease rapidly as speed increases until it reaches full-load torque. Full load torque is that torque produced when the motor is operating at its rated voltage, frequency and speed. Current requirements for the motor for starting, pull-up, breakdown and full-load torque also vary. When the motor is first started it momentarily consumes several times its full load current. If a motor is started with no load applied to it, it will come up to its idle speed. Even though no external force is applied, a motor under this condition will consume about half its full load current. The importance here is that the motor under any load condition will consume at least half its rated full load current. Starting current, also known as locked-rotor current, is measured from the supply line when the motor is at rest just prior to acceleration. As the motor accelerates, the current will rapidly fall until the motor reaches full speed. The initial starting current or lockedrotor current can be 600% of the motors final full-load current requirements. A NEMA B motor that is started by connecting it to the power supply at full voltage (240V) and full frequency (60 Hz) will develop 150% of its starting torque and 600% starting current.

The VFD operates the motor both at a reduced voltage and reduced frequency. The same motor will now start at approximately 150% torque and 150% current. The VFD can significantly reduce the locked rotor current too because it allows the motor to operated at a reduced speed consuming only the horsepower necessary to move the load. The VFD allows the motor to gradually reach a set speed that is less than the speed of the constant speed motor under normal operation. Again, the VFD provides a considerable advantage over conventional equipment since it starts a motor under a reduced torque and a reduced starting current. This VFD attribute allows a small generator to be used for small horsepower applications. Variable Speed Motor Control Application The full load current requirement is based on a motor delivering its rated horsepower under load. More current will be consumed if the motor is overloaded and less if under loaded. It is these relationships that are used in emergency variable frequency speed (VFD) motor control applications. The VFD is used to provide only the horsepower necessary to keep the load or maintain the minimum pumping requirements, by reducing motor speed. In these applications, the motor will operate in this mode, until power is restored. The VFD is used to operate the motor efficiently under at a reduced load, at a reduced horsepower and thus at a reduced current draw.

The formulas that govern motor horsepower requirements are shown below: Formulas for Motor Horsepower Requirements: T k Torque Constant depending on load conditions Frequency (Hz) Current under load Speed in rpm

T = k X Volts X IW F

HP = T X N 5250

F IW N

. With a VFD both the voltage and the frequency can be adjusted. As the motor is started with VFD it will gradually ramp to the speed needed to accelerate this load. The Horsepower requirement can be exactly matched to the torque that the motor is required to move. In most all field applications encountered, the horsepower requirements needed by the pump will be less than the horsepower that has been supplied for the application.

Single Phase to Three Phase Power Conversion Another advantage of the VFD is that it can also convert single phase input voltage to three phase output voltage required by a three phase motor. The VFD is most effective in applications of small horsepower requirements that fall below 20 horsepower. This condition applies to about 90% of the lift stations used in most municipal applications in Florida. Municipal applications almost always use three-phase power to motors for pumping applications. This is because of the high efficiency losses that occur as a result of the very high amperage needed for single phase service and the larger equipment such as breakers, starters and wiring needed to accommodate it. For example, a 3 HP motor served with single phase service would require 34 amps compared to 11 amps for a three phase 3 HP motor. As previously discussed, when the pump is operating against lower head and/or reduced pumping conditions, the horsepower requirements are reduced. The lower horsepower requirements for the motor can then be directly matched using the VFD. This directly affects the amount of current that must be provided by the generator. For example, when using the 3 HP motor mentioned above that required 11 amps but actually using 2 HP, the amperage needed is reduced proportionally by the VFD with only about 8 amps required. There are a few limitations in operating a motor at reduced frequency and voltage that needs to be mentioned. First is that all, according to NEMA Standards, Domestic motors can be operated at 50 Hertz if voltage and horsepower ratings are appropriately reduced. Class B motors are designed to be operated at this reduced frequency. However, below this frequency heat will not be dissipated as fast since the motor is turning slower. Overheating of submersible pump motors have not been found to be a problem when operated as low as 40 hertz because of the higher heat transfer rate provided by moving water. However, operating at speeds below 30 Hertz causes other problems and may require boost voltage to prevent motor damage. Thus, it is not recommended that a VFD ever be set to operate a motor below 30 Hertz. Per manufactures recommendation, the VFDs should be de-rated by 25% or one motor size. For example, it is recommended that the VFD rated for 10 HP be used for a maximum 7.5 HP installation and a VFD rated at 7.5 HP unit be used for a 5 HP installation, etc.

Sizing Considerations for VFD Units The plot below illustrates the torque requirements at full-load for a centrifugal pump installation. It is prudent engineering to over design the motor/pump combination for the actual torque conditions as shown by the 100% point. The VFD allows the motor/pump combination to operate at any point along the curve. Note that the useable part of the curve is that portion of the curve at a speed greater than 50% speed of full speed. The basis of adjustable frequency (VFD) control is that changing the frequency of the input voltage changes the speed of the motor. In emergency service VFD/generator installations, the pumping head requirements will be lower than that encountered under normal conditions. This condition will be the direct result of damages that occur to residences and private businesses such as restaurants. These contribute no or lower flow or lower water demand. Additionally, under extreme emergency conditions, large numbers of people will have evacuated the area. The need to operate small HP pumping units at full capacity is rarely encountered in these situations. However, there are some instances such as a pump down of a wet well, filling of a water tank, etc. where full speed operation may be desireable.

Percent Full-Load Torque

Min Setting

Recommended VFD Operating Range

Recommended Frequency Set-up for VFD Control

The actual HP requirements will be always be dictated by the actual torque requirements (head and pumping requirements) encountered in the field. The chart is intended to give a good starting point for VFD set up. Since the head conditions will typically be the controlling factor, a good starting point for a VFD has been found to be a speed setting around 45 Hz for most installations. 7

The table below provides a good estimate of the head and pumping conditions that can be accommodated by changing the speed (N) resulting from the use of a VFD. For example, at 42 Hz, a 5 HP motor/pump installation would theoretically operate at about 1.8 HP, at 70% of its rated speed of 60 Hz, could pump against 50% of its rated head and provide 70% of its rated pumping capacity. At a speed of 48Hz, it would require 2.5 HP and be capable of pumping against 65% of the design head conditions delivering a flow of 80% of the original design requirements. Under field conditions the VFD can be set to a minimum value of 45 hertz, then gradually increased until the operating speed is raised enough to fully or partially open a check valve. The speed is then increased to a desirable level that maintains a constant flow rate and level condition in the wet well.

Brake Horsepower Requirements for a Centrifugal Pump: Max. Head (% H) and Pumping Capacity (%Q) For Speed Reduction (N) Changes (% Full Speed) 60 Hz N=100% H=100% Q=100% Bhp
1 2 3 5 7.5 10 15

54 Hz N=90% H=85% Q=90% Bhp

.7 1.3 2.0 3.3 4.9 6.5 9.8

48 Hz N=80% H=65% Q=80% Bhp

.5 1 1.5 2.5 3.8 5.0 7.5

42 Hz N=70% H= 50% Q=70% Bhp

.4 .7 1.1 1.8 2.6 3.5 5.3

36 Hz N = 60% H= 35% Q=60% Bhp

.2 .5 .7 1.2 1.8 2.3 3.5

Recommendations for Sizing Single Phase Generators The biggest advantage of VFD pump control is that small single phase generators that can be obtained at any building supply company such as Lowes or Home Depot can be used to power small water and wastewater facilities in an emergency situation. There are a few considerations in selecting a generator since the kilowatt rating is not directly applicable to three phase motor application. 8

It is always best to provide a generator sized larger than needed since the cost difference is nominal but the additional power and start up capability may be needed. Field conditions may also require full horsepower operation. The suggested sizing requirements are to multiply the HP of the installation by 1000 and then select a generator in a range that provides at least a 50% safety factor. Below are some suggested guidelines. Note that some of the recommendations show that the generator must supply to a HP less than nominal to provide a 1.5 safety factor. In these cases the VFD would be set to a HP rating less than nominal nameplate rating on the motor. For example in the case of a 7.5 HP motor, a 6.5 HP setting using a 10,000 watt generator would provide a 1.5 safety factor. However, the power provided might not be enough to provide the needed HP in the field at the lower setting. It would be much better to use a 12,500 generator that would provide a 1.6 safety factor for the 7.5 HP and reduce the HP in the field as appropriate. Although the smaller generator may work for a specific application, IT IS NOT RECOMMENDED THAT THE GENERATOR BE SIZED INTENTIONALLY BELOW THESE RECOMMENDATIONS. Single Phase Generator Size (watts) 5500 6500 8000 9,000 10,000 12,500 15,000 Approx. Cost Approx. Weight HP Appl. Safety Factor

$1000 $1300 $1650 $1900 $2000 $2200 $2500

160 lbs. 280 lbs 300 lbs. 400 lbs

3 <5 5 >5 <7.5 <10 10

1.8 1.3+ 1.6 1.6+ 1.3 1.3+ 1.5

Note that in selecting an 9,000 watt instead of an 8,000 watt generator for a 5 HP installation, a safety factor of 1.6 is sufficient. However, the increase in output of the 9,000 watt unit is 12.5% and costs only $250 more. The incremental cost of $250 for this added insurance may be well worth the expenditure. The installation may require the full 5 HP or perhaps even more. When making a decision where about $3,000 will be invested in a VFD and a generator, the $250 expenditure provides a desirable extra margin of safety. The costs of the nest higher watt generator will always be marginal, and it is suggested that the larger unit be chosen in these kinds of decisions to provide for unknown field conditions that may dictate running the motor/pump at or above design HP values.

Methods of Connecting the VFD in the Field There are three recommended methods for connecting a VFD to a motor: 1.) direct to power the pump panel, 2.) direct to the motor/pump using a separate control circuit, and 3.) direct to the motor/pump with a constant setting. These are discussed below: Direct Connection Using Existing Pump Controls In this method of connection the line power is disconnected and the VFD is connected to one motor/pump input lead just below the breaker. The VFD is controlled through the existing pump control panel using a relay that intercepts the motor starter command. In this mode 110V must be supplied by the generator to operate the motor controls. Making the connection in this way allows the lift station heaters to function. Disconnections and re-connections to the VFD must be made at the motor starter and at the motor three phase input connection. The secondary pump is shut off to limit the current demand. The VFD can be used to operated the pump at reduced or full capacity as needed. Direct Connection Using Supplied Control Circuit In this method of connection the VFD is connected to the motor input leads. A supplied control circuit consisting of two float balls is set up in the field. In this method of connection only the disconnection of the motor input leads and re-connection to the VFD is necessary. Direct Connection Using No Control Circuit In this method of connection the VFD is connected to the motor input leads. The VFD is set to control the motor at a reduced speed. Under this mode the motor will operate continuously. In the direct connect to the motor/pump connection, the VFD is set at a low setting that keeps the wet well pumped down but supplies a continuous stream of water to the submersible pump/motor for cooling and lubrication. A VFD controller used in this mode is the simplest of the installation methods, and in an emergency mode following a hurricane, the VFD can be shut off at night to conserve fuel after pumping down the collection system and restarted in the morning when use of the wastewater collection system increases. This installation mode is the easiest and most common type of installation of the VFD/generator combination. This method can also be used in a rotation to service a number of lift stations or in a queuing operations where the VFD/generator is rotated, servicing the most needed lift

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station and then moving to the next critical one. How the VFD/generator is used is dictated by the field conditions and how many units can be made available. Connecting the VFD directly to power a pump panel will not allow the VFD to be used below 60 Hz unless phase monitoring equipment is disengaged, and the VFD will not provide a soft start. This is not the preferred connection method although it has been used successfully in limited applications generally where horsepower requirements are below 3 HP. Some Advantages Provided by the VFD/Generator Combination In emergency operations, there will be multiple power outages to an overwhelming number of lift stations. The conventional method used is to bring in portable generators and/or use pumper trucks to service smaller stations in a queuing method, i.e. servicing the most critical and moving to the next most critical. Equipment and labor resources will be quickly overwhelmed leading to stressful and potentially unsanitary and unsafe conditions. The use of the VFD/Single Phase Generator combination provides a simple and economical solution to these short-term problems. Some of the advantages of a VFD/generator compared to using a conventional threephase generator are illustrated in the table below.

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VFD/Single Phase Generator Comparison to Conventional Three Phase Generator Use For Lift Stations 20 HP and Smaller
NO. 1. 2. 3. Small VFD/Single Phase Generator Generator Cost and VFD cost less than $3,000 Generators in 5 HP range available locally. Several Small generators can be transported in the bed of a conventional pick up truck. Generator set up can be performed by maintenance personnel. Generators run on gasoline that is generally in adequate supply locally. VFDs are extremely versatile and can handle ranges of smaller HP sizes. Small generators are portable and can be handled easily by two employees Small generators require minimal maintenance and can be considered depreciated in 3 to 5 years Generators can be obtained and deployed easily by affected utility Emergency response is immediate protecting health and meeting needs of citizens for water and wastewater service Generators can be carried through back yards and placed in areas that are inaccessible to utility vehicles Use of these generators frees larger units for deployment elsewhere Conventional Three Phase Generator Generator for 30 KW Cost $13,000 to $15,000. Larger units can approach $30,000. Generator for 5 HP station special order large trailer mounted item. Each generator must be pulled by a recommended ton vehicle. Generator set up requires the services of a commercial electrician Generators run on diesel fuel. Obtaining fuel and fueling in emergency situations can be difficult and require fueling vehicles Generators costs vary slightly in smaller sizes, thus larger sized units are frequently used at small lift stations. Large generators typically require crew of two to three people to set up and require special electrical skills Large generators require considerable specialized maintenance, frequent exercise (recommended monthly under load) and require protected storage. Service life is 20 years. Transport of large generators to emergency areas requires outside crews to housed in the areas for extended periods Emergency response lags as assessments of areas and movement of equipment from long distances progresses.

4. 5.

6. 7. 8.

9. 10.

11.

12.

Utility vehicles can not access some areas immediately after storms because of the amount of debris and trees that are knocked down. Large generators supply is limited and priority application results in some areas waiting extended periods for help.

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Frequently Asked Questions 1. What type of generators do I need and how many do I need for my system? Lift stations that are fed from other lift stations must be provided with a method of supplying auxiliary power or support such as a pump-around or tanker service. Lift stations that feed into a 12 or larger force main must be provided with an emergency generator by DEP regulations.. Lift stations larger than 3 horsepower will typically use 240V, three phase service. Small generators typically provide 120V, single phase power and can not be used unless a phase converter (or VFD) is used. The minimum size three phase generator generally available and provided in emergency operations are 40 KW and are usually much larger than necessary. These units cost in the $20,000 to $25,000 range. Although each system is different, experience indicates that at least one portable generator is needed to support a maximum of 7 stations if they are close together and can be continually serviced in a route. If the stations cannot be serviced in this manner more generators will be needed. 2. How do I determine what size and how much will a single phase generator will cost for a small lift station? To determine the single phase generator needed first determine the largest motor to be operated in the station and multiply it by 1000. There is a table provided in this paper that accommodates the required safety factor. Single phase generators can be purchased for about $0.25 per watt with the price decreasing as the generator size increases. They can supply power to one pump in the station connected to a VFD. Single phase generators are locally available, economical, and can be easily moved to a site using existing personnel and transport vehicles (van or pick up.) 3. How do I determine what size VFD I will need and what do they cost for a small lift station. VFD are rated by the range of minimum to maximum HP applied. Generally the ranges are 0 to 5 HP, 5 to 10 HP and 5 to 20 HP. The VFD is downwardly compatible, that is a 20 HP VFD will also operate down to a 4 HP motor. The cost of the VFD runs about $650 for the smaller unit, $850 for the intermediate and $1450 for the larger unit (5 to 20 HP range.) VFDs act as a phase converter and convert the 240V, single phase power to 240 V, three phase power.

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4. How do I determine the proper field setting for the VFD for a lift station installation? This paper provides some general guidelines for a starting point for system set up. However, each set up is different and it usually takes a few minor adjustments in the field to provide an acceptable set point. The VFD comes equipped with an interactive menu screen and keyboard that allows operator adjustment with very little instruction. There are only a few settings required and these are based on the size of the motor and use of its nameplate data, if available. If the information is not available, standard electrical charts can be used with the same results. The table below shows the typical settings used in a VFD/Single Phase generator application. There will be two wire connections and a ground connection from the generator on the input side to the VFD, and three output and a ground connection on the output side of the VFD to the motor/pump being operated. Typical Settings Used for a VFD Single Phase Generator Installation VFD Setting Frequency FLA Description Set for 60 Hz for US Motors Full Load Amp requirement from Nameplate or from Table Setting for Operating Frequency for de-rating of pumping capacity Input/Output Voltage of VFD Motor Protection, typically set at 1.5 Allows motor to ramp to full speed; setting 0 to 5 seconds

Low Frequency

Voltage Over Current Prot. Acceleration

Generally the VFD/generator will be used only in an emergency situation. In this situation concern is providing a short-term means for a temporary water or wastewater electrical connection that will restore minimal service. The VFD/generator installation is intended for that interim period of time when no line power is available from the power company, until the time it is restored. Attempting to provide full pump capability to every utility installation, in an emergency situation, is impractical because of the limited availability of three

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phase generators, the cost of transport, the cost of installation and servicing and the labor requirements needed to manage an operation of this magnitude. 5. Where do I obtain a VFD and what Size VFD(s) and generator(s) do I need. VFDs are manufactured by Square D and/or Telemecanique and are the Altivar 31 model. These have been used successfully in testing in Naples Florida for this purpose. They can be obtained from Grainger and other electrical supply companies. VFD units should be sized with a safety factor of 25% (downsize the highest HP rating for the VFD by 25%, i.e. for a 7.5 HP application use a VFD rating of at least 10 HP.) As discussed in the paper, FRWA recommends a generator sized by multiplying the HP at the location by 1,000 and adding a 50% safety factor.

6. Where can I obtain assistance with my installation? Contact Florida Rural Water Association at 850-669-2748 or at frwa.net.

This paper was prepared by Robert McVay, P.E., Water Trainer for Florida Rural Water Association. The paper presents experienced gained at installation in the City of Naples. Naples successfully piloted the use of single phase generators/VFD combinations in lift station for emergency applications following hurricane Wilma that made landfall there. These units were also successfully used in Broward County during the 2005 hurricane season by Florida Rural Water Association.

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