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Abstract
The inverter control strategy is the key to pump energy-saving operation and should be established based on the current
system configurations and system requirements, which is not the case in practice. As a result, the characteristics of
pump system requirements and a combination pump with inverter were studied, and the mathematical models were
established. A new model for an optimal inverter control strategy based on the current system configurations and system requirements was then established, and a method combining golden section search and genetic algorithm was formulated to solve this optimal model. This model sets up an optimal inverter control strategy to increase the efficiency of
pump operation following a process line near the minimum requirements to improve operation conditions. The implementation difficulty of the control law was also reduced. Finally, the optimized model was applied to an industrial circulating pump system, and the result showed that the model can not only determine the optimal inverter control strategy
but also evaluate the current operation situation of the pump configuration and determine the energy-saving potential
for the current configuration, which can aid in the subsequent energy-saving reconstruction.
Keywords
Energy-saving technology, inverter control strategy, variable pressure water supply, pump system characteristics
Introduction
Pumps are widely used in industrial and service sector
applications. Pumps consume approximately 10%
40% of electricity in these sectors.1,2 Pumping systems
are found to have a significant potential for energy efficiency improvements; using inverters in pumping applications, variable speed pumping has been shown to be
effective in reducing total pumping costs, particularly
in systems that require a wide range.38
Despite being capable of adjusting the rotation
speed of the pump, an inverter cannot achieve energy
savings directly. Energy saving can only be achieved
through the optimal operation control strategy.5,6,9,10
Energy-saving efforts are affected by the optimization
degree of the control strategy and the equipment configuration.911 As a result, the pump system should
possess an established inverter control law for energysaving operations.
The variable pressure control law1215 which followed the system characteristics could achieve the minimum supply for system requirements without throttle
loss. However, the present pump configuration tends to
promote the practice of sizing pumps conservatively to
ensure safety margins for the process, which could
cause the pump to operate under low efficiency. This
practice results in low operating efficiency and high
maintenance costs with high noise. Second, due to the
high price of the inverter, not all pumps are equipped
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Head
80%
110%
% Flow
Single-pump model
The range of the preferred continuous operation can be
defined according to some criteria; for instance, based
on the requirement that the efficiency must not fall
below 80%85% of the maximum efficiency of the
pump in question. The allowable ranges can be defined
by the efficiency must not fall below 70% of the maximum efficiency.
Considering the general centrifugal pump, the QH
characteristics can be expressed as follows
H = Hx SQ2
Q 2 QA , QB
In this interval, with the head He, the flow range can
be recorded as
( q
Hx He
Sx
Qc (He) =
He 2 HA , HB
He 62 (HA , HB )
HX
HA 2
QA Qe
SQ2e
Qe 2 QA , QB
Qe QA
Luo et al.
l1
H
l2
System characteristics
A
Operation zone
Efficiency area
n0
C
D
Multi - pump
characteristics
Single pump
characteristics
nmin
HA 2
Q ,
QA l1
Hl2 =
HB 2
Q
QB l2
QA
Qc
QB
QB
He
HA
q
He
HA
He HC
He \HC
He \HB
He HB
Hmin =
2
HX
kmin
HB 2
QB Qe
Hmax =
HX
HA 2
QA Qe
SQ2e
SQ2e
Qe \QD
Q QD
Qe QA
Q\QA
7
8
x
X
wi QCik (He ) +
i=1
n
X
wi QCik (He ) +
i=1
n
X
wi QVikmin (He ),
i=x
n
X
wi QVikmax (He )
i=x
where n is the number of pumps, x expresses the constant speed operation pump, i denotes the ith pump, k
is the kth type of pump, and wi is the switch vector. In
the configuration of the ith pump selection, if the pump
is in operation, we use 1; otherwise, the value is 0.
HS
HDmax
HDmax
HDmin
HDmin
QDmin
QDmax
HRmin
QDmin
10
HS
HRmax
QDmax
H
Hs1
Hs2
A
Qmin
Qmax
Luo et al.
HS1
A
HS2
D
C
2.
Qmin
Qmax
3.
Pump
Configuration
Operation
demand
area
Efficient
operation area
Opeartion
Characteristcs&
Demand zone
Compare
Demand Flow
Optional
operating area
Optimal
scheduling
Energy cost
Switch
number
Min ?
<=1?
Supply head
Invert control
law
dH (w, w0 ) =
n
X
wj w0j
12
j=1
where I is the number of pumps, wi is the operating status of pump i for the next step, w0i is the present operating status, and wi and w0i are both switch variables.
Finally, for every Hei 2 HR, some switch control
scheme wij and variable control switch schemes kij are
available.
Optimal evaluation model. Based on the current switch
conditions, a lower switch number yields more preferable results. For Qz, the switch conditions are used as
inputs by the optimal evaluation model to calculate the
current power consumed to prepare for the optimal
selection.
Evaluation objective function. In a typical pumping system, an inverter control law focuses on the effect of
energy savings. The evaluation objective is the energy
consumption of the pump unit.16
The commonly used model considers the shaft horsepower of the pumps as objective function because the
energy consumption of the motor and inverter is significantly less than that of the pump. The objective function can be mathematically expressed as
f1=
I
X
wi Pi (Qi , ki )
13
i=1
14
Luo et al.
Pump model
Qden (m3/h)
Hden (m)
Qmin (m3/h)
Qmax (m3/h)
N (r/min)
1#
2#
3#
4#
20SA-10
20SA-10
20SA-10
20SA-10
2850
2850
2850
2850
58
58
58
58
1710
1710
1710
1710
3848
3848
3848
3848
960
960
960
960
n
X
Qi
15
i=1
HST = Hi
16
Application
Profiles of the pump station
A sample model is a circulating water pumping station,
one of the most important facilities in an alumina plant
r
70:39 He
Qv max = Qv min =
1:789e 6
For this pump group, the efficient area can be
expressed as
10000
Q (m3/h)
8000
6000
4000
2000
0
6
7
Month
10
11
12
"
QZ =
3
X
wi 3 QC (He ) +
i=1
wi QC (He ) +
wi 3 QVmin (He ),
i=x
i=1
1
X
1
X
n
X
wi 3 QVmax (He )
i=x
For this pumping system, the basic demand characteristic obeys equation (10), the maximum design flow
is 8500 m3, and minimum design flow is 1500 m3
Hdem = 31 + 3:51 3 107 Q2
17
HR max = 56:4
HR min = 31 + 3:51 3 107 Q2e
Qe 2 1500, 8500
Luo et al.
Pump model
Qden (m3/h)
Hden (m)
Qmin (m3/h)
Qmax (m3/h)
N (r/min)
5#
14SH-9B
1425
58
855
1853
1450
r
71:17 He
Qv max = Qv min =
7:488e 6
QH characteristics
2
H = 71:17 3 k 7:488e 6 3 Q
where k is the speed regulation ratio. If the pump operates at constant speed, k is equal to 1.
QP characteristics
P = 146:4 3 k 3 + 0:05 3 k 2 3 Q
+ 4:4e 5k 3 Q2 1:44e 8 3 Q3
For this constant speed pump, He 2 [45.4, 60.1]
The operation area should also change. The singleinverter control law with pony pump is shown in
Figure 14.
As shown in Figure 14, the efficient area of singleinverter control with pony pump can cover the entire
operating area. From this point, this equipment was
applicable for this application. This control law can
achieve the minimum requirement operation in the flow
area of 40006000 m3. Thus, from an energy-saving
operation perspective, this approach may not be ideal.
As shown in Figure 15, the shaft power under different flow requirements of the three schemes can be
10
Original scheme
Single inverter configuration
Single inverter with pony
Two inverter configuration
9,075,400
1,329,500
1,434,100
1,504,800
14.6
15.8
16.6
Save
Investment cost
Original scheme
Single inverter
Single inverter with pony
Two inverter
5.45
4.65
4.6
4.54
0.7977
0.84138
0.91572
1.5
1.75
3
1.8
2
3.3
25
Single inverter
mul
20
15
10
0
0
10
15
20
25
30
Year
-5
Figure 17. Multi-control laws for single invert with pony pump
configuration.
Luo et al.
11
Conclusion
In this work, a new model for an optimal inverter control strategy based on the current system configuration
and system requirements is presented. The main conclusions of this study are as follows:
Figure 18. Shaft power of multi-control law with pony pump
configuration.
1.
Original configuration
Optimal invert control law
Minimum requirement control
9,075,400
1,434,100
1,461,100
15.8
16.1
Figure 19. Efficient area operation ability of multi-control law with pony pump configuration: (a) region of efficient operation and
(b) ability of efficient operation.
12
2.
follow a process line near the minimum requirement line to improve the operation condition,
such that the implementation difficulty of the
control law is also reduced. As a result, for different pump system configuration modes or different requirement laws, the inverter control
strategy should vary.
By optimizing the model calculations, the optimal inverter control strategy can be obtained,
and the current operation situation of the current pump configuration can be evaluated to
identify energy-saving potential opportunities
for the current configurations and prepare for
the subsequent energy-saving reconstruction.
Funding
This project was supported by The National Natural Science
Fund (No. 51409125 ), the China Postdoctoral Science
Foundation (No. 2014M551515), Priority Academic Program
Development of Jiangsu Higher Education Institutions,
Jiangsu University fund assistance (No. 13JDG082), Jiangsu
postdoctoral research grants program (No. 1302026B), and
University Natural Science Foundation of Jiangsu Province
(No. 14KJB470002).
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