Energy Optimizing Using VFD

Frequency Converters
• Variable-frequency drives (VFD’s) working
with pumps, allow for smooth starting
(ramping) & reduces the stress on the motor
& network

• Applying VFD’s to pumps enables speed

adjustment according to actual need and
allows pumps to work at optimal efficiency
throughout the system curve. They also allow
for limit settings providing full control over
pumps.

• Combination of VFD & High efficiency motor

will usually provide substantial energy
savings. Example - If the flow is reduced by
20%, the power consumption is reduced by
50%.
Note: When working with VFD’s - the
motors must be fitted with an insulated
bearing to avoid the bearing currents that
destroy the motor bearings.
Typical Pump
Applications with
Frequency Converters
Available for all Pump applications
• Chilled and Hot water Pumps
• Condenser Water Pumps
• Booster Pump

VFD Specifications
• 1.1 kW – 1.4 MW, 200 V – 690 V
• IP20 ,IP21, IP55, IP66, NEMA 12 and NEMA4X
• Supply voltage 3 x 380 – 480 V ±10%
• Supply frequency 50/60 Hz
• Output voltage 0 – 100% of supply voltage
• Output Frequency Closed loop 0 – 132 Hz
Typical Pump
Applications with
Frequency Converters

• Low cost of ownership – no periodic maintenance/

replacement cost
• ROI is typically below 6 months.
• High efficiencies – up to
98% efficiency
• Internal fan & main capacitor designed for life of drive
Low operating costs
System protection:
Protecting the application
Protecting the motor
Protecting the drive
Energy Optimizing Using VFD
DESMI Pumps
Duty Point achieved by choosing a pump with full
size impeller BELOW the duty point and adjusting
the rpm UP with VFD to hit exact duty point.
Full size impeller = bestefficiency!
Most Other Pump Brands
Duty point is achieved by choosing a pump ABOVE the
required duty point and trimming impeller size down at
nominal speed to hit exact duty point.
Trim impeller = trim away efficiency!
at nominal speed.
Energy Optimizing Using VFD

Using full size impeller instead of trimmed impeller Benifits of full size impeller :

• Duty Point achieved by choosing pump with full

size impeller and adjusting the rpm UP to hit
max. duty point. (is often HIGHER than nominal
rpm) Max duty point power consumption
determines the motor size.

• Pump always works at optimal efficiency point

due to max size impeller and speeding up/down
of pump.
Energy Optimizing Using VFD
• All DESMI pumps are supplied with Duel
Frequency motors (50/60 Hz power operation)
Over speeding Motor with Variable Frequency Drive
• Example : 4-pole motor 37/44.4 kW name plate
rated will have output power of 37 kW @ 50 Hz
power supply . Same motor will give 44.4 kW if
the Power Supply is 60 Hz

• Motors & Pumps are designed for over speeding

of 25% Nominal motor speed (name plate
speed)
• Example : atypical 4-pole 50 Hz ,37 kW motor
will have nominal speed of 1480 rpm (name
plate speed)
Energy Optimizing Using VFD
• While same motor could have up to 1.25x50 Hz
speed regulated by using VFD up to 62.5 Hz
Over speeding Motor with Variable Frequency Drive
• Pump speed is not the nominal motor speed in
case of DP regulation !
• If the pump DP is running at 1714 rpm then the
• 2-POLE >>>>> 2945 RPM Frequency is 57.133 Hz
• 4-POLE >>>>> 1470 RPM
• 6-POLE >>>>> 975 RPM • The synchronous speed can be calculated as:
n = f (2 / p) 60 (1)
• 8-POLE >>>>> 735 RPM
where
n = shaft rotation speed (rev/min, rpm)
f = frequency of electrical power supply (Hz,
cycles/sec, 1/s)
p = number of poles

• Motor shall be capable to increase speed up to

60 Hz, reduce speed to 25-30 Hz within the
range of number of poles
• The more risk operation starts from 25-20Hz.
where the cooling from motor fan might be not
enough to cool down the motor (so when motor
has PTC, it will be stopped)
Energy Optimizing Using VFD • The difference between the synchronous speed
of the electric motor magnetic field, and the
shaft rotating speed is slip - measured in RPM or
Over speeding Motor with Variable Frequency Drive--- frequency.
• Slip increases with increasing load - providing a
greater torque

• It is common to express the slip as the ratio

between the shaft rotation speed and the
synchronous magnetic field speed.
• s = (ns - na) 100% / ns (1)
• where
• s = slip
• n motor =na=ns(1-s)
• ns = synchronous speed of magnetic field
• 4-POLE >>>>> 1470 RPM (rev/min, rpm)
n motor = 1470 rpm • na= n motor = shaft rotating speed (rev/min,
ns = 1500 rpm rpm)
n motor = ns (1-s) • When the rotor is not turning the slip is 100 %.
• Full-load slip varies from less than 1 % in high hp
s = 1-(1470/1500)=1-0.98=0.02=2%
motors to more than 5-6 % in minor hp motors.
• The synchronous speed can be calculated as:
ns = f (2 / p) 60 = 120 f/p (1)
Energy Optimizing Using VFD
• While same motor could have up to 1.25x50 Hz
speed regulated by using VFD up to 62.5 Hz
Over speeding Motor with Variable Frequency Drive
• Pump speed is not the nominal motor speed in
case of DP regulation !
• If the pump DP is running at 1714 rpm then the
• 2-POLE >>>>> 2945 RPM Frequency is 57.133 Hz
• 4-POLE >>>>> 1470 RPM
• 6-POLE >>>>> 975 RPM • The synchronous speed can be calculated as:
n = f (2 / p) 60 (1)
• 8-POLE >>>>> 735 RPM
where
n = shaft rotation speed (rev/min, rpm)
f = frequency of electrical power supply (Hz,
cycles/sec, 1/s)
p = number of poles

• Motor shall be capable to increase speed up to

60 Hz, reduce speed to 25-30 Hz within the
range of number of poles
• The more risk operation starts from 25-20Hz.
where the cooling from motor fan might be not
enough to cool down the motor (so when motor
has PTC, it will be stopped)
Energy Optimizing Using VFD Nominal Motor nameplate
Speed (Synchronous Speed) :
• 2-POLE >>>>> 2945 RPM
Over speeding Motor with Variable Frequency Drive • 4-POLE >>>>> 1470 RPM
• 6-POLE >>>>> 975 RPM
• 8-POLE >>>>> 735 RPM
Common pump speed ranges as per design recommendation:
• 2-POLE >>VFD@60 Hz>>> 3600 RPM>>> Design at 100% of full speed
Optimum speed design • 2-POLE >>VFD@54 Hz>>> 3240 RPM>>> Design at 90% of full speed(reserve of 10% more)
• 2-POLE >>VFD@50 Hz>>> 2970 RPM>>> Design at nominal sync speed
• 2-POLE >>VFD@25 Hz>>> 1500 RPM>>>Design min allowable speed for sufficient air fan cooling

Common pump speed ranges as per design recommendation:

• 4-POLE >>VFD@60 Hz>>> 1800 RPM>>> Design at 100% of full speed
Optimum speed design • 4-POLE >>VFD@54 Hz>>> 1620 RPM>>> Design at 90% of full speed(reserve of 10% more)
• 4-POLE >>VFD@50 Hz>>> 1470 RPM>>> Design at nominal sync speed
• 4-POLE >>VFD@25 Hz>>> 750 RPM>>>Design min allowable speed for sufficient air fan cooling
Energy Optimizing Using VFD Nominal Motor nameplate
Speed (Synchronous Speed) :
• 2-POLE >>>>> 2945 RPM
Over speeding Motor with Variable Frequency Drive • 4-POLE >>>>> 1470 RPM
• 6-POLE >>>>> 975 RPM
• 8-POLE >>>>> 735 RPM
Common pump speed ranges as per design recommendation:
• 6-POLE >>VFD@60 Hz>>> 1200 RPM>>> Design at 100% of full speed
Optimum speed design • 6-POLE >>VFD@54 Hz>>> 1080 RPM>>> Design at 90% of full speed(reserve of 10% more)
• 6-POLE >>VFD@50 Hz>>> 1000 RPM>>> Design at nominal sync speed
• 6-POLE >>VFD@25 Hz>>> 500 RPM>>>Design min allowable speed for sufficient air fan cooling

Common pump speed ranges as per design recommendation:

• 8-POLE >>VFD@60 Hz>>> 900 RPM>>> Design at 100% of full speed
Optimum speed design • 8-POLE >>VFD@54 Hz>>> 810 RPM>>> Design at 90% of full speed(reserve of 10% more)
• 8-POLE >>VFD@50 Hz>>> 750 RPM>>> Design at nominal sync speed
• 8-POLE >>VFD@25 Hz>>> 375 RPM>>>Design min allowable speed for sufficient air fan cooling
 Full Speed Pump vs. VFD Operation
Pump running with Soft Starter
(Constant Speed)
• Pump always works at full rpm. Duty point is
achieved by picking a bigger pump and
trimming impeller size down to hit exact duty
point. Max duty point Non-Overload Power
determines the motor size.
• If needed – pump flow can be adjusted with
valves, however only little change in power
consumption.
Pump is only efficient (typically not max
efficiency due to trimmed impeller) in specific
duty point. Efficiency drops dramatic if
conditions change.
• Typically, you will end up with a larger pump
and smaller motor than the VFD operated
pump.
Pump running with VFD
(Variable Speed)
• Duty Point achieved by choosing pump with full
size impeller and adjusting the rpm UP to hit max.
duty point. (is often HIGHER than nominal rpm)
Max duty point power consumption determines
the motor size.
• If needed – Pump speed can be adjusted to actual
need, thus saving energy. (VFD use is not limited
to applications with flow variations)
Pump always works at optimal efficiency point
due to max size impeller and speeding down of
pump.
• Typically, you will end up with a smaller pump +
smaller motor than the non-VFD full speed pump.
 Comparison – Typical Pump Selection Example:
Constant Speed vs. Variable Speed

Constant Speed Drive Variable Speed Drive

Pump Selection Constant Speed: Pump Selection Variable Speed:
• Trimmed Impeller Size • Max Impeller Size
• Constant motor speed operation • Over synchronies operation possible
• Best efficiency at duty point only • Best efficiency at all duty points
 Constant Speed vs. Variable Speed

Constant Speed Drive Variable Speed Drive

 Valve vs. VFD Flow Control (Power Consumption)
Partial Power Consumption
P [kW]
50 P50
[kW]
40 40 Partial Power Saving
30 30
20 20
10 10
0
0
0 200 400 600 800 1000 1200 1400
Q [l/s]
0 200 400 600 800 1000 1200 [m3/h]
Q1400
H [mLC] H [mLC]
18 18

16 16
Partial Load
14
Design DP 14

Flow increase
12 Flow increase 12

10 10

1680 rpm
8 8 Design DP
6 6

4 4 Partial Load
1470 rpm
2 2 920 rpm
Constant Speed Drive Variable Speed Drive
0 0
0 200 400 600 800 1000 1200 Q
1400[m3/h] 0 200 400 600 800 1000 1200 Q1400
m³/h]
 Comparison – Typical Pump Selection Example:
Constant Speed vs. Variable Speed

• Output Power (P2) will be maintained after reaching nominal speed (50 Hz)
• Torque will be decreased after reaching nominal speed (50 Hz) but still within the range for motor shaft drive up to (60 Hz)
Summary:
Advantages of VFD
Operated Pumps:
• Optimal efficiency with max size impeller
• Allows selection of smaller pumps and motors.
• Full pump/system control and protection
• Energy saving – money saving – CO2 saving.

Other important Points:

• VFD operation not only for variating flow
applications.
• VFD has very short payback time. Low operating costs
• Flexible Operation Possibilities