Energy Savings in Water and Wastewater Segment

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Energy Savings in Water and Wastewater Segment

• Danfoss Industries Pvt. Ltd.

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Presentation Overview

• Introduction to Danfoss
• Danfoss Core Business
• Energy savings other benefits with VFD control
• VFD applications in water and wastewater segment

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Danfoss in brief

• 78 years of experience within energy-efficient
  technologies
• Solutions ready to combat climate challenge
• Global competence center for energy efficiency
  rooted in Southern Denmark
• The Bitten and Mads Clausen Foundation holds the
  majority of shares in Danfoss

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Danfoss core businesses focus on Climate Energy
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Danfoss First company to mass produce a.c.
variable frequency drives (VFD)
VFD evolution
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Water energy --- precious resources

• Climate change is increasing pressure on global
  fresh water resources
• At the same time demand for energy is rising
• Both are contributing to increased concern for
  the environment
• VFD can provide significant energy savings,
  reduce water loss, and provide other benefits in
  water, wastewater irrigation systems

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Pump life cycle costs

• 20 of the worlds energy is consumed by pumps
  
• Initial capital and whole of life maintenance
  costs 5 of the total life cycle cost
• Energy costs 95
• 95 of pumps installed are over sized (Selected
  for worst case condition safety margin)
• Methods of flow control to meet average (lower)
  flow or varying demand include e.g.
• - Impeller trimming
• Throttling valve
• Bypass valve (3-way)
• Variable Frequency Drive (VFD)
• British Pump Manufacturers Association

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95
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VFD (Variable Frequency Drive)
Electronic unit that varies the fixed mains
voltage frequency to control the speed of
standard a.c. electric motors

• Infinite speed control from 0-50Hz over-speed
  operation with some limitations

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Typical energy savings with VFD on centrifugal
pumps

• Flow is proportional to speed
• Power varies to the cube of the speed
• change
• 20 reduction in speed
• 50 reduction in energy
• 50 reduction in speed
• 80 reduction in energy

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Throttling Valve compared to VFD
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Throttling valve compared to VFD

• VFD gives 35 energy savings compared to
  throttling valve (On typical
  variable flow applications)

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Energy consumption of single multiple pump
systems

Single VFD controlled pump
100
Standard cascade control with 1 x VFD pump
multiple fixed speed pumps
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48
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Master follower with 1 x VFD per pump
Note kWh figures are approximate relative ,
based on sample test

• Master follower best energy efficiency

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Other benefit reduced water loss

• Smooth starting stopping with VFD
• reduces mechanical stress
• Less damage to piping valves
• Lower possible system operating
• pressure also reduces water loss
• (Non revenue water, which in
• developing countries is 30 of water
• supply)

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Application examples

• Ground water abstraction
• Reverse Osmosis
• Water distribution
• Wastewater treatment
• Irrigation

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Groundwater abstraction

• VFD allow control of draw down
• on deep well submersible pumps
• Constant level, flow or pressure
• Benefits (e.g.)
• Energy savings
• Reduced mechanical stress leakage
• Chemical dosing to match flow

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Application examples

• Ground water abstraction
• Reverse Osmosis
• Water distribution
• Wastewater treatment
• Irrigation

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Reverse Osmosis

• Membranes are used to filter salt
• other impurities from water
• Variables are Flow, Temperature
• and Salinity
• Brackish water requires less
• pressure than sea water
• Benefits (E.g.)
• VFD can maintain constant output flow
• as filters block
• Elimination of pressure surges
• extends the membrane life.
• Longer time between backwash cycles.
• Less energy consumption -
• lower speed with clean filters.

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Application examples

• Ground water abstraction
• Reverse Osmosis
• Water distribution
• Wastewater treatment
• Irrigation

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Constant pressure with water tower/ elevated
storage tank

• Water Towers maintain constant pressure in the
  water distribution system
• and provide a certain capacity
• Pumps are used to fill the water tower, normally
  based on level control

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Alternative system - pressure control with VFD
Water reservoir

• The VFD adjusts the pump speed based on a
  feedback signal from the pressure transmitter to
  maintain a constant pressure with changes in flow
  
• Note Booster pumps may also be utilised to
  overcome pressure loss in networks with e.g.
  significant elevation in the field.

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Water Distribution

• VFD controlled pumps replace water tower to
  maintain constant pressure, irrespective of
  demand

Flow

PRESSURE

• Benefits
• Constant pressure with changing flow
• Elimination of water hammer
• Reduced water leakage
• Less energy consumption
• Less maintenance / lower whole of life cycle cost

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Application examples

• Ground water abstraction
• Reverse Osmosis
• Water distribution
• Wastewater treatment
• Irrigation

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Typical modern Wastewater treatment plant
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Typical Wastewater treatment plant (WWTP) process
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Typical energy distribution at WWTP
Typical cost distribution at WWTP
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Fans

• Applications (E.g.)
• Odour control
• Ventilation
• Cooling towers

• Benefits
• Exact air flow to match demand
• Energy savings (20 reduction in
• speed gives 50 saving in energy)
• Constant pressure or temperature etc.
• Less wear (EG Extends belt life)
• Reduced audible noise
• Parallel fan operation possible

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Application examples

• Ground water abstraction
• Reverse Osmosis
• Water distribution
• Wastewater treatment
• Irrigation

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Irrigation

• Applications
• Lift station pumps (Level control)
• Deep well submersible pumps
• Transfer pumps

• Benefits
• Constant level with changing flow
• Less water hammer / mechanical stress
• Lower risk of pipe breakage
• Potential energy savings

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Summary of benefits of VFD control

• Energy savings (E.g. 35 when compared to
  throttling valve)
• Low in rush current / low torque surges less
  mechanical stress (E.g. prevent water hammer,
  gearbox damage, belt breakage)
• Less water leakage due to lower possible
  operating pressure (I.e. extend life of
  aging infrastructure)
• Increased flexibility /improved system
  performance (E.g. control to match actual demand
  not design demand)
• Advanced control diagnostic interface
  possibilities (E.g. SCADA)
• Less maintenance / lower whole of life cycle
  costs
• Environmentally friendly solution!

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VLT AQUA Drive

• Dedicated VFD for all applications in Water,
  wastewater irrigation
• 0.35kW 1.4MW power range
• Suit both constant variable torque loads
• Automatic Energy optimiser
• Built-in pump control protection
• functions
• Optimum ingress protection
• High efficiency ( 98)
• Lowest cost of ownership

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Global focus

• Water
• Wastewater
• Irrigation
• Power generation
• Steam, hot water gas supply
• Waste processing recovery

• Our vision is to be recognized as the most
  dedicated supplier of Drives solutions in the
  Water Wastewater Irrigation sector world wide
• Sales service in 100 countries, including
  India
• 40 year track record
• Dedicated product organisation

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Over 25 year track record globally in Asia
Pacific

• 1000s of Drives Soft Starters in service
• Water supply treatment
• RO / Desalination recycling
• Wastewater treatment
• Pumping Stations
• Irrigation
• Power generation
• District heating
• Waste processing recycling

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Global References

• Bisalpur Water  Supply Project Project aims to
  reduce dependence of
• Jaipur city on ground water resources. Under this
  project 400 MLD of raw water is
• pumped from Bisalpur Dam to Clear Water treatment
  plant at Surajpura.
• Yamuna Interceptor project Delhi Jal board.
• Yen So Park is one of Vietnams most important
  development projects,
• Yen So Park entrails the development of a sewage
  treatment plant capable
• of treating 200,000m3 or half of Hanois waste
  water per day.
• Energy saving using back channel cooling and
  installation space saving.
• Pressurized system for Booster pumping stations
  in Bulgaria.

Danfoss can accept no
responsibility for possible errors in printed
material. Please consult
equipment design guides / manuals for specific
details / verify data. All images contained in
this presentation are the property of Danfoss A/S
or other parties where relevant must not be
copied. VLT is a registered trademark of Danfoss
Drives)
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• Please consider the environment use VFD for
  your next application
• Thank you!

Danfoss can accept no
responsibility for possible errors in printed
material. Please consult
equipment design guides / manuals for specific
details / verify data. All images contained in
this presentation are the property of Danfoss A/S
or other parties where relevant must not be
copied. VLT is a registered trademark of Danfoss
Drives)