| confidential/property of danfoss power electronics| thursday, 16 july 2015 | 1 presenting power...

| Confidential/Property of Danfoss Power Electronics| Wednesday 19 April 2023 | 1Presenting Power Electronics

Energy Savings in Water and Wastewater Segment

Danfoss Industries Pvt. Ltd.

| Confidential/Property of Motion Controls | Wednesday, April 19, 2023 | 2

Presentation Overview:

Introduction to Danfoss

Danfoss Core Business

Energy savings & other benefits with VFD control VFD applications in water and wastewater segment


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


Danfoss’ core businesses focus on Climate & Energy


Danfoss = First company to mass produce a.c. variable frequency drives (VFD)

VFD evolution

2003 2007 1998199319881983197819731968


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


Pump life cycle costs

~ 20% of the world’s 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

5%

95%


VLTAC 3Ø

Electronic unit that varies the fixed mains Electronic unit that varies the fixed mains voltagevoltage & & frequencyfrequency to to control the speed of standard a.c. electric motorscontrol the speed of standard a.c. electric motors

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

VFD (Variable Frequency Drive)VFD (Variable Frequency Drive)


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


Throttling Valve compared to VFD


Throttling valve compared to VFD

Control with valves Control with VSD

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


Energy consumption of single & multiple pump systems

Single VFD Single VFD controlled pumpcontrolled pump

Standard cascade Standard cascade control with 1 x VFD control with 1 x VFD pump & multiple pump & multiple fixed speed pumps fixed speed pumps

Master – follower Master – follower with 1 x VFD per with 1 x VFD per pump pump

Master follower = best energy efficiency

100%100%

Note: kWh figures are approximate relative %, based on sample test

53%53% 48%48%

43%43%


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)


Application examples

Ground water abstraction

Reverse Osmosis

Water distribution

Wastewater treatment

Irrigation


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




Reverse Osmosis

Water distribution


Irrigation


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.




Reverse Osmosis

Water distribution


Irrigation


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

Pum ping stationwithHigh serv ice pum p

Sim plif iedwellwith pum p

Source fromsurface water

Sim plif iedtreatm ent plant

Source fromgroundwater

House BX

House B1

Consum er Network B

BoosterStation

Basem ent

Industrialconsum erConsum er Network A

House A1

House AX

House A2

Elevated Storage Tank

Landscape

Booster

Treatment p lant


Pressure Set point

From The Source

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.

Alternative system - pressure control with VFD

Water reservoir


Water – Distribution

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

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

Flow




Reverse Osmosis

Water distribution


Irrigation


Typical modern Wastewater treatment plant


Typical Wastewater treatment plant (WWTP) process


Typical energy distribution at WWTP

55%

10%

8%

8%

4%

15%

Activated Sludge

Primary P.S. Clarifier

Heating

Solids Dewatering

Raw Water P.S.

Other

28%

46%

12%

7%3% 4%

Energy

Staffing

Solids Disposal

Other

Maintenance Materials

Chemicals

Typical cost distribution at WWTP


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

Fans

Applications (E.g.)

Odour control

Ventilation

Cooling towers




Reverse Osmosis

Water distribution


Irrigation


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


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!


•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

VLT® AQUA Drive


Global focus

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

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


1000’s of Drives & Soft Starters in service

Water supply & treatment

RO / Desalination & recycling


Pumping Stations

Irrigation

Power generation

District heating

Waste processing & recycling

Over 25 year track record globally & in Asia Pacific


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)

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 Vietnam’s most important development projects, Yen So Park entrails the development of a sewage treatment plant capable of treating 200,000m3 or half of Hanoi’s waste water per day. Energy saving using back channel cooling and installation space saving.

Pressurized system for Booster pumping stations in Bulgaria.


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)

| confidential/property of danfoss power electronics| thursday, 16 july 2015 | 1 presenting power...

Documents

vfd slide

water energy

climate energy slide

danfoss slide

vfd control vfd applications

energy efficiency

worlds energy

typical energy savings