Pump Reconstruction for Water Reservoir Markvarec (UV Horka, Sokolov)

1. Pump reconstruction for water reservoir Markvarec(UV Horka, Sokolov)SPEL, spol. s r.o. SPEL spol. s r.o., Tridvorska 1402, 280 00 Kolin tel.: 321 579 060 fax: 321 579 040 www.spel.cz Vladimir Kraft SPEL Kolin tel.: 321579061 e-mail: kraft@spel.cz

2. Pump water reservoir MARKVAREC before reconstruction • 3 horizontal pumps to one collective draugh • The pumps are not able to next reliable operation • By producer the general repair of the pump is not possible • Pumps are powered by asynchronous motors 400kW, 6kV. • Motors are directly switch to supply network by contactors without starter. • Delivery of the convenient spare contactors without modification of MV cabinets are not solved.

3. Pump water reservoir MARKVAREC before reconstruction • By large torque inrush at start is reduced durability life of mechanical pumps parts = frequent unplanned outage through the repair. • Before every start of the pump is necessary to use vacuum air pump. • Water reservoir is filling by one or two pumps (160 litre/sec) • Third pump is always like reserve.

4. Machinery room – before reconstruction

5. Variant of resolution - consideration 1. Exchange of 3pcs. pumps are necessary When new, so vertical in design to wet reservoir. Reason: - lower operating costs, elimination vacuum air pump - lower demands on space in machinery room - there is no need to use suction piping - they are convenient to usage with variable frequency drive 2. If we use vertical pumps, we must use new corresponding motors through constructional reason. 3. Question:„Stay at MV (6 kV) or use motors on LV (400V) ? “ ------------------------------ This is necessary to consider from technical aspect and financial expenses on operating, servis and starting this motors.

6. Variant of resolution Now we consider combination of following possibilities: Power supply voltage for motors: 400 V or 6 kV ? Method of start and control a)switching the pump direct tothe supply network b)soft starter (smooth start and stop without torque inrush and without current overload) c)variable frequency drive (speed control, smooth start and stop without torque inrush and current overload)

7. Variant of resolution Now we consider individual combinations previous possibilities: Switching the pump direct to the power supply network 400V 6 kV great starting current torque inrush „water hammer“ (durability of clutch and armatures) system voltage drop reconstruction of MV cabinets with new switching elements is necessary improper for frequent switching We don´t advise this resolution

8. Other variant of resolution suppressed starting current without torque inrush „water hammer“ doesn´t exist high durability of coupling and armatures without system voltage drop there is enough space for cabinet there is not enough space for cabinet proper for frequent switching price 3x higher then LV We advise this resolution Starting the motor through the soft starter to the supply network 400V 6 kV

9. Other variant of resolution benefits like soft starter plus: continuous regulation of flow through the UV reduction of power? payment for 1/4 hour maximum price 5x higher then soft starter the best solution from technical aspect optimal for P > 0,5MW We advise this resolution Speed control of pump by variable frequency drive: 400V 6 kV

10. Machinery room before reconstruction

11. Pump before reconstruction

12. Control room Workstation APS SW ControlView SW, control, monitoring, grafs, archiving data Data Highway 485 DH-485 LIME CHEMISTRY Machinery room FILTRY DeviceNet FLEX I/O DeviceNet FILTR 1 …. FILTR 10 FLEX I/O Incoming 2.pump Markvarec PanelView 900 control of the pump, servovalve, compenzation measuring: temperature of the winding, temperature of the bearing, voltage remote/local selector, Start/Stop, ScanPort - communication with Soft Starter fault message RM23 3. pump Markvarec

13. Soft starter - semiconductor starter Intended to asynchronous motors: - start up control - optimalization of the run - stop control

14. When use the Soft Starter ? • remove the consequence of the direct connection motor to the net: • system voltage drop owing to high motor starting current • mechanical damage of the equipment (mechanical clutch, gearbox, machinery) • pressure and torque inrush in the pipe • Displace the motor switching from • star-delta switching starter • switching reactor • slip-ring motor • centrifugal coupling • Communication, protection, monitoring

15. Voltage in the network 50 Hz 50 Hz 50 Hz Voltage to the motor 50 Hz 50 Hz 50 Hz M 3 ~ How the soft starter work? • Control processor changes effective value of output voltage

16. Softstarter - SMC Dialog Plus Smooth start and stop of the pump U (V) 400V break torque of the motor t (s) run stop of the pump start up time

17. SMC Dialog Plus – main benefits • Proper overcurrent protection of motor • Non-load detection, detection of blocked motor • Phase balancing • Diagnostic • Monitoring • Communication • Settings by demands of application (soft start, current limit, soft stop, braking, low speed)

18. SMC Dialog Plus- Diagnostics • Power loss • Unload motor • Stall motor (Jam, Stall) • Voltage fluctuation • Phase rotation • Overvoltage • Undervoltage • Overheating • Tyristor failure • Overload • Get over the maximum starts per hour Diagnostics prior to ….

19. Soft starter SMC Dialog Plus- Monitoring • Currents in 3 phases • Voltage in 3 phases • Power in kW • Consumption in kWh • Motor thermal protection • Power factor of running motor • Total motor running time Communication

20. After the reconstruction

21. First start

22. Pump with motor Motor KONCAR 450kW, 400V + pump MSA Dolni Benesov 180 l/sec.

23. Control room UV Horka

24. Application notes • reliability (correct proposal, setting in operation, user) • before the soft starter must by always place quick-break fuse • durability (ambient conditions, capacitor, fan, overvoltage, temperature in cabinet) • overvoltage protection is functional only with proper fuses! • negativ influence from switching of compensation capacitors (harmonical breakdown, overvoltage up to a few kV) • delivery of spare parts (service contract, service technicist, spare parts store, swiftness of service mission, expertness) • maintainance=cleanness, cooling, checking a evidence activity (errand or telemonitoring) • refresher courses (SPEL Kolín), literature

25. Pumps – energy saving with variable frequency drive flow2 flow1 speed2 speed1 = Power (kW) Throttle method ( )2 speed2 speed1 draught2 draught1 25 = 20 ( )3 speed2 speed1 power2 power1 = 15 10 Speed control 5 Flow (%) 0 20% 40% 60% 80% 100% Note: If we confuse two stage regulation and permanent continuous speed regulation (flow), then we nearly always can decrease payment for ¼ hour maximum.

26. …in water service