1 Overview In industrial enterprises, the motor is one of the most widely used and the largest number of electrical equipment. Currently, a large number of AC motors are working at a fixed speed, which has more and more can not meet the production process for automation requirements. At the same time, its operation in low power factor and low efficiency conditions, the power is a huge waste. Due to the increasingly fierce market competition in the petrochemical industry, new requirements have been put forward on the type, quality and quantity of petrochemical products in our factory. In order to meet the requirements of these processes, the original drive motor, increase the inverter system. This can not only smoothly change the amount of material delivered to meet the requirements of the production process, but also achieved the effect of energy saving. In our factory often line, often used in the second inverter system, both the power source is to change the process parameters of the implementing agencies, it replaces the original implementing agencies - control valve, making media transmission process control has undergone changes. 2 energy-saving operation of variable speed drive In the actual production process, the load of various types of pumps are greater than the actual choice of production flow, and in actual operation, the required flow is often much smaller than the design flow, if The motor used can not speed control, usually only by regulating the valve to control the flow, the result in the valve will cause great energy loss. If you do not valve regulation, but let the motor speed operation, then, when the required flow decreases, the motor speed decreases, the energy consumed will be significantly reduced. H (n1) and H (n2) are the curves of Q = f (H) when speed regulation, and R1 and R2 show the pipeline resistance curve when valve is adjusted. Valve control, due to reduce the flow, turn off the valve, so that the valve friction becomes larger, Q2 → Q1, A → B, HA → HB power control valve P1 by 0HBBQ1 said. When the speed control, Q2 → Q1, A → C, HA → HC speed control power consumption P2 by 0HCCQ1 said that if P1> P2 means that when the speed control power consumption is less than the power consumption when the valve throttle. P = rQH Pump shaft power Q Flow H Head r Liquid heavy PB-PC = Q1 (HB-HC) r when operating at points B and C. This is the amount of energy saved. For the pump load, there is the following expression: Q1 / Q2 = n1 / n2 H1 / H2 = (n1 / n2) 2 P1 / p2 = (n1 / n2) 3 It can be seen from the above formula that when the speed drops by 1/2, Down 1/2, the pressure dropped 1/4, the power down 1/8, that power and speed into the third power relations decline. If you do not close the valve, but the motor speed down, then with the pump output pressure decreases, the same flow in the case of transmission, the original consumption of the valve on the power can be completely avoided. Not installed in the inverter, the pump outlet flow control by the outlet valve regulation. Small flow, by closing the valve control, increased pump pressure, so that some of the energy consumed in the export valve. Using the inverter, you can reduce the pump speed, the pump head is also reduced accordingly, the motor output power is also reduced, thus eliminating the original consumption in the pump outlet valve on the pipe pressure. 3 Inverter system control scheme I plant the Changbian pump B109 and Chang II pump B114 motor power were 75kW and 55kW, speed 2982 rev / min, rated voltage 380V, rated current of 132A and 103A respectively, the rated outlet flow Respectively 28.520M3 / h and 20M3 / h. Under normal working load, the motor is working at the rated speed of 2982rpm, the speed can not be adjusted. In order to keep the flow stable, the method of controlling the outlet valve is used to control, that is, the differential pressure transmitter detects the flow signal to the PID regulator, and then the PID regulator outputs the 4-20mA control signal to control the opening of the outlet regulating valve Control outlet flow and keep the flow stable. The actual operation of the original system, there are the following problems: (1) large throttling, the throttle valve outlet pump is close to half the rated flow, waste a lot of electricity. (2) low control accuracy, large fluctuations in outlet flow (about 3%). (3) motor work at rated speed, output power consumption. (4) motor noise, pump and pipeline valve pressure, can easily lead to leakage. According to the above system requirements of the system, we designed the inverter system to follow the following principles: a, to maintain a stable outlet flow; b, outlet flow control accuracy of 0.5%; c, the motor speed range should be 0 ~ 2982 rpm / Min; d, according to the working characteristics of the pump, the system design should be based on the principle of constant torque; e, energy saving; f, system design using frequency and dual frequency switch to ensure the continuity of production and reliability, G, the use of two DCS output contacts, all the way to control the original control valve, all the way to control the inverter, the inverter fault status, DCS can automatically identify the frequency of the fault signal, and then switch to the control valve to regulate the flow. When the inverter is in normal operation, the control valve is in the fully open position. Following the above principle, after the research and comparison, we have chosen the Toshiba A5P inverter. The inverter has advanced technology, complete functions, compact structure, high reliability, designed for pump and fan load design. FRH: Frequency setting; ACC / DEC: Acceleration / deceleration control circuit; A / D: A / D conversion; V / F: Vfb conversion; BD: Base drive circuit; CPU: Microprocessor; LED: Display circuit The main circuit of the inverter is a typical "AC-DC-AC" SPWM voltage type main circuit. Frequency converter control circuit: Frequency given FRH (ie speed given) through the ACC and DED acceleration and deceleration control circuit into a frequency and voltage reference signal, respectively, through the A / D converter circuit and the V / F function generator circuit, and then Into the CPU, the formation of SPWM pulse, IGBT control signals to drive the IGBT, so that the voltage is constant, the frequency of constant AC, after the inverter, into a voltage and frequency adjustable AC. A5P inverter control system using the entire computer sampling, calculation, real-time control, accident alarm and display. 4 Inverter system operation In 1997 July, I plant in the usual line pump and often two pump motor installed Toshiba A5P inverter, the operating conditions and frequency comparison, as follows: (1) the motor operating parameters and Comparison of Energy Conservation Power Saving Power = ((39.16 × 0.82 × 380) - (16.3 × 0.9 × 168) × 1.73 = 16846 (W) Power Saving Rate = ((39.16 × 0.82 × 380) - (16.3 × 0.9 × 158) )) / (39.16 × 0.82 × 380) = 79% Power saving = (44.6 × 0.8 × 380) - (20 × 0.9 × 121) × 1.73 = 19688 (W) Power saving rate = (44.6 × 0.8 × 380) - (20 × 0.9 × 121)) / (44.6 × 0.8 × 380) = 83% As can be seen from the comparison table, the use of frequency converter can meet the production needs, but also a lot of energy. (2) Comparison of control accuracy In the same process conditions, the use of frequency and frequency operation, draw the pump outlet flow fluctuation curve. Pump frequency control, the flow control accuracy is very high, the recorder recorded curve is a very smooth record line. 5 Application Effect and Economic Benefit Analysis Since the inverter was put into operation, it has reliable operation, high degree of automation, remarkable energy-saving effect and good economic benefits. (1) Steady process control: Due to the high-precision adjustment of the inverter, the high-speed transmission of the regulating signal reduces the hysteresis caused by the previous instrument control, so that the system control accuracy is improved, the pressure is stable, and the product quality is improved. (2) Significant energy saving effect: Year-by-year calculation of 8,000 hours, pump 114/1 Energy Savings: Power Savings Rate × Motor Power Frequency × Working Hours = 79% × 21.11 kW × 8000 hours = 133415 kWh Pumps 109/2 years Power Savings: Power Savings × Motor Power Frequency × Working Hours = 83% × 23.45 kW × 8000 hours = 155,708 kWh Total Savings for Pump 114/1 and Pump 109/2: Power Savings × Price = 289123 × 0.50 = 144561 Yuan inverter transformation costs 150,000 yuan, so just one year or so, you can recover the investment. (3) reduce the amount of maintenance: As the outlet valve is fully open, the motor running at reduced speed, making the pipe pressure drops, reducing the leakage of process equipment, reducing machine wear and tear, reducing the motor temperature rise, equipment maintenance cycle extension. Because the frequency changer replaces the control valve, has solved the high control valve breakdown to produce the influence, causes the measuring appliance maintenance quantity to reduce. (4) The system has realized the soft start: Because the frequency changer has the soft starting function, reduced the impact to the electric wire netting. 6 Inverter applications should pay attention to the problem (1) with the inverter must meet the requirements of the process, in a particular environment, the old device of the pump due to head, flow restrictions, the inverter may not be applicable, and not Variable working conditions of the pump should not be used. Can not be stereotyped copy, but from the process conditions, the parameters of the pump itself may be. (2) Inverter speed regulation, the need for electrical, instrumentation, technology, equipment and various professionals in close cooperation in order to ensure the safe operation of the inverter. Engineering and technical personnel in the installation of investment before the relevant professionals to be trained. (3) most of the production equipment, instrumentation valves are mostly used off valve. After using the inverter, the wind is changed to open the wind regulation, you need to pay attention to avoid accidents.
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