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Frequency Converter Advantages & Considerations
There are many advantages to implement frequency converters on pumping and lots of other applications which will provide significant savings in the short and long term.
Process – There are numerous process benefits to be realized by being able to manipulate the speed of a motor/pump by the frequency inverter.
Energy Savings – Energy savings can be significant by matching the motor to the amount of work required as well as running the motor/pump at it's most efficient speed.
Reduce System Stress – The use of a frequency converter reduces mechanical and electrical stress, while virtually eliminating hydraulic stress (Water Hammer).
Extends Component Life - Frequency converters extend the life of pumps, motors and other equipment by running them at a slower speed and by eliminating violent stops and starts.
Reduces Maintenance – See reduce stress. Also reduces well maintenance by slowing the speed of water rushing in for well recharge.
Demand Savings – Reducing the speed of a pump can significantly reduce its electrical demands.
Electrical Benefits:
Frequency converters have numerous applications in various industries:
ie. water supply system:
We have also noticed a number of customers that were up-sold frequency converters with features that they did not need, which ultimately increased the purchase price of the frequency converter.
The Myths
Too expensive: Frequency converter prices have dropped considerably over the past few years. As a result it is often less expensive to implement a frequency converter rather than a conventional starter and a flow control valve.
Many manufacturers are promoting frequency converters by offering an incentive. Incentives combined with the energy savings, often results in short pay back periods.
Cheaper to use one frequency converter on two pumps: The price of frequency converters makes it affordable to install a frequency converter on each motor. With each motor having it's own frequency converter, you have redundancy and avoid the risk of one frequency converter failing and rendering 2 pumps unusable.
Special motor required: It is recommended to use inverter duty motors with frequency converters. However, we have not found an existing motor that did not work. It may somewhat shorten the life of old motors, however this cost is minimal compared to the savings that are obtained. In most cases the old motors are quite inefficient compared to new motors. We would not recommend replacing the existing motor until it is no longer serviceable.
Considerations
Cable length: Long cable lengths affect the system and may require extra hardware.
Bypass: Bypass requirement is completely a redundancy issue. However, it is usually not required and adds 30-40% to the cost of the frequency converter.
Environment: The environment in which the frequency converter will reside determines the type of enclosure required as well as cooling considerations. frequency converters cannot operate at extreme high temperatures. Altitude also should be considered because of cooling issues.
Harmonics: Harmonic considerations are often over exaggerated. When frequency converter load size is small and the available utility power is large, the effects generally go unnoticed. There are Filters or Traps available if harmonics are a concern. 12 and 18 pulse frequency converters will significantly reduce harmonics but also greatly increase the price.
Power Factor: Frequency converters usually have a power factor close to infinity.
Capacitors: Capacitors are not to be used with frequency converters.
This is really a very simple question. Do you have to run this pump at full speed? If not then more than likely the use of a frequency converter rather than a soft start will provide more benefits and have a shorter pay back.
A soft starter can provide savings related to mechanical and electrical stress, but it will not provide any energy savings because it cannot run the pump at a slower RPM.
Process – There are numerous process benefits to be realized by being able to manipulate the speed of a motor/pump by the frequency inverter.
Energy Savings – Energy savings can be significant by matching the motor to the amount of work required as well as running the motor/pump at it's most efficient speed.
Reduce System Stress – The use of a frequency converter reduces mechanical and electrical stress, while virtually eliminating hydraulic stress (Water Hammer).
Extends Component Life - Frequency converters extend the life of pumps, motors and other equipment by running them at a slower speed and by eliminating violent stops and starts.
Reduces Maintenance – See reduce stress. Also reduces well maintenance by slowing the speed of water rushing in for well recharge.
Demand Savings – Reducing the speed of a pump can significantly reduce its electrical demands.
Electrical Benefits:
- Power Factor Correction
- Single to Three phase conversion
- Open Delta phase balancing
- Built in motor protection
Frequency Converter Applications
Frequency converters have numerous applications in various industries:
ie. water supply system:
- Maintain a constant pressure in a closed loop system or if the tower is out of service.
- Maintain a level in a basin with varying inflow. Reducing or possibly eliminating the constant starting/stopping of pumps.
- Reduce energy consumption by slowing the pumps down.
- Improve process by maintaining a constant or desired flow to a water treatment facility.
- Maintain a constant pressure in an irrigation system.
- Maintain a constant Dissolved Oxygen level.
- Feed a treatment process with a constant flow.
We have also noticed a number of customers that were up-sold frequency converters with features that they did not need, which ultimately increased the purchase price of the frequency converter.
The Myths
Too expensive: Frequency converter prices have dropped considerably over the past few years. As a result it is often less expensive to implement a frequency converter rather than a conventional starter and a flow control valve.
Many manufacturers are promoting frequency converters by offering an incentive. Incentives combined with the energy savings, often results in short pay back periods.
Cheaper to use one frequency converter on two pumps: The price of frequency converters makes it affordable to install a frequency converter on each motor. With each motor having it's own frequency converter, you have redundancy and avoid the risk of one frequency converter failing and rendering 2 pumps unusable.
Special motor required: It is recommended to use inverter duty motors with frequency converters. However, we have not found an existing motor that did not work. It may somewhat shorten the life of old motors, however this cost is minimal compared to the savings that are obtained. In most cases the old motors are quite inefficient compared to new motors. We would not recommend replacing the existing motor until it is no longer serviceable.
Considerations
Cable length: Long cable lengths affect the system and may require extra hardware.
Bypass: Bypass requirement is completely a redundancy issue. However, it is usually not required and adds 30-40% to the cost of the frequency converter.
Environment: The environment in which the frequency converter will reside determines the type of enclosure required as well as cooling considerations. frequency converters cannot operate at extreme high temperatures. Altitude also should be considered because of cooling issues.
Harmonics: Harmonic considerations are often over exaggerated. When frequency converter load size is small and the available utility power is large, the effects generally go unnoticed. There are Filters or Traps available if harmonics are a concern. 12 and 18 pulse frequency converters will significantly reduce harmonics but also greatly increase the price.
Power Factor: Frequency converters usually have a power factor close to infinity.
Capacitors: Capacitors are not to be used with frequency converters.
Frequency converter OR Soft Starter?
This is really a very simple question. Do you have to run this pump at full speed? If not then more than likely the use of a frequency converter rather than a soft start will provide more benefits and have a shorter pay back.
A soft starter can provide savings related to mechanical and electrical stress, but it will not provide any energy savings because it cannot run the pump at a slower RPM.
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