Adaptive mixing A new operating philosophy

Transcription

1 May 3, 2018 Adaptive mixing A new operating philosophy LARS UBY, SR. APPLICATION SPECIALIST XYLEM WATER SOLUTIONS

2 A new operating philosophy to adapt mixing functions in line with process demands therefore cutting energy and Asset Management spending. 2

3 Plan 1. What s in an adaptive mixer, and how can it be imagined to reduce spending? 2. Savings 1 anoxic/anaerobic zone mixing at Le Thuit 3. Savings 2 fine tuned anoxic mixing at South Shore 4. Savings 3 oxidation ditch control at Eiterhagen 5. Savings 4 asset rationalisation resilience 6. Savings 5 asset rationalisation inventory 3

4 From the (provisional) technical and breakout programmes (2018): -Variable Speed Drives -reliability -maintenance strategies -risk profile -maintenance -affects the resilience of VSD s -how the life of these important assets can be extended. -Enhanced resilience -reliability -smoother operation -intelligent control system -without constant intervention -significant energy savings -reduced wear -increased uptime -more consistent treatment. -Starting, stopping and running -resilience -Using Variable Speed Drives -Soft Starters -reliability of assets -ease of setup -TOTEX costs -panel costs -maintenance strategies. 4

5 What s in a Flygt adaptive mixer? Flygt Dirigo drive unit Power electronics Software Optimised propeller IE4 motor efficiency

6 Imagine the savings (asset management) When planning One (or very few) size fits all. Reduced collective spares / spare parts bank. Highly efficient and redundant multimixer installation to be turned up during inspection/service/relocation of one of the units. Optimised, pre-programmed and protected Variable Speed Drive requires a minimum of overhead. When testing / rearranging / upgrading a process One (or very few) and the same size still fits all. What to do with control 6

7 Imagine the savings (operation) Without control Make use of the combined high efficiency of the motor and propeller. With occasional control Fine tune during installation (remove design uncertainty margins). Adapt to process changes (e.g. settleability during summer vs. winter). Adapt to seasonal changes (e.g. flow or load variation). Set in extraordinary tank floor scouring, scum mobilisation etc. when required. With continuous control Meet varying through flow or need for active volume, e.g. in anoxic zones. Meet strongly varying liquid levels, e.g. in retention tanks. Meet varying air flow in oxidation ditches. 7

8 What s in a Flygt adaptive mixer? Flygt Dirigo drive unit Power electronics Software Optimised propeller IE4 motor efficiency

9 Le Thuit With kind cooperation of Veolia operating STEP Le Thuit Le Thuit (midway Paris Le Havre by River Seine) 2 x 340 N mixers required (single speed) 1 x 340 N single speed+ 1 x 340 N adaptive in parallel Energy check after ~22 days: Mixer Cumulated kwh (Power analyser) SR 4630 single speed 685 SR 4220 adaptive 401 Energy savings 41,5% 9

10 What s in a Flygt adaptive mixer? Flygt Dirigo drive unit Power electronics software Optimised propeller IE4 motor efficiency

11 South Shore Data courtesy of MMSD Milwaukee Metropolitan Sewerage District South Shore Water Reclamation Facility, USA In Basin 26: - Turned down continuous mixing to the pain point - Tried Low / High mixing intensity scenarios - Monitored TSS / DO / ORP / Ortho-P distributions Mixer TSS st.dev. (g/l) Consumed W/m 3 < SR 4320 adaptive < >

12 What s in a Flygt adaptive mixer? Flygt Dirigo drive unit ISO/ AGMA Gear box Power electronics software Optimised propeller IE4 motor efficiency

13 Oxidation Eiterhagen Eiterhagen KA, (midway Frankfurt Hannover) Aeration On / Off in the outer ring Ni/Deni Mode Operating Time (h/yr) Electric Power (kw) SR 4410 SR 4320 Single speed Adaptive Energy Savings (kwh/yr) (%) Nitrification Air On Denitrification Air Off kw 1.06 kw % kw 0.60 kw % Total % Holland: More complex aeration control Similar savings were achieved 13

14 What s in a Flygt adaptive mixer? Flygt Dirigo drive unit Power electronics software Optimised propeller IE4 motor efficiency

15 Asset rationalisation resilience Autocorrects-Alarms-Logs prevent undue operation & stops Reduce speed on overload Autocorrect direction of rotation Wear & tear minimisation Soft start/stop/ramp Smallest required speed possible Adaptive Single speed Environmental insulation 70+ years of motor protection now includes VSD protection against thermal variation, dust exposure, oxidizing environment, No more fan failures! 15

16 What s in a Flygt adaptive mixer?

17 Asset rationalisation inventory Fewer mixer types onsite for smaller mixers & parts inventory Optimised, pre-programmed VSD reduces install/reinstall cost Flexibility increases efficiency when reusing mixer in new conditions 17

18 From the (provisional) technical and breakout programmes (2018): -Variable Speed Drives -reliability -maintenance strategies -risk profile -maintenance -affects the resilience of VSD s -how the life of these important assets can be extended. -Enhanced resilience -reliability -smoother operation -intelligent control system -without constant intervention -significant energy savings -reduced wear -increased uptime -more consistent treatment. -Starting, stopping and running -resilience -Using Variable Speed Drives -Soft Starters -reliability of assets -ease of setup -TOTEX costs -panel costs -maintenance strategies. 18

19 Thank you for listening! Any questions? 19