KSB Product and Technology for Pump Energy Saving KSB 用 ...

KSB AN Product Management and Business Development

Dr. Baogang Wang

Qingdao, 20190809

KSB Product and Technology for Pump Energy Saving

KSB 用于泵节能的产品技术

Dr Wang, Energy Saving 20190809 2

Contents

1. KSB Introduction

KSB 简介

2. Energy Consumption of Systems

系统的能量消耗

3. Energy Saving Technologies of Pumping Systems

泵系统的能量节约技术

4. Case Study of Retrofitting a Chinese Coal-fired Power

Plant

一个中国燃煤电厂的技术改造案例学习

Backup


Contents

1. KSB Introduction

KSB 简介






Plant


Backup

KSB Group and Brand

About us 凯士比集团

KSB is one of the leading suppliers

of pumps, valves, system solutions

and services.

Our brand stands for quality,

excellence, reliability and a global

perspective.

凯士比是世界领先的泵,阀及系统设备制造商,服务商.

以高质量, 精益求精, 可靠性和全球化致力打造的国际品牌.

1. KSB Introduction

KSB 简介

4 Dr Wang, Energy Saving 20190809

It all started with an idea

Experience since 1871

创始于1871年

With his invention of the boiler feed apparatus more than 140 years ago, Mr. Johannes Klein laid the foundations for today’s global success story we know as KSB.

从140多年前发明的锅炉给水设备开始, Johannes Klein 成就了今天的KSB.

Manufacture of

Valves since 1872

Pumps since 1873

工厂始建于

阀门 1872年

泵 1873年

1. KSB Introduction

KSB 简介


Applications

Know-how for a Variety

of Applications

技术的各种应用

Water transport 水输送

Waste water treatment 水处理

Energy conversion 能源

Process engineering 流程工业

Building services 楼宇

Solids transport 矿山

1. KSB Introduction

KSB 简介

6

Dr Wang, Energy Saving 20190809

Applications

Our range of products and

services

各种产品和服务

Everything from a single

source: pumps and valves,

services and system

solutions

一切皆源自于：泵，阀，服务，以及系统解决方案


1. KSB Introduction

KSB 简介

Serving Valued Customers in China

Nuclear Pump Biz Non Nuclear

Pump Biz

KSB Valves

(Shanghai)

Co., Ltd.

凯士比阀业

(上海)有限公司

KSB

Shanghai

Pump Co.,

Ltd

上海凯士比泵

有限公司

Shanghai

Electric – KSB

Nuclear Pumps

and Valves Co.,

Ltd

上海电气－凯士比核电泵阀有限公司

KSB Shanghai Pump

Co., Ltd

上海凯士比泵

有限公司

KSB Pump & Valve

Technology Service

( Tianjin ) Co., Ltd

凯士比泵阀技术服务（天津）有限公司

Valve Biz Service Biz

Serving Valued Customers with

market oriented quality Products

& Services

Achieving long-term objectives

of sustainable growth &

profitability

为客户提供市场导向的优质产品及服务

从中达到可持续性增长及盈利的长期目标

KSB in China

凯士比在中国

Strategy, Organisation &

Corporate Culture

战略, 组织结构 & 企业文化


1. KSB Introduction

KSB 简介


Contents

1. KSB Introduction

KSB 简介






Plant


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10

Total power consumption is appr. 300

TWh

总能耗大约300万亿度

The industrial sector uses by far the

highest amount of electrical power

工业部门是目前电能使用量最高的

Within industry, pumps are the largest

consumers of energy.

工业中，泵是能量消耗最大的“客户”

High savings potential: on average

40%

具有很高的节能潜力：平均40%

Miscellaneous 2% 其它

Road traffic 24% 交通

INDUSTRY 42%

工业

Agriculture 2% 农业

Residential 30% 居民

Power consumption in the EU

(Total distribution)

在欧盟的能量损耗（总分配）

Other 32% 其它

PUMPS 30% 泵

Compressed air,

refrigeration,

compressors 24% 压缩机，制冷

Ventilators / fans 14% 风扇

Power consumption in Industry

在工业中的能量损耗

2. Energy Consumption

of Systems

系统的能量损耗


in Europe 在欧洲

11

Converting and using energy

efficiently

高效的转化和使用能源

From primary to useful energy

从最初到转为有用的能源

In pumping systems:

Useful energy = Fluid energy

demand

在泵系统：

有用的能量=流体所需的能量

Site

en

erg

y末端能耗

Electricity

bill 电费

More efficient

& rational

use of energy

更有效合理利用能源

Prim

ary

en

erg

y

Use

ful

en

erg

y

Efficient

energy

conversion 有效能量转换


Efficient

energy

conversion

有效能量转换


of Systems


Installation

安装

9%

Energy

能量

32%

Maintenance & Repair

维护/维修

20%

Downtime

停工期

9%

Operation

操作

9%

Pump

泵

14%

Environment

环境

7%

Investment 投资

~ 30%

Energy

能量

~ 32%

Ava

ilab

ility 适

用性

En

erg

y C

on

su

mp

tio

n 能

量消

耗

The role of system

efficiency

系统效率的角色

Reliability 可靠性

~ 38%



of Systems


Example: Life cycle costs of chemical pumps

例如：化工泵的生命周期成本

Source: Fraunhofer IML, KSB AG: „Forschungsprojekt ReMain”, 2008

op

era

tin

g h

ou

rs 操

作时

间

SES System Efficiency Services

系统效能服务

Histogram of operating hours

操作时间柱状图

Example of a chemical plant

Research project Re-Main‘

研究项目 Re-Main‘

05/21/ - 06/10/2009

65 pumps measured

参与测试的泵有65台



of Systems


Identification of saving

potentials

节能潜力鉴别

Source: Automation, KSB AG 2009

- optimization of single components

单个零件的优化

(e.g. high efficiency drives IE2

(EFF1), IE3 (NEMA Premium) or IE4

(Super Premium))

(例如，驱动IE2,IE3,IE4)

- trimming of impeller

叶轮的切割

- review of safety margins

再次检查安全余量

- adequate pump control

适当的泵管理

- demand related operation

需要相关操作

- reduction of flow resistance

流动阻力的减小

- dimensioning of piping

管道尺寸的标注

M 3~

3~

3~

M 3~

3~

3~

Module子系统

Components

零部件

approx. 3,5%

大约3.5%

M

System主系统

up to

60%

up to

10%


Product related

governmental directives and

regulations

和政府指导和规范相关的产品


of Systems


Pump Failures

泵的问题

Corrective Maintenance

改善性维修

Energy- and

Maintenance Costs

能源与维修费用

Preventive Maintenance

预防性维修

Failure Analysis

问题分析

Energy Audit

能源审计

System Analysis 系统分析

System Analysis

系统分析

Additionally

另外

Site Acceptance Test

现场验收试验

Measurement during design

stage

设计阶段的测量

15 Source: F. Schäfer, KSB, 2013 Dr Wang, Energy Saving 20190809


of Systems



Contents

1. KSB Introduction

KSB 简介






Plant


Backup

17

Example 1:

Feedwater System HG Pump

例1：给水系统 HG 泵

Combined Cycle Power Plant 联合循环发电厂

Source: F. Schäfer, KSB, 2013 Dr Wang, Energy Saving 20190809

3. Energy Saving of

Pumping Systems

泵系统的能量节约

18

Energy savings 节省能量 25 %

(2.800.000 kWh, 1.800 t CO2)

Invest 投资 75.000 €

ROI 投资回报率 0.35 years

Combined Cycle Power Plant 联合循环发电厂

2 Feedwater Pumps HGC 5/8+2

Retrofit of Feedwater Pump 1 in 2010

Retrofit of Feedwater Pump 2 in 06/2012 completed

2台给水泵HGC 5/8，其中1号给水泵改进于2010年，2号给水泵

改进于2006年，2012年完成


3. Energy Saving of

Pumping Systems


Example 1:

Feedwater System HG Pump

例 1：给水系统 HG 泵

19

Example 2:

Cooling Water Circuit PEZ Pump

例 2：冷水循环 PEZ 泵

On-site measurement vertical pumps type PEZ 1200-1300

Identification of operating conditions (blade pitch angle)

Failure analysis (vibration measurement)

现场测量立式泵PEZ 1200-1300

确定运转环境(叶片安装角)；失败分析(振动分析)

Increased vibration

values in tangential

direction

切向增加的振动评估

veff = 6-10 mm/s

rot. freq.: fn = 6.45 Hz

Peak峰值: f = 16.125 Hz

0.5 times blade passage

frequency (32.25 Hz)

叶片通过频率的0.5倍


3. Energy Saving of

Pumping Systems


20

Inspection 检查

Damaged wear ring section (cavitation marks)

损坏的耐磨环断件(汽蚀造成)

Damaged impeller blades

损坏的叶轮叶片


3. Energy Saving of

Pumping Systems


Engineering Services

工程服务

Example 2:

Cooling Water Circuit PEZ Pump

例 2：冷水循环 PEZ 泵

Industrial Power Plant, HDB 150/7, 2.3 MW

工业发电厂，HDB 150/7, 2.3 MW

New operating points defined by customer由用户指定的新工作点

Increase in efficiency required必须的效率提高

21

Optimization Measures 最优测量

Implementation of blindstage 不确定级数的实现

Cellular profile wear ring 蜂窝状抗磨环

Change in gap clearance 间隙变化


3. Energy Saving of

Pumping Systems


Example 3:

Feed Water System HDB Pump

例 3：给水系统 HDB 泵

22

Example 4:

Water supply wells – Submersible

borehole UPA pumps

例4：供水井 — 深井潜水UPA 泵

Overall efficiency is influenced mainly by

总效率主要受以下影响：

Changed operation conditions (i.e. extension of water supply)

运行工况的改变（如增加水的供应）

Changes made in pipings or treatment plant

管道或污水净化厂的改变

Changes in groundwater level

地下水位的改变

Sedimentation of iron ochre

赭色铁质的沉淀

Wear of pump parts

泵部件的磨损

Slow changes within the water supply wells (gravel etc,)

在供水井中的缓慢变化（砂砾等） Dr Wang, Energy Saving 20190809

3. Energy Saving of

Pumping Systems


23

Measurements of borehole pumps

深井泵的测量值

Automatically includes system

measurements

自动包含了系统测量值

Process data:

分析数据：

Pressure (ps, pd)压力

Power consumption (P)能耗

Motor current (I)电机电流

Flow rate (Q)流量


Example 4:

Water supply wells – Submersible

borehole UPA pumps


3. Energy Saving of

Pumping Systems


24

Proposal “Fixed speed”

建议的定速

Invest: ~ 2.500,-- EUR

Tariff: 0,17 EUR/kWh

投资：约2500欧元

电价：0.17欧元/千瓦时

ROI: 1,75 years

投资回报：1.75年

Savings after 10 years:

14.280 EUR

10年后能节省：25650欧元

39,200

30,800

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

Current operation Proposal "fixed speed"

Power

consumption 能耗

[kWh/a]

Current operation

现在运行点

Proposal „fixed speed“

建议的定速

Hours of operation

[h/a] 4.000 4.000

Discharge

[m³/a] 133.200 133.200

Energy consumption

[kWh/a] 39.200 30.800

Energy saving

[kWh/a] / 8.400 (21,4 %)


Recommendation 建议

Extract of Project 提取项目

Example 4:

Water supply wells – Submersible borehole UPA pumps


3. Energy Saving of

Pumping Systems


25

Proposal variable speed drive

„VSD-S“ 建议的调速驱动

Invest: ~ 7.800,-- EUR

Tariff: 0,17 EUR/kWh

投资：约7800欧元

电价：0.17欧元/千瓦时

ROI: 3,05 years

投资回报：3.05年

Savings after 10 years:

25.650 EUR

10年后能节省：25650欧元

39,200

24,110

0

10,000

20,000

30,000

40,000

50,000

Current operation Proposal "VSD-S"

Power consumption [kWh/a]

能量损耗[kWh/a]

Current operation Proposal „VSD-S“

Hours of

operation [h/a] 4.000 7.011

Discharge

[m³/a] 133.200 133.209

Power

consumption

[kWh/a]

39.200 24.110

Energy saving

[kWh/a] / 15.090 (38,5 %)


Extract of Project 提取项目

Example 4: Water supply wells –

Submersible borehole UPA pumps


3. Energy Saving of

Pumping Systems


26

Product information产品信息

SETCON 机电一体化的调速装置

Variable speed electro-mechanical drive train concept for Industrial Applications

up to 95% System Efficiency (incl. main drive),

> 3% Saving Energy Costs to existing concepts,

Lower Initial Costs ( > 20% cost reduction versus Frequency Converter )

Easy Integration

Speed range 100%

Soft-start


Power Range up to 16 MW (up to 25 MW for pumps)

Speed Range up to 6500 rpm (pumps)

Speed Range up to 15000 rpm (compressors)

3. Energy Saving of Pumping Systems



AC 6,6/10 KV

MV - Level

AC 690 V

LV - Level

FC 4Q

size 20% of total power

690 V

air-cooled Power

Power

Control Cabinet (Panel)

Control Signal

Planetary gearing

Product information产品信息

SETCON 机电一体化的调速装置

3. Energy Saving of Pumping Systems



Contents

1. KSB Introduction

KSB 简介






Plant


Backup


Background

背景

Shanxi Tonghua power plant has been operated since 2009 with BFP aggregate, consisting of Shenyang BFPs and Voith

fluid coupling and SEC motors. Since the BFP unit operates in partial loads area, its efficiency is low and its output cannot

meet the power plant production requirements.

山西同华电厂自2009年起使用锅炉给水泵机组，它由沈阳锅炉给水泵机组、Voith液力耦合器和SEC电机组成。由于锅炉给水泵机组运行在部分负荷区域，其效率较低，且机组输出不能满足电厂的生产要求。

It could be some reasons that the BFP operation point design was far away from the operation point required from plant.

That leads to low efficiency of BFP agregate. Through changing BFP aggregate equipments the power plant operator can

easily achieve the larger output of plant electricity generation and improvement of BFP aggregate energy consumption.

可能是由于锅炉给水泵设计的运行点大大偏离的实际需要的运行点的原因，造成给水泵机组低的输出。通过改变锅炉给水泵机组的设备和其参数，电厂业主可以容易的实现更大的电力输出，同时也改进锅炉给水泵机组的能源消耗。

Project background and Roadmap for BFP Aggregate with VFD Control

变频器控制的锅炉给水泵项目背景和发展思路

4. Case Study of Retrofitting a Chinese Coal-fired Power Plant



Siemens

VFD

西门子进口变频器

SEC

E-Motor

变频电机

Lepu 乐普公司总承包

EPC 提供变频器配套

VFD provider

KSB-SH

凯士比泵

给水泵机组

产品

Gear Box

Company

齿轮箱厂

增速齿轮箱

Customer

Tonghua

Power Plant

电厂客户

同华电厂

Ordering

EPDI

电力设计院

装置设计

和方案论证

Test &

Installation

试验和安装

装置试验

在电厂进行

Offer

Feedback反馈

Oil Station

Company

油站

装置供油




E-Motor


一个中国燃煤电厂的技术改造案例学习 BFP Aggregate with Voith Coupling before retrofitting

技改前带Voith耦合器的锅炉给水电泵机组


BFP Aggregate with VFD after Retrofitting

技改后，变频器控制锅炉给水泵机组方案




After retrofitting 技改后 2 x 50%

One Unit: 1x BFP+ 1x BP+ 1x Gear Box + 2x motors + 1x VFD

每个机组：1x 主泵 + 1x 前置泵 + 1x 齿轮箱+ 2x 电机+ 1x 变频柜

设备名称 BFP 主泵CHTD6/6

BFP Motor

主泵电机

Gear box

齿轮箱 GGS670

VFD 变频柜

BP

前置泵

BP-Motor

前置泵电机

BFP Flow rate

主泵流量

Aggregate Eff.

机组总效率(计算）

功率P （kW） 10500 12500（6.6kv,

效率96.9%）

11380

效率98.6% 12500 615.96

710 (10kv,效率95.8%)

1166.03 t/h 79.14%（不含VFD）

转速n （rpm） 5607 1490 1490 ~ 5607 / 1480 1480 / /

Before retrofitting 技改前 3 x 35%

One unit: 1x BFP+ 1x BP + 1x motors + 1x Voith Coupling

每个机组: 1x 主泵 + 1x 前置泵 + 1x Voith 耦合器+ 1x 电机

设备名称 BFP-主泵MDG346

BFP Motor

主泵电机

Voith coupling

液力耦合器 R16K 500M

BP

前置泵

BP-Motor

前置泵电机

BFP Flow rate

主泵流量

Aggregate Eff.

机组总效率（计算）

功率P （kW） 8942 11000 (10kv, 效

率96.4%） 94.5%(设计工况) 217 与主泵同轴 725 t/h 75.71%

转速n （rpm） 6650 1490 1490 ~ 6650 1490 1490 / /

Comparison of BFP aggregate equipments parameters

before and after Retrofitting

技改前后，机组装置方案参数比较



34

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