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Application of Huifeng Inverter in Energy Saving Reform of Deep Well Pump
Yantai Yu-Cable Plant has its own deep well water supply system, which is powered by a deep well pump with a rated flow of 30 m³/h and a lift capacity of 120 meters. Previously, groundwater was pumped into a 300 m³ reservoir, and then two additional pressurized pumps were used to supply water to the entire factory and living area. A high water tower, standing at 28 meters with a capacity of 80 m³, was also installed in the living area to regulate pressure and ensure a stable water supply.
However, since last year, the groundwater level has risen significantly, from -20 meters to -8 meters. This change allowed the deep well pump to increase its flow rate from 30 m³/h to 40 m³/h, resulting in a system operating under high flow and low lift conditions. The water supply now exceeds the actual demand, leading to unnecessary energy consumption.
To address this issue and reduce power usage, the factory decided to upgrade the water supply system. Based on the original design, the pump was originally sized for lower water levels. With the current higher water table, the pump operates under lighter load, similar to a fan pump. Therefore, the decision was made to retrofit the pump with a variable frequency drive (VFD) to optimize performance.
Feasibility analysis showed that the pump’s flow (Q) is directly proportional to the motor speed (N), while the head (H) is proportional to the square of the speed. Power consumption (P) is proportional to the cube of the motor speed. By adjusting the motor speed, we can effectively control both flow and pressure.
During the transformation, the existing remote pressure gauge was retained. It serves as a sensor for pressure detection at the water outlet, displaying real-time pressure values on-site. The pressure signal is converted into a 0–5 V voltage signal, which is sent to the inverter’s control unit. Using a PI controller, the inverter adjusts the pump speed based on the difference between the set pressure and the actual feedback, ensuring accurate water supply.
After the transformation, the factory conducted a comparison. Before the upgrade, the pump operated at around 80A with an actual power of 40kW. After the VFD installation, the working current dropped to approximately 50A, with an actual power of 25kW. This resulted in a reduction of reactive power consumption by 15kW. Annual energy savings are estimated at 136,800 kWh, equivalent to about 96,000 yuan in cost savings.
Since the completion of the transformation on September 16, 2000, the system has been running smoothly for over four years, with nearly 40 million kilowatt-hours saved in electricity. The plant is highly satisfied with the results, as the project not only reduced energy costs but also improved system efficiency and reliability.