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Application of Huifeng Inverter in Energy Saving Reform of Deep Well Pump
Yantai Yu-cable Plant has its own independent deep well water supply system. The system 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 directly to the entire factory and residential area. A high-level water tower with a height of 28 meters and a capacity of 80 m³ was also installed in the living area to regulate water pressure.
Since last year, the groundwater level has risen significantly, from -20 meters to -8 meters. As a result, the deep well pump's flow rate increased from 30 m³/h to 40 m³/h. This led to a situation where the entire system operated at high flow and low lift, far exceeding the actual water demand. To address this issue and reduce energy consumption, the factory decided to upgrade its water supply system.
Based on the original design, the deep well pump was originally sized for lower water levels. Now that the water level has risen, the pump operates under light load, making it suitable for fan-like operation. Therefore, we opted to use a frequency inverter for speed control of the pump motor.
Feasibility analysis of the transformation showed that the pump’s flow (Q) is proportional to the motor speed (N), the head (H) is proportional to the square of the motor speed, and the power (P) is proportional to the cube of the motor speed. By adjusting the motor speed, we can effectively control both the flow and the head of the pump.
During the transformation, we kept the remote pressure gauge in place. It served as the pressure detection sensor at the water outlet, displaying real-time pressure values on-site. Changes in pressure were converted into a 0–5V voltage signal and sent to the inverter’s control unit. Using a PI controller, the inverter adjusted the pump speed based on the difference between the set pressure and the feedback pressure, ensuring stable and efficient water supply.
After the transformation, the factory conducted a comparison between pre- and post-transformation performance. Before the upgrade, the pump operated at around 80A with an actual power of 40kW. After the transformation, the current dropped to approximately 50A, with an actual power of 25kW. The reactive power consumption was reduced by 15kW, resulting in significant energy savings. Annual electricity savings were estimated at 136,800 kWh, equivalent to a cost reduction of 96,000 yuan. The project was completed on September 16, 2000, and has been operating smoothly for over four years. To date, the plant has saved nearly 40 million kWh of electricity. The factory is highly satisfied with the results of the upgrade.