Energy Savings in Water and Wastewater Segment Danfoss Industries Pvt. Ltd.

Presentation Overview: Introduction to Danfoss Danfoss Core Business Energy savings & other benefits with VFD control VFD applications in water and wastewater segment

Danfoss in brief 78 years of experience within energy-efficient technologies Solutions ready to combat climate challenge Global competence center for energy efficiency – rooted in Southern Denmark The Bitten and Mads Clausen Foundation holds the majority of shares in Danfoss

Danfoss’ core businesses focus on Climate & Energy

VFD evolution Danfoss = First company to mass produce a.c. variable frequency drives (VFD) 1968 1973 1978 1983 1988 1993 1998 2003 2007

Water & energy --- precious resources Climate change is increasing pressure on global fresh water resources At the same time demand for energy is rising Both are contributing to increased concern for the environment VFD can provide significant energy savings, reduce water loss, and provide other benefits in water, wastewater & irrigation systems

Pump life cycle costs 5% 95% ~ 20% of the world’s energy is consumed by pumps # Initial capital and whole of life maintenance costs = ~ 5% of the total life cycle cost Energy costs = ~ 95% ~ 95% of pumps installed are over sized (Selected for worst case condition + safety margin) Methods of flow control to meet average (lower) flow or varying demand include e.g.: - Impeller trimming Throttling valve Bypass valve (3-way) Variable Frequency Drive (VFD) # British Pump Manufacturers Association 5% 95%

VFD (Variable Frequency Drive) Electronic unit that varies the fixed mains voltage & frequency to control the speed of standard a.c. electric motors Infinite speed control from 0-50Hz +over-speed operation with some limitations

Typical energy savings with VFD on centrifugal pumps Flow is proportional to speed Power varies to the cube of the speed change 20% reduction in speed = 50% reduction in energy 50% reduction in speed = 80% reduction in energy

Throttling Valve compared to VFD

Throttling valve compared to VFD Control with valves Control with VSD VFD gives ~35% energy savings compared to throttling valve (On typical variable flow applications)

Energy consumption of single & multiple pump systems Single VFD controlled pump 100% Standard cascade control with 1 x VFD pump & multiple fixed speed pumps 53% 48% 43% Master – follower with 1 x VFD per pump Note: kWh figures are approximate relative %, based on sample test Master follower = best energy efficiency

Other benefit – reduced water loss Smooth starting & stopping with VFD reduces mechanical stress Less damage to piping & valves Lower possible system operating pressure also reduces water loss (Non – revenue water, which in developing countries is ~ 30% of water supply)

Application examples Ground water abstraction Reverse Osmosis Water distribution Wastewater treatment Irrigation

Groundwater – abstraction VFD allow control of draw down on deep well submersible pumps Constant level, flow or pressure Benefits (e.g.:) Energy savings Reduced mechanical stress & leakage Chemical dosing to match flow

Application examples Ground water abstraction Reverse Osmosis Water distribution Wastewater treatment Irrigation

Reverse Osmosis Membranes are used to filter salt & other impurities from water Variables are Flow, Temperature and Salinity Brackish water requires less pressure than sea water Benefits (E.g.:) VFD can maintain constant output flow as filters block Elimination of pressure surges extends the membrane life. Longer time between backwash cycles. Less energy consumption - lower speed with clean filters.

Application examples Ground water abstraction Reverse Osmosis Water distribution Wastewater treatment Irrigation

Constant pressure with water tower/ elevated storage tank Water Towers maintain constant pressure in the water distribution system and provide a certain capacity Pumps are used to fill the water tower, normally based on level control

Alternative system - pressure control with VFD Water reservoir The VFD adjusts the pump speed based on a feedback signal from the pressure transmitter to maintain a constant pressure with changes in flow Note: Booster pumps may also be utilised to overcome pressure loss in networks with e.g. significant elevation in the field.

Water – Distribution VFD controlled pumps replace water tower to maintain constant pressure, irrespective of demand Flow PRESSURE Benefits: Constant pressure with changing flow Elimination of water hammer Reduced water leakage Less energy consumption Less maintenance / lower whole of life cycle cost

Application examples Ground water abstraction Reverse Osmosis Water distribution Wastewater treatment Irrigation

Typical modern Wastewater treatment plant

Typical Wastewater treatment plant (WWTP) process

Typical energy distribution at WWTP Typical cost distribution at WWTP Typical energy distribution at WWTP Activated sludge processes (fans/blowers) account for more than one half of energy consumption at typical wwt facilities. Pumps also consume a large share of energy, generally requiring about 15 % of total plant use. Heating and solids dewatering are processes sometimes employed to treat solid waste matter that has been removed from wastewater streams. Other processes such as chlorine mixing and effluent filtering each use less than 4% of consumed energy

Fans Applications (E.g.) Odour control Ventilation Cooling towers Benefits Exact air flow to match demand Energy savings (20% reduction in speed gives ~ 50% saving in energy) Constant pressure or temperature etc. Less wear (EG: Extends belt life) Reduced audible noise Parallel fan operation possible

Application examples Ground water abstraction Reverse Osmosis Water distribution Wastewater treatment Irrigation

Irrigation Applications Lift station pumps (Level control) Deep well submersible pumps Transfer pumps Benefits Constant level with changing flow Less water hammer / mechanical stress Lower risk of pipe breakage Potential energy savings

Summary of benefits of VFD control Energy savings (E.g. ~35% when compared to throttling valve) Low in rush current / low torque surges = less mechanical stress (E.g.: prevent water hammer, gearbox damage, belt breakage) Less water leakage due to lower possible operating pressure (I.e.: extend life of aging infrastructure) Increased flexibility /improved system performance (E.g.: control to match actual demand & not design demand) Advanced control & diagnostic interface possibilities (E.g.: SCADA) Less maintenance / lower whole of life cycle costs Environmentally friendly solution!

VLT® AQUA Drive Dedicated VFD for all applications in Water, wastewater & irrigation 0.35kW – 1.4MW power range Suit both constant & variable torque loads Automatic Energy optimiser Built-in pump control & protection functions Optimum ingress protection High efficiency ( 98%) Lowest cost of ownership

Global focus Water Wastewater Irrigation Power generation Steam, hot water & gas supply Waste processing & recovery Our vision is to be recognized as the most dedicated supplier of Drives solutions in the Water & Wastewater & Irrigation sector world wide Sales & service in ~100 countries, including India ~ 40 year track record Dedicated product & organisation

Over 25 year track record globally & in Asia Pacific 1000’s of Drives & Soft Starters in service Water supply & treatment RO / Desalination & recycling Wastewater treatment Pumping Stations Irrigation Power generation District heating Waste processing & recycling

Global References Bisalpur Water  Supply Project: Project aims to reduce dependence of Jaipur city on ground water resources. Under this project 400 MLD of raw water is pumped from Bisalpur Dam to Clear Water treatment plant at Surajpura. Yamuna Interceptor project: Delhi Jal board. Yen So Park is one of Vietnam’s most important development projects, Yen So Park entrails the development of a sewage treatment plant capable of treating 200,000m3 or half of Hanoi’s waste water per day. Energy saving using back channel cooling and installation space saving. Pressurized system for Booster pumping stations in Bulgaria. Danfoss can accept no responsibility for possible errors in printed material. Please consult equipment design guides / manuals for specific details / verify data. All images contained in this presentation are the property of Danfoss A/S or other parties where relevant & must not be copied. VLT® is a registered trademark of Danfoss Drives)

Please consider the environment & use VFD for your next application Thank you! Danfoss can accept no responsibility for possible errors in printed material. Please consult equipment design guides / manuals for specific details / verify data. All images contained in this presentation are the property of Danfoss A/S or other parties where relevant & must not be copied. VLT® is a registered trademark of Danfoss Drives)