Variable Flow Control through VFD for Level Precision & Energy savings in Power System
In almost every industrial facility, there is always a fluid pumping system depending upon the application. The flow rate is usually a critical parameter which must be controlled precisely and smoothly. The systems used for flow rate control and precision are generally valve based solutions which ar
2025-06-28 16:36:33 - Adil Khan
Variable Flow Control through VFD for Level Precision & Energy savings in Power System
Project Area of Specialization Internet of ThingsProject SummaryIn almost every industrial facility, there is always a fluid pumping system depending upon the application. The flow rate is usually a critical parameter which must be controlled precisely and smoothly. The systems used for flow rate control and precision are generally valve based solutions which are not as efficient as they are thought to be, they suffer from unresponsiveness, corrosion, sticking, and leakage. In these systems, the pump is set to work continuously throughout the process even when the fluid is not needed as the flow rate is actually controlled by the valve itself, thus increasing the depreciation rate of the pumping system.
A more reliable way of controlling the flow rate and precise flow tends to be in pump speed adjustment through VFD (Variable Frequency Drive). They are proficient of varying the output pace with eliminating the mechanical pulleys. Reducing the pump speed reduces the pressure imparted to the fluid which in return reduces centrifugal power consumption, providing smooth flow for precise level management.
This project will shed light on how to use VFD based pumping system for precise flow, centrifugal pump curves and loop performance advantages with characteristics of PID (Proportional Integral Derivative).
Project ObjectivesThe goal of the project is to attain a smooth yet effective flow of the water with the help of PID. The user only needs to input the desired operating value of pump in percentage. It is designed keeping in view the scalability and possibility of installing different pumps within the system. Therefore, a closed system consisting of two tanks namely supply tank and process tank placed with a vertical distance of approx. 1 meter. A solenoid valve acting as a drain valve in the process tank returns the water to the supply tank. The amount of water remains the same as it is used again and again keeping in view its importance and our responsibility to save it as much as possible. The whole system let us visualize how PID controller maintains and achieve the set value in minimum time without the interference of a human, it decides the values of P, I and D controllers itself to effectively minimize the error signal and attain the set value given by the user through Human Machine Interface (HMI). Further monitoring sensors, for example, PT100 and Level switches are installed in order to provide the attributes of the fluid within the tank. Temperature monitoring is essential to keep the temperature of the fluid in check as it may affect the internals of the pump, whereas level switches in the process and supply tanks indicates the level at which the fluid has risen. In the supply tank, the lowest level of the water is indicated by a level switch so that the pump would not run empty. And in process tank, four level switches determines the level of water, the highest one triggers the solenoid drain valve which returns the excess water back into the supply tank so that it would not overflow.
Project Implementation MethodThe Overall System model is divided into two parts; one is operating panel which consists of PLC, VFD, HMI, and relays. The second one is hardware panel which consists of supplier tank, process tank, pump, flow meter, level switches, and PT100. Both parts are synchronized with each other and continuously communicating with each other through analog and digital sensors to run throughout the whole process of flow.
Benefits of the ProjectTo know the working of Flow and its control in Industrial Level.
Technical Details of Final Deliverable
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 79500 | |||
| PLC Fatek | Equipment | 1 | 22000 | 22000 |
| HMI | Equipment | 1 | 21500 | 21500 |
| VFD | Equipment | 1 | 10000 | 10000 |
| VALVES | Equipment | 2 | 8000 | 16000 |
| Wires, Switches | Miscellaneous | 1 | 10000 | 10000 |