Variable Speed Pumping in Thermal and Nuclear

Power Plants: Frequency Converter versus

Hydrodynamic Coupling
Martin Sirov
1
, Zdenk Peroutka
1
, Jan Molnr
1
, Jan Michalk
2
, Miroslav Byrtus
3
University of West Bohemia /
1
RICE /
2
Dept. of Electromechanics and Power Electronics /
3
Dept. of Mechanics, Pilsen,
Czech Republic,
e-mail: sirovy@rice.zcu.cz, peroutka@ieee.org, jmolnar@rice.zcu.cz, jmichali@kev.zcu.cz, mbyrtus@kme.zcu.cz

Abstract In this paper, a comprehensive case study analysis
of flow control methods and appropriate technical
implementations for high-power pump systems employed in
thermal and nuclear power plants or heating plants will be
presented. The main attention is focused on a comparison of
two advanced variable speed control strategies employing VSD
with frequency converter and VSD with hydrodynamic
coupling.
In addition, we have included comparison with conventional
flow control methods like throttling, bypass and on-of control.
The calculations were performed in the software, which we have
developed for design, optimization and sophisticated
comparison of these drives.
It is presented the methodology and developed models for
evaluation of the whole drive chain from hydraulic system over
pump, drive components and power supply.

Keywords Software, Simulation, Case study, Modeling,
Efficiency, Variable speed drive, Electrical Drive, Induction
motor, High Voltage power converters, Hydrodynamic
Coupling, Generation of electrical energy, Water transport,
Optimal control
I. INTRODUCTION, MAIN GOALS, MOTIVATION
The energy is becoming increasingly more expensive, less
abundant and the incentive to use it more efficiently is
increasing. In order to adequately estimate saving potential in
existing installations and to optimize new installations, good
tools that can assist in this work will be required. University
of West Bohemia has been involved in a project to design
software that can be used to provide safe estimates for a
comparison among major flow control methods and drives:
i) fixed speed drives throttling, bypass, on-off control
ii) variable speed drive for both variants either with
frequency converter or with hydrodynamic coupling.
Variable speed drives are progressively replacing fixed speed
drives in many applications. But what is actually the final
effect in practice? Does this trend always lead to increase of
technical and economic indicators? When consider variable
speed drives, which technology is the more suitable and for
which application? The answers on these questions are very
essential, especially due to very different nature of the drives
and due to application in the area of power systems, where a
tiny error in the estimation of energy efficiency in the design
phase leads to serious energy and/or financial losses during
lifetime.
The paper presents a part of a research project dealing
mainly with life cycle cost optimization of high-power
variable speed drives especially intended for boiler feed
pumps and cooling water circulating pumps in power and
heating plants [1]. We have already presented in [2] the first
part describing in very detail software features and developed
models for VSD with frequency converter. This contribution
focuses on the second part VSD based on hydrodynamic
coupling and includes also comparison with conventional
flow control methods employing fixed speed drives.
Due to a very different nature of compared drives it is a
challenging task to determine what the most suitable drive
would be for a particular application, especially for power
systems where a tiny efficiency improvement causes
substantial energy consumption and/or CO2 emission
reduction. Therefore, it is important to explore the case from
case in very detail to get as much as reliable and precise
results. To the authors best knowledge, there is no publicly
available software for such comparisons that can adequately
account for the differences.
II. THE SOFTWARE TOOL INTRODUCTION
The complex software tool has been developed in order to
provide a comparison of behavior, features and efficiency
under various operational conditions for each component of
the drive chain from the load to the power supply network.
The software also includes basic economical evaluation
features such as operational costs, payback period or lifetime
savings calculations.
Fig. 1 Preview of developed software MV Pump & Fan Save 1.2 Beta
IEEE PEDS 2011, Singapore, 5 - 8 December 2011
978-1-4577-0001-9/11/$26.00 2011 IEEE
228
Great emphasis was given to the software maximal
flexibility and an intuitive user control at the same time - see
Fig. 1. It is possible to calculate a user case study in very
detailed manner or to use the software build-in functions to
quickly design a drive model for evaluation purposes.
III. MODELLING
This section describes methodology and steps of the
evaluation process over the whole drive chain beginning with
the hydrodynamic system and pump over fixed speed and
variable speed flow control methods to components of drives
both for fixed speed and variable speed variants.
It presents the physical and mathematical background of
modeling together with the proposed models and simulation
software features.
In general, it is necessary to describe the load i.e. to know
the hydraulic system configuration and operating profile.
Then it is possible to evaluate the efficiency of the all
components in the chain beginning with the pump & control
over gearbox, electrical motor, frequency converter or
hydrodynamic coupling to the power supply transformer. This
is commonly no problem for fixed speed machines where the
parameters and curves at nominal operating points are
available. However, for variable speed drives it is necessary
to use specific techniques which are able to calculate drive
loss values at the actual operating points, using the individual
characteristics of the investigated drive in question.
Then it is possible to determine the annual and lifetime
energy consumption, drive operating costs and other
economical and technical drive indicators.
A. Operating Profile
In the (Fig. 2), you can see an example of an operating
profile of a 800 MW Thermal Power Plant which has been
taken as a referenced one for the comparison of declared flow
control methods.
B. Hydraulic system
It is considered a hydraulic system with a constant pressure
control. Hydraulic system curve (1) is determined by static
and dynamic pressure according to Newtonian liquid flow
equation (2), (3).
For typical hydraulic system curve see Fig. 3.
To evaluate efficiency of a particular flow control method,
an ideal hydraulic power (4) and appropriate energy
consumption according to operating profile (5),(6) has to be
defined.
Ideal hydraulic power and/or power consumption matches
the hydraulic power used while employing variable speed
control see Fig. 5, i.e the control efficiency equals one.
Alternative fixed speed methods like throttling, bypass or
on-off control are outside of the nominal operating point
always lossmaking.
C. Pump
Selection of the right pump for a specific application is
one of the most important steps. There are several types of
pumps based on different principles and appropriate for
different situations. Centrifugal pumps are the most common
in the power and/or heating plants with the typical pump
curve shape see Fig. 3, red curve.
However, the pump performance curves are often defined
only at the pump nominal speed. The following equations
also called affinity rules - (7) - (9) are used to recalculate
pump performance curves for variable speed [3, 4]. The
( )

= +
S i ST f i i
H H H Q

(1)
2





i
f i f N
N
Q
H H
Q

(2)

f -N N ST
= H H H

(3)

{0,1,..., 1} =
OP
i n


H
S
Hydraulic System Pressure; H
ST
Hydrostatic Pressure; H
f

Dynamic Pressure; Q Flow; Subscript i i-th point of operating
profile; Subscript N Nominal value; n
OP
number of operating
points


- - -
.
. . ; [ ]
3600

=
L
HSI i S i S i
g
P P H kW

(4)
.
; [MWh]
1000

=
HSI i i
HSI i
P t
E

(5)
1
0

=
=

OP
n
HSI HSI i
i
E E

(6)
P
HSI
Ideal Hydraulic Power;
L
Liquid Density; g Gravity
Acceleration; E
HSI-i
Ideal (minimal) Energy consumption in operating
point i; E
HSI
Total Ideal (minimal) Energy consumption
0%
0%
0%
1%
7%
17%
22%
24%
22%
7%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Operating time [%]
Flow [%]
Fig. 2 Operating Profile
1700
1900
2100
2300
2500
2700
2900
3100
3300
3500
0 200 400 600 800
H
e
a
d

[
m
]

Flow [t/h]
Pump & System characteristics
Nominal speed System curve
Speed range 3507 - 3999 rpm
Affinity curve
Fig. 3 Pump & System Curves
H
i
H
Nx
229
impeller diameter is considered unchanged.
It is proved in (10) that the efficiency keeps unchanged
using affinity rules (7) - (9). An efficiency curve recalculation
for any speed is expressed in (13).
The sample of final pump efficiency curves for a
hydraulic system with a relative high ratio of hydrostatic and
hydrodynamic head see Fig. 4. It is evident that the pump
efficiency is highly dependent upon the pump flow. However,
this negative effect can be reduced while employing variable
speed control. The advantage of variable speed control is
increasing or decreasing with the operating speed range
variability which is determined by the ratio of hydrostatic and
hydrodynamic head.
D. Variable Speed Flow Control (C1)
To evaluate pump efficiency under variable speed control,
it is necessary to derivate the pump speed for any operating
point. The operating point is to be find on the intersection of
hydraulic system curve - Fig. 3 red curve with pump curve -
Fig. 3 grey. Pump speed is then obtained from (14). The right
operating point (intersection of orange and grey curve for
particular flow) could be find by construction of affinity
curve (orange) beginning in the zero point and crossing the
operating point (Fig. 3 H
i
). Then relating point on pump
nominal Q-H curve (Fig. 3 H
Nx
) is approximated.
Pump efficiency for any operating point is then (15).
Control efficiency equals one from the variable speed
principle itself -(16), (17).
1 1 1
2 2 2
=
Q N D
Q N D

(7)
2
1 1 1
2 2 2

=


H N D
H N D

(8)
3
1 1 1
2 2 2

=


P N D
P N D

(9)
2 3
1 1 1 2 1 1 2
2 2 2 1 2 2 1
1

= = =

Q H P N N N
Q H P N N N

(10)
2
2 2
2 1 2 1
1 1
; H

= =


n n
Q Q H
n n

(11)
( ) ( )
2 2 1 1 1 2
; ; = = =
n n n n
f Q f Q

(12)
( )
1
2 2 1 2
2


=



n n
n
Q Q
n

(13)
H pressure, Q flow; N rotational speed; D impeller diameter;
efficiency; Subscript 1 original state; Subscript 2 transformed state
1
1
.

=
PC i
PC i N
PN x
H
N N
H

(14)
1 1
1
.
N
PC i N PC i
PC i
N
f Q
N

=



(15)
1 1
1
; ;
=>
PC i S i PC i S i
HPC i HSI i
Q Q H H
P P


= =
=

(16)
1
1 1
1
HC i
C i C i
HSI i
P
P

= => =

(17)
NPCx-i pump speed under control C
X
in the operating point i; N
N

pump nominal speed; HPCx-i pressure in operating point i for control
C
X
; HPN-x operating point on the pump nominal Q-H curve
according to pump affinity law. (see Fig. 4); Cx-i control method
efficiency for controlregulaci C
X
; PHPCx-i hydraulic power in the
operating point i for control method C
X
; QPCx-i pump flow
quantity in the operating point i for control C
X
; HPCx-i pump
pressure in the operating point i for control C
X
; PCx-i pump
efficiency in the operating point i for control Cx
Fig. 4 Pump Efficiency curves
3507
4050
Fig. 5 Energy Consumption per time period for selected Pump Flow
Control Strategies
230
E. Fixed Speed Flow Control
Principle of selected fixed speed flow control strategies is
apparent from the Fig. 5. It could be observed, that fixed
speed flow control methods are except the nominal
operating point always loss making. Next, it is derived
efficiency evaluation for selected fixed speed flow control
methods.
1) Throttling (C2)
Pump speed equals to pump nominal speed over the whole
operating range (18). Pump efficiency is then obtained for any
operating point from pump nominal efficiency curve (19).
Pump hydraulic power is expressed in (20) and efficiency of
flow control method in (21).
2) Bypass (C3)
Pump speed and pump efficiency and pump hydraulic
power are declared in the same way like in previous case -
(18)-(21). The pump flow quantity and head in the case of
bypass flow control is then (22).
3) On-Off Control (C4)
On-Off control is a very specific flow control while it
actually operates only at nominal operating point. It is not
possible to control the flow in a real time. However, it is
possible to control the flow quantity in a time period (average
value). Flow quantity is then determined by the ration of run
and stop time. It is apparent, that this method could be applied
only for the applications which include capacity and it is
possible to vary flow around the set-point in hysteresis range.
F. Gearbox
If a pump nominal speed is too high for direct connection
to an electric motor, a gearbox must be installed between the
pump and the electrical motor.
Gearbox efficiency calculation is simplified and it is
supposed to be constant in the whole operating range.
Gearbox is an optional device in the software and could be
enabled or disabled according the user application.
G. Electrical Motor
In the current version of the software an induction machine
is considered. The efficiency of the induction machine, when
it is speed controlled, can be depicted as dependent upon two
parameters - motor stator frequency (or if you like
synchronous speed) and mechanical (shaft) load [2]. Hence, it
is not accurate to simply use the motor raw datasheet nominal
characteristics for the motor efficiency calculation.
This is similar for the induction machine power factor
recalculation. The power factor is dependent upon motor
stator frequency and the mechanical (shaft) load, which is
proportional to the slip frequency.
Next it is derived how to transform motor efficiency and
power factor from the nominal speed characteristics to the
curves matching motor operating states.
Transformations of the motor nominal curves into the
characteristics fitting for the defined load are valid under
following assumptions:
Frequency converter is operated under fixed Volt/Hertz
control. The motor is not operated in field weakening -
thus, it is considered constant magnetizing current.
Then, the motor current under nominal load, can be
considered as nominal and Joules losses are dominant.
Motor nominal electrical loss curve does not change
significantly in the relation to motor per unit load (15).
Motor mechanical losses do not significantly impact the
overall efficiency within the speed range of considered
pump applications with a high static head. Hence, the
change of mechanical losses with the speed is neglected
and the nominal mechanical loss curve is considered in
the operating speed range unchanged. (i.e. the worst case
is calculated, while calculating efficiency for lower
speeds)
Motor power under rated torque condition changes
linearly according to stator frequency.
The motor efficiency is then defined by (13).

, ( ) ( )
m
m
P
P f p f p
P P
= = =
+
(1)
Motor losses are expressed by (14) and motor relative load
by (15).

1 ( )
( )
( )
N
mN
N
p
P p P P f p
p

= = (2)

m
N
mN
N
P M
p
M
P

= =

(3)
{ }
;
2, 3, 4 .. number of method (C2,C3,C4)
=

PCx N
N N
x

(18)
( )
;
Cx i N PCx i
f Q

=

(19)
2 2 2
2 2 2
; (Q );
.
. . ; [kW]
3600
PC i S i PC i N QH PC i
L
HC i PC i PC i
Q Q H f
g
P Q H

= =
=

(20)
;
HCx i
Cx i
HSI i
P
P

=

(21)
3 3
( (Q ));
PC i N HQ N QH S i PC i S i
Q f f H H

= =

(22)

= =
=
4 4
4 4 4
;
.
. . ; [kW]
3600
PC i SN PC i SN
L
HC i PC i PC i
Q Q H H
g
P Q H

(23)
4 1
0
.
OP
i
PC avg SN n
i
i
t
Q Q
t

=
=

(24)
4
4
. *
; [MWh]
1000
HC i
HPC i
P t
E

=

(25)
4
4
HPC i
C i
HSI i
E
E

=

(26)
231

The estimate of the motor power factor for the load points
was done with the following assumptions:
Motor flux current remains unchanged under motor
fixed Volt/Hertz control. Therefore, motor current is
independent on the motor speed and depends only on the
shaft torque.
Motor apparent power is proportional to the motor
speed.
The motor power factor (16).

cos
( ) ( )
( )
cos ( , )
m m
N
N
P P P
S p S
p S
f p

= = =

=
(4)
The software provides user with the default induction
motor curves for the user defined specific power or lets to the
user to enter custom motor curves for that case several
validating functions are implemented also to prevent entering
unacceptable data. This can help to prevent faulty conclusions
due to data entry mistakes.
H. Frequency Converter (FC)
There are several available converter topologies and
different power devices able to be chosen as well as
possibilities of their control e.g. [5]. Hence, it is impossible
to propose general mathematical model of the converter
providing a high accuracy results. The most optimal way is to
obtain needed information concerning FC efficiency in
demanded range of power from the manufacturer as an
efficiency characteristic in the relation to the load apparent
power. The second possibility when the manufacturer is not
able to supply the required efficiency characteristics is to use
a simplified approximation formula of converter losses as a
parabolic function of converter current:
2
converter
P a i b i c = + + (5)

Finally, if we are not able to get any information from FC
supplier, it is possible to consider its efficiency as constant
value (e.g. nominal value), because it changes only about 2%
in a wide range and even less in an application with a high
static head. If the converter is not specified at all, the
efficiency value can be chosen e.g. in a range of 96-98,5%.
I. Transformer
Transformer is an optional choice in the case study
calculation. The efficiency of the transformer is dependent
upon the load of the transformer and upon the character of the
load - power factor [6]. Efficiency is generally expressed by
(18). Losses of the transformer are divided into no-load losses
independent on the load and load losses. These are generally
available in a transformer datasheet. (19) .

cos
cos
out out L
in out L
P P S
P P P S P

= = =
+ +
(6)

2
0 LN
P P P L = + (7)

N
S
L
S
= (8)

It is also possible to find transformer optimal load where
the transformer works with best efficiency. This is important
especially while dimensioning the transformer. If we
differentiate the efficiency expression (18) with respect to the
per unit load (20), we get the relation for transformer best
efficiency load point (21).
0
BEP
LN
P
L
P

(9)
From (18)-(21) we get the maximal efficiency value:
0
max
0 0
cos
cos 2
N L
N L LN
P S
P S P P

=
+
(10)
For the typical ratio of transformer no-load losses to load
losses it is optimal to choose the transformer size so that the
real load of the transformer is within the range of 50%-80%
of the transformer nominal load see [2].
J. Hydrodynamic Coupling
Hydrodynamic coupling (Fig. 6) works as torque/speed
converter. It is powered with a constant speed induction
machine connected directly to the distribution network.
Output speed is controlled by the filling of the machine by oil.
In the Fig. 7, see the example of an efficiency curve for the
advanced type of hydrodynamic coupling. The curve has to be
usually obtained directly from the manufacturer, due to
specific adjustments to customers application. However,
when there are no available data from the manufacturer, it
could be used linear characteristic instead.
Legend to equations 13 - 15
P
m
- Pump mechanical shaft power, P
mN
- Pump nominal mechanical
shaft power, P - Motor losses, p - Relative load of the motor,
N
-
Motor efficiency at rated stator frequency (typically 50 Hz), -
Motor speed,
N
= Motor nominal speed
P
converter
= Converter losses, a,b,c - Coefficients of the parabolic
function from the manufacturer.
S - Transformer apparent power,P - Transformer losses, P
0
-
Transformer no-load losses, P
LN
- Transformer nominal load losses
L = per-unit load
1 Primary wheel
2 Secondary wheel
3 Box
4 Cover of a control bar
5 Oil Basin
6 Oil Pump
7 Control bar
Fig. 6 Hydraulic Coupling scheme [7]
92,16%
96,73%
91%
93%
95%
97%
1
2
5
6
1
2
6
1
1
2
6
6
1
2
7
2
1
2
8
0
1
2
9
0
1
3
0
1
1
3
1
4
1
3
2
9
1
3
4
4
1
3
6
3
1
3
8
4
1
4
0
5
1
4
2
6
1
4
4
6
E
f
f
i
c
i
e
n
c
y

[
%
]

Speed [rpm]

Fig. 7 HC advanced type efficiency curve
232
IV. CASE STUDIES
In this chapter, we have included a sample of case studies.
We have chosen two typical applications of high power
pumps, where the differences among the employed drives are
well observable to verify the proper functionality of the
software and meet reader with differences in the drive
behavior and suitable areas of usage for each drive.
The first case study considers boiler feed pump application
in thermal power plant for the results see Fig. 8. The
specific at this case is the very high static head, which leads to
very high pump zero flow speed getting closer to the pump
nominal speed. The overall speed variability is therefore
relative small.
If we compare variable speed control with frequency
converter and with hydrodynamic coupling, the frequency
converter leads from the efficiency point of view. However,
the comparison has been made with conventional
hydrodynamic couplings with linear speed-efficiency curve.
According to the principle - Fig. 4 - fixed speed control
methods provide good results at nominal operating point and
get worse while getting down with the flow.
The second case study considers a cooling water circulating
pump see Fig. 9. The specific at this case is the very low -
under ideal conditions no - static head in the system. All the
pressure losses are caused by friction. This configuration
leads to very high variability in the speed. If we have a look at
the results, it could be observed following:
i. It is possible to clearly see the advantage of variable
speed control methods against the fixed speed
controls.
ii. Variable speed control with frequency converter
provides significantly better results comparing to
variable speed control with hydrodynamic coupling.
On-Off control has been calculated just as a theoretical case
of application with a high and low static head. It is not
suitable for boiler feed pump application.
In both presented examples VSD with frequency converter
provides higher efficiency in the whole operating range.
However, it has to be always considered the case from case
while making decision which drive is the most suitable for a
particular application.
Fixed speed flow control methods namely throttling,
bypass and on-off control provide relative well results in
applications with a high a static head and if taking into
account economical parameters, they are able to compete in
specific applications.
Fixed speed flow control methods for low static head
applications work with a very low efficiency and should be
avoided or used just as a backup solution.
The final decision which drive is the most suitable
significantly influences several factors mainly the operating
diagram (based load power plant or peak operation), type of
hydraulic system (high/low static head and/or speed
variability), reliability, system complexity, service availability
and ability etc.
No less important is the economical site which has to be
taken into account. The software also provides basic
economical indicators like net present value (NPV) or
payback period.
V. CONCLUSIONS
Pumping systems stands for a majority of the energy
consumption not only in the power or heating plants but
generally on the worldwide energy consumption scale. Design
of these systems is a matter of several technical disciplines
from mechanical engineering to electrical machines, power
electronics and control systems. In the practice, the job is
realized by several manufacturers which understand perfectly
their field but it is necessary to pay a big attention also to the
complex design. According to the practice, a majority of
pumping systems dont work in their optimal operating
conditions what leads to extra losses, early ageing and extra
costs.
Hence, we have developed software dealing with the whole
process of the pumping system design and provide the
designer with detailed calculation results and operating
characteristics of the system.
Main conclusion of the paper can be summarized into
following points:
i. We have developed software, which makes possible
comparison of both, the most advanced pumping system
configurations of today - pumping systems realized by
(i) variable speed drive with frequency converter and (ii)
variable speed drive based on a hydrodynamic coupling.
ii. It is possible to evaluate case study of any hydraulic
system and commonly used flow control methods in a
very detail and precise manner.
iii. This paper presents the original results and research
approaches dealing with comparison of high-power
variable speed drives and fixed speed drives for
pumping systems with a constant pressure control.
iv. The results clearly show the suitability of compared
variants in the relation to two different commonly used
pump applications.
v. It explains the physical background of modeling and
proposed steady-state models for simulation and
evaluation of
i. variable speed flow control methods VSD
with frequency converter and VSD with
hydrodynamic coupling
ii. fixed speed flow control methods throttling,
bypass, on-off control
vi. Specific recalculation techniques which are able to
transform device rated parameters and characteristics at
nominal operating point to required operating
characteristics according to variable speed character of
the drive has been proposed.
vii. It has been presented sample case studies, which has
verified the proper function of the software on a real
application of pump systems in thermal power plants
i. boiler feed pump application
ii. cooling water circulating pump application
ACKNOWLEDGMENT
This research has been supported by the European
Regional Development Fund and Ministry of Education,
Youth and Sports of the Czech Republic under project
No. CZ.1.05/2.1.00/03.0094: Regional Innovation Centre for
Electrical Engineering (RICE) and the project of Student
Grant System SGS-2010-037.
233
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Converter, 14th International Power Electronics and Motion Control
Conference, New York: IEEE, pp. T6-70 - T6-77, 2010
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[7] www.voith.com


Fig. 8 Boiler Feed Pump Application: Pump Power 6 500 kW Hydrostatic head 2550 m Nominal operating point: Flow 625 m3/h, Head 2650 m
Nominal pressure loss on the control valve in the case of throttling: 50 m


Fig. 9 Cooling water circulating pump application: Pump Power 300 kW

Hydrostatic head 0 m

Nominal operating point: Flow 800 m3/h, Head 80 m

Nominal pressure loss on the control valve in the case of throttling: 5 m

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[
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Flow [%]
Boiler Feed Pump Application
FC HC Throttling Bypass On-Off
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[
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Flow [%]
Cooling Water Circulating Pump Application
FC HC Throttling Bypass On-Off
234