Intelligent pump control boosts energy saving

A new pump control software module for drives has been launched by ABB. Featuring six pump control functions, the new Intelligent Pump Control (IPC) software eliminates the need for an external PLC, and can help save energy, reduce downtime and prevent pump jamming and pipeline blocking.

The IPC is a software add-on for ABB industrial drives, which cover a power range from 0.55kW to 5,600kW. It contains all the common functions needed by water and waste utilities, industrial plants and other pump users.

Where several pumps are operated together and the required flow rate is variable, IPC uses multi-pump control. Each pump is controlled by its own drive – one is speed adjusted with the rest running at constant speed, giving a smooth control with no pressure peaks.

Preventive maintenance is important for all industrial equipment and the IPC achieves this through its anti-jam function.

When the function is triggered, the pump is run at high speed and either reversed or stopped in a number of user-defined cleaning cycles, clearing built up particles and avoiding corrosion.

IPC also eliminates the need for flow meters with its flow calculation function,

used to control a singlepump installation.

Sensorless flow measurement is possible and, alternatively, data can be supplied

via pressure transmitters.

The package’ sleep boost function runs the pumps to boost the pressure or

water level prior to shutdown, extending the pump’s sleep time and so saving energy. It also avoids unnecessary starting and stopping, and helps to flush the pipelines.

The pump priority control enables pump operators to plan their maintenance and boost energy efficiency by operating pumps near their best efficiency point.

In a system where the consumption rate is greater during the day, the drive

can be programmed to operate higher capacity pumps during daytime and smaller units at night.

The software also incorporates ABB’s adaptive programming utility, enabling users to customise drives for specific applications.

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