How to deal with ai-driven automation economy

This paper summarizes the intelligent pump, focusing on its energy saving, life cycle cost, intelligence and economic benefits. Keywords intelligent pump Energy-saving intelligent cost-effective intelligent pump is a general term for pumps or pump systems that have certain computer processing ability and can partially replace artificial intelligence. With the development of science and technology, especially the rapid development of computer and information technology, the traditional pump manufacturing industry is developing in the direction of energy saving, intelligence and modernization. It should be said that the design, manufacture, operation, maintenance, type selection and sales of pumps have room for intelligent development. But at present, the most obvious advantages of intelligent pump are energy saving and automatic control, and it is precisely because of energy saving that intelligent pump was first proposed. First of all, the energy-saving potential of the pump is a big energy consumer. According to the data, the electricity consumption of water pumps accounts for about 20% of the total electricity consumption in China, and the motor power matched with water pumps accounts for about 45% of the total motor capacity in China. In petroleum and chemical plants, the power consumption of pumps is higher, reaching 59% and 26% respectively. Therefore, the energy saving of the pump is a great event. In China, in the past, the energy loss of pump operation system was great, and the adjustment of centrifugal pump mostly adopted the methods of valve control and opening and closing bypass. A survey data abroad shows that the average efficiency of 1690 pumps in 20 factories is only 40%, and the efficiency of 10% pumps is even only 10%. The above figures show that the pump industry has great energy-saving potential. If the operating efficiency of all pumps in service in China can be improved by 1%, it can save 4.4 billion kW of electricity every year? H, equivalent to 3.8 billion yuan of electricity (Shanghai's industrial electricity consumption during peak hours is 0.865 yuan /kW? H calculation). The improvement of pump efficiency includes two aspects: one is the improvement of design efficiency of pump main machine. Because designers have tried their best to improve the efficiency of the host at the design work point when designing products, it is also very difficult to improve the efficiency of 1%. The second is to improve the efficiency of the whole pump operation system. Some data show that the efficiency of the whole pump system can be improved by 30% or even higher after the original bypass regulation is changed to variable speed regulation. Therefore, the significance of intelligent pump lies not in the intelligent pump itself, but in the whole intelligent pump system of the pump. The appearance of intelligent pump makes the adjustment of centrifugal pump enter a modern mode and brings a brand-new management concept, so it can be said that it is a revolution in pump system engineering and management, and it is also an inevitable trend of pump industry development. Because the flow of centrifugal pump is directly proportional to the first power of speed, the lift is directly proportional to the square of speed, and the power is directly proportional to the cube of speed, if the bypass regulation of centrifugal pump is changed to speed regulation, the effect will be very obvious. If the flow rate drops 10% ~ 20%, the parameters of the pump are generally shown in table 1 (regardless of the influence of performance curve). But in fact, centrifugal pump is affected by performance curve. When the flow decreases, the lift will increase, so the lift required by the process can still be maintained, and the energy-saving effect will be slightly lower than the value in table 1 The energy-saving effect of other adjustment methods is between the two. Table 1 comparison of frequency conversion control and bypass control of centrifugal pump serial number control mode frequency conversion control bypass control 1 00% 90% 80% 80% ~100% 2 motor speed n/(r n/(r/min) 295026552366 10081641005 power consumption change (%) 1007348 100 second, life cycle cost LCC(LifeCycleCosts). Life cycle cost? Refers to the cost covered by the whole process from product planning to product scrapping. It includes both the perspective of producers and the perspective of consumers. But consumers buy products from manufacturers. Therefore, product cost plus product profit, plus consumption cost, becomes the whole life cycle cost of users. According to? Life cycle cost of pump? According to the author of the book 1, the life cycle cost of the pump includes four parts: equipment initial installation cost, operation cost (i.e. electricity fee), maintenance cost and other expenses. For a typical medium-sized pump industrial device, the proportion of its four parts is shown in figure 1. Figure 1 Four basic cost figures of pump life cycle cost 1 cost ratio (salary, price factor, etc. ) is formulated with reference to foreign standards. The initial cost of the equipment in the figure only accounts for 10% of the total cost. In fact, due to different manufacturers, the purchase price may vary by 30%, but for pumps whose service life exceeds 15 years, the initial equipment installation fee is often the least considered factor in their life cycle cost. There are often different views on the maintenance cost. In figure 1, the maintenance cost refers to the spare parts cost plus labor cost, which usually accounts for 25%~40% of the whole life cost. Therefore, its impact on the pump economy is more important than the initial cost of buying a pump. Energy consumption can be measured or calculated according to the performance curve, accounting for the largest proportion, reaching 45% in the figure 1, and even as high as 70% in some statistics. Table 2 Summary of practical cases of life cycle cost saving. Industrial sector/application case saving method saves cost, investment payback period (year), whole life cycle saves cost Euro 1 construction industry/air conditioning single bypass regulation large pump single throttle control large pump 3 variable speed regulation pump electricity fee 47,80070,4002 paper industry/circulating water pump installed two circulating water pumps with different working conditions. The electricity fee is 0.57 1 1.9003 chemical/condensate export pump. The electricity fee and maintenance cost of a new small motor is 0.063.1107,008,6004. The water pump in the water supply/distribution station is replaced with a water pump with normal efficiency. In 0005, due to the load reduction of wastewater/sewage pumps, three large pumps 1 were replaced with small electricity charges and maintenance charges of 3.338, 1006 steel mill/water circulation took measures to improve the surface efficiency of impellers, and the electricity charges of 0.425,8007 chemical/process export pumps were cancelled, and the electricity charges and water charges of 0.285,7008 household appliances/natural water pumps were cancelled. 0009 mine/pump-changing motor, high-efficiency motor electricity charge 1.822, 500 10/power station/cooling water circulating pump, outlet hydraulic characteristics of pump 1 original volute pump, 2 adjustable blade diagonal flow pump, 3 adjustable inlet guide vane mixed flow pump, electricity charge 1.40.4. 18, 394, 000 14, 5 18, 0001building/household use circulating pump to replace small pump electricity bill 930 12 building/office use circulating pump to rebuild electricity bill/kloc- Third, the intellectualization of water pump should work hard in two aspects. One is to hope that the efficiency curve of centrifugal pump is relatively flat, and the efficiency change is as small as possible when the flow changes. However, the potential in this area is very limited, so the focus is on operation and operation. When the external process flow changes, the intelligent system of the pump should be able to receive the information of process parameter changes in time, run automatically quickly and feed back the operation results to the regulating valve or frequency converter, accurately adjust the required valve opening or motor speed, and complete the response under variable working conditions. Among all the adjustment methods, variable speed adjustment is the most energy-saving. Therefore, the intelligent system of pump should mainly include the following kits: pump host, variable frequency motor, frequency converter, signal sensor, control module, programmable controller and so on. VFD(VariableFrequencyDrives), also known as variable frequency governor, is controlled by the feedback information of intelligent operation, and converts the input alternating current with the frequency of 50Hz into the corresponding current output with the frequency of Hz. The frequency conversion range of three-phase motor is 0-60Hz, and that of single-phase motor is 40-70hz. Speed of variable speed motor n=60f( 1? In s)/P formula, the frequency of alternating current after F frequency conversion is usually 40 ~ 50hz. If the slip ratio s=0.007 and the motor electrode logarithm P= 1, the frequency of 80% ~ 90% flow regulation is f=45Hz and 40Hz respectively (see table 1). Programmable controller PLC, also known as programmable logic controller, is an electronic system for digital operation. It uses programmable memory to perform logical operations internally. It is an automatic control device with computer as the core, which is used to control various machinery or production processes instead of relays. The programmable controller of intelligent pump can control the operation, maintenance management, cavitation prevention, diagnosis and alarm of pump system. The PumpSmart intelligent controller of ITT High Quality Pump Company (see Figure 2) is a more advanced integrated controller. Control module, programmer, etc. It has been made into a whole and the parameters have been set. Generally speaking, users do not need to program themselves. The typical intelligent pump system and monitoring principle are shown in Figure 2 and Figure 3. Its corresponding code meaning is: C? Console, CM? Control module, d? Motor, p? Pump host, PLC? Programmable controller? Signal sensor, VFD? Frequency converter. The working process of the intelligent pump system is as follows: when the parameters of the outside (process flow) change (such as when the outlet pressure drops due to excessive flow), the signal is transmitted to the control module CM through the inlet and outlet signal sensor T installed at the inlet (or outlet). The control module consists of several integrated circuit modules, such as power system module CM 1, data acquisition module CM2, drive control module CM3, information display module CM4, input and output module CM5, etc. The control module displays the result on the signal cabinet C (or control cabinet) through operation, and sends a frequency modulation command to the frequency converter VFD. After receiving the FM command, the variable speed motor D starts to decelerate, and the outlet flow of the pump (main engine) P gradually decreases, so that the system reaches a new balance. Also connected with the control module is a programmable controller, which can store the performance curve, fluid density and control parameters of the pump in advance. Under normal circumstances, pre-stored parameters do not need to be adjusted. When the parameters change significantly, the pre-stored parameters can be reprogrammed. The performance curve of the pump is parabola, and its descending section is generally adopted. It is obtained during the design or testing of the pump, and can be programmed in parts with a simple mathematical model. Four. The development and utilization of energy-saving pump has a long way to go, which is the result of the joint efforts of all pump industries, so there is such a major breakthrough as intelligent pump. Many companies at home and abroad have done a lot of work in this field. For example, ITT High Quality Pump Company introduced and demonstrated a series of products of intelligent pumps to China earlier, and put forward the concept of life cycle cost, which greatly improved the efficiency of pump system operation. Shijiazhuang Yiao Technology Development Co., Ltd. took the lead in research and development? Power saving calculation and system design of variable frequency speed regulation of water pump? The quantitative calculation problem of power saving is solved. Many individuals have also contributed to the development of energy-saving pumps, such as Li Donggui of Dalian. Who invented them? Intelligent pump for industrial process? Patent (domestic patent number ZL 01211714.5, international publication number WO02/66835AI). The rapid development of intelligent pump also depends on the development of frequency conversion technology, so it can also be said that intelligent pump is an example of successful application of industrial control automation in pump industry. At present, many articles in different technical fields have introduced examples of pumps and frequency conversion control in industry. The application of intelligent pump is a systematic project, involving many industries applied by users. This system engineering considers not only technology, but also economic and social benefits. Now, the technical problems of intelligent pumps should be said to be gone, right? Bottleneck? Not long ago, in PSC2005, the 6th China International Exhibition of Fluid Machinery and General Equipment, ITT High-quality Pump Company exhibited the demonstration system of compound intelligent pump, which fully demonstrated the advanced nature and reliability of ITT intelligent pump to the audience. What users need to consider is the input-output ratio, that is, the increased investment due to the adoption of intelligent pumps will take several years to recover. The author thinks that the scientific consideration is that the new factory accepts the thinking mode of LCC, and the payback period of the old factory is less than 2~3 years. Another issue that needs to be focused on is social benefits, which is actually a national energy policy issue. It is reported that in 2003, China's GDP accounted for 3.8% of the world's total, but its global energy consumption accounted for 1 1%. China's energy consumption per unit GDP is 4.3 times that of the United States, 7.7 times that of Germany and France, and 1 1.5 times that of Japan. China energy experts call for? China's economic operation is still a extensive economic growth mode with high input and high consumption, which has brought many problems, such as resource depletion and environmental pollution, and is unsustainable? . Therefore, in the huge energy management space of the pump industry, it is not only the economic interests of enterprises, but also the responsibility of citizens to the country to dig deep into the energy-saving potential and popularize the application of energy-saving systems (intelligent pumps). (Excerpted from General Machinery, No.9, 2005) Author: Chen Chucheng, National Chemical Equipment Design and Technology Center Station; Tianhua Chemical Machinery and Automation Research and Design Institute Chen Zonghua Reference 1? pumpingsystems？ ，europampandhydraulicininstitute，200 1