Plant Equipment Co. · Engineering Console

VSD Optimization for KOP MAX3 3M 6×4-16

Customer: Nobel NC · Slurry HNO₃ · SG 1.040 · Candle filter circuit · Commissioned 24 Apr 2026

PUMP KOP MAX3 3M 6×4-16 OCM X2A · S/N 83514-1588-1225
MOTOR ABB M2BAX 250SMA 4 · 55 kW · 1479 rpm · 102 A · η 94.6%
IMPELLER Ø397 mm · open · max sphere 26.9 mm
REFERENCE Flowserve Durco Mark III 3K6X4-16 · curve B421V

VSD Controls LIVE

Motor Speed 1200rpm

600800100012001450

VFD Frequency 41.4Hz

derived from rpm · 50 Hz ↔ 1450 rpm

Discharge Butterfly Valve 40% open

10%25%50%75%100%

Candle Filter ΔP (fouling) 0.5bar

clean12fouled · 3

Required Process Flow 250m³/h

150200250300

System Friction @ Q=250 (drifts with deposits) 3.0m

135710

Solves for minimum power at the target flow while keeping η ≥ 70% and operation inside the Mark III safe envelope.

Quick Scenarios

QH Performance Map · Affinity-Scaled N = 1200 rpm

Operating safely. Pump intersects system at requested flow.

Pump curve (current rpm)

Pump curves (other speeds)

System curve (current valve + filter)

● Best Efficiency Point (BEP)

◆ Operating point

✕ Field gauge measurements (scaled to 1450 rpm-eq)

Operating Point OK

Flow Q

—m³/h

Head H

—m

Pump η

—%

floor = 70%

Shaft Power

—kW

of 55 kW rated

Q / Q_BEP

—%

safe band 70–120%

NPSH required

—m

available ≈ 8 m est.

ABB ACS580 panel readouts (what your operator sees)

Output Power · 01.14

—kW

to motor terminals

Motor Current · 01.07

—A

of 102 A nameplate

Grid Draw (calc)

—kW

utility bill basis

η_motor

—%

load-dependent

▸ Engineering Summary

VFD setpoint— Hz

Motor rpm—

Valve position—%

Filter ΔP— bar

Static head12 m

Spool loss— m

Other friction— m

Valve loss— m

Motor current~— A

Specific energy— kWh/m³

Constraint Watchdog

On-Site Optimization Logbook

Record real measurements at the plant — compare against the model in real time to find true sustainable operating points.

Speed rpm

Valve %

Flow (meter) m³/h

Suction P bar g

Disch. P (DP2) bar g

Filter ΔP bar

Notes (optional)

Model predicts enter fields to see live comparison…

#	Time	rpm	Valve	Q meas	Q pred	ΔQ	H meas	H pred	ΔH	Suc	DP2	Filter	P shaft	Notes
No measurements recorded yet. Enter readings above and press Save row.

Calibration drift: record 3+ measurements to see how the model is tracking reality.

Pump Model Basis KOP MAX3 3M 6×4-16 with Ø395 mm open impeller. H-Q curve anchored to KOP nameplate (Q=250 m³/h, H=53 m at 1450 rpm) and curve shape from Flowserve Durco Mark III 3K6X4-16 curve B421V (15″ trim region). Affinity laws: Q ∝ N, H ∝ N², P ∝ N³. BEP ≈ 290 m³/h at 77%. Curve is valid only for 0 ≤ Q ≤ 400 m³/h at 1450 rpm — beyond that, no manufacturer data exists and the model returns nothing rather than extrapolating.

System Curve Basis Static head 12 m + candle filter ΔP (0–3 bar) + friction (Q²) + butterfly. Friction at Q=250 is operator-adjustable (1–10 m range, persists across sessions) because slurry pipe deposits drift over time. Default 3.0 m calibrated against 46 commissioning measurements (filter ≈0.5 bar throughout, customer recommended 1100 rpm/62.5% valve → 248 m³/h matches measured mean). Butterfly K is two-zone: 1.21 below 45% opening, 2.39 above 50%.

Power Chain (Motor + VFD) Hydraulic power P_hyd = ρ·g·Q·H. Shaft = P_hyd / η_pump. Motor input (ACS580 signal 01.14 "Output Power") = shaft / η_motor where η_motor varies with load per ABB nameplate (IE3: 93.9% at 50%, 94.7% at 75%, 94.6% at 100%, fitted quadratic). Motor current (signal 01.07) = P_motor_in / (√3 · 400 V · PF), with PF ramping 0.50→0.83 from 25%→100% load. Grid draw = motor input / 0.97 (ACS580 IE2 drive class per EN 50598-2).