Energy savings on motor driven systemsBase your investment calculations on facts

Fanie Steyn, March 2013

Content

1. Motor driven systems2. Savings on pumping systems3. IE4 motor drive package.

Who knows what the most effective energy saving device is?

The stop button?

What is a motor?

‘95% of all motors are oversized’

Losses

= Pin - Pout

kW In

kW out

=90%

Losses

= 10kW

100kW

90kW

What is a system?

ProcessInput Output

System

ProcessInput Output

Losses

System

Input

System input

ProcessInput

Motor driven system

Process OutputInput

Motor driven pumping system

Star

Delta 250kW

4P

Starter Motor Coupling Pump Valve @ 80% System Total100% 94.9% 85% 73% 60% 35%x x x x =

Conventional pumping system

Star

Delta 250kW

4P

Starter Motor Coupling Pump Valve @ 80% System Total100% 94.9% 85% 73% 60% 35.3%100% 95.3% 85% 73% 60% = 35.4%

Saving0.4%

x x x x =

Conventional pumping system

Star

Delta

250kW

10P

Starter Motor Coupling Pump Valve @ 80% System Total100% 94.9% 85% 73% 60% 35%100% 95.3% 99% 73% 60% = 41%

Saving15%

xxxx =

Pumping system optimisation

250kW

10P

Starter Motor Coupling Pump Valve @ 80% System Total100% 94.9% 85% 73% 60% 35%100% 95.3% 99% 73% 60% = 41%98% 95.3% 99% 74% 100% = 69%

Saving49%

=x x x x

VSD Pumping system optimisation

Option 1 Option 2

Star

Delta

VSD

250kW

10P

250kW

4P

Starter Motor Coupling Pump Valve Total Equipment Input 1 year energy Payback 10 year energyCost kW 8,000h Cost

0.64 RkWh 1.51 RkWhOption 1 R 70,000 + R 91,000 + R 25,000 + R 260,000 + R 40,000 = R 486,000 = 234 kW = R 1,197,568 R 19,086,150Option 2 R 220,000 + R 370,000 + R 12,000 + R 260,000 + R 0 = R 862,000 = 119 kW = R 607,232 8months R 9,677,714

Additional capital Demandreduction 10 year saving

R 376,000 115 kW R 9,408,435

Low hanging fruit?

Option 1 Option 2

Star

Delta

VSD

250kW

10P

250kW

4P

Starter Motor Coupling Pump Valve Total Equipment Input 1 year energy Payback 10 year energyCost kW 8,000h Cost

0.64 RkWh 1.51 RkWhOption 1 R 70,000 + R 91,000 + R 25,000 + R 260,000 + R 40,000 = R 486,000 = 234 kW = R 1,197,568 R 19,086,150Option 2 R 220,000 + R 370,000 + R 12,000 + R 260,000 + R 0 = R 862,000 = 119 kW = R 607,232 8months R 9,677,714

Additional capital Demandreduction 10 year saving

R 376,000 115 kW R 9,408,435

Low hanging fruit?

I need to fit 9200 CFLs to get the same yearly energy saving?

Changes the speed of a motor

Full process control

Match the demand required by load

Reduce energy demand

Variable speed drives VSDs

Affinity Laws

Centrifugal pumps & fans follow the Affinity laws

Flow almost always restricted

Q n

H n²

P n³

0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60 70 80 90 100

% P

ower

requ

ired

% Flow rate

Pump Power

Required power Throttling

VSD Power

Saving ~ 20%

Power wasted by throttling a pump

0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60 70 80 90 100

% P

ower

requ

ired

% Flow rate

Pump Power

Required power Throttling

VSD Power

Saving ~ 35%

Power wasted by throttling a pump

0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60 70 80 90 100

% P

ower

requ

ired

% Flow rate

Pump Power

Required power Throttling

VSD PowerPossible

Savings!

Power wasted by throttling a pump

We need to look for opportunities to reduce the pump speeds

Actuator or

Throttling Valve

Basic lessons!

Balance & regulates voltage to motor

Soft starter

Reduce starting current

Lower maximum demand charge

Motor protection

Endless options

Built in recording of saved power

Payback time only months!

More benefits

You can change the speed

Replacing a very old inefficient motor

Replacing oversized motors 50%

High efficient motors save when?

IE4 motor drive package

Motor efficiency reduced at lower loads

Efficiency data needed for the whole motor-drive package and for the entire speed range

ABB is the first manufacturer to provide efficiency curves for packages

New package efficiency curves cover the entire speed range

Motor-drive package efficiency

Same stator technology combined with synchronous reluctance rotor

Performance comparable to permanent magnet motors, but without magnets

Energy losses reduced by up to 40%

Compliant to the upcoming efficiency class IE4

Synchronous Reluctance motor with VSD

standard motor+

special rotor

standard drive+

new software

A new revolutionary Drive Package!

IE4 Motor-drive package

Package efficiency for the entire speed range IE4 SynRM vs. IE2 Induction

SynRm Technology has higher efficiency at partial load

in comparison to classical induction motors

Institution of Mechanical Engineers

“Reported that 60 percent of manufacturers says rising power bills

are their biggest fear!”

Nothing!

Change lights

Water heating (timers, heat pumps, solar…)

Insulation

Fix leaks

Change the process control (VSDs, high efficient equipment)

Human behaviour (energy management plan)

Timing

Nothing!

Change lights

Heating water (timers, heat pumps, solar…)

Insulation

Fix leaks

Change the process control (VSDs, high efficient equipment)

Human behaviour (energy management plan)

Human behaviour

VSDs, high efficiency

Leaks & Insulation

Heating

Lights

Again!

Timing

…….what happened to the “low hanging fruit” concept?

……are you still looking in the wrong place?

…... are you only scratching the surface?

When do you fit a VSD?• All new motor installations

• When you want to save energy

• When you see a valve (throttled)

• Improve process control

• When contactor fails (star/delta).

When do you buy a high efficient motor?• All new motor installations

• When old motor fails (no rewinds below 45kW)

• When fitting a VSD?

Savings VSD up to 50% Motors + VSDs

Buy real energy saving products

Base your investment calculations on facts!

Conclusion

Thank you!