Energy Efficiency Masterclass

for Industry

2Government of South Australia

ICN Gateway

• Pivotal link between major project

requirements and suppliers

• ~70,000 company listings

• ~$400 billion in projects

Setting the Scene

Industry and Energy Efficiency

• Competitive Business Environment

• Industry Productivity

• Energy Prices

• Industry Response

Industry Response

• Focused Assessments (AS/NZS 3598.2)

• Type 1 Audit - to identify key opportunities

• Type 3 Audit – focusing on key areas only

• Business Case for Investment

• Competes with other industry investments

• Finance for implementation

Aim

Participants will leave this session with a clear

understanding of key energy efficiency

improvements that can be implemented within their

organisations.

Objectives

Masterclass Objectives address three themes:

• Financial

• Practical

• Technical

Kevin JonesBranch Manager, CAPS

SUBHEADING

ENERGY EFFICIENT COMPRESSED AIR SYSTEMSPresented by Kevin Jones, CAPS Australia

1. Why Compressed Air?

2. 5 x Facts About Compressed Air

3. Review Maintenance & Managing Leaks

4. Compressed Air Energy Auditing

5. Case Studies & Upgrading Equipment

AGENDA

MOST INDUSTRIES DEPENDHEAVILY ON COMPRESSED AIR.

COMPRESSEDAIR.

Flexible Convenient

Clean Safe

Highly Energy Intensive!

5 FACTS ABOUTCOMPRESSED AIR.

FACT#1

Compressed air is used

extensively by industry.

10-15% of all industrial electricity is used to generate compressed air.

ALL OTHER ELECTRICITY DEMANDS.

COMPRESSED AIR

FACT#2

Compressed air is an inefficient form of energy.

90% of input electrical energy is discharged as waste heat. 10% Compressed Air

90% Waste HeatAir Compressor

FACT#3

Compressors can be inefficient at part load.

At 50% load, typical controls consume 85% power.

WA

STE

FACT#4

Compressed air is wasted profusely.

Typically, only 50% of compressed air is used for productive demands.

Productive Demands

LeaksInnappropriate

Uses

System Losses

Artificial Demands

FACT#5

Electricity is by far the greatest cost of compressed air.

Over 10 years, the energy cost will be 10 to 30 times the initial capital cost.

Capital

InstallationMaintenance

Energy

REVIEW &MAINTENANCE.

Why servicing pays.

• Less prone to breakdown

• Efficiency drops

REVIEW &MAINTENANCE.Leak Detection – Leak Management

WHY ARE AIR SYSTEMSINEFFICIENT?

Old and inefficient equipmen

t

HOW CAN THEYBE IMPROVED?

8kW LossesH

igh

Eff

icie

ncy

Var

iab

le S

pee

d

Air

Co

mp

ress

or

Op

erat

ing

at 5

0%

Lo

ad

70

kW

Inp

ut

Elec

tric

ity

60

kW

Load

ed P

ow

er

Typ

ical

Air

Co

mp

ress

or

Op

erat

ing

at 5

0%

Lo

ad

Systems Approach

24

46kW

Heat Recovery System

Transmission

System

1kW Non-Productive Waste

5kW Productive

Demands

10

0kW

Load

ed P

ow

er

6kW

Compressed Air Generated

Transmission

System

5kW Non-Productive

Waste

5kW Productive Demands

18

0kW

Inp

ut

Elec

tric

ity

10kWCompressed Air Generated

90kWWasted Heat

60% Reduction in Energy

Consumption!6

0kW

Un

load

ed

Po

wer

60kWLosses &

Unusable

Waste Heat

AIR ENERGYAUDITING.

FLOW POWER PRESSURE

What you don’t measure, you can’t improve!

What are the

savings with an

upgrade in

technology?

How much does it cost

to operate your system

annually?

How does your system vary?

Daily, weekly, monthly, quarterly,

annually?

Develop an

understanding of

the system

How do we

compare with

best practice?

AIR ENERGYAUDITING.

• Relatively simple and low costs

• Collect system data during typical operational week

• Determine equipment and capabilities

• Develop a baseline of demand and performance

• Review and confirm appropriate service regime

• Uncover compressed air issues (i.e. pressure or quality)

WHAT ARE THEOPPORTUNITIES?

SUPPLY SIDE• Efficient part-load

compressors• Multi-stage compression• Storage and controls• Pressure set points• Maintenance• Heat recovery

DEMAND SIDE• Detect and fix leaks• Inappropriate demands• Central sequence control• Pressure drop issues• Pressure regulation• Demand anomalies

CASE STUDY #1SIMPLE MANUFACTURING APPLICATION.

• Manufacturing facility seeking energy savings opportunities

• Only one compressor in operation

• Data logging and analysis undertaken

• Along with a demand-side review

Freq

uen

cy (

%)

Demand Profile

Po

we

r (k

W)

Efficiency Profile

Actual Demand

Equipment Capacity

HOLISTICSOLUTION.

SUPPLY SIDE• Smaller Compressor

with Variable Speed installed

• Reduced pressure set point

DEMAND SIDESmall reduction in demand via identification and repair of a few leaks, plus change in usage practises

OUTCOMES.

• Implemented solution saves $45k/annum in electricity.

• Additional savings in maintenance.

• Payback on total project cost within 1.7years.

• More reliable equipment.

• Delivers more stable pressure and less wear and tear on downstream equipment.

CASE STUDY #2KILCOY PASTORAL.

• Abattoir seeking compressor upgrade with energy savings

• Three compressors in operation (3 constant speed unloading)

• Data logging and analysis undertaken

• Project recommendations undertaken by client

• One new large VSD compressor with two existing compressors

• Data logging for verification purposes confirmed savings

PLANT ROOMBEFORE.

STACKED AVERAGE POWER CHART.

PRESSURE RANGE CHART.

PLANT ROOMAFTER.

AVG. POWER BEFORE VS AFTER

PRESSURE BEFORE VS AFTER

SYSTEM EFFICIENCYIMPROVEMENT.

Theoretical Ideal

System before upgrade

System after upgrade

Demand profile

BEFORE & AFTERSTATISTICS.

July 2012

3 x 75kWFixed Speed units

February 2013

1 x 160kW VSD +2 x 75 kW fixed speed

Change

Average Flow (m3/min) 23.8 26.2 +10 %

Average Power (kW) 201.1 159.6 - 20.6 %

Average Pressure (kPa) 744.8 735.7 - 1.2 %

Air Production Efficiency (kW/m3/min) 8.4 6.1 - 27.4 %

Overall System Efficiency (kW/m3/min) 10.1 6.8 - 32.7 %

▪ Slight increase in average flow

▪ Vast improvement on overall system efficiency

▪ Savings in the region of $15,000 per month

OUTCOMES.

• Implemented solution saves $15k/month in electricity

• Additional savings in maintenance

• Payback on capital cost within 2 years

• More reliable equipment

• Delivering more stable pressure and less wear and tear on downstream equipment

IN CLOSING.

• Compressed air a very costly ‘invisible’ energy.

• Significant opportunities exist for substantial cost savings with fast payback on solutions.

• Seek assistance from specialised professional services providers

THANK YOU

Craig DurrheimBusiness Development Manager, Danfoss Drives

43 | Danfoss Drives

Electrical Motor ControlsEnergy Efficiency Expo22nd August 2018

Craig Durrheim

BDM SA / NT

Overview1) Developments in motor technology2) Considerations when using VSDs3) Enhancements in VSD technology

45 | Danfoss Drives

46 | Danfoss Drives

BasicSystem

AlternativeSystem

AdvancedSystem

VLT®

FlexConceptTM

Mechanicalefficiency

Worm gear 70% Helical gear 89% Bevel gear 95%Optimized bevel gear

96%

Electrical Efficiency

AC MotorIE1 1.5 kW

77,2%AC Motor

IE1 1.5 kW77,2%

AC MotorIE2 1.5 kW

82,8% PM motor 96%

Inverterefficiency

StandardInverter

95% FC(D)302 97% FC(D)302 97% FC(D)302 97%

Chain efficiency

88%

TOTALefficiency

51,3% 62,6% 71,5% 89,4%

ENERGY SAVING

Efficiency comparison:

IE classes Gears

47 | Danfoss Drives

Energy Savings:

63%!

from 4 kW

to 1.48kW

Assuming 3000 Hrs/year and 15c/kWh savings approx. = $1,134 / year

A Coca Cola Plant

48 | Danfoss Drives

Considerations when utilising Variable Speed Drives

50 | Danfoss Drives

Relationship Flow, Pressure & Power for Centrifugal Motors

100kW load at 90% speed, running 10% longer, savings approx. = $9,000 / year.

Cost of 110kW VSD approx. = $10k

51 | Danfoss Drives

LCC =Cic+Cin+Ce+Co+Cn+Cs+Cenv+Cd Cic = initial capital cost

Cin = installation & commissioning costs

Ce = energy costs Co = operating costs

Cm = maintenance costs Cs = downtime & lost production costs

Cenv = environmental costs

Cd = de-commissioning & disposal costs

Two most significant factors: Energy costs Maintenance costs

Variable Speed Drive (VSD) / Power

Drive System (PDS) design can

significantly impact on Life-Cycle Costs

Typical VSD Life-Cycle Costs

52 | Danfoss Drives

Radiated noise

Motor cable

VFD Motor

Motor cable type & length impact RFI conducted emissions on mains supply

Harmonics: 50-2500Hz, Conducted:

9kHz-50MHz, Radiated: 50MHz-2GHz …..

The length & type of motor cable effect the level of conducted RFI emissions on the mains supply

53 | Danfoss Drives

RFI Environment & Product Standards (Note *)

(Note *: Or equivalent local standard)

Generic Environment standard* VSD Product standard

- Facility operators must comply with EN 55011*

- VSD manufacturers must conform with EN 61800-3

1st Environment / Class B Residential Environment: All sites directly connected to the public low voltage power grid, including light industrial areas, are classified as residential or business & commercial environments. (I.E.: do NOT have their own HV/MV distribution transformer)

2nd Environment / Class A Industrial Environment: Operating sites NOT directly connected to the public low voltage power grid, which do have their own HV/MV distribution transformer

54 | Danfoss Drives

Harmonics: causes Harmonics are primarily caused

by loads that draw current in a non-sinusoidal manner. I.E: Non-linear loads, E.G.: UPS, Computer power supplies, VFD, Etc.

Variable Speed Drives (VSD)

Most common design uses 6 pulse rectifier (6 diodes)

5th & 7th harmonic currents

The level of harmonic current depends on:

DC bus capacitor size

Load

Dc / AC chokes, or other filters used??

55 | Danfoss Drives

EMC: Harmonics EffectsCurrent Distortion

Adds to system losses, E.G.:

Overloading / premature aging of transformers, cables & switchgear

Stressing of PF correction caps.

Nuisance tripping of protection relays & circuit breakers, etc

Voltage distortion

Can disturb other equipment:

Malfunction, erratic operation & breakdown of electronic equipment

Increased eddy current losses & torque ripple in DOL connected motors connected to same grid

56 | Danfoss Drives

Output Waveforms (dV/dt vs Sinewave filters)

57 | Danfoss Drives

Our standard Product

Danfoss VLT® Drives have peak voltage and rise

time values compliant with IEC60034-25.

Depending on motor cable type and length on

400V systems, Danfoss VLT® Drives have typical

peak voltage and rise time values compliant with

IEC60034- 17 (curve C in figure 17) Rotating

electrical machines – General Requirements –

Rating and Performance.

Simulation Tools

Danfoss with assistance of SABER software

estimates the dv/dt and Vpeak at the motor

terminals.

Sine Wave Output Filters

Complies with IEC 60034-17

requirements for general purpose

motors with cables up to 500M

<90Kw (1kM for >110kw)

Guaranteed EMC performance

up to 300 M of unshielded cable

Dv/dt Filters

dv/dt<500V/microsec

Upeak <900V

max cable 150m

HF-CM Core

The filter reduces the high-

frequency noise radiated by

motor cables shielded/unshielded

Output Filter Types

58 | Danfoss Drives

Ingress Protection Standards

• IP rating according to IEC 60529

IP54 typically suitable for switch

room. IP55 / 66 may be possible in plant

area <90kW – check conditions

59 | Danfoss Drives

Corrosion Protection

• Levels of contaminants according to IEC 60721-3-3

Note: Class 3C3 protection offers the

high level of protection &

potentially lower maintenance cost

Enhancements in VSD technology

61 | Danfoss Drives

Maintenance functionality

Inverter protection

Motor Side monitoring:

• Earth Fault• Short Circuit• Missing Motor Phase• Motor thermal • Over Current• Electronic Shear pin

Line Side:• Missing supply phase

protection • Transient Protection

Inverter protection

Motor Side monitoring:

• Field Isolator • Short circuit• Earth fault

Line Side:• Missing supply • Transient Protection

Load torque monitoring

(profile data external)

Functions at Run Predictive actionsFunctions at Stop

Helps warn of issues before productions starts reducing

start-up delays.

Minimises damage to plant and equipment during

production

Allows external application profiling to predict application

performance

62 | Danfoss Drives

Application - Filter monitoring & Airflow control (Volume[m3/h] or Pressure[Pa])

1) Filter clog monitoring:• Reduce energy

comsumption• Clean air & indoor

climate

PID Pressure regulation:2. Volume flow3. Pressure level

(air channel)1 2

3

2

31

AHU/RTU

63 | Danfoss Drives

VLT® drive with enclosure size EExtremely compact and powerful

Back-channel cooling with heat pipe technology

• Unique ducted back-channel passes cooling air over heat sinks

• 90% of heat losses are exhausted directly outside of the enclosure

• Dramatically reduces temperature rise

• Reduces contamination of the electroniccomponents.

Built-in options• Fuses

• Disconnect and fuses

• Mains shield

• Brake chopper

• Regen terminals

• Load share terminals

• RFI filter

• Space heater

• USB through door

• Heat sink access panel

• Corrosion-resistant back-

New E Frame Drives:355 to 450kW: 600 W x 2043H500 & 560kW: 700 W x 2043H

64 | Danfoss Drives

Average 85% heat dissipated via segregated back channel using outside cooling air (>/= 110kW)

D–Frame (110-315kW) = 90%E-Frame (355-450kW) = 85%F-Frame (>/500kW) = 80%(400V, 6P drives)

Average 15% heat dissipated into switch room = average 85% reduction in switch room A/C heat load. (>/= 110kW)

85% average lower switch room A/C heat load using thru wall Back Channel Cooling (BCC)

65 | Danfoss Drives

The size of and heat load from AC drives often impacts the cost of switchrooms

4m Shorter

66 | Danfoss Drives

Hypothetical ROI ExampleConsidering BCC (Back Channel Cooling) & Physical size reduction.

• 6 x 450kW, 6 x 110kW, 4 x 55kW VSDs.

•Total VSD Power = 3580kW

•Total Watt loss approx. = 90kW

•No BCC AC Power required approx. = 30kW

•With BCC AC Power required approx. = 6kW

•No BCC: AC Power = $13.5k/annum (+6x5kW AC units)

•With BCC: AC Power = $2.5k/annum (+2x5kW AC units)

•Space saving = 4 linear m @ $12k / m = $48k

67 | Danfoss Drives

Solar Pump Drive

AC 3P TERMINATION

Change over switchAC – 0 – DC

M3

˜

400V, 50Hz 3 PHASEAC SUPPLY

˜

˜

=

DC SUPPLY FROM SOLAR PV CELLS

DC 2P TERMINATION

SPD

DI

20X-100X

Switch enclosur

e

Driven by Drives

Vikram KenjleEnergy Manager, University of Adelaide

Vikram Kenjle – Energy ManagerThe University of Adelaide

2018 Energy Efficiency Expo and Seminar

Cogeneration & Heat Recovery

Topic -

Agenda

• Overview

• Value of Cogeneration & Heat Recovery

• Key Benefits & Pitfalls

• Improving Existing Systems

University of Adelaide 72

What is Cogeneration / CHP?

University of Adelaide 73

Source: Carbon Trust UK, 2012

(80%) ....OVERALL EFFICIENCY…. (55%)

Cogeneration or Combined Heat &Power (CHP) is the simultaneousproduction and use of electricity andheat energy to provide high energyefficiencies (> 80%)

Efficiency can be further boosted(~90%) by adding an absorptionchiller to form a Tri-generation unitor Combined Cooling, Heat & Power(CCHP)

Typical components of a CHP / CCHP

University of Adelaide 74

Source: Adapted from CIBSE, UK CHP Group

Natural gas / LPG / Diesel / Biomass / Waste Oil etc

Turbine / Reciprocating Engine

Grade of heat recovered

Value proposition of CHP / CCHP

University of Adelaide 75

If sized and used appropriately, CHP / CCHP can deliver:

• Reduced energy costs – extract more value from input fuel • Reduced network costs – peak demand management• Improved energy security – island mode (may not be for

whole site)• Improved environmental footprint – depending on choice of

input fuel• Semi-dispatchable power plant – user controlled and not

depended on intermittent sources

UoA Trigen Systems

University of Adelaide 76

Plant Accelerator Building (2009)

• 3 x 65kWe micro-turbinescoupled with an absorptionchiller as first stage

• High efficiency chillers &condensing boilers as support

• Operating 24/7 – serving theplant growth rooms

UoA Trigen Systems

University of Adelaide 77

Ingkarni Wardli Building (2010)

• 337kWe reciprocating gas engine coupled with an absorption chiller as primary

• High efficiency electric chiller as secondary (or backup)

• Further enhanced by geo-thermal cooling and cooling tower heat recovery

Potentials pitfalls of CHP / CCHP

• Under utilisation due to changes to business operations– Staged system can provide some flexibility, but can add upfront cost

– Shared system (Industrial Parks)

• Grid connection complexity and cost – Early engagement SAPN can save a lot $$$ downstream

• Variation to supply / price of input fuel

– Multi-fuel system can provide flexibility, but comes at a cost

University of Adelaide 78

Heat Recovery

Opportunities:

• Boiler flue losses and blowdowns

• Cooling Towers

• Air compressors

• Ventilation systems

• Heat stored in products leaving the process

• Heat in cooling hydraulic oil systems

• Heat emitted by Data Centres / Communication rooms

University of Adelaide 79

Heat Recovery

Economics:

• Understand quantity and quality of waste heat

• Identify heat demands in your facility and assess if these can be met directly (or as pre-heat)

• Identify if supply & demand are coincident, as adding storage can prove costly

University of Adelaide 80

Example: air-compressor heat recovery

University of Adelaide 81

Source: Atlas Copco, Sweden

Applications

Domestic hot water

Space Heating

Product Drying

It is there for the taking!

Microgrids, Storage and Smart Technologies

Topic -

Agenda

• Overview

• Establishing Microgrids

• Energy Storage Systems

• Benefits for Early Adopters

University of Adelaide 83

SA Power prices compared to OECD

University of Adelaide 84

Source: Carbon + Energy Markets (CME), 2017

0.00

5.00

10.00

15.00

20.00

25.00

30.00

0

10

20

30

40

50

60

Ave

rage

wei

ghte

d r

ate

(ce

nts

/kW

h)

Tota

l co

nsu

mp

tio

n (

kWh

/ye

ar)

Mill

ion

s

Year

TOTAL (kWh) AVERAGE WEIGHTED RATE (c/kWh)

UoA 20 year electricity & cost trend

NEM commencement

150% increase in unit rate (2008 – 2018)

Traditional centralised electricity supply model

University of Adelaide 86

Source: Adopted from the US Dept of Energy

Rapid disruption to the centralised model

University of Adelaide 87

Source: Energy Networks Association, Australia

Understanding your load profile

University of Adelaide 88

Load Duration Curve

University of Adelaide 89

Role of energy storage

University of Adelaide 90

Source: Adopted from the US Dept of Energy

‘Firming up & Grid Stabilisation’ ‘Energy Price Arbitrage, Demand Management & Security’

Is it the right time to invest in storage?Lithium-ion battery pack ($/kWh)

University of Adelaide 91

Source: Deutsche Bank, 2018

Batteries are not the only storage solutions

University of Adelaide 92

Source: University of Birmingham, Energy Storage Centre

Optimal choice of storage technology depends on end nature of application, criticality, risk appetite and overall business case

Microgrid

University of Adelaide 93

A microgrid can be defined as a distributed power system with the ability to self-supply, manage, and operate with or without the main utility grid as required (US Dept of Energy, 2016)

Typical architecture of a microgrid

University of Adelaide 94

Source: Reilly, Cleveland OH, Grid of the Future, 2017

Microgrid management system

University of Adelaide 95

Source: Dashboard, Siemens Australia 2018

Microgrid Ownership Structures

University of Adelaide 96

Source: WBCSD, Microgrid for C&I customers, 2017

UoA Roseworthy Project (commenced)

University of Adelaide 97

• 1.2MW Solar PV farm

• 500kW / 2000kWh vanadium flow battery

• Partial campus microgrid

Benefits

- Demand Management (and hence lower network costs)

- Reduced electricity cost (load shift during high price event)

- Island mode (increased resilience & faster recovery)

- Lower carbon footprint (depending on choice of DERs)

- Increased cybersecurity (for defence sector)

University of Adelaide 98

Early Adopters – Risk versus Reward

• Potential risk

– Higher upfront cost

– Technical issues and disruptions

– Microgrid standardisation still under works

• Potential rewards

– Possible grants from various government agencies

– Potential cost subsidisation from Tier 1 suppliers to demonstrate proof-of-concept as well as gain market leadership

– Easier network connections due to interest and will from grid operators to learn from pilot projects

– Improved energy security and price fluctuations

University of Adelaide 99

THANK YOU

University of Adelaide 100

Vikram Kenjle

Energy Manager - The University of Adelaide

Email: vikram.Kenjle@adelaide.edu.au

Tel: (08) 8313 5556

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