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Manufacturing Energy Efficiency – Process, Technology and Mind-Set
Industrial Motors Case
Colin Koh
Lim Kim Hai Electric – Precicon D&C Pte Ltd – Lim Kim Hai Power Distribution
Table of Content
• Manufacturing Energy Efficiency
• Process, Technology
• Industrial Motor Efficiency
• Culture & Mind-Set : Energy Management System
Precicon D&C Pte Ltd
Energy Use in A Manufacturing Business
Energy Use Distribution Generation Purchase
User 1 Electricity electrical Substation Electricity
User 2 Steam Boiler House Natural Gas
User 3 Hot Water Hot Water Plant Fuel Oil
User 4 Process Water CHP Plant Diesel
User 5 Cooling Water Cooling Tower Renewable
User 6 Refrigeration Regeneration Plant Water
User… Compressed Air Industrial Gas Utility Export
Process Gases Vaporiser
HVAC Air Compressors
Lighting Renewable Energy Plant
Waste Water Effluent Treatment Effluent
Waste Disposal/Reuse
Source: Energy Management in Business kit Oung 2013
Precicon D&C Pte Ltd
Visualisation and Optimisation
Source: www.EnMS-doc.com
Precicon D&C Pte Ltd
Industrial Energy Efficiency Measures
Source: envision
Precicon D&C Pte Ltd
Precicon D&C Pte Ltd
Residential Industrial Commercial Residential
Electric Motors
Low Hanging Fruits
• Insulation • Efficient Lighting • Plugging Air-Leak • Boiler Tuning • ASD (VSD) • Efficiency Motor
Source: NEEC 2013: 3M
Precicon D&C Pte Ltd
Lighting Energy Saving Solution
ROI Budget
TCOO
Initial Investment
Operating Hours
Energy Saving
Quality of Light Ave Illuminance (Lux)
Uniformity
Lumen Maintenance
Colour Temp. (K)
Instant Start
Ease of Maintenance Fitting Design
LED Design
Cost of Replacement
Product Quality LED Technology
IEC / Energy Star
Efficacy lm/W
Beam Angle
CRI
No IR & UV
Lifetime
Instant Start
LESS
Best ROI
Customer for customer who focuses on
initial investment and specific payback
Best Lighting
Customer who wants best lighting
specification and performance
LESS
Best Product
Customer who focuses on product
specification, application and
replacement
Best Value
Customer who focuses on product life
span, energy and money saving
Precicon D&C Pte Ltd
Energy Efficiency – Electric Motor and Drive System (EMDS)
Large Saving
Good Saving Small Saving Electric Motor
Core Motor System
Motor + Pump + VSD
Total Motor System With Transmission, Gears and Motor
Entire System with Pipe Pump and Motor, VSD
Source: A+B International, 2008.
Motor O&M Best Practice
• Right Sizing & High Efficiency Motors
• Right Application of VSD
• Power Quality: Balance Three Phase Voltage
• Ventilation, Bearing, Thermal Scanning, Vibration Analysis
• Consider TCO rather then first cost
Precicon D&C Pte Ltd
IEA: 2011
Motor Size (KW) Energy Consumption (%) Volume (Pcs) Application
0.75 9 2 Billion Appliances, Fan, Pump
0.75-375 68 230 Million Pump, Fan, Conveying, Compressors, Process
above 350 13 600,000 Industrial & Infrastructure
Global Electric Motor & Drive System
System Approach for EMDS
Right Sizing: Factors That Leads to Over Design of Motors
• Process Pump Required 20KW motor • Designer: 10% add for head and flow • Design Checker: 10% add to ensure pump work
when install • Procurement Department: Purchase the next
available frame size • Pump original design: 10-20% add for safety
margin • Final Motor size: 30-40KW
Precicon D&C Pte Ltd
(OEM, system specifier, plant manager, energy manager and senior manager, executive)
Understanding Motor Size and Energy Consumption
Data Logger @ less than
S$200.00* per motor !
(Logger & 100A CTs)
VSD Can Reduce Energy 30%-50%
Motor systems that are likely to be appropriate for VSDs are those with the following characteristics:
• Drive a centrifugal fan, pump, or blower and operate long hours (> 2000 hours/yr.)
• Fluid or air flow varies over time and control systems such as valves, throttles, or dampers are used to regulate the flow and pressure
Precicon D&C Pte Ltd
Source: CEE
Motor Loads and ASDs: Common Applications and Energy Considerations
Precicon D&C Pte Ltd
Motor Load Type Common Applications Energy Considerations
• Centrifugal fans
• Centrifugal pumps
• Blowers
• Axial fans
• HVAC systems
Constant Torque Load • Mixers
• Conveyors
• Compressors
• Printing presses
Constant Power [hp] Load • Machine tools
• Lathes
• Milling machines
• Punch presses
Lower speed operation results in significant
energy savings as shaft power of the motor
drops with the cube of the rotational speed
Lower speed operation saves energy in
direct proportion to the rotational speed
reduction.
No energy savings at reduced speeds;
however, energy savings can be realized by
attaining the optimized cutting and
machining speeds for the part being
produced. A time limiting switch device
controlling no-load operating time saves
energy, too.
Variable Torque Load
• Power [hp] varies as the cube of the
rotational speed
• Torque varies as the square of the
rotational speed
• Torque remain constant at all
rotational speeds
• Power [hp] varies in direct
• Develops the same power [hp] at all
rotational speeds
• Torque varies in inverse proportion
to the speed
Energy savings with speed control for a centrifugal pump without static pressure head
Full Speed (%)
Pow
er In
pu
t (%
) By-Pass Control
Pumping System without Static Pressure Head
Speed Control With Magnetic Coupling
Pump Power Required
Speed Control With VSD
Throttle Control
On-Off Control
Source: Ferreira, 2009
Fan & Pump Loads
Flow is directly proportional to speed. No need for valves & dampers
Horsepower is directly proportional to the cube of the speed.
1 HP = 746 watts (How do we pay for power?)
The basic Affinity laws can be converted for use with centrifugal fans and pumps.
FLOW = RPM’s
HP= (RPM’s)³
A 10% reduction in speed = 27% reduction in power!
Precicon D&C Pte Ltd
Case Study of VSD Energy Saving
Precicon D&C Pte Ltd
A 50hp centrifugal pump operating 4,067 hours annually, with a 75% load factor, a throttling valve to regulate flow to 70% on average, and primarily frictional losses and negligible static head.
Annual Energy Cost (Without ASD) = 50hp/0.93 x 0.75 x 0.746kw x (1.0)2 x 4,067hr x S$0.2 = S$24,467 Annual Energy Cost (With ASD) = 50hp/0.93 x 0.75 x 0.746kw x (0.7)2 x 4,067hr x S$0.2 = S$11,989 (VSD Cost approximate S$6,000) = Pay Back in 6 Months
Annual Saving = S$12,478 (50%)
VSD reduces Motor speed By 30%
VSD)
VSD
Power Quality: Unbalance Voltage
% voltage
unbalance
Winding
temp.
(Degree C)
I2R
losses
(%of
Total)
Efficiency
reduction
Expected winding life
(Years)
0 120 30% — 20 years
1 130 33% Up to 1/2% 10
2 140 35% 1-2% 5
3 150 38% 2-3% 2.5
4 160 40% 3-4% 1.25
5 180 45% 5% or more Less than 1
Precicon D&C Pte Ltd
Motor Life Cycle Cost
Life Cycle Cost = C + E(t) + M
Where:
C = initial capital cost plus installation
E(t) = total energy cost = Hr/yr x $/kWh x avg. kW x years
M = total maintenance cost = annual $ x years
For example, a 10 HP motor operates 50% of the time at an average output of 7.5 HP. Its efficiency is 88%. Purchase price is $1,000 and installation is $200. The motor is expected to last 10 years and cost $50/year to maintain. Electricity price is $0.25/kWh C = $1000 + $200 E(t) = 8760 x 0.5 x {(7.5 x 746)/0.88} x 0.25 x 10 M = $50 x 10 Life Cycle Cost: $1,200 + $69,619 + $500 = $71,319
Cost of Motor against Life Cycle Cost = 1.7%
High Efficiency Motors
(From Standard to High/Premium/Super Premium Motors)
Singapore Energy Efficiency Market Size
Frost & Sullivan
Best Practices: ISO 50001 Make Easy
Source: www.EnMS-doc.com
Precicon D&C Pte Ltd
Thank You Colin Koh
[email protected] http://www.linkedin.com/in/colinkoh
Lim Kim Hai Electric – Precicon D&C Pte Ltd – Lim Kim Hai Power Distribution