SIMTech SMC 2013 Manufacturing Energy Efficiency : Industrial Motor

Manufacturing Energy Efficiency – Process, Technology and Mind-Set

Industrial Motors Case

Colin Koh

[email protected]

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


Visualisation and Optimisation

Source: www.EnMS-doc.com


Industrial Energy Efficiency Measures

Source: envision



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


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


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


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


(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


Source: CEE

Motor Loads and ASDs: Common Applications and Energy Considerations


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!


Case Study of VSD Energy Saving


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


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


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

mailto:[email protected]

http://www.linkedin.com/in/colinkoh

SIMTech SMC 2013 Manufacturing Energy Efficiency : Industrial Motor

Technology

Transcript of SIMTech SMC 2013 Manufacturing Energy Efficiency : Industrial Motor