Drives and motors

Energy appraisal for lowering energy use and CO2 emissions A practical guide to energy efficiency using AC drives and electric motors

Why saving energy is everyones responsibility

Carrying out an energy appraisal of the motor-driven applications across a plant or process can reveal significant ways to reduce costs. The monetary savings provided by an energy appraisal come from lowering the amount of electricity being consumed - hence lower utility bills - and reducing carbon dioxide (CO2 ) emissions. A drive* and electric motor* combination, when used to control the speed of applications such as pumps and fans, can reduce the energy bill by up to 70 percent with a payback in less than 12 months. When it is considered that 65 percent of the total electricity at industrial sites is consumed by electric motors, the need for an effective energy appraisal is even more apparent. The findings of an energy appraisal, therefore, affects everyone in an organisation, whether that is a maintenance engineer, a process engineer, a facilities manager, a financial controller or a board director. ABB has developed a very simple energy appraisal process that it or one of its authorized channel partners, can carry out. This guide describes the energy appraisal process; shows the benefits of implementation; highlights the impact on real-life industrial applications; and demonstrates some of the key drive and motor features that further enhance energy savings.

For more detailed advice, please contact your local ABB sales office directly or visit www.abb.com/energyefficiency to view a video demonstration of the energy appraisal process. *Drives and motors Around the world there are many names and acronyms that are used for electronic variable speed drives. These include VSD (variable speed drive), ASD (adjustable speed drive), VFD (variable frequency drive), AFD (adjustable frequency drive), frequency converter, inverter and just drive. The frequency converter is an electronic device that converts alternating current (AC) of one frequency to alternating current of another frequency. ABB widely uses the word AC drive to mean a frequency converter. International standards, however, are basically using the term frequency converter.

An energy appraisal starts with a tour of the plant.

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Energy appraisal process

What makes a good energy appraisal? ABB has devised a simple and methodical energy appraisal process that presents end-users with hard, compelling facts about the electricity they can save. It achieves this by rapidly identifying some key applications that can benefit immediately from the use of drives and electric motors. An energy appraisal is normally carried by an ABB engineer or one of ABBs authorized local channel partners who can identify relevant applications that will generate energy saving results. This identification will help the end-user target their investment so that it generates the highest possible savings and delivers the best return on investment.

There are six steps to an efficient energy appraisal: 1. Outlining the scope of supply 2. Monitoring and data collection 3. Data analysis 4. Recommendations 5. Implementation 6. Verification and follow-up

Centrifugal fans and pumps are typical variable torque applications to be considered.

Energy appraisal process l Energy appraisal for lowering energy use and CO2 emissions 3

Six steps to an efficient energy appraisal

Power required (%)

1. Outlining the scope of supply An ABB engineer or one of ABBs authorized channel partners visits the end-user to get an understanding of their facility including location of the applications, an inventory of motors, any health and safety restrictions as well as anything unusual that might affect the energy profile. Energy appraisals are most suitable for processes with variable torque applications that obey the cube law, running continuously and where flow is controlled by a mechanical means such as valves or dampers. This is where the savings from a drive really start to look good compared to the investment cost. Centrifugal fans and pumps are typical variable torque applications. The requirement for torque (and hence current) increases with the square of the speed. The voltage again varies in proportion to the speed, so power actually varies in proportion to the cube of the speed. Hence, by reducing the speed by a certain percentage, the power reduces by the cube of the speed change. So 80 percent speed results in (0.8)3 = 51 percent power.

100 90 80 70 60 50 40 30 20 10 0 0 20 40 Flow (%) Recirculation Throttling Cyclic control VSD Pump Saving potential 60 80 100

Often payback times of less than two years and sometimes under one year, can be achieved.

Complete motor nameplate data is collated and each application may be photographed for easy recognition in the appraisal.

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During the energy appraisal priority is given to: Variable torque applications, such as centrifugal pumps and fans, with priority to those which are operating with partial flow (i.e. valves, dampers). Saving potential up to 70 percent. Typical payback times of less than one year. Variable torque applications with motor running at constant nominal speed (full flow) but where partial flow at lower constant speed can be enough. Saving potential up to 30 percent and more. Typical payback time one to two years. Continuously running old motors with incorrect power rating (motors running sub-optimal point). Saving potential up to 5 - 8 percent. Typical payback time one to two years. Continuously running old motors with correct power rating (poor motor efficiency). Saving potential: 1 5 percent. Typical payback time two to three years. Other standard applications (i.e. screw compressors, mixers) that can be updated with drive control with speed reduction. Saving potential up to 20 percent and more. Typical payback time two to three years. Other questions that may be asked include: How old are the installed motors?

How efficient are the installed motors? Are there pumps and fans that run for long times and/or with variable loads? Do you have motors that are too large or too small for the process - check motor plate values? What load variations does the process have? What position are your flow control devices (valves, throttles, dampers) operating in for most of the time? In many instances, answers to these typical questions may not be readily available. But this does not restrict the energy appraisal. ABBs expertise in motor-driven applications means it can easily assess the condition of the installed base of motors or drives and make educated or calculated assessments of what is needed. ABB also engages with the plants process engineers to determine the exact design criteria for the various processes. This gives ABB a clearer understanding of how the process is meant to operate and its critical design operating points, thereby ensuring that the correct motor and/or drive is selected.

Selected applications may be monitored to determine electricity consumption.

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Six steps to an efficient energy appraisal

2. Monitoring and data collection During a walk around the facility, the engineer will spot typical applications that may be running inefficiently. The engineer will look not only at fixed speed motors but also any drives currently used, to see if the application is running at maximum efficiency. The selected applications may be monitored in order to accurately determine which applications are consuming the most energy. If this stage is necessary then it may be performed over a seven-day period, to gain a complete picture of the plants typical energy use. 3. Data analysis Following the collection of the data, the findings are analysed and potential savings identified using dedicated software. The findings are methodically presented, with tables and graphs being created to help identify where savings are likely to arise. Among the data available includes an estimation of present energy usage, areas of potential savings, payback time if an investment is made in drives and/ or motors, carbon dioxide emission reduction, along with many other key facts and analysis.

4. Recommendations An action plan is prepared, usually comprising an Executive Summary and a detailed engineers report, highlighting applications that can save the most. The figures will normally be translated into monthly savings, and there will be detailed recommendations for fitting particular drives or motors. Often the recommendations will show that drives can provide excellent savings in particular applications. The report shows the expected payback time on fitting new equipment.

Monitoring may take place over several days.

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5. Implementation Using the recommendations from the energy appraisal, ABB can identify the correct drive and motor for the respective application. In many instances, it can help with the installation and start-up or commissioning of the drive and motor. This includes setting the correct parameters to ensure that the drive or motor is operating at its optimum energy efficiency. 6. Verification and follow-up Once new equipment is fitted, it is normal to track the actual savings against the predictions shown in the engineers report. This will also help justify the investment in drives and electric motors. ABB provides life cycle services to ensure that the drive or motor is looked after throughout its working life. For example, during the operation and maintenance stage, ABB can continually monitor the energy consumed by the motor and compare this with the original specification. It may be that the process is changing or that the drive or motor is at a specific stage in their maintenance schedules. Whatever, the reason, any deviation can be adjusted to ensure that the drive and the motor are always performing at their optimum.

Findings are documented before being analysed using dedicated software.

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Reasons to consider an energy appraisal

As energy prices continue to fluctuate and firms are pressured into reducing their carbon footprint, there has never been a better time for industry to consider the merits of drives and high efficiency motors. Surprisingly, negotiating better prices with existing energy suppliers is often cited as a preferred energy saving technique ahead of installing drives and motors. Yet this makes little sense when all suppliers are being forced to increase their prices and are likely to continue to do so as future energy costs are forced upwards. During an energy appraisal, ABBs engineers may also review existing business operations and technology to identify the scope for improvements in energy efficiency and reduced CO 2 emissions in such areas as: Low-cost or no-cost investment opportunities in reducing CO2 emissions The scope for employing available technology, including drives and electric motors for applications such as pumps, fans and compressors

Availability of suitable energy loans and grants that may apply to the organisations sector and specific technologies (depending on local knowledge) Other benefits of an energy appraisal may also include: Clearly identified energy savings and CO2 emissions reduction Estimated payback times Review of current preventive maintenance schemes Following an energy appraisal, ABB offers advice on: Replacing drive or motor components as part of a preventive maintenance plan Upgrading entire systems to the latest technology or to extend the functionality of existing drives and motors Retrofitting existing drives with modern technology Recycling of all removed drives and motors to the latest legislation

An action plan is prepared comprising engineers report and an Executive Report.

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Energy appraisal impact on real-life industrial applications

Steelworks A large steelworks in northern Italy wanted to increase its competitiveness through a significant reduction in the amount of energy being used, which accounted for up to 30 percent of its manufacturing costs. Before the efficiency goals were defined, technicians from the client and from ABB worked together to analyze the installation itself. After considering return of investment (ROI) periods, a series of drives were installed in the most critical points, especially on the combustion air fans on the furnaces, which previously had been regulated using choke dampers. The installed motor base was also renewed, with an initial batch of 100 high efficiency low voltage motors replacing the same number of standard efficiency motors. Adding together the applications that have been installed, and those that are planned for the future, by its completion the project expects to cut the energy being used by 3,000 MWh per year, which could save up to $560,000 every year on its energy bill.
Summary Energy saving CO2 reduction Segment and application About 2,300 MWh a year 1,288 tons/year Steel manufacturer, combustion air fans

Salt plant ABB equipment installed for just $32,000 is saving over $32,000 a year at a UK salt plant. Replacing a single oversized fan motor with a smaller one equipped with speed control, cut energy being used on one of the plants dryers by over 60 percent.
Summary Energy saving CO2 reduction Segment and application About 1,640 MWh/year 918 tons/year Food and beverage, fans

Cranes Rapid, precise and efficient control of crane movements reduces stresses on the system and the operator. In modern container cranes, AC drives control all three movement directions. Hoisting movement is most demanding and a regenerative ABB AC drive gives energy savings when braking.
Summary Energy saving CO2 reduction Segment and application About 190 MWh/year 95 tons/year Harbors, crane

Steelworks saves 2,300 MWh.

Over $32,000 per year saved at a salt plant.

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Energy appraisal impact on real-life industrial applications

Brass manufacturer A brass manufacturer is saving $210,000 a year in energy costs with ABB AC drives. An energy appraisal covering the fume extraction filter plant revealed significant savings on filtration units, one with a 250 kW fan and the other with three 132 kW fans.
Summary Energy saving CO 2 reduction Segment and application About 3,300 MWh/year 1,500 tons/year Metal, fans

Fertilizer plant One of Europes leading producers of fertilizers and animal feed phosphates upgraded five process fans with ABB AC motors and drives, replacing existing motors and mechanical flow control systems. Reduction in annual electricity consumption is in excess of 4,000 MWh with annual energy cost saving of some $210,000.
Summary Energy saving CO2 reduction Segment and application About 400 MWh/year 224 tons/year Chemical, fans

Plastics manufacturer A plastic film manufacturer upgraded its 93 kW compressor with ABB AC drives and saved 37% off its energy bill. After sealing all leaks, a transducer was installed to monitor system pressure. Improvements are expected to save $12,000 per year or $375,000 over the installations lifetime.
Summary Energy saving CO 2 reduction Segment and application About 203 MWh/year 89 tons/year Plastics and rubber, compressor

Chemical plant A chemical plant in China replaced its existing constant speed acid pumps and fans control with 8 x ABB AC drives totalling 977.5 kW. The applications run about 8,000 hours a year and the average energy saving is 37 percent lower, resulting in a payback of about 6 months.
Summary Energy saving CO2 reduction Segment and application About 1,200 MWh/year 672 tons/year Chemical, pumps and fans

Brass manufacturer benefits from energy appraisal.

Fertilizer plant reduces electricity consumption.

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Energy appraisal impact on real-life industrial applications

Cooling towers Cooling towers typically use banks of fans, each feeding cooling cells. Within the cells, a fan moves outside air through a spray of water, allowing heat to dissipate. With variable speed control, the energy saving can be 60 percent. With 100 kW total motor power and 4,000 h/year, this means:
Summary Energy saving CO 2 reduction Segment and application About 200 MWh/year 112 tons/year HVAC fans

Sugar cane mill A sugar plant in Honduras replaced five steam turbines, which were driving the cane mill, with ABB AC drives and induction motors. The steam, produced by the steam turbines, can be used to generate electricity which will feed the whole plant and can even be sold to the grid.
Summary Energy saving CO2 reduction Segment and application About 24,366 MWh/year 12,183 tons/year Sugar cane mill

Petrochemical plant A refinery in Argentina replaced a steam turbine, which was driving a blower, with an ABB AC drive and an induction motor. The Energy Intensity Index (EII) improved by 10.5% within one year.
Summary Energy saving CO 2 reduction Segment and application About 7,650 MWh/year 3,780 tons/year Petrochemical, blower

Cement A Mexican cement plant is saving 5,300 MWh annually since replacing the existing damper fan control of two 735 kW fixed speed ID fans with ABB AC drives. Additional benefits included improved productivity, which has boosted revenues by about 574,000 per year, whilst giving a reduction in maintenance by 97 percent. The payback time has been estimated at six months.
Summary Energy saving CO2 reduction Segment and application About 5,300 MWh/year 3,650 tons/year ID fans

Cooling towers reduce CO2 by 112 tons/year.

Mexican cement plant saves 5,300 MWh.

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Energy Appraisal brochure/Feb 2010

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