ABB drives and motors6-stage energy saving plan

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The sunfl ower is highly effi cient in converting the sun’s rays into useful energy. The energy use in our industrial society is far less effi cient, but with high effi cient motors and drives, energy waste can be substantially reduced to make your operation more environmentally friendly.

Saving energy with drives and motors

ABB has delivered millions of AC drives during the last twenty years. During this time, vast experience of how industry can save energy in the most effective ways has been built up. The installed drives bring not only reduced energy costs to its owners but also improved process control, increased production capacity, reduced maintenance costs and less reactive power.

ABB’s experienced staff can help with energy appraisals at your site. The energy effi ciency of different machines in an industrial plant is not always easy to detect without in-depth study and analysis, but ABB’s experts know, through their experience, where to look for energy waste. Applications suspected to be ineffi cient are singled out for closer study and measurement. To convince you further, a test drive can be fi tted to demonstrate the potential savings.

Introduction

ABB’s experience has been captured in the six-stage energy saving plan:

ABB drives save energy

In 2006, the installed base of low voltage AC drives saved about 130 TWh, equivalent to the annual consumption of electricity of more than 32 million households in the 27 members countries of the European Union. This reduced CO2 emissions by more than 100 million tonnes, more than the annual emissions of a country like Finland.

Stage 1 - the factsWhy is everybody talking about energy? It’s about saving costs and, on a wider scale, slowing down climate change.

Stage 2 - the savingsIn half-a-day, an energy audit can help identify the applications that offer the best energy saving opportunities.

Stage 3 - the fi nanceSee how energy effi cient products pay for themselves over time and fi nd out about the options that make payback even quicker.

Stage 4 - the productsChoose from a wide range of energy effi cient equipment that can help your company achieve great cost savings.

Stage 5 - the proof See how other users have achieved great energy savings with the help of ABB motors and drives.

Stage 6 - the actionNow that you have the tools and the information, you can move forward and make a difference in your own organization.

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Stage 1 - the facts

Climate change – what is it?

Eleven of the last twelve years are among the warmest on record since 1850, according to the United Nations’ Intergovernmental Panel on Climate Change (IPCC). Sea levels are rising, consistent with what can be expected as a result of global warming.

How is it tackled?

Climate change is a global problem requiring actions on a global scale. Before 2012, developed countries will have to reduce their greenhouse gas emissions by 5 percent below 1990 levels. For many countries, such as the EU member states, this means some 15 percent below their expected greenhouse gas emissions in 2008.

How does this affect industry?

With a combination of penalties and incentives, governments are trying to move their industry in a direction so the country as a whole can meet its Kyoto targets. In particular, emissions trading schemes, where industries pay for their emissions of greenhouse gases, are likely to add to energy costs in the future. Companies that need more CO2 credits will have to buy these on the open market. Prices of CO2 credits are expected to increase in the coming

years. Regardless of whether your own company is effi cient or not, electricity prices will go up for everyone as the power generation industry’s costs for emission permits are passed on to consumers.

What is happening in the energy markets?

In addition to this, energy prices have become volatile as a result of uncertainties in the supply situation. The prices for fuels such as coal, oil, gas and electricity have risen for more than fi ve years and are unlikely to come down signifi cantly anytime soon.

How does this affect me and my department?

Businesses of all sizes need to become more energy effi cient. You can either grasp the opportunities offered by improved energy effi ciency, or become forced into action by energy prices that rise rapidly with or without government interference.

Energy effi ciency cannot be introduced overnight. It is the result of a determined effort over time. A good place to start is to look at your motor and drive applications.

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The relationship between a pump’s speed and its energy requirement is known as the cube law, because the need for power increases with the cube of the speed. This means that a small increase in pump speed requires a lot more power, but also that a modest speed reduction can give signifi cant energy savings. Using a drive, a pump or a fan running at half speed consumes only one-eighth of the power compared to one running at full speed.

Managing motors wisely

It is startling to realise that that an 11 kW motor costing about 1,100 euros can consume over 90,000 euros worth of electricity over a 10-year operating life. Energy effi ciency is far more signifi cant to the bottom line than the purchase price of a motor. Yet, the natural instinct of many plant managers is to send a failed motor out to be rewound, although motor rewinding will cause effi ciency to drop.

The importance of drives and motors

About two-thirds of industrial electricity is used by motor systems. Motor systems are widely used in a large number of applications, the dominating ones being pumps and fans.

Using drives to save energy

Not only are pumps and fans very numerous, they also have great energy saving potential. Therefore, targeting pump and fan applications will be a great start for any energy saving programme.

Many electric motors – if not most – are oversized, because they are sized for a worst-case scenario that rarely or never occurs. Pump fl ow is typically moderated with a valve, while excessive air fl ow from a fan is controlled with vanes. By forcing the fl ow through a constriction, energy is wasted through friction which is increased until the correct fl ow is achieved.

Stage 2 - the savings

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Stage 2 - the savings

The solution is to adopt a motor management policy that gives clear guidelines on when to purchase high effi ciency motors. As a rule, small motors and motors with long running hours should be replaced. Large motors, motors that run only occasionally and motors in unusual frame sizes can be rewound. But there are also times when replacement of a fully functioning motor can be justifi ed on energy grounds.

Fast and effi cient energy appraisal

The starting point for a successful energy saving programme is to decide just where energy can be saved. An ABB representative will meet with you to discuss in detail the requirements for a successful energy appraisal, including suitable applications to target.

An on-site appraisal is undertaken with extensive analyzis of selected applications. Using ABB’s dedicated software, the fi ndings are analyzed and potential savings rapidly identifi ed. ABB’s experience has been captured in ABB’s Energy Appraisal Scheme.

1. Scope of supplyAn ABB representative meets with you to discuss in detail the requirements for a successful energy appraisal, including suitable applications to target.

2. Data collectionAn on-site appraisal is undertaken with extensive analysis of selected applications.

3. Data analyzisUsing ABB’s dedicated software, the fi ndings are analyzed and potential savings rapidly identifi ed.

4. RecommendationAn action plan is prepared, comprising an executive summary and a detailed engineer’s report. The fi gures are translated into monthly savings.

5. ImplementationThe fi ndings are implemented and the actual savings are monitored alongside the predicted results.

6. TrainingThe process is so easy that we encourage our customers to learn the procedure themselves, enabling them to take direct control over their energy savings.

7. Standardize/specify By specifying and standardizing on proven motors and drives, you can be assured the predicted savings will materialize.

Replacing existing drives and motors

If an average 1980s motor and AC drive are replaced with a new high effi ciency motor and state-of-the-art drive from ABB, the payback time due to energy consumption could be 12 to 36 months. A new drive is also likely to improve reliability, reduce running costs, boost productivity and maximize the capacity of the system.

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Variable speed drives are very cost-effective and often give payback in months on energy savings alone. In addition, by optimising the speed to the needs of the process, users often fi nd they get better product quality and reduced maintenance costs.

However, some companies, not least small and medium sized enterprises, are reluctant to take the fi nancial risk. In many countries there are state, local or utility incentives that promote energy effi ciency and can help reduce the initial fi nancial burden.

Energy effi ciency increases profi ts

Finance is central to any successful energy saving project, but sometimes, engineers and accountants don’t speak the same language. This can be an obstacle when trying to secure fi nance for your energy saving project.

The key is to translate any fi gures into monetary savings – how much less money will the company be spending with the new drive in place? Many successful companies have a committee to discuss energy and resource management. In this forum,

your ideas can be explored from different angles, increasing the chance that they will be accepted in other parts of the company.

An installation of drives from ABB can offer rapid repayment. To take one example from real life, a manufacturer who installed an ABB drive on one of its fans found that a speed reduction of 20 percent resulted in a 56 percent reduction in power - from 118 kW to 51 kW; this saved over 440,000 kWh a year.

The cost of the drive was 7,800 euros and the energy savings 24,000 euros per year or 2,000 euros per month, giving a straight payback of four months. After the four months, the drive has continued to save money for the company every month and will continue to do so for the rest of its life. Not many other investments offer this type of payback - imagine for instance how much more you would need to sell to improve annual profi ts by 24,000 euros.

Stage 3 - the fi nance

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Stage 4 - the products

Save energy with effi cient motors

High effi ciency motors are generally 3 percent more effi cient than basic designs. ABB’s high effi ciency motors satisfy the demand for reduced energy costs without an excessive cost penalty. ABB also offers an extremely wide motor range, enabling you to easily fi nd the right motor for your application.

A high effi ciency motor maintains effi ciency across a wider load range than a basic model.The high effi ciency motor retains much more of its effi ciency across the speed range.Energy effi cient motors are also more reliable than basic motors, because less of the energy is converted to heat, keeping the temperature low inside the enclosure.

ABB offers comprehensive ranges of low voltage motors, ranging from 0.055 to 1000 kW.

ABB’s portfolio of low voltage motors

Standard motors in aluminum, steel and cast iron frames Motors for hazardous areas, all protection types Marine motors Special motors for numerous applications

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Choosing energy effi cient drives

AC drives reduce energy wastage in all phases of operation. Changing production volumes by mechanical means is very ineffi cient. With AC drives, this can be achieved by changing the motor speed. Particularly in pump and fan applications, this saves a lot of money, because the shaft power is proportional to the fl ow rate (see page 4).

Whatever your application, ABB offers the most extensive AC drive product range available, ranging from 0.18 kW to 100 MW.

ABB’s portfolio of AC drives

ABB low voltage AC drives0.18 to 5600 kW, 100 to 690 VABB medium voltage AC drives 315 kW to 100 MW

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Stage 4 - the products

Further benefi ts of variable speed drives include:

Reduced maintenance through smooth starting Accurate process control through infi nitely variable stepless speed controlFull motor protection protects cables and motor against many faultsSoft start and stopping avoids mechanical damage to the processWide range of speed, torque and power gives accurate speed control that results in process optimisation and better product quality Improved power factor helps maintain motor effi ciency at reduced loadEMC protection against interference with other sensitive equipmentProduction increase through more appropriate motor speed

Lifecycle management model

ABB has developed a product lifecycle management model for proactive service, to maximize availability and performance. This model provides not only optimum support to end-users but also a smooth

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ABB drive lifecycle management model

Active Classic Limited Obsolete

■ The drive, with complete lifecycle services, is available for purchase.

■ The drive, with complete lifecycle services, is available for plant extensions and spare parts.

■ Some product enhancements can be made.

■ Spare parts and repair services are available as long as materials can be obtained.

■ Migration to a new ABB drive is recommended.

■ ABB cannot guarantee availability of lifecycle services for technical reasons or within reasonable cost.

■ Migration to a new ABB drive is recommended.

Drive lifecycle phases:

Complete lifecycle services Limited lifecycle services

ABB follows a four-phase model for managing drive lifecycles, which brings enhanced customer support and improved effi ciency.

Most ABB drives are supported for more than 20 years.

Lifecycle services are: selection and dimensioning, installation and commissioning, training and learning, technical support and remote services, maintenance, spare parts, repair, retrofi ts, replacement and recycling.

transition to a new drive when the service life of the current drive ends.

The model divides a product’s lifecycle into four phases: active, classic, limited and obsolete. Each phase has different implications for the end-user in terms of services and support provided.

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Stage 5 - the proof

Ventilation exhaust loses reduced

A Finnish hospital wanted to reduce energy wasted through ventilation exhaust air. The hospital’s HVAC system was renewed with advanced building control system, heat recovery and 60 ABB AC drives (2.2 to 37 kW). Specifi c heat energy consumption is now lower than for any other hospital in area.

Energy saved = 4,840 MWh/yearReduction in CO2 emissions = 2,420 tonnes/year

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Salt maker saves over 175,000 euros a year on a single fan

ABB equipment installed for only about 37,400 euros is saving over 175,000 euros a year at a salt plant in the U.K. Replacing a single oversized fan motor with a smaller version equipped with speed control has cut the energy consumption on one of the plant’s dryers by over 60 percent.

Energy saved = 1,640 MWh/yearReduction in CO2 emissions = 722 tonnes/year

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Ski lift regenerates energy from downhill run

A regenerative AC drive from ABB saves more than 46,000 kWh per year at the Sugarbush ski lift in Vermont, United States, offering higher effi ciency than a traditional DC system. The drive is unaffected by power failures and the harmonics generated by the drive have been reduced dramatically.

Energy saved = 46 MWh/yearReduction in CO2 emissions = 20 tonnes/year

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Drive saves fi lm manufacturer’s compressor costs

ABB drives have helped a manufacturer of plastic fi lm in the U.K. to upgrade its 93 kW compressor and save 37 percent off its energy bill. After all air leaks had been sealed, a pressure transducer was installed to monitor the system pressure. The improvements are expected to save about 9,970 euros per year or some 293,000 euros over the lifetime of the installation.

Energy saved = 203 MWh /yearReduction in CO2 emissions = 89 tonnes/year

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Stage 5 - the proof

Pumping station boosts energy savings

A Beijing water utility designed a new booster pump station with AC drive control instead of throttling. The station handles the water supply for around 200,000 inhabitants, and the energy savings through the use of drives have been calculated at approximately 30 percent. This represents an annual energy saving of about 1,000 MWh. Greenhouse gas emissions are also reduced: the drives based pumping station releases half a million kg less carbon dioxide into the atmosphere than it would if throttling were used. The system’s payback time has been estimated at 18 months.

Energy saved = 1 000 MWh/yearReduction in CO2 emissions = 440 tonnes/year

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Concrete savings for cement plant

A cement factory in Jiangsu province, China, installed AC drives to operate kiln fans. The drives replace hydraulic couplings on a 5,000 tpd production line. The resulting energy savings amount to 2.8 kWh/t, which totals 4,200 MWh annually. The drives have produced savings of about 150,000 euros and reduced carbon dioxide emissions by 2.1 million kg annually.

Energy saved = 4,200 MWh/yearReduction in CO2 emissions = 2,100 tonnes/year

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Cement plant improves productivity

A Mexican cement plant is saving 5,300 MWh annually since replacing the existing damper fan control of two 735 kW fi xed speed ID fans with ABB AC drives. Additional benefi ts include improved productivity, which has boosted revenues by about 574,000 euros per year, whilst giving a reduction in maintenance by 97 percent. The payback time has been estimated at 6 months.

Energy saved: 5,300 MWh/year Reduction in CO2 emissions: 2,650 tonnes/year

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Stage 6 - the actions

Do your own energy survey – we show you how

ABB’s process is so easy that we encourage customers to learn the procedure themselves and take direct control of their energy savings.

For your fi rst energy survey, contact ABB. During the survey, you will receive training to enable you carry on the work by yourself.

To help you, you will have ABB’s Pump Save/Fan Save tool. This enables you to calculate how much you can save by replacing a fi xed speed, damped or throttled, centrifugal load with a variable speed drive solution. Based on motor power, running hours, duty cycle and electricity tariff, the calculator estimates the savings, selects a product and works out the payback time, so that a self-assessment can be made. The Pump Save/Fan Save tool can be downloaded from www.abb.com/drives.

Useful websites

European Commission’s energy pagehttp://re.jrc.ec.europa.eu/energyeffi ciency Software for choosing energy effi cient motors

United Nations Framework Convention on Climate Changehttp://unfccc.int General information on climate change and the Kyoto agreement

The United Nations’ Intergovernmental Panel on Climate Change (IPCC)www.ipcc.ch Established to assess scientifi c, technical and socio-economic information relevant for the understanding of climate change, its potential impacts and options for adaptation and mitigation.

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ABB OyDrivesP. O. Box 184 FI-00381 HelsinkiFinlandTelephone +358 10 22 11Telefax +358 10 222 2764Internet www.abb.com/drives

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ABB Switzerland Ltd Medium Voltage Drives CH-5300 TurgiSwitzerland

Telephone +41 58 589 27 95 Fax +41 58 589 29 84 Internet www.abb.com/drives

ABB Oy MotorsP.O.Box 633FI-65101 VaasaFinlandTelephone +358 10 22 11Fax +358 10 22 47372Internet www.abb.com/motors