Up to 30% saving in motor applications

By : Johan Hendrawan

+62 81 287 207 727

Up to 30% saving in motor applications
Summary

Schneider Electric - Oct 2011 > Introduction

Summary
2

> Energy Efficiency in Motors

> Drives Benefits with Pumps & Fans
> Energy Saving with Constant
Torque Applications
> Schneider Solutions
> Conclusions
> Quiz
Introduction
The Energy and CO² emission challenge

These trends are here to last unless we act !

3
Thefacts The
need

Energy demand by 2050

vs CO2 emissions to avoid
Electricitydemand by dramatic climate changes
2030

Source: IEA Source: IPCC 2007, figure (vs. 1990

2008 level)

Energy efficiency is the best wayout of the

energy dilemma
4
Schneider Electric Oct 2011 5
Introduction
... And The Energy Consumers

● … and are also the 1st energy consumers!

31% >2% 18 21 28%

Industry Data centres & Transportation
& Infrastructure networks
% %
Buildings motors
Residential
● Main energy consumption is for heating, cooling,motors, lighting,
electronics and appliances
7
Introduction
Energy Saving

Energy : a small save at home is a big save at the power plant!

● 1 Unit saved at home = 3 units saved at the Power Plant

● 30% global energy saving =

● 1 year of electricity delivered by 2000 coal-fired power plants
● 800 million tons of CO2 saved

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Energy Efficiency in Motors
Global Motor Costs

Energy bill = Motor cost x 100

• Where goes your money ?

Energy
97%
Installation
& Maintenance : 2%

Investment : 1%

Big Motor:
Global costs during Motor Life (average 15
1 Month Energy Bill = Motor
years) Cost
Beyond the investment, the key point is to secure an efficient motor control

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Energy Efficiency in Motors
Energy Wastes

How your money is wasted ?

● Car example :
…try to regulate the speed of your car
● keeping one foot on the accelerator
● the other on the brake.
Brake
● Pump example :
… try to adjust the pump output
● running the motor at full speed
● control the Flow with a Throttle

still one of the most common control methods in industry

….. with a considerable waste of energy
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Energy Efficiency in Motors
Energy Saving

How to optimize your installation ?

● use the right Motor with good efficiency

about 5% of saving

● use a variable speed drive to control your motor

up to 50% of saving

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Energy Efficiency in Motors
Motor Efficiency

● Electrical motor efficiency (η) is the ratio between the mechanical

shaft output power and the electrical input power
● Internal losses (electrical, mechanical, magnetic, …)
● For a similar motor power range the
motors have not all the same efficiency
● In Europe a classification for low voltage
AC motors has been created :
● EFF 1 : High efficiency motors
● Price : 130% of standard motor
● EFF 2 : Standard efficiency
motors
● Standard price
● EFF 3 : Poor efficiency motors
● Low cost motors
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Energy Efficiency in Motors
Motor Sizing

● Not to oversize your motor !

● The maximum efficiency is obtained for the motors between 60% to 100% full load

● Electrical motors are very often oversized

● Significantly over sizing a motor :

● Increases the capital cost
● Decreases the functional motor efficiency
● Can increase the motor’s operating speed (and so the energy consumption)

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Energy Efficiency in Motors
Load Characteristics

The main target The next step

(first priority) (second priority)

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Drives Benefits with Pumps & Fans
Physical Laws for Centrifugal Loads

● It ’s pure physics : due to the laws that govern centrifugal fans and
pumps,
the volume of air or water decreases directly with fan or pump speed
● Affinity laws of centrifugal loads :

Flow = f (motor speed)

Pressure = f (motor speed)2

Power = f (motor speed)3

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Drives Benefits with Pumps & Fans
Physical Laws for Centrifugal Loads

● So, a small reduction in speed produces a significant reduction in power

● Relevant applications : fans, pumps, compressors

● The resisting torque of centrifugal pumps and fans varies with the square
of
the speed : Tr = kN² Torque Torque
Cn Nominal

50%

25%
Starting
Torque
Speed
50% 70% Nn
● A huge potential VSD market :
● Today, less than 10% of these motors are controlled with Variable
Speed Drives
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Drives Benefits with Pumps & Fans
Pumps : Fundamental Characteristics
● The major parameters used in pumping BEP

are
● :Flow rate Q : Volume of fluid transported per unit of time
(m3/s)
● Head H : Pressure at a given point of circuit expressed in
m as the height of the fluid in vertical column
● A pump’s Total Dynamic Head TDH represents the
pressure differential between the inlet and the outlet
expressed as the fluid column height
● Pressure P expressed in Pascal (Pa)
Pr = ρ g H ρ : density of the fluid (kg/m3)
g : acceleration due to gravity (9,81
m/s²)
● Mechanical power : P = (1 / η) Pu with Pu = Pr Q
● The pump’s efficiency η varies with the flow rate.

● Best Efficiency Point BEP

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Drives Benefits with Pumps & Fans
Pumps : Operating Point
● Simplified distribution circuit :
● Z : Water column height between the suction point and the point
at which the fluid is used.
● R : Head loss due to frictions in the
conduits. Proportional to the square of the
flow rate.
● Operating Point : intersection between
circuit and pump curves.

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Drives Benefits with Pumps & Fans
Pumps : Varying the Flow Rate at a Fixed Speed
● Use of downstream valves from the pump :
● Reduction of the effective cross-section of the B
pipe downstream from the pump
A
● Increase in head loss in the circuit
● Pressure increases at the outlet C
● Dissipation of energy in the fluid

Energy Lost

Effective
● Using a by-pass Energy
circuit :
● By-pass valve which returns some of pumped
fluid back to the source
● Flow rate is closely controlled A

● Drawback : low energy efficiency

C

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Drives Benefits with Pumps & Fans
Pumps : Varying the Flow Rate at a Variable Speed
● Use a variable speed drive :
● Reduction of the flow rate by altering the pump’s rotational speed
● The TDH curve at lower speed has homologous form (parabola) than nominal curve
Energy Saved compared Energy Saved compared
to By-Pass Valve to Downstream Valve

A A

C Effective C
Energy

● We can observe a significant reduction in power in the variable

speed configuration

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Drives Benefits with Pumps & Fans
Fans : Conventional Installation

● Motor supply : direct on line

● Motor speed = nominal speed

● Flow variation is obtained by device of

restriction or pressure loss - valve,
incliner, multi leaf damper, ...

● The flow reduction makes fall very little

the absorptive power

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Drives Benefits with Pumps & Fans
Fans : Installation with VSD Drives

● Motor supplied with a variable speed

drive

● Elimination of the restriction device

● Flow variation is obtained directly

by varying the motor speed

● The flow reduction drops considerably

the absorbed power

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Drives Benefits with Pumps & Fans
Other Benefits ...

● Added to Energy Saving, used a Variable speed drive has many

other advantages :
● Less mechanical stress on motor and system (water hammer,
cavitations, ...)
● Less mechanical devices – Less Maintenance
● Process regulation with PID regulator
● Reduce pumps or fan noise
● Performance and flexibility
● Easier installation and settings
● Can be controlled with BMS, field bus, …

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Schneider Solutions
PID Regulator

● The whole range of Drives integrate functions to

consume the energy only necessary for the application
● PID Regulator
● Function used to regulate a process (i.e. pressure in water circuit) with a
reference and a feedback given by a sensor
● Function suitable for regulation in buildings
● Sleep / Wake Up Function
● Function which supplements PID control, in order to avoid prolonged operation
at excessively low speed when neither useful nor desirable

Output
Sleep /
PID Motor
Wake Up Frequency
Reference
Feedback

Sensor

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 Schneider Solutions
Example : Schneider Electric Grenoble (F) : Primary Pumps on Heating

● Services actions
● Installation of Variable Speed Drives on primary
pumps of the installation of heating
● Two VSD 15 kW installed on the 2 primary
pumps which provide the heating of buildings
T1, T2 and T7 on Grenoble plant
● Project in collaboration with Dalkia

● Schneider Benefits :
2007- 2008 2008 - 2009 Saving
Period April - February
Without With
VSD VSD

Electric 277 MWh 106 MWh

Consumption
61,7%

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Conclusions
The Drive Benefits

The Benefits to use variable speed drives are :

● An optimized electric consumption
● Saving in electricity costs between 15 and over 50% are achieved
● Enhanced performances
● More comfortable utilization
● Easier installation – Less maintenance
● Significant reduction of noise pollution

● Allow to save money

● Very quick return on investment : between 9 and 24 months

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Conclusions
The Drive Benefits

Speed Drive usage must become obvious !

It is natural for … do the same for
Bulbs Motors !
Traditional New Electromechanical
generation generatio Speed Drives
n

What has changed ….. ……. what could change !

● Consumption ÷5 ● Consumption, up to - 50%
● Less Mechanical stress & less
● Life duration x5 Vibration Noise
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Schneider Electric Oct 2011

38

Main conclusion
● Speed Drive is a must to control ● Active player to reduce global
GHG emission warming (could be supported by local
governmental incentives)

● Energy consumption ● Electricity bill reduced up to 70%

mastered ● Productivity enhanced thanks to
operation & maintenance cost
control

● Global solution approach

● Performance guaranteed thanks
to expertise & ready to use cubicle
 Summary
Schneider Electric - Oct 2011

39

Up to 30% saving in motor applications!!

Thanks for your attention

Make the most of your energy !
More info:

Johan Hendrawan
+62 81 287 207727