© ABB Group November 25, 2016 | Slide 1

The Energy Management Exhibition 2016 Unlocking the Innovation Hidden within Today’s Variable-Speed Drives

John Guthrie: UK Energy Efficiency Manager: Drives & Motors

Energy – Is it Still an Issue? Rising Demand

China

105% 195%

India

126% 282%

Europe and

North America

11% 31%

M. East and

Africa

73% 131% Growth in primary

energy demand

Growth in

electricity demand

IEA forecast 2006-30

© ABB Group November 25, 2016 | Slide 3

Energy – Is it Still an Issue? Rising Cost

Source: DECC Quarterly Energy Prices; June 16

“Improving energy efficiency worldwide is the fastest,

the most sustainable and the cheapest way to reduce

greenhouse gas emissions and enhance energy

security.”

(Final statement of G-8 summit, Germany, June 2007)

“On average, an additional dollar invested in more

efficient electrical equipment, appliances and buildings

avoids more than two dollars in investment in

electricity supply.”

(International Energy Agency's World Energy Outlook)

Energy – is it Still an Issue? Fast and cheap: technology is already available

Energy – Is it Still an Issue? Is the message getting through?

© ABB Group November 25, 2016 | Slide 6

Energy – Is it Still an Issue? Is the message getting through?

© ABB Group November 25, 2016 | Slide 7

How can we make savings?

Why the focus on Energy for Motors?

65%

95% Oversized

Control methods for pumps

Variable speed On/off control

Bypassing Throttling

In this situation, what do you do?

70 A: Take your foot off the gas

B: Or keep it on and use your brakes to slow you

down

Centrifugal Loads – Fixed Speed v Variable Speed

0

20

40

60

80

100

120

0 20 40 60 80 100

Flow (%)

Po

wer

(kW

) Power to Produce

Useful Flow

Power to Fixed

Speed Pump

Power Input to VSD

----- Inlet Guide Vane

Balloon Machine Demo

Energy & Productivity Appraisal Team

Site Survey

Report

Energy & Productivity Appraisal Joe Bloggs Bits

Prepared by: John Guthrie

ABB Ltd

Tel: 01234 567 890

25/02/2015

Innovative Technologies Synchronous Reluctance Motor

© ABB Group November 25, 2016 | Slide 16

• New rotor design – no cage, no magnets…no losses

• Motors runs cooler with even higher reliability and

longer bearing lifetime.

• Runs extremely quietly

• 2 Flavours:

• IE4 Super Premium Efficiency SynRM motors.

Same size and output power as comparable IE2

induction motor.

• High output SynRM motors. Offers up to two

frame sizes smaller motor at the same output

power, or increased motor power at the same

frame size.

• Verified package efficiency statements according to

EN 50598-2 standard to help determine overall

system efficiency of calculate payback times

• The IE4 SynRM motors together with the ABB drive

provide an overall package efficiency greater than

IES2

The proof Sandcastles Blackpool

Introduction

Sandcastle Water Park is a council run facility &

their biggest utility user, with a target to save 8% of

overall energy use.

The management of the park were keen to improve

the energy efficiency of the pool installations.

Circulation Pumps

4 off Circulation Pumps rated at 15kW

Full load Current 30A

Currently utilised in a 2 duty 2 standby

Peak periods utilised 3 duty 1 standby

Following discussions it was agreed that the flow rate MUST

be maintained and cannot be reduced, the typical way of

energy saving

As the pumps are used on a circulation system with no static

head, a decision was made to try “Parallel Pumping”

Circulation Pumps

The Theory

Flow = 50%

15kW Motors Flow Speed

Power Speed3

30kW

VSD Calculations

Flow = 0.5

Therefore speed = 0.5

Power = Speed3

Power = 0.53 x 60 kW

= 0.125 x 60 kW

= 7.5 kW

Flow = 50%

15kW Motors

7.5kW

Flow & Pressure

The flow rates and filter differential pressure were noted beforehand

Initial Findings

2 Motors consume

2 x 17 kW

Total - 34 kW to achieve

required flow X X

Panel Modifications

Start of Trial

3 Motors @ reduced

speed 78% = 3 x 8kW

Total - 24kW to achieve

required flow X

Phase 2 Trial

4 Reduced speed Motors

@ 68% consume 4 x 4.5kW

Total - 18kW to achieve

required flow

Flow & Pressure

But more importantly the flow rates and pressures across the sand filters had been maintained

Investment Payback

Investment Payback

3 Pump

Operation £15,900 15 months

4 Pump

Operation £15,900 12 months

Customer Comment Maintenance Manager

Says McNichol: “I would not have believed it if I hadn’t seen it with my own eyes.

We didn’t have to think twice about it and we gave the go ahead for a permanent

installation.”

Plastic Injection Moulding

Machine producing moulded panels for Automotive

Industry.

55kW motor driving 3 hydraulic pumps off the one shaft

Different pressures required at different parts of the

cycle

Plastic Injection Moulding

Identified digital signals from the machine’s own PLC

control system that could be used to control the drive.

VSD now runs the motor at two speeds:

45Hz when max pressure is required – Clamping &

Injection

35Hz at all other times

0

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60

70

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Fixed Power (kW)

ABB Power (kW)

50% Saving

The proof

• 28 AHU across BRI & St Luke’s Hospitals.

• Critical areas such as Infection Control & Theatres

all have duty/standby systems.

• Local AVP worked closely with the on-site BMS

company to integrate the HVAC drives via

BACnet.

• Controlled around ambient temperature & reduced

speed during night time.

• Drives ranging from 0.75 kw – 30 kw delivering

over £26k per year energy saving.

• Bradford Teaching Hospitals NHS Foundation

Trust awarded the Carbon Trust Standard in 2009

for its commitment to reducing carbon footprint

The proof

The proof

© ABB Group November 25, 2016 | Slide 35

Productivity Improvement It’s not all about energy…!

The proof A Wealth of Experience

Number of Reports: 3367

Total Current Running Costs: £247,501,178

Total Investment: £87,376,977

Total Annual Saving: £77,588,640

Total Annual Energy Saving: 2,329,214 MWh

Total CO2 Saved: 1,025,182 tonnes

ABB & our Authorised Value

Providers are identifying

savings for our customers

every working day

Here to Help..!

• Appreciation of VSD benefits

• For Elec & Mech Engineers

• ‘Hands On’ Exercises

• 6 – 8 engineers per course

• 5 hours duration

• Locally or at ABB

• Can be tailored to suit

Here to Help..!

Now you can make a difference

© ABB Group November 25, 2016 | Slide 39

Launch of the AVP Energy Toolkit App Available from the Apple store

Calculates energy savings when switching a

pump or fan running DOL to one using a

variable-speed drive

Calculates annual financial savings based on

energy savings and user entered electricity

cost

Calculates reduction in carbon emissions

Selects suitable drive from its built-in

database

Allows user to e-mail results to AVP for follow

up.

© ABB Group November 25, 2016 | Slide 40