It is more than 40 years since the technology of variable-speed drives (VSDs) entered the market. Yet despite electric motors accounting for some 65 percent of industrial energy consumption, only 5 percent of installed motors are speed controlled. While not all motors are suitable for speed control, there is still a large proportion that could be. Yet when asked what is the most effective way to reduce energy, UK business responded with “change energy supplier”. Without doubt the most effective way to get real energy savings is to install energy efficient motors and VSDs. In this presentation John Guthrie looks at the impact of VSDs on a diverse range of sectors, offering real examples from hospitals and swimming pools to data centres and car parks.

1. © 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

2. 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

3. © ABB Group
November 25, 2016 | Slide 3

4. Energy – Is it Still an Issue?
Rising Cost
Source: DECC Quarterly Energy Prices; June 16

5. “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

6. Energy – Is it Still an Issue?
Is the message getting through?
© ABB Group
November 25, 2016 | Slide 6

7. Energy – Is it Still an Issue?
Is the message getting through?
© ABB Group
November 25, 2016 | Slide 7

8. How can we make savings?
 Why the focus on Energy for Motors?
65%
95% Oversized

9. Control methods for pumps
 Variable speed On/off control
 Bypassing Throttling

10. 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

11. Centrifugal Loads – Fixed Speed v Variable Speed
0
20
40
60
80
100
120
0 20 40 60 80 100
Flow (%)
Power(kW)
Power to Produce
Useful Flow
Power to Fixed
Speed Pump
Power Input to VSD
----- Inlet Guide Vane

12. Balloon Machine Demo

13. Energy & Productivity Appraisal Team

14. Site Survey

15. Report
Energy & Productivity Appraisal
Joe Bloggs Bits
Prepared by: John Guthrie
ABB Ltd
Tel: 01234 567 890
25/02/2015

16. 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

17. The proof
Sandcastles Blackpool

18. 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.

19. Circulation Pumps

20.  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

21. 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

22. Flow & Pressure
 The flow rates and filter differential pressure were noted beforehand

23. Initial Findings
 2 Motors consume
 2 x 17 kW
 Total - 34 kW to achieve
required flow
XX

24. Panel Modifications

25. Start of Trial
 3 Motors @ reduced
speed 78% = 3 x 8kW
 Total - 24kW to achieve
required flow
X

26. Phase 2 Trial
 4 Reduced speed Motors
@ 68% consume 4 x 4.5kW
 Total - 18kW to achieve
required flow

27. Flow & Pressure
 But more importantly the flow rates and pressures across the sand
filters had been maintained

28. Investment Payback
Investment Payback
3 Pump
Operation £15,900 15 months
4 Pump
Operation £15,900 12 months

29. 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.”

30. 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

31. 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
10
20
30
40
50
60
70
00:00:01
00:00:11
00:00:21
00:00:31
00:00:41
00:00:51
00:01:01
00:01:11
00:01:21
00:01:31
00:01:41
00:01:51
00:02:01
00:02:11
00:02:21
00:02:31
00:02:41
00:02:51
00:03:01
00:03:11
00:03:21
00:03:31
00:03:41
Fixed Power (kW)
ABB Power (kW)
50% Saving

32. 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

33. The proof

34. The proof

35. © ABB Group
November 25, 2016 | Slide 35
Productivity Improvement
It’s not all about energy…!

36. 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

37. 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

38. Here to Help..!
 Now you can make a difference

39. © 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.

40. © ABB Group
November 25, 2016 | Slide 40