ABB 13676 Sustainability Guide1 3AFE68902037 REV B 23 1 Lowres

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ABB motors and drivesDriving energy eciency worldwide

Sustainability

guid

eNo.1


2/54 Sustainability guide No. 1 - Driving energy eciency worldwide


3/54Sustainability guide No. 1 - Driving energy eciency worldwide

ABB motors and drivesDriving energy eciency worldwide

Sustainability guide No. 1

3AFE68902037 REV B ENEFFECTIVE: 23.1.2009

Copyright 2009 ABB. All rights reserved.



Contents

Chapter 1 Introduction .......................................................................... 7

Chapter 2 - The energy dilemma ............................................................. 8

Growing needs, diminishing resources, increasing environmental concerns 8Europe could cut energy consumption by 20 percent ..................................... 9Climate consensus: something has to be done .............................................. 9Atmospheric warming reaches new levels .................................................... 11Industry uses over 40 percent o total world electricity .................................. 11

Chapter 3 - Europe takes action ............................................................ 14The EUs bold advance ................................................................................. 14Momentum is building up ............................................................................. 15Raising awareness among decision makers.................................................. 15Most productive employees .......................................................................... 16Management must be proactive ................................................................... 16ESCO: an ecient nancing model ............................................................... 17Monitoring systems essential ........................................................................ 17

Chapter 4 - Sustainable and ecient energy use ................................. 19

Quick, eective and low cost ........................................................................ 19Energy eciency needs to become ashionable ......................................... 20Global demand or drives ............................................................................. 20Two-thirds o industrial electricity used by electric motors ............................. 21Better control and higher eciency ............................................................... 21

Chapter 5 - ABB motors and drives or ecient control ...................... 23

Potential or major energy savings ................................................................ 23Hal speed or only a quarter o the energy ................................................... 23Subsidies or high eciency motors .............................................................. 24New standards pave the way or international harmonization ........................ 25Developing an eective motor management policy ....................................... 27AC drives are the ideal solution or speed control ......................................... 28Looking at the entire lie cycle ....................................................................... 29

Chapter 6 - Energy audits identiy potential savings ............................. 30

Evaluating how energy is used ..................................................................... 30Recommendations based on actual data ..................................................... 31

Additional savings rom unexpected sources ................................................ 31Payback within months ................................................................................ 32Tools help with nancing calculations ............................................................ 34



Chapter 7 - Case studies: big savings with modest investments .......... 35

China: Plastics plant cuts energy consumption by 30 percent ...................... 35China: Substantial energy savings and reduced emissions ........................... 36Finland: Drives help to cut water utilitys energy bill ....................................... 38Germany: Drives keep natural gas supplies fowing smoothly ...................... 39Honduras: Sugar plant boosts annual revenues by $1 million ....................... 41India: Improved an control increases eciency at cement plant ................... 43Netherlands / international: High eciency motors cut running costs ............ 44Sweden: Mining company acquires only high eciency motors .................... 46UK: Salt producer saves over 1,600 MWh per year ...................................... 47US: Drives play key role in helping to preserve vegetable crops .................... 49US: University o Texas saves millions through boiler retrot .......................... 50



Chapter 1 Introduction

Fossil uels are non-renewable. Signicant untapped reservesare still available, but their extraction is becoming increasinglymore dicult and expensive. It is clear that i the world continuesto use its ossil uel resources at present consumption rates theywill be exhausted in a relatively short time.

In a situation where energy needs are rising and supplies arediminishing, one obvious course o action is to use energy moreeciently. This guide examines how readily available, tried andtested technologies variable speed drives and high eciencymotors - can help to save energy and reduce greenhouse gasemissions.

Motor-driven pumps and ans, or example, provide signicantscope or energy saving. Many such applications are operatedin a very inecient manner: the motor drives the pump or anat ull speed, and the desired rate o fow o liquid or gas isachieved by throttling the output by means o valves, vanesor other mechanical devices. Operating this way - running themotor at ull speed and then restricting the output - can becompared to driving a car with one oot on the accelerator and

the other on the brake.

Pump and an systems can generally be run more ecientlybe adding a variable speed drive (VSD). A VSD will regulatethe motor speed to match the precise needs o the processand thereby boost the eciency o the entire system. In 2008the worldwide installed base o ABB drives saved about160 terawatt-hours (TWh), which is equivalent to the annualconsumption o more than 39 million amilies. The drives alsoreduced carbon dioxide emissions by around 135 million tonnesin the same year.

AC drives and high eciency motors are being installed inall kinds o applications all over the world. This guide gives anumber o real-lie examples where drives and high eciencymotors have not only reduced energy consumption but alsoprovided other benets such as better quality products,reduced greenhouse gas emissions, and less wear and tear onprocess equipment.



Chapter 2 - The energy dilemma

Growing needs, diminishing resources, increasingenvironmental concerns

Fossil uels are non-renewable and at present consumptionrates the world will exhaust its ossil uel resources in a relativelyshort time.

New ways o providing energy such as atomic usion andhydrogen uel cells will not become properly viable or someconsiderable time. Renewable sources can make up part o the

shortall, but are also subject to limitations. Proposals or windturbines invariably meet strong resistance rom people living inthe aected locality, or example, and biouels still need a greatdeal o development work beore they can be used in place oexisting uels.

Meanwhile, world energy consumption is steadily rising. Worldconsumption almost doubled rom 1973 to 2004 and continuesto rise, albeit at a slower rate. By 2030 it is estimated that some25 percent more energy will be used than in 2010.

Figure .1. Although renewables and atomic energy have increased their

relative shares o world energy supplies, ossil uels still provide the major

part o world energy.



The energy dilemma

Figure .. World energy needs appear insatiable. It is expected that energy

use will rise by some percent rom 010 to 00.

Europe could cut energy consumption by 20 percent

Using the available energy more eciently is an ideal way tomeet ever-rising energy needs and secure energy supplies.

According to the EUs Green Paper on Energy Eciency, the EUcould save at least 20 percent o its current energy consumption.This is equivalent to the present combined energy consumptiono Germany and Finland, or 60 billion euros per year.

By 2030, on the basis o present trends, the EU will be 90 percentdependent on imports or its oil; the corresponding gure or gaswill be 80 percent. Making a real eort to cap EU energy demandat present levels and subsequently reduce it would represent abig step towards securing EU energy supplies.

The application o energy eciency measures would also helpto create many new, high quality employment opportunities.Furthermore, with a successul energy eiciency scheme,some o the 60 billion euros saved on energy would go towardsincreasing the EUs competitiveness and promoting better livingconditions or its citizens. In this way an average householdcould save up to 1,000 euros per year, depending on its energyconsumption.

Climate consensus: something has to be doneThe world is living it up. Western countries seem to be consumingever more energy, and as living standards in the developingcountries improve, the rest o the world is catching up.



The energy dilemma

A consensus among politicians, scientists and industry leadershas been building: something has to be done. This is underlinedby the results o a study conducted by the IntergovernmentalPanel on Climate Change (IPCC), which was presented in early2007 in Paris.

The IPCC study investigates the natural and human drivers oclimate change, examines climate processes, and presentsestimates o uture climate change. Analysis o ice coresspanning many thousands o years shows that globalatmospheric concentrations o carbon dioxide, methane andnitrous oxide have increased markedly as a result o humanactivities since the mid 1700s and now ar exceed pre-industrialvalues. Global increases in carbon dioxide concentrations are

primarily due to ossil uel use and land-use change, whileincreases in methane and nitrous oxide concentrations areprimarily due to agriculture.

The global atmospheric concentration o carbon dioxide hasincreased rom a pre-industrial value o about 280 parts permillion (ppm) to a level o 379 parts per million (ppm) in 2005.

The annual rate o increase in the carbon dioxide concentrationwas higher during the 10 year period rom 1995 to 2005 than atany time since the beginning o continuous direct atmospheric

measurements.

Figure .. Carbon dioxide emissions have grown in all parts o the world.The level is now over one and a hal times greater than 0 years ago.



The energy dilemma

Atmospheric warming reaches new levels

Increasing levels o carbon dioxide are leading to atmospheric

warming. There is no longer any ambiguity about the warmingo the climate system. It is evident rom the many changesthat can be observed: increasing global average air and oceantemperatures, rising sea levels, and widespread melting o snowand ice covers.

O the twelve years between 1995 and 2006, eleven rank amongthe 12 warmest years since 1850, when instrumental records oglobal surace temperatures started to be kept.

Numerous long-term climate changes have been observed

on the continental, regional, and ocean basin scales. Theseinclude changes in Arctic temperatures and ice behavior,widespread changes in amounts o precipitation, ocean salinity,and wind patterns, and changes in extreme weather conditionsincluding droughts, heavy precipitation, heat waves, and tropicalcyclones.

Projections indicate that warming o about 0.2C per decade canbe expected during the next two decades. Even i concentrationso all greenhouse gases and aerosols were kept constant at year2000 levels, a urther warming o about 0.1C per decade would

be expected.

Continued greenhouse gas emissions at or above currentrates would cause urther warming. They would also inducemany changes in the global climate system during the presentcentury that would very likely be greater than those observedduring the previous one hundred years. Even i greenhouse gasconcentrations were to be stabilized, anthropogenic warmingand sea level rise would continue or centuries due to thetimescales associated with climate processes and eedbacksystems.

I all the ice in Greenland melted, the sea level would rise byseven meters. Even with less dramatic changes the world acesa rise in sea level o between 20 centimeters and one meter,depending on the estimate, during this century.

Industry uses over 40 percent o total world electricity

The world is demanding more and more electricity. From 1973to 2004 world electricity consumption almost tripled. Industryaccounts or just over 40 percent o total consumption.



The energy dilemma

Energy saving is without doubt the quickest, most eective andmost cost-ecient way o reducing greenhouse gas emissions,as well as improving air quality, particularly in densely populatedareas.

The IPCCs Mitigation o Climate Change report nds thatin order to satisy demand or energy it is oten more cost-eective to invest in improving end-use energy eciency thanin increasing energy supply. Improving eciency has a positiveimpact on energy security, local and regional air pollutionabatement, and employment.

The report also concludes that economic potential in theindustrial sector is predominantly ound in the energy intensive

industries. The available mitigation options are not being ullyused either in the industrialized or developing nations.

Many industrial acilities in developing countries are new andincorporate the latest technology with the lowest specicemissions. However, many older, inecient acilities remain inboth industrialized and developing countries. Upgrading theseacilities can deliver signicant emission reductions.

The slow rate at which capital goods are turned over, lack onancial and technical resources, and limitations in the ability

o rms, particularly small and medium-sized enterprises, toaccess and absorb technological inormation are key barriersto the ull application o the available mitigation options.

Figure .. World consumption o electricity has almost tripled in thirty years.



Potential electricity savings (billion kWh/year)

EU-15 EU-25 France Germany Italy UK

High eciency

motors 24 27 4 6 4 3Variable speed

drives45 50 8 10 7 6

Applications

(pumps, ans,

compressors)

112 125 19 26 17 15

Total 181 202 31 42 28 24

The energy dilemma

The Motor Challenge Programme - a voluntary scheme promotedby the European Commission to help companies improvethe energy eciency o their electric motor driven systems- estimates that such systems account or approximately 65percent o the electricity consumed by industry in the EU.

Switching to energy ecient motor driven systems throughoutEurope could produce savings amounting to 202 billion kWh inelectricity consumption, which is equivalent to a reduction o10 billion euros in annual operating costs or industry.

Table .1. Switching to energy ecient motor driven systems in the EU could

save over 00 billion kWh annually.

Rising energy prices have orced companies to seek wayso limiting their energy consumption. In the UK it has beenestimated that the chemical industry uses 22 percent o allthe energy used by UK manuacturing. This industry accountsor 2 percent o the countrys gross domestic product (GDP)and employs some 230,000 people. It is acing average priceincreases o 70 percent or gas and 60 percent or electricity,prompting companies within the industry to look or wayso urther improving their energy eiciency beore theircompetitiveness is eroded by cheaper imports. Energy pricerises are aecting companies across the board, rom largemultinationals to small, local businesses, and not only in thechemical industry but in printing, ood production and otherenergy intensive sectors, too.

Sources:

EU Green Paper on Energy Eciency

Intergovernmental Panel on Climate Change: Climate Change 00

International Energy Agency: Key World Energy Statistics 00

www.abb.com/energyeciency

www.energywatch.org.uk

www.leonardo-energy.org

Energy Ecient Motor Driven Systems, The Motor Challenge Programme



Chapter 3 - Europe takes action

The EUs bold advance

November 2006 saw agreement on a new energy eciencyaction plan by European energy ministers. The measuresproposed in the plan will lead to an estimated 20 percentimprovement in energy eciency by 2020. In March 2007 theCouncil o Europe adopted a signicant energy and climatepackage, which is based on three main elements: building atrue internal energy market, shiting to low carbon energy, andpromoting energy eciency.

The EU is now committed to reducing greenhouse gas emissionsby at least 20 percent by 2020. Furthermore, the Heads o Stateand Government have endorsed a binding target o 20 percentor the share o overall EU energy consumption to come romrenewable supplies.

Climate change is denitely the headline issue, but security oenergy supply is also a critical topic, says Ms. Sirkka Vilkamo,Deputy Director General and Head o the Renewables and EnergyEciency Division at Finlands Ministry o Trade and Industry.

At present there are around 20 EU Directives which relate toenergy. The Energy Perormance o Buildings Directive, orinstance, stipulates certain measures but does not speciynumerical objectives. There is certainly good potential orsavings in this area, as around 40 percent o the energyconsumed in the EU is used or heating and cooling buildings.The Energy Services Directive passed in May 2006, by contrast,does lay down numerical objectives. This Directive applies to allenergy using sectors, with the exception o businesses involvedin emissions trading, and aviation and maritime bunker uels.

It provides an indicative 9 percent objective or energy savingover the period 20082016.

In 2016 we have to be able to show that we have achievedsavings o 9 percent. This does not mean, however, that in 2016we should be consuming 9 percent less energy than in 2008.The obligation is to implement measures that generate savings so the idea is that i we had not done anything we would beconsuming 9 percent more in 2016, explains Heikki Visnen,Senior Adviser at the Energy Department o the Finnish Ministryo Trade and Industry.



Europe takes action

It is dicult to show that savings have really taken place whenenergy consumption is steadily on the rise. The challenge ormember states is to prove that something that no longer exists the kilowatt-hours o energy consumption taken out o use did in act once exist.

Momentum is building up

In all elds and sectors there is a lot that can be done. The goalo increasing energy eciency by 20 percent implies a reductionin energy consumption o 13 percent rom todays levels.

The underlying objective o increased energy eciency is toreduce climate change. Ideally, this is something that the whole

world should be involved in, but the EU is prepared to act alonei other parties are not yet prepared to participate.

The two key drivers are the need to avoid compromising currentoperations and the desire to cut emissions. While renewableenergy has been more o an issue in the public debate, recentstudies show that improving energy eciency has been seen asa more ecient tool at the EU level and even at the world level.The EU has played an active role with new energy eciencyinitiatives, and will now also be active on the global scale.

Looking back over the last ten years, there has been a lot otalk about energy eciency. Now there is real momentum to dosomething. The objectives set by the EU clearly show its currentambitions, Visnen says.

Now we have actual numerical objectives the pressure is reallyon. This makes the whole thing much more serious. Emissionstrading has been one way o steering developments in the rightdirection, says Sirkka Vilkamo.

Raising awareness among decision makers

Heikki Visnen acknowledges that improving energy eciencyis not in itsel part o the basic business o companies. However,companies and government can work together because betterenergy eciency also makes businesses more competitive.

Energy costs may be small relative to a companys turnover,meaning that the nancial advantages o energy eciency arenot particularly visible. However, better energy eciency cansignicantly lower production costs and provide the best return

on investment. Thereore, it is important to raise awarenesso energy eciency among decision makers. In Visnensexperience, the main issue is oten not that o nding thenecessary unding but simply o making the decision to use it.



Europe takes action

We have been running an energy eiciency agreementscheme or the last ten years. Its greatest value has been ingetting companies interested in the benets energy eciencycan provide. In addition, those companies that were alreadyinterested have received extra support or their work. One o thebenets o the energy eciency agreements is that they providea network through which knowledge can be shared, he says.

When a company decides to enter into an agreement, it makesa commitment to analyze its existing situation and improve itsenergy eciency - by boosting the eciency o its productionprocess, or instance. In return the company can be grantedsubsidies or energy audits and energy eciency investments.

Energy eciency agreements now cover more than 60 percento the total energy consumption in Finland. Visnen believesthat a voluntary agreement-based system provides the optimumcost-eciency because it leaves room or individual thinkingand fexibility in the measures taken.

Most productive employees

The energy eiciency improvements achieved have to bemeasurable or eedback purposes. Heikki Visnen comparesthe eedback loop to the real-time uel consumption displays

ound in many cars. Drivers remain strongly motivated todrive economically when they see how it reduces their uelconsumption and benets them nancially.

The employees involved in company energy programs maywell be the most productive members o the workorce. Thereare not very many people who can directly contribute, say, hala million euros per year to their companys bottom line, hesays. He stresses that companies should not limit their energyeciency activities to standalone projects: best practices canand should be duplicated in other plants.

Companies should also ensure that energy eiciency isestablished as part o their purchasing guidelines. Class Aequipment may be slightly more expensive than less ecientproducts, but the dierence in price is rapidly recovered whenoperating costs are taken into consideration.

Management must be proactive

Sirkka Vilkamo points out that the signing o an agreement

is only the rst step: it has to be adopted by the companysmanagement. She says that energy audits, one o the obligationscontained in the agreements, can be compared to periodichealth checks.



Europe takes action

Heikki Visnen explains that the audit approach provides asolid basis or subsequent action: All the companies that havejoined the scheme have started by doing an energy audit. Basedon the audit ndings, the company then decides when and howit will take the next step. In industry, investment payback timeso two to three years are usually easible, while in other sectors,such as local authorities, the payback time can be between veand ten years.

The agreements have prompted a wide range o measuresaiming to increase energy eciency. These include acquisitiono new production equipment, VSDs, compressed air and heat-recovery systems.

ESCO: an ecient nancing modelThere is also an alternative way o nancing the investments. Itis known as energy perormance contracting - the investmentsare paid back over time by the energy savings that are realized,says Visnen.

These Energy Service Company (ESCO) operations can achieveeven better eiciencies by implementing entire projects- rom energy audits to nancing and investments. In manycompanies in Finland this concept has established itsel as an

everyday way o implementing investments to boost energyeciency. Previously the ESCOs had to take out a loan to coverthe investment, but now the usual practice is or the ESCOcontract to be sold to a commercial nance provider once theinvestment has been commissioned and the level o realizedsavings veried.

Further work needs to be done to gain broader acceptance orESCO agreements, but as Heikki Visnen conrms once acompany has tried the system it is then easier to put togethera second agreement to implement improvements elsewhere at

the same site. Energy eciencies are oten built on a step-by-step basis.

Monitoring systems essential

Heikki Visnen believes that energy eciency agreements willplay a decisive role in ensuring that the EUs energy eciencygoals are reached, especially because it is necessary to collectinormation on the amount o savings realized.



Europe takes action

There are dierences between the member states in respect othe amount o inormation on energy eciency that is collected,and the methods used to calculate energy savings. The EnergyServices Directive seeks to harmonize the methodologies usedor calculating savings. While this is a necessity or certain typeso measures, it may however prove quite problematic with others.Climate conditions pose quite dierent challenges betweenNorthern and Southern Europe, or instance. Guidelines on themethodologies or calculating energy savings are now beingdeveloped but it remains to be seen how much harmonizationcan nally be achieved.



Chapter 4 - Sustainable and ecientenergy use

Quick, eective and low cost

Many solutions have been put orward to combat climatechange. Renewable energy, carbon capture and biouelsstand out among the main ones. All three approaches arevalid and must be pursued, but at present most o the requiredtechnologies are either not yet ready to be applied in practice,still too expensive, or involve undesirable side eects.

By contrast, ABB supplies technologies that can help to reducecarbon dioxide emissions immediately and they can be deployedquickly and at low cost. The idea is to use energy more eciently.ABB has been developing energy ecient technologies ormany years, and solutions incorporating these technologies canproduce big savings in energy and emissions.

ABB supplies technologies that can help to reduce carbon dioxide emissions

immediately.

In industry the biggest reductions in emissions in the short termwill come rom measures to run processes more eciently. Ototal electricity consumption, industry accounts or about 40percent, o which two-thirds is used by electric motors. VSDscan reduce the energy consumption o motors by 50 percent

in many applications, and yet less than 10 percent o motorsare operated by drives. This represents a antastic opportunityto bring about a dramatic reduction in emissions using readilyavailable, low cost and proven technology.



Sustainable and ecient energy use

Energy eciency needs to become ashionable

ABBs mission is to pursue power and productivity or a better

world. Panu Virolainen,, Vice President, Technology, o ABBsLow Voltage AC Drives business eels that the idea behind themission is nowadays so sel-evident that it does not require anyexplanation. Ater a moments thought he adds that in practice itmeans that ABB helps customers to use electrical power eectivelyand increase industrial productivity in a sustainable way.

For large corporations energy eciency may also have becomea sel-evident way to increase productivity and curb risingenergy costs. It is among small and medium sized enterprisesthat the savings and benets are less obvious. Virolainen says

somewhat jokingly - that energy eciency needs to becomeashionable to become more widely adopted.

In act, market statistics indicate that energy eciency is onthe way to becoming a ashion. Sales o AC drives have beengrowing steadily at an annual rate o 610 percent.

We are now seeing the same kind

o urgency as there was in the 10s

when the oil crisis caused energy prices

to sky-rocket. ABB came up with a

solution to save energy by controlling

the requency o the power supply. Sincethen the technology has evolved into a

highly reliable and cost-eective means

o controlling industrial processes,

Virolainen says.

In the 21st century energy savingis still a hot topic, but there isalso another major concern:greenhouse gas emissions haveto be cut. AC drives are much

smaller and cost a lot less than 30 years ago. Prices o electronicequipment have been heading downwards or a number o yearsand, coupled with rising energy costs, this means that paybacktimes or energy saving equipment have become much shorter.As a result, installing AC drives on even small machines hasbecome an attractive option.

Global demand or drives

Pumps, ans, compressors and extruders account or a largeproportion o industrial drive applications. Virolainen states

that the actual operation point o these originally designed tobe. In many cases energy is wasted because the fow o liquidor gas is regulated by means o a brake or throttle mechanism.The idea behind an AC drive is to adjust the speed to matchthe point o operation.




The worldwide installed base o ABB drives saved about 160 TWhin 2008, which is equivalent to the annual consumption o morethan 39 million amilies. The drives also reduced carbon dioxideemissions by around 135 million tonnes in the same year.

With high powered machinery even incremental changes inenergy eciency can bring about big savings relative to thepurchase price but, as Virolainen points out, the trend is to equipsmaller and smaller machines with AC drives.

In Japan, or instance, many rooms have individual ventilationequipment consisting o a small motor, a ventilator and an ACdrive. These low-cost integrated packages are used to controlthe airfow in all rooms individually. This equipment is widely

used in Japan, where energy prices have generally been veryhigh. Europe has not yet caught up in this respect, saysVirolainen.

Two-thirds o industrial electricity used by electric motors

In industry, 65 percent o total electricity consumption is usedor driving electric motors. Using AC drives, motor speeds canbe controlled according to demand, making possible savingso up to 70 percent in energy consumption.

In Europe, demand or AC drives has been signicantly boostedby emissions trading and other measures to cut back carbondioxide emissions. Demand has also been increased by theact that there are now only limited oil resources available ataordable prices. For its part, the US has also started to lookor ways to reduce its dependence on oil. Utilizing the availableenergy more eciently is one o the most obvious solutions.

China, by contrast, has dierent problems. Production volumesare growing so rapidly that it is not possible to build sucientpower plants to meet the demand. In order to keep its growth

on track, China will have to save energy. India aces the samekinds o challenges.

Better control and higher eciency

ABB has a well-established procedure to help customerssave energy. This begins with an energy audit, which usuallyproduces clear suggestions or areas that can be improved.Large companies have tended to lead the way, because energyis usually a major cost or them.



The main argument or acquiring AC drives is to save energybut, as Panu Virolainen explains, drives also provide bettercontrol over the entire process. Using drives could mean that aproduction machine can be used or dierent kinds o materialsor manuacturing recipes, or instance.

When xed-speed motors without drives were used, speedchanges required the use o innitely-variable speed drives,belts or gear boxes. Hydraulics were also oten needed, whichcould mean oil leakages. Speed control mechanisms oten ledto losses in power transmission.

Todays AC drives eliminate these kinds o problem. A urtheractor in avor o drives is that the prices or mechanical solutions

are not decreasing and in some cases are even increasinggradually - while the prices o AC drives have declined steadilywith advances in control electronics.

The scientic principles underlying the operation o AC driveshave remained the same or a number o years. They havebecome the oundation or a proven technology that hasbeen enhanced with sotware based solutions or controllingproperties such as pressure, temperature, or fow rates.




Chapter 5 - ABB motors and drives orecient control

Potential or major energy savings

With electric motors accounting or an estimated 65 percento industrial energy use, any increases in eciency clearlyprovide the potential or major savings. The energy consumptiono electric motors can be reduced in two main ways byimplementing ecient speed control and by increasing theeciency o the motors themselves.

VSDs are by ar the most eective method o controlling motorspeeds. In practice, however, control is oten still implementedwith throttling valves in pump systems, vanes in an applications,or gears or belt drives in rotating machinery. Belt drives,gearboxes and hydraulic couplings all add to the ineciencyo the system, and require the motor to run at ull speed all othe time. In addition, mechanical drives can be noisy as well asdicult to service, as they are situated between the motor andthe driven machinery.

Mechanical drives oten seem cost-eective at rst sight,but they waste energy. Running a motor at ull speed whilethrottling the output is rather like trying to control the speedo a car by keeping one oot on the accelerator and the otherone on the brake part o the output produced is immediatelywasted. Taken over industry as a whole, the total amount oenergy wasted in this way is huge: o the estimated 65 percento industrial energy that is used by electric motors, some 20percent is lost by throttling mechanisms.

Hal speed or only a quarter o the energy

In pump and an applications, VSDs can cut energy bills by as muchas 60 percent. A pump or an running at hal speed consumes onlyone quarter as much energy as a unit running at ull speed.

As a small reduction in speed can make a big dierence in energyconsumption, and because many pump and an systems run atless than ull capacity or much o the time, VSDs can producehuge savings. This is particularly so when compared to motorsthat are continuously running at ull speed, even though motorshave improved in eciency by an average o 3 percent over the

last decade. It has been estimated that AC drives supplied byABB over the past ten years or the speed control o pumpsand ans have reduced electricity consumption by around160 TWh per year worldwide.



ABB motors and drives or ecient control

Regulating motor speeds has the added benet that productionincreases can easily be accommodated without the need or extrainvestment, as AC drives can easily manage speed increases o520 percent. By matching the perormance o the motor to theneeds o the process, drives can produce major savings whencompared to the wasteul practice o running the motor at ullspeed against a restriction to modulate output. In an ideal world,energy would be applied with pinpoint accuracy when and whereit was needed, and no energy would be wasted.

Despite the obvious energy saving advantages, 97 percento all motors in applications under 2.2 kW have no orm ospeed control at all. This corresponds to some 37 millionindustrial motors sold annually worldwide. This might have

been understandable in the past, as a small drive cost in theregion o $500 (400 euros) per kW. Drives across the range havebecome smaller and cheaper over the past ew years, however,and now start at around $150 (100 euros) per kW.

This can make investment in a VSD a viable proposition onenergy grounds alone. In addition, the new generation o drivesis smaller and so installation might be possible in places wherespace constraints were an issue in the past. The latest drivesare also more energy ecient than their predecessors.

ABB is leading the way in developing drive technology, withstate-o-the-art control techniques such as direct torque control(DTC). A eature o DTC which contributes directly to energyeciency is motor fux optimization, which greatly improvesthe eciency o the total drive (the controller and the motor),especially in pump and an applications. The drives themselvesare becoming leaner too, not only smaller in size but moreenergy ecient to manuacture, with smaller circuit boards andenclosures made o recyclable plastic.

Subsidies or high eciency motors

In many countries nancial incentives are now available toencourage investment in high eciency motors. The DanishEnergy Agency is one o the leading organizations in the eld.It has published a list o high eciency motors and oersa subsidy o $10 (7.70 euros) per kilowatt or both new andreplacement units purchased rom the list. This scheme ispromoted direct to the 4,000 largest motor users.

The USA and Canada have introduced the Energy Policy andConservation Act (EPAct). Among other legislation to improvethe environment, this specically targets motors rom 0.75 to150 kW as prime candidates or improvement. A scheme similarto the Danish one has been adopted, with a published list ohigh eciency motors and reduced electricity taris or userso the listed products.




The US Department o Energy also requires the eciency ratingto be indicated on the motor nameplate, the energy eciency tobe displayed prominently in all literature and marketing material,and the inclusion o other markings to acilitate the enorcemento energy eciency standards. Failure to comply with theserequirements results in severe penalties.

New standards pave the way or international harmonization

The IEC has introduced two new standards relating to energyeicient motors. IEC/EN 60034-2-1 speciies new rulesconcerning eciency testing methods and IEC 60034-30 denesnew eciency classes or motors.

ABB welcomes the new IEC standards, as their eect will be tolevel the playing eld or motor manuacturers. The new standardwill tighten up procedures and enable manuacturers to publishmore accurate eciency values. The new classication standardharmonizes the currently diering requirements around the worldregarding eciency levels o induction motors. It will hopeullyput an end to the diculties experienced by manuacturerswhen producing motors or a global market.

Emissions will be reduced signicantly i a majority o motormanuacturers take steps to improve the eciency o their

products. Motor users will benet by having access to moretransparent and easier to understand inormation, and will beencouraged to install high eciency motors exclusively.

IEC/EN 60034-2-1, which came into orce in September 2007,introduces new rules concerning the testing methods to beused or determining losses and eciency. The documentationsupplied with the motor must state which method is used. O themethods available under the new standard, ABB uses the indirectmethod with stray load losses determined by measurement.

The resulting eciency values dier rom those obtained underthe previous IEC testing standard, IEC 60034-2: 1996. It mustbe noted that eciency values are only comparable i they areobtained using the same method.




Figure .1. The EU has published energy eciency categories or motors. There

are three class levels: E1, E, and E, applying to low voltage two- and

our-pole motors rated rom 1.1 to 0 kW. The aim is to phase out production

o less energy ecient machines.

IEC 60034-30 was introduced in October 2008 and denes threeIE (International Eciency) eciency classes or single-speed,three phase, cage induction motors.

IE1 = Standard eciency (eciency levels roughly equivalent

to EFF2 under the European eciency scheme) IE2 = High eciency (eciency levels roughly equivalent toEFF1 under the European scheme and identical to EPAct in theUSA or 60 Hz) IE3 = Premium eciency (new eciency class in Europe andidentical to NEMA Premium in the USA or 60Hz)Eciency levels dened in IEC 60034-30 are based on testsmethods specied in IEC 60034-2-1: 2007.

Compared to the old CEMEP eciency classes (EFF1, EFF2& EFF3) in Europe, the scope been expanded to include 2-, 4-

and 6-pole motors and rated outputs rom 0.75 to 375 kW. Thenew eciency classes thereore cover almost all motors. Twodrawbacks o the old European system were that there was nomandatory minimum eciency and the system was not congruentwith classication systems applied in other parts o the world.

IEC 60034-30:2008 does not include rules on implementationo the new eciency classes. In EU countries implementationis subject to a decision by the European Commission, whileelsewhere it is subject to national legislation. ABB is closelymonitoring the drating o this legislation and is taking steps to

ensure its products will comply with the new requirements whenthey enter into orce.




Developing an eective motor management policy

Motors can be designed to minimize losses and thus increase

eciency by improving those aspects o design and constructionthat give rise to the main losses. The greatest losses are theiron losses that occur in the rotor and stator, accounting or 50percent o the total loss. These losses can be reduced by usinglow loss steel and thinner laminations. Copper losses accountor 20 percent, and can be decreased by using an optimum slotll design and larger conductors. Bearing riction and windagelosses total 23 percent and can be reduced by using a smallercooling an. Stray losses, which account or 7 percent o thetotal, can be reduced by improving the slot geometry.

Users can also do a great deal to ensure they are getting thehighest eciency rom their motors. A motor management policyis a very useul tool in this respect and should be put in place.One policy decision should be to select high eciency motorswhen purchasing new equipment, and minimum acceptableeciency values should be specied. The policy should alsoinclude criteria or deciding whether to replace or rewind a ailedmotor. This ensures that the decision can be made long beoreactual ailure occurs.

The table below shows an example lie cycle cost assessment, in

this case a comparison between two standard 15 kW electric motorso dierent designs running at 12 kW. Motor A is manuactured byABB, motor B by a competitor. Although motor A requires morecopper and iron to manuacture than motor B, this makes motorA more ecient in operation, meaning that it uses less electricitythan motor B over its lietime. The example assumes that bothmotors operate or 8,000 hours per year or 15 years.



Table .. Environmental impact o two standard 1 kW motors o dierent

designs. Motor A is rom ABB.

AC drives are the ideal solution or speed control

VSDs can save a lot o energy and money in applications wheredemand varies. They enable users to minimize their equipment

lie cycle cost and improve perormance.

Electric motors are behind virtually everything that moves, andare by ar the biggest users o electricity in industry and buildingsystems. The energy eciency o many motor installations can bedramatically improved with VSDs which ensure that motors onlyrun at the speeds and times required. Drives are inexpensive andeasy to install, but most motors are nevertheless let running at asingle speed or long periods o time, oten without any workingload.

The potential savings are signicant a pump or a an runningat 80 percent speed only uses 64 percent o the energy andslightly more than 50 percent o the power used by one runningat ull speed. The problem is exacerbated by the act that many

Environmental impact

over lie cycle

Motor A: 12 kW

91.1% efciency

Motor B: 12 kW

91.1% efciency

Use o resources

Coal (kg) 16,370 20,690Gas (kg) 2,070 2,620

Oil (kg) 3,240 4,090

Steel (kg) 27 24

Copper (kg) 0.9 0.8

Aluminum (kg) 4 4

Silicon (kg) 1.1 1.0

Emissions

Carbon dioxide (kg) 62.940 79.560

Sulur dioxide (kg) 495 626

Nitrogen dioxide (kg) 136 172

Hydrochloric acid 8.8 11.1

Metals (g) 538 538

Heavy metals (g) 1.1 1.1

Solid waste (kg) 117 106

Particles (kg) 30.4 38.4

Other (kg) 12 1 5

Total EPS indices 8.260 ELU o which 10.430 o which

99.4% 99.5%

rom operation rom operation

(EPS = Environmental Priority Strategies in Product Design; ELU =Environmental Load Units)




motors are oversized, using more energy than the applicationactually needs. This is because motors are only available witha certain number o xed speeds. Users tend to get the nextbigger sized motor relative to the requirement and then throttlethe output, or instance by using a valve to reduce the waterfow in a pumping application.

By reducing the speed o the motor, a drive can help to ensurethat a pump, or instance, uses no more energy than necessaryto achieve the required fow. In addition to the energy savings,other benets include accurate control and less mechanical wear,reducing maintenance and extending the lietime expectancyo the system. While payback times o two to three years arenormal, payback times as short as six months can sometimes

be achieved on the basis o energy savings alone.

Looking at the entire lie cycle

Motors are oten overlooked when energy eciency measuresare under consideration because the large numbers o motorsin use mean that each individual unit may seem insignicant inisolation. However, it is precisely their great number that makesmotors so important.

To minimize running costs, users should look at the whole lie

cycle, starting with the acquisition o new equipment and newplant design. How much less would the equipment cost overits lie cycle i a VSD were tted rom the outset? Getting anoversized motor means paying or output that is not needed,and it also translates into ineciency because the motor is notully used.

Taking a proactive approach to energy eciency can helpcompanies o all sizes to achieve substantial savings. Manypump and an applications run at constant speeds, even thoughvariable speed operation would oten give ar better perormance

at much lower cost. I a 100 kW an is throttled by 50 percent,or instance, the investment in a VSD would probably have apayback time o less than two to three years.

Drives operate by switching the xed mains supply voltage toa variable voltage and requency in response to an electricalcontrol signal. When coupled to a an or pump motor, the changein requency will result in a corresponding change in motorspeed. This means that the motor speed can be set on the basiso external parameters such as water fow or air temperature.




Chapter 6 - Energy audits identiypotential savings

Evaluating how energy is used

Few industrial systems are, in practice, optimally dimensionedrom the point o view o energy eciency. It is an extremelychallenging task to design an optimized plant with hundredso actuators, valves, pumps, ans, etc. or a complex processwhile taking into account a range o parameters rom varyingdemand to ageing equipment. The investment cost or boththe (re)design and selection o control technology still remains

a major decision criterion, even i it only represents less than 5percent o the plants lie cycle costs.

In order or a company to reduce its energy costs, it needs toevaluate how it uses energy. An energy audit is a systematicexamination o key pump and an applications that includesthe monitoring o energy consumed both beore and ater thechange to VSDs.

The audit denes where and how much energy can be saved byinstalling VSDs. These gures are then translated into a potentialmonthly saving indicating how much energy costs could bereduced by installing the recommended equipment.

Users sometimes nd it hard to believe that a 20 percent reductionin speed can produce a 50 percent saving in energy. The savingscan be veried, however, and the best way to start is with an energyaudit. ABBs Energy Audit Scheme produces recommendationsbacked up by careul analysis o collected data.

Figure .1. At 0 percent airfow, the commonly used guide vane system uses

over three times the energy o a VSD and motor combination.



Energy audits identiy potential savings

Recommendations based on actual data

The audit process begins with a brieng where the customerdescribes the process and its operation to ABBs audit sta.The audit team explains in detail how the audit is perormedand also outlines the costs.

The investments that are recommended

as a result o the audit will be paid or by

the energy savings realized. The payback

time can be as short as six months,

and in most cases the investments are

ully covered in - years, says Jukka

Tolvanen, Energy Eciency Market

Manager at ABB LV drives.

The irst meeting prepares theground or urther analysis, whichis preceded by a walk-through othe production acilities. This givesthe audit team the opportunity togather more detailed inormationabout equipment such as pumps,ans, and extruders that areoperating in the process. The exact output values o all the motors arenot always known, but the plate values can be noted.

During the walk-through the auditors also collect other relevantinormation about how the machines are used. Inormation onwhether or not machines are driven at ull power, operatedcontinuously, and whether or not they are throttled, is importantor the audit process.

Data loggers are installed and let on-site in some cases ora ew weeks - to record data on parameters such as power,current, and fow. In some cases a compact, transportable ACdrive unit is brought in to provide real usage data to justiy the

investments, Jukka Tolvanen explains.

The audit is usually restricted to the motors or parts o theproduction process that provide the biggest potential or savings.Based on the data collected during the audit, ABB computeshow much energy and carbon dioxide emissions could be savedby installing VSDs. Ater the rst audit is completed and anyrecommended investments have been implemented, urtheraudits are oten commissioned.

Additional savings rom unexpected sources

Jukka Tolvanen says that in many cases installing drives not onlysaves energy but also leads to savings in other areas that aremore dicult to evaluate beorehand: Calculating the power




savings is relatively easy, but once the new equipment is inplace we oten realize that the temperature and noise levels inthe plant have decreased dramatically.

When machines are operated at the required speed and onlywhen necessary, they need less cooling. This usually meansthat they do not need servicing as oten, which, in turn, providesurther cost savings. Sometimes there has even been a decreasein the consumption o raw materials in one plant there wasa an that was always run at ull power, and it turned out thatlightweight particles o the raw material were simply beingblown away.

In another instance an audit recommended that the plants

compressors should be tted with AC drives. When this wasdone it not only reduced the overall energy consumption butalso resolved an overheating problem. Previously, when thecompressor in question reached a certain temperature it wasautomatically turned o to protect the machine. Once driveshad been tted the compressors could be operated withoutinterruption, Jukka Tolvanen recalls.

In the longer term there will be an increasing diversity o motorsand drives, meaning that customers are likely to need even morehelp to get the most out o their equipment. While customers

ocus on their own businesses, we can use the audit processas a stepping stone towards achieving greater eciencies orthem.

An energy audit is oten very revealing or customers, as it showsthem how they can cut their energy bills and let the savingspay or the new equipment. In many countries there are EnergySaving Companies (ESCOs) that oer lease-back arrangementsto nance the investment in new equipment.

Payback within months

The payback time or VSDs is oten a matter o months on thebasis o energy savings alone. In addition, by optimizing the speedto match the requirements o the process, users oten nd theyget better product quality and reduced maintenance costs.

To take an actual example rom manuacturing industry, a UKcompany installed an ABB drive to operate a an. By reducing thespeed by 20 percent the drive produced a 56 percent reductionin power (rom 118 to 51 kW), saving over 440,000 kWh a year.The cost o the drive was GBP5,600 (8,000 euros) and the energysavings amounted to GBP17,000 (24,300 euros) per year orGBP1,400 (2,025 euros) per month. The straight payback wasthereore just our months. The drive has naturally continuedto save money or the company every month, and will do so




or the rest o its lie. There are ew other investments that canoer this type o payback boosting the companys prots byGBP17,000 (24,300 euros) per year would require a signicantincrease in sales.

The rewards or investing in energy ecient motors are lessdramatic but still worth pursuing, as direct-on-line installationsare so common. The electricity consumed by the motorrepresents the overwhelming part o its lietime cost. Thepurchase cost is very small in comparison and is overtaken bythe electricity cost ater three months o continuous operation.A 90 kW energy ecient motor can cost GBP1,500 (2,140 euros)more to buy than a standard eciency model, but can save overGBP10,000 (14,290 euros) over the course o a ten-year service

lie compared to the standard eciency unit.

In addition, because the high eciency motor has lower energylosses it will have a lower running temperature giving improvedreliability. This makes high eciency motors a better choice incritical applications, or instance in the paper industry wheredowntime costs are high.

Figure .. Savings begin to accumulate ater a relatively short period o time:

in this example the payback period is just our months.

In the UK small and medium sized companies may be eligibleor avorable loans to help purchase energy saving equipment.Many other countries have their own systems or nancingenergy ecient investments.




Tools help with nancing calculations

ABB oers two dierent tools to help make nancing and

investment decisions easier:

PumpSave or comparisons between variable speedAC drives and other pump control methods.FanSave or comparisons between variable speedAC drives and other an control methods.

These tools help users to calculate the payback period orinvestments in ABB drives. The Net Present Value (NPV) o theinvestment can also be calculated, taking the actual cost ocapital and equipment service lie into consideration. Customers

can download these tools rom www.abb.com/drives or ask orassistance rom their local ABB oce or ABB drives channelpartner.

Companies seeking to cut their energy costs do not even needto use their own cash resources or bank borrowing acilities.Other ways o nancing AC drive and motor packages include(availability may vary depending on country or region) hirepurchase arrangements, nance leases, operating leases,and Energy Service Company (ESCO) agreements.



Chapter 7 - Case studies: big savingswith modest investments

China:Plastics plant cuts energy consumption by 30 percent

The Petrochemical Plastic Factory in Daqing, northern China,manuactures a range o petroleum-based plastics and syntheticmaterials. Annual output is some 8,000 9,000 tons.

Issue

Productivity at the Daqing plant was below expectation becausethe motor used to drive the continuous mixer was limited totwo speeds. The 1,300 kW motor, which was acquired 20 yearsago, is a 6- and 8-pole, 6.0 kV machine with two xed operatingspeeds o 750 and 1,000 rpm. Fixed speeds meant that the mixercould not run at its optimal operating point, and could not reactto the sudden load changes that occur during the polyethylenemixing process. This led to poor product quality and requentbreakdowns, which reduced output.

Solution

ABB was asked to investigate how the mixers perormancecould be improved in order to boost productivity without anyloss o consistency to the plastics being mixed. The answer wasan ABB drive, together with a locally supplied input isolationtransormer.

An important aspect o this solution is the use o a sine lter,which eliminates harmonics to the motor, allowing the existingmotor to continue in use without derating. The ABB drive enables

the motor speed to be varied rom 500 to 1,000 rpm. As a resultthe mixer works at its optimal operating point with the addedadvantages o smooth starting and rapid reaction to suddenload changes. Both product quality and process eciency haveimproved substantially.

Benefts

Power requirements are reduced as the motor speed can now bevaried to precisely match the demands o varying mixer loads.

Loads can range rom less than six to around ten tons o mixmaterials. With a load o approx. 9.5 tons, the motor previouslyused 1,215 kW. Following installation o the ABB drive, the samemixer load requires only 1,150 kW o motor power.



Case studies: big savings with modest investments

Location Petrochemical Plastic Factory, Daqing, China

Segment and application Plastics - Mixer

ABB drive enables variable speed operation

instead o previous xed speeds

Savings and benefts - 30 percent reduction in energy consumption

- improvements in process eciency and

product quality

The plant estimates that the drive has reduced energyconsumption by 30 percent. The payback period or thecomplete system has been calculated at around two years. Thedrive is o standard design and can thereore be easily retrottedto existing motors. In the case o the Daqing plant, connectingthe drive to the existing motor simply meant changing the motorconnection rom star to delta.

China:Substantial energy savings and reduced emissions

Chinas energy needs are growing as its economy expands.Many Chinese companies have embraced VSD controltechnology, with the dual aims o saving energy and cutting

back greenhouse gas emissions. The three examples below,representing three dierent industries, show the kinds o savingsthat are being achieved.

Cement: A cement actory in Jiangsu Province has installed anumber o ABB drives to operate kiln ans. The drives replacehydraulic couplings on a production line. The resulting energysavings amount to 2.8 kWh/t, which totals 4,200 MWh annually.In addition to producing savings o RMB1.68 million (163,110euros), the drives have also reduced carbon dioxide emissionsby 2.1 million kg annually. Estimated payback time or the systemis 1-2 years. The introduction o drives has also reduced reactivepower issues.




Location Cement actory,Jiangsu Province

Water utility, Beijing Aluminium Corporationo China, Qinghai

Segment and

application

Cement Fans Water Pumping Metal - Fans

ABB drives operatekiln ans

ABB drive control atbooster pump station

ABB drives control ansin exhaust gas cleaningsystem

Savings and

benefts

- annual energysavings o 4,200 MWh

- annual energy savingapprox. 1,000 MWh

- annual energy savingso approx. 8,000 MWh

- 2.1 million kg annualreduction in CO

2

emissions

- 500,000 kg less CO2emissions

- 4 million kg annualreduction in CO

2

emissions

Water: A Beijing water utility designed a new booster pumpstation with ABB drive control instead o throttling. The stationhandles the water supply or around 200,000 inhabitants, and theenergy savings through the use o drives have been calculatedat approximately 30 percent. This represents an annual energysaving o about 1,000 MWh. Greenhouse gas emissions are alsoreduced: the drives based pumping station releases 500,000 kgless carbon dioxide into the atmosphere than it would i throttlingwere used. The systems payback time has been estimated at18 months.

Aluminum: The Qinghai branch o Aluminium Corporation oChina acquired seven 315 kW drives to control ans in an exhaustgas cleaning system. The ans, with a combined rating o 1,820kW, were previously run at a xed speed. The drives havebrought about annual energy savings o around 8,000 MWh. Inaddition greenhouse gas emissions have been cut by 4 millionkg yearly. The drives have not only increased the eciency othe plant, they have also enhanced system stability. The paybacktime or the investment is one year.




Finland:Drives help to cut water utilitys energy bill

Pietarsaaren Vesi, the water utility which serves the town oPietarsaari in Finland, states that ABB drives and new pumpshave reduced energy consumption by 30 percent and helped tomaintain more stable pressure in the distribution system.

Issue

Pietarsaaris water supply is taken rom a local river. Followingtreatment, the water is pumped to a 1,500 cubic meter above-ground storage tank and pressure boosting station. The pressureboosting station eeds water directly into the distribution system

and seeks to maintain constant pressure in the pipes. The stationis equipped with two 75 kW and one 37 kW electric pumps, witha diesel-powered pump as back-up.

The drives at the pressure boosting station eature intelligentpump control (IPC), an optional sotware package or ABB driveswhich incorporates all the unctions generally required by pumpusers. The Pietarsaari installation uses IPCs multipump control,pump priority, and fow measurement unctions. Multipumpcontrol is used to operate several pumps together. Each pumpis controlled by its own drive, with one being speed adjustedand the rest run at constant speed. This results in smoothcontrol with no pressure peaks. Fail-sae operation is achievedby implementing the control connections in a star conguration,which also provides instant system recovery capability.




Location Water distribution system in Pietarsaari,

Finland

Segment and application Water - Pumps

ABB drives with intelligent pump control

operate pumps at a pressure boosting station

Savings and benefts - 30 percent reduction in energy consumption

- more stable pressure reduces pipeline

stress

Pump priority control balances the operating time o all the pumpsin the system over the long term. This acilitates maintenanceplanning, and can boost energy eciency by operating pumpscloser to their best eciency point. In water supply systemsthe consumption rate is generally greater during the day, so thedrives are programmed to operate the higher capacity pumpsduring daytime and the smaller unit at night.

Benefts

Pressure control is crucial in this application, as the pressureboosting station supplies water directly to the distribution system.The industrial drives with IPC maintain stable pressure without anyhammer eect. This reduces pipeline stress, resulting in ewer

leaks and reduced maintenance requirements. At the same timethe use o drives avoids the disturbance to the electrical networkthat is oten caused by direct-on-line starting.

According to Pietarsaaren Vesi, the upgrade has resulted insignicant energy savings over the previous direct-on-lineconguration: Together with our new pumps, the drives haveenabled us to reduce our energy consumption by about 30percent. The pressure in the system is much more stable, whichhas reduced leaks, reduced maintenance needs, and increasedend-user satisaction, says Jan Snellman, Automation Engineer.

Germany:Drives keep natural gas supplies fowing smoothly

WINGAS GmbH is one o Germanys major gas suppliers, withpipelines bringing gas rom northern Russia and the North Seato the nations most important industrial centers. The companyis a joint venture between Wintershall AG o Germany and

OAO Gazprom o Russia. WINGAS uses ABB drives to operatecompressors at its compressor station at Weisweiler and gasstorage acility at Rehden.




Issue

To transport natural gas eciently over large distances the gashas to be compressed. To build up and maintain the requiredpressure, compressor stations are located at intervals alongthe pipelines.

Solution

The WINGAS compressor station on the WEDAL (WesternGerman Link) pipeline at Weisweiler uses an ABB drive to powera 12.5 MW compressor. This drive unit has been in operationsince the beginning o 1999.

ABB has also supplied two 12.5 MW drive units to power

compressors at the natural gas storage acility at Rehden. Thecompressors boost the gas pressure to 300 bar to enable it tobe injected into rock, which provides a natural storage medium.The Rehden acility has a capacity o 4.2 billion cubic meters onatural gas, making it the largest o its kind in Western Europe .

Benefts

The use o ABB drives provides considerable savings in energyand maintenance costs and thus high productivity. Furtherbenets include minimum noise levels and zero carbon dioxideemissions.

When compared with gas turbines, ABB drives have lower initialinvestment costs and operating expenses and, thereore, shorteramortization times. The drive system used by WINGAS has

demonstrated its reliability and proven technology in numerousinstallations. Standardization has positively impacted the costs,availability and reliability o this type o large drive.




Location WINGAS compressor station at Weisweiler

and storage acility at Rehden, Germany

Segment and application Oil and Gas - Compressors

ABB drives control compressors that

compress gas or transportation and storage

Savings and benefts - low energy consumption

- savings in maintenance costs, higher

productivity

- zero carbon dioxide emissions

Honduras:Sugar plant boosts annual revenues by $1 million

Compania Azucarera Hondurena S.A. is one o the largest sugarcompanies in Honduras. The companys Santa Matilde sugarplant operates 155 days per year and has a capacity o 10,200tons o cane per day, with an increase to 12,000 tons per dayexpected. To optimize energy use at the plant, the companyreplaced ve steam turbines, which were used to drive the canemill, with ABB drives and induction motors.

Issue

Sugar plants produce steam by combustion o bagasse, which

is the principal waste product rom sugar production. Part o thesteam is used to power turbines, which in turn drive the cane-crushing mills. The rest o the steam is used to generate electricityor use in the plant. Under normal operating conditions, sugarplants generate enough electricity to satisy their own energyrequirements and can at times sell energy to the grid.

The cost o electricity in Honduras is relatively high because it ismainly generated with uel oil. It thereore makes sound businesssense to minimize energy use at the plant so that more energycan be delivered to the grid.

Solution

By using VSDs and electric motors instead o steam turbines tooperate the cane mill, the steam can now be used exclusively

ABB has so ar supplied and installed more than 120 mediumvoltage VSDs or chemical, oil and gas applications. More than1,950 MV drives, with a total power o 8,100 MW, are in useworldwide and represent the entire range rom 300 kW to100 MW. Customers can choose rom various drive systemssuch as voltage-source converters, thyristor-controlled motorsand sub-synchronous converter cascades or motors withspeeds up to 7,000 rpm.




to generate electricity, which will eed the whole plant and canbe sold to the grid.

According to Jorge Arriaga, Engineer at the plant, The peopleat Santa Matilde are very pleased with the perormance o theABB drives. Our plants overall energy eciency has increasedtremendously since we replaced the steam turbines with drives.Today, we are not only energy sel-sucient, but we have alsoincreased our annual revenues by around $1 million by sellingexcess energy to the grid. Furthermore, the process runs muchmore smoothly than beore.

Benefts

In the past, the cane mill was driven by ve 750 kW steam turbinesor a total o 3,750 kW. Given that the turbines require 35 pounds osteam per kilowatt, about 131,000 pounds o steam were requiredto drive the cane mill. Ater replacing the steam turbines withelectrical drives, the 131,000 pounds o steam could be used togenerate electricity at a rate o 12.7 pounds/kW.

This results in additional generation o 10,300 kW/h, which isused to eed the drives. Furthermore, excess energy totalingaround 6,550 kW can be sold to the grid. This creates about$1 million (769,200 euros) per year in additional revenue or

the company. As a result the payback time or the MV driveinvestment was about one year.

Location Compania Azucarera Hondureana sugar mill at

Santa Matilde, Honduras

Segment and application Food and beverage Sugar cane mill

ABB drives and induction motors used to drive

cane mill

Savings and benefts - increased energy eciency, with excess energy

worth approx. $1 million sold annually

- smoother process operation




India:Improved an control increases eciency at cement plant

The Chettinad Cement Corporation Ltd (CCCL) plant in Karikkali,India, has an annual capacity o approx. 1.2 million tons. Itwas Indias rst cement plant to install ABB drives or speedand torque control o the bag house, raw mill, cement mill andpreheater ans.

Issue

Electrical energy costs represent about 1520 percent o thetotal production cost o cement, putting cement plants amongthe largest industrial energy consumers. Large ans account

or the majority o the electricity consumed. In the past, Indiancement producers have used Cascade converters - also knownas Slip Power Recovery Systems (SPRSs) - to control the speedo the process ans. However, due to inherent problems withSPRSs such as poor operation in weak networks and increasedharmonics, producers are now considering the use o VSDs.

Solution

VSDs can reduce energy consumption rom around 90 to 70

kWh/ton o cement produced. The method used to control thefow rate not only has a major impact on costs, but will also aectproductivity. ABB drives eature fux optimization to reduce totalenergy consumption when operating below the nominal load.Total eciency can be improved by up to 10 percent.




Benefts

According to CCCLs Deputy General Manager, K. Narayanan,Medium voltage VSDs represent a new concept or the Indiancement industry. Compared to the SPRSs used in the past, ABBsMV AC drives oer much more operating fexibility with speedvariation rom 0 to 100 percent, while considerably reducingmaintenance costs.

Another advantage o drives is that the high starting currents- quite normal with any o the conventional starting circuits now belong to the past. VSDs bring down the ratings o thevarious starting circuit components and reduce stresses. Weare very pleased with the perormance o the ABB drives weve

installed.

Compared with the operating speed range o Cascadeconverters (60100 percent), VSDs oer much higher fexibilityover the entire speed range (0100 percent).

The use o an IGCT (Integrated Gate Commutated Thyristor)power semiconductor as an integrated protection device reducesthe ABB drives parts count, providing outstanding reliability andavailability. In addition, the ride-through unction enables thedrive system to withstand power supply disturbances.

Netherlands / international:High eciency motors cut running costs

DSM is a highly integrated group o companies that suppliesthe lie sciences and material sciences sectors with a range oproducts including high perormance materials, polymers and

industrial chemicals. It has annual sales o 6.3 billion euros and22,000 employees in over 200 locations worldwide.

Location Chettinad Cement Corporation, Karikkali,

India

Segment and application Cement - Fans

ABB drives or speed and torque control

o bag house, raw mill, cement mill and

preheater ans

Savings and benefts - total eciency improvement o up to

10 percent

- enhanced fexibility

- reduced maintenance costs



Issue

We have ound that repaired motors are less energy ecientthan new ones. I we compare a new high eciency motor withan old motor, we see a considerable dierence: the energyeciency o the old motor decreases ater it is repaired, saysMaintenance Engineer Peter Pieters.

Solution

When deciding whether to purchase a new motor or repair anold one, we consider the price o the new motor and how it willdepreciate over the ollowing our years, says Pieters.

Benefts

Even the most expensive new high eciency motor will costless over the long term taking into consideration the initialinvestment, the lie expectancy o the bearings and energylosses. We use around 20,000 motors at DSM, so choosingnew high eciency motors will lead to a very signicant annual

reduction in running costs.

DSM is committed to reducing energy consumption. Byimproving the energy eciency o our motors and equipment aswell as o our energy resources such as electricity and steam,we are making our own contribution to a better world, addsBen Odman, Director o Electrical Engineering and Consultancyat DSM.


Location Facilities in the Netherlands and worldwide

Segment ChemicalsSavings and benefts - signicant reduction in running costs

- supports commitment to reduce energy

consumption



Sweden:Mining company acquires only high eciency motors

LKAB is an international high technology minerals group basedin Sweden. It supplies upgraded iron ore products and industrialminerals, and employs over 3,500 people.

Issue

Electric motor eciency is extremely important to LKAB. Thecompany uses almost 15,000 electric motors at its mines andother acilities, accounting or 90 percent o LKABs annualelectricity consumption o around 1.7 TWh. This gure represents1 percent o Swedens total electricity consumption.

Solution

Nearly ten years ago, LKAB placed itsel rmly in the oreront oindustrial energy eciency when it announced that it would onlyacquire energy ecient motors in the uture. They are slightlymore expensive to purchase, but you save money in the longrun the purchase price represents only about 1 percent o thetotal costs associated with running the motor over its servicelie, says LKABs Lennart Mukka. For LKAB and other industrial

customers, ABBs process perormance high eciency motorsare now the obvious choice.

Benefts

By replacing its existing motors with high eciency motors,LKAB has achieved signicant savings. At the same time, energyecient motors provide LKAB with the operating capacity itneeds without additional maintenance load.




A urther benet o ABB process perormance motors is that ABBcan on request guarantee their eciency. The advantageso this became clear to LKAB during the 1990s, when electricmotors were audited at one o its plants. The audit revealed thatmotors supplied by other manuacturers were oten less ecientthan specied by the vendor. In contrast, when ABB markets itshigh eciency motors as the most energy ecient motors inthe world, it can back its claims with an eciency guarantee.

UK:Salt producer saves over 1,600 MWh per year

UK salt producer Salt Union has the capacity to produce aroundone million tons o salt every year at its Runcorn site. Thecompany says that ABB equipment costing just GBP20,000(28,570 euros) has cut energy consumption by over 60 percent,

resulting in savings exceeding GBP100,000 (142,850 euros) peryear.

Issue

As part o the production process, salt is passed through dryerswhich use ans to suck air in. As well as ood-grade, puredried vacuum salt, the plant also produces a courser granularproduct used in applications such as dishwashers. The dryeror this product previously used a an to suck air through at arate controlled by a damper. The damper was 95 percent closedduring normal operation, so most o the energy consumed wasbeing used to suck air through the narrow constriction.

Solution

An energy audit was perormed by Central Electrical, an ABBDrives Alliance member, to determine the potential or energysavings. The original an motor was rated at 337 kW, but CentralElectricals calculations showed that 132 kW should be sucientto create the drat needed by the dryer. Thats a huge energy

saving when you think we run the unit or about 8,000 hours ayear, says Dave Mullin, Electrical Plant Improvement Engineer.In act, its equivalent to over 1,600 MWh per year.

Location Mines and other acilities in Sweden

Segment Mining

Savings and benefts - signicant savings in energy costs

- capacity needs met without additional

maintenance load




The reason why the original an was signicantly oversized canbe traced back to a previous process. The dryer was ormerlyused to process vacuum salt crystals, which are much smallerthan the spherical, 2-3 mm diameter particles in granular salt.These ne crystals created a ar bigger pressure drop acrossthe dryer than the coarse product that is processed today.The old an was replaced by a smaller version, operated bya 132 kW our-pole motor coupled to an ABB drive.

Benefts

The resulting energy savings now average GBP9,000 (12,860euros) a month, or GBP100,000 (142,850 euros) per year. Thean was probably on the generous side to start with. Years agoit was common or engineers to add a saety margin, DaveMullin explains. But once the duty changed it became grosslyoversized.

Ken Tym o Central Electrical says that this type o problem iscommon: Industries and processes change, but there are a loto areas that manuacturers dont seem to consider. Sometimes

the main task is to inorm end users about the energy savingsthat are achievable. At Salt Union, energy-saving initiatives arenot conned to the process. Even the small amount o wasteheat produced by the ABB drive is being put to work warmingup the switch room in winter.


Location Salt Union, Runcorn, UK

Segment and application Food and beverage - Fans

Oversized an replaced and tted with an

ABB drive

Savings and benefts - energy consumption reduced by over60 percent

- savings exceeding GBP100,000

(142,850 euros) per year



US:Drives play key role in helping to preserve vegetable crops

Onions and potatoes are big business in certain parts o theUS. In Oregon, Washington and Idaho, or example, onionscontribute over $125 million (96 million euros) to the economyannually. The impact o potato production or the same threestates is even more signicant upwards o $1 billion (769.2million euros) annually.

Issue

To ensure high quality, onions and potatoes must be storedat optimal temperatures and humidity levels. JMC Ventilation

Rerigeration, LLC, specializes in custom ventilation andrerigeration systems or potato and onion storage. TheKennewick, Washington-based company applies new andexisting technologies to provide precise, on-site and remoteenvironmental control that helps ensure vegetable quality andreduce mass loss (shrinkage), while saving energy.

Solution

A crucial component in JMCs systems, ABB VS

ABB 13676 Sustainability Guide1 3AFE68902037 REV B 23 1 Lowres

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