Solar Thompson’s Pies
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Make the most of your energy Thompson’s Pies, based in Newcastle is a respected and well established medium sized bakery. For over 50 years the privately run business has earned a valued reputation for producing pies, sausage rolls and pastries for wholesale distribution. The bakery also supports numerous local charities and supplies local schools and sporting facilities. Its peak production time is during winter. It was during such a period that Thompson’s Pies began experiencing power supply issues at their manufacturing site of 30 years. The ageing electrical infrastructure struggled to keep pace with the ongoing demand of a busy and expanding factory. The Challenge Thompson’s Pies was experiencing electrical problems and power outages, caused by the high start up currents of air compressors, which in turn caused the service fuses to blow. The utility identified that the problem could be solved by replacing the pole mounted transformer located outside the premises; at the expense of Thompson Pies. It was at this time that management decided to seek alternatives. Thompson’s Pies Commercial solar system PROJECT AT A GLANCE Project Type Energy efficiency upgrade Location Newcastle, New South Wales Product Solar PV system Variable speed drives Power factor correction Customer benefits Energy and cost savings Improved reliability $28,000 predicted annual savings Solar
Transcript of Solar Thompson’s Pies
Make the most of your energy
Thompson’s Pies, based in Newcastle is a respected and well established medium sized bakery. For over 50 years the privately run business has earned a valued reputation for producing pies, sausage rolls and pastries for wholesale distribution. The bakery also supports numerous local charities and supplies local schools and sporting facilities. Its peak production time is during winter.
It was during such a period that Thompson’s Pies began experiencing power supply issues at their manufacturing site of 30 years. The ageing electrical infrastructure struggled to keep pace with the ongoing demand of a busy and expanding factory.
The ChallengeThompson’s Pies was experiencing electrical problems and power outages, caused by the high start up currents of air compressors, which in turn caused the service fuses to blow.
The utility identified that the problem could be solved by replacing the pole mounted transformer located outside the premises; at the expense of Thompson Pies. It was at this time that management decided to seek alternatives.
Thompson’s PiesCommercial solar system
PROJECT AT A GLANCEProject Type
Energy efficiency upgrade
LocationNewcastle, New South Wales
Product
Solar PV system
Variable speed drives
Power factor correction
Customer benefits
Energy and cost savings
Improved reliability
$28,000 predicted annual savings
Solar
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Schneider Electric 78 Waterloo Road, Macquarie Park, NSW 2113 AUSTRALIA Telephone: 1300 369 233 www.schneider-electric.com.au
All brand names, trademarks and registered marks are the property of their respective owners. Information contained within this document is subject to change without notice. As a global specialist in energy management with operations in more than 100 countries, Schneider Electric offers integrated solutions across multiple market segments, including leadership positions in Utilities & Infrastructure, Industries & Machines Manufacturers, Non-residential Building, Data Centres & Networks and in Residential. Focused on making energy safe, reliable, efficient, productive and green, the Group’s 140,000 plus employees achieved sales of 24 billion Euros in 2012, through an active commitment to help individuals and organisations make the most of their energy.
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Diagnosis and SolutionThompson Pies already had a trusted relationship with Schneider Electric, so they contact them to identify opportunities for energy and cost savings, at the same time as improving the reliability of the electrical supply to the building. To identify these opportunities Schneider Electric first carried out an energy audit of the plant.
The survey identified that the inrush current of one particular air compressor was a major contributor to the failure of the service fuse. The solution was to install an Altivar Variable Speed Drive (VSD). Installing the VSD saw a sharp reduction in the start up current; smoother and more reliable motor operation; a reduction in the number of start stop cycles and reduced energy consumption.
The survey also found that with the large number of motor loads used through the building, the power factor was only 0.7. The solution was to install a VARSET Power Factor Correction unit, rated at 90kVAR. The power factor improved from 0.7 to 0.99, which saw the peak kVA demand reduce from 180kVA to 130kVA representing a potential cost saving of $6,000 per annum.
Expansion PlansWhile the original goal for Thompson Pies was to ensure continuity of supply, potential expansion plans to the site and rising energy costs lead to the decision to invest in a commercial roof top solar system. An 80kW system was proposed for this project, with the majority of the energy produced, to be consumed on site.
Schneider Electric Conext TL 15kW and 20kW inverters were selected for this project. The inverters provide dual MPP trackers with a wide voltage range, peak efficiency of greater than 98% for fast ROI. And with local technical support and a leading warranty program, the customer could be rest assured that any issue that may arise in the future would be rectified in a timely and professional manner by Schneider Electric.
A standard feature of the Conext TL inverters is the embedded Modbus communication card. This allows connectivity with a large range of Schneider Electric products, as well as the option to easily add third party monitoring solutions. An interface between the Conext TL inverter and the Schneider Electric Ethernet Gateway EGX300 was developed using the ModBus protocol to allow the owner to monitor the performance of the solar system. The EGX300 gateway can store up to 200 days of historical data including operating status of the inverters, daily energy harvest as well as energy consumed on site and exported back onto the grid.
The solar system is predicated to save $22,000 per annum in energy costs and reduce greenhouse gas emissions by 30,000 kgs, and achieve a payback for the owners in approximately five years.
Future Energy SavingsThompson Pies is seeing the rewards of partnering with Schneider Electric to deliver energy efficiencies and a strategy to protect against future increases in energy costs. Thompson Pies are now considering a lighting upgrade, where existing high bays will be replaced with the new range of low power induction lamps from Clipsal by Schneider Electric
