ABB DriveSave offers big users guaranteed energy savings

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1 1 13 newsletter of ABB drives and motors in the UK energisecustomer ABB DriveSave offers big users guaranteed energy savings ABB has launched a risk and reward scheme for large energy consumers that guarantees energy savings from multiple motor-driven applications across a site. Designed for industries such as metal processing, chemical, oil & gas and pulp & paper, ABB s DriveSave will suit companies willing to invest between 500,000 to 2 million on achieving target savings from 5,000 MWh and above per year, with a return on investment in under three years. DriveSave works by measuring the energy consumption of all suitable pump, fan and compressor applications. Based on this measurement ABB assesses the potential savings and agrees the figures with the end user. It is then ABB s responsibility to install the quantity of variable-speed drives necessary to achieve these guaranteed savings. In addition the scheme offers a five year warranty for all of the installed drives, together with a five year preventive maintenance programme. To find out more call DRIVES ( ) or visit Mega record for drives in 2012 ABB electric drives save a record 310 million megawatt hours in 2012 = The output from 31 nuclear power stations A saving of 260 million tons of CO 2 emissions Equivalent to or years power consumption for 26 million UK customers ABB drives saved a record 310 million megawatt-hours (MWh) of electric power last year, an increase of 19 percent compared with the previous year. This is the equivalent of the output of 31 nuclear power stations or over three years consumption of all the UK s households. DriveSave is aimed at large energy users. News in brief l ABB now offers a marine energy appraisal to help ship operators cut energy wastage. The appraisal will suggest where variable-speed drives can be used in areas such as seawater cooling pumps and engine room ventilation fans. l A new guide from ABB looks at how the retail sector can use variable-speed drives and high efficiency motors to cut energy use in typical applications such as cooling towers and refrigeration. l ABB won the EEF Future Manufacturing Awards 2012, North West Region Green and Growth Award, for persuading customers to adopt energy saving measures for motor-driven processes and developing an energy appraisal app that helps them reduce their carbon footprint and electricity bills.

2 News Steel maker saves 78,000 on pump and fan applications Two Tata Steel plants in South Yorkshire are saving a total of 78,000 a year on their energy costs following the installation of ABB drives. For the company s Rotherham plant, ABB Drives Alliance member Halcyon Drives supplied, installed and commissioned three 90 kw and two 75 kw ABB industrial drives to control two critical water pumping applications. Halcyon installed hire drives on the flume flush pumps and filter feed pumps, with total savings calculated at 68,000 a year once the ABB drives were fitted permanently. The expected return on investment is around 13 months. Tata Steel is also saving 10,000 a year on an application at its Stocksbridge plant. An important part of the finishing process at the plant is the scarfer, which uses a propane burner to remove impurities from the steel. The impurities, in the form of waste gases, are then removed by an exhaust fan, run by a 132 kw motor. Originally, the fan was run constantly at full speed, with its output constricted by a damper. This was controlled by a PLC that signalled the damper to open when more air flow was needed, when scarfing was in progress. Following installation of a 132 kw ABB industrial drive by Halcyon, the plant is saving energy costs of around 9,700 per annum, while also saving 82.5 metric tonnes of CO 2. The ABB drive achieved a payback time of less than one year. 78,000 per year total energy savings for Tata Steel. To find out more call DRIVES ( ) or visit United Utilities saves 19,000 at water pumping station The Drummer s Lane water pumping station, owned by United Utilities, is saving over 19,000 per year on its energy costs following the replacement of its existing Heenan variable-speed drives with new drives from ABB. The existing drives were overheating and tripping out before they could achieve full power. This caused a severe problem for the pumping station when a fire broke out in one of the drive cabinets. United Utilities already had a long standing relationship with ABB Drives Alliance member The Central Group. Central are very good at performing replacements and repairs at short notice, says Tony Holden, field service engineer with United Utilities responsible for Drummer s Lane. Central performed an energy appraisal and found that running the pumps with three 400 kw ABB industrial drives could reduce the pumps load by 70 A. Another advantage was the chance to reduce the use of cooling fans. Instead of the seven fans used previously, the ABB drives need only two fans in the summer and none in the winter, further cutting energy use. The ABB drives produced a saving per hour for the duty and assist pump combined of 47 kw. This gives a yearly saving of some 19,213 in energy costs for the application, producing a payback time of just over three years. We are very pleased with both the drives and the standard of work that The Central Group carried out, says Holden. The drives were installed without a hitch and we now have a very reliable process as well as gaining significant energy savings. To find out more call DRIVES ( ) or visit 19,000 per year energy savings for United Utilities. 02 ABB energise 1 13

3 News Galvanising company to save 10,000 on fume extraction Medway Galvanising Company Ltd in Kent is set to save over 10,000 a year in electrical energy costs while cutting CO 2 by 60 metric tonnes a year, following the installation of an ABB standard drive on its fume extraction system. Part of its galvanising service, an 10,000 a year energy savings for Medway Galvanising. To find out more call DRIVES ( ) or visit 1,000 a week savings for Laois County Council An ABB drive has cut pump maintenance costs for a local authority in Ireland by 1,000 a week. The water services department of Laois County Council in the Republic of Ireland had problems with the sewage pump at Mountmellick pumping station. The pump was prone to ragging 1,000 a week savings for Laois County Council. extraction system over the company s zinc dipping bath is used to extract the harmful fumes given off in the process. The fan on this extraction system was initially run at full speed for 24 hours a day. Mid Kent Electrical (MKE), an ABB Drives Alliance member installed an energy monitor on the application over a complete production week to determine its exact energy use. This showed that the motor would use over 215 MWh a year, at a total cost of around 20,000. Following this, an ABB variablespeed drive was fitted and the monitoring repeated. This showed that with the variable-speed drive in place, Medway Galvanising would achieve a reduction of just over 105 MWh a year at a cost of around 9,800. This is an annual reduction in running costs of 10,200 and a cut in CO 2 production of some 60 metric tonnes a year. with rags fouling the pump inlet and preventing the pump from operating normally. It therefore needed to be lifted and cleared three to four times a week. Each lift cost 270. Laois County Council contacted ACS Drives and Control Systems Ltd, an ABB Drives Alliance member, for a solution. ACS installed a 15 kw ABB industrial drive for water and wastewater. This comes with a series of pump functions, one of which is pump cleaning. When the function is triggered, the pump is run at high speed and either reversed or stopped in a number of userdefined cleaning cycles. This helps to prevent congestion through the build-up of particles. With a purchase cost of 2,500 and an average saving of 1,000 a week, the payback time is two and a half weeks, giving Laois County Council an excellent return on investment. To find out more call DRIVES ( ) or visit Visitors get a clear view of Roman bath One of the UK s major visitor attractions is using ABB drives to ensure that condensation does not obscure visitors views. Visitors to the Roman Baths in Bath come to see how the early engineers used a natural spring to provide bathing facilities for the temple and spa complex. A glass walkway allows people to walk across the main drain that carries overflow water from the baths to the River Avon. The problem was that condensation on the glass from the warm water obscured visitors views of the drain. ABB Drives Alliance member APDS installed a 0.37 kw ABB machinery drive controlling a fan. Using the drive s real time clock, the system runs at full speed, 50 Hz, throughout the night on cheap rate electricity, clearing the condensation from the glass walkway. It then runs at 33 Hz throughout visitor hours to keep condensation away and to keep the noise to a minimum. Hot spring water seen clearly at Roman Baths. To find out more call DRIVES ( ) or visit ABB energise

4 News Energy and Productivity Improvement Plan Two sides of the process coin - improving energy and productivity Saving energy and improving productivity are the two major ways that variable-speed drives (VSDs) can help increase the efficiency and effectiveness of a motordriven process. A professional appraisal of motor-driven systems can highlight where a company can use modern VSDs to improve on one or the other aspect or even both. As companies face increasing competition, improving energy efficiency and increasing productivity are two of the main factors in the battle for profitability and the two goals are often closely linked. The rising demand for energy will inevitably increase its price, yet surprisingly few businesses know of the most effective methods of reducing their energy use. For instance, only 34 percent of respondents in a survey had performed a company-wide energy audit. Most businesses are unaware of the significant electrical energy saving opportunities of using a VSD and high efficiency motor on motor-driven applications, such as pumps, fans and compressors. Similarly, most businesses are largely unaware of the significant productivity benefits that drives and high efficiency motors can bring such as lowering maintenance, reducing wastage and cutting costly downtime. To help users of motor-driven applications tackle these issues, ABB has evolved an Energy and Productivity Improvement Plan to provide industry and commerce with the information, products and services needed to improve their processses. ABB s energy appraisal analyses a plant s motor-driven applications. Product features Service features Drives adjust the output of an application, such as a pump or a fan, by controlling the speed of the motor, ensuring it runs no faster than it needs. This often cuts energy consumption from between 20 to 50 percent. ABB offers a wide choice of VSDs to suit any application, including machinery drives, motion control drives and industry-specific drives. Some of the most modern drives have builtin energy calculators to monitor energy consumption. VSDs are also used to control motor speeds and torques to manage line speed and process variables such as thickness, grain formation and winding tightness. Use of variable-speed also allows pump users to exploit smart benefits and solve old problems such as water hammer, cavitation and shaft shear at starting. A number of features and functions of VSDs can contribute to better process control. ABB offers services to help minimise costs and improve performance throughout a drive s life. The life cycle stages include pre-purchase, ordering and delivery, installation and commissioning, operation and maintenance, upgrade and retrofit and replacement and recycling. As part of the pre-purchase stage, having an ABB energy and productivity appraisal, will highlight which applications will benefit from installing VSDs either by energy savings or improved productivity. Other issues might include the possibility of retrofitting existing drives with modern technology or recycling of all removed drives and motors to the latest legislation. ABB s expertise in motor-driven applications means it can easily assess the condition of the installed base of motors and drives and make educated and calculated assessments of what is needed. 04 ABB energise 1 13

5 News Proving the point Over the years, hundreds of applications have used VSDs to save energy and improve productivity. Typical projects include one for Manchester Airport, where ABB drives and motors retrofitted to AHUs are saving around 4,000 MWh a year and cutting 2,000 metric tonnes of CO 2. In the food and beverage sector, ABB installed its drives for HVAC at Tamar Foods bakery, cutting energy use by 219 MWh a year and giving a payback of around 12 months. Another bakery benefiting from ABB VSDs is the Village Bakery, where an ABB general machinery drive has allowed a 10 percent reduction in tin greasing agent. The previous drive was so slow and inaccurate that the machine had to start spraying the greasing agent before it saw each tin. Now the greasing agent ends up in the tins. The ABB drive can also optimise the speed of the conveyor to match the size and throughput of different products more accurately. In this case the unit is programmed with four different speeds, leading to savings of around 25 percent in the running costs for the line. Manchester Airport, where ABB drives and motors retrofitted to AHUs are saving around 4,000 MWh a year and cutting 2,000 metric tonnes of CO 2 Another productivity improvement was achieved for tomato grower John Baarda, where a conveyor system uses ABB servo motors and ABB high performance machinery drives to control the speed of the tomato handling conveyors, while an ABB component drive runs rollers on the conveyors, allowing the tomatoes to be turned automatically and inspected for quality. The system doubled the packing rate of the tomatoes. To find out more call DRIVES ( ) or visit Bakery benefiting from ABB VSDs. Tomato grower John Baarda. ABB energise

6 Motors Scheme aims to improve understanding of electric motor ownership costs A scheme to raise the awareness among end-users about the true cost of owning electric motors is launched by ABB. Alongside purchase price and the cost of running, the campaign sets out to highlight the costs associated when a motor is not running. The cost of not running is the direct cost to a continuous process industry of lost production due to a motor failure. Such costs vary widely, depending on the industry, but typically can be around 79,000 per annum. A typical motor will, over a 20 year period, consume 200 times more than its purchase price in energy costs alone, says Steve Ruddell, global marketing manager for ABB motors and generators. However, throughout the life cycle of the motor there are numerous other factors that impact on its running costs and affect the true cost of ownership. If these are not taken into account at the outset then the actual total costs of owning that motor will cost many thousands of Euros. ABB has devised a formula which shows that the cost of ownership is the purchase price and installation costs plus the cost of running plus the cost of not running. For example, a 45 kw motor costing 1,738, with 94.1 percent efficiency and running for 6,000 hours per annum would cost 2,079,633 over a 20 year life. This assumes an average electricity price of 0.09 and the downtime cost per annum of 79,000. When expressed as a ratio of purchase price over total cost of ownership the result is very small, showing that the true cost of owning a motor is far more important than the initial purchase price. While better efficiency means lower running temperatures, which contribute to higher reliability, in future years, it will become increasingly difficult to improve efficiency levels. What users need to consider is the cost of ownership. How much does it actually cost to own and operate motors throughout their life? Key to this is motor reliability. For this you need to consider bearings, stator windings, shaft coupling and the rotor bar. In particular more consideration needs to be given to A typical motor will, over a 20 year period, consume 200 times more than its purchase price in energy costs. impact of heat and the temperature rise on insulation, windings and bearings and what this can lead to. Remember, 70 percent of all motor failures are down to the bearings. If motors run cooler then the bearings last longer and the motor is inherently more reliable. Which is more expensive to own: an electric motor that costs 790, or one with a price tag of 1,185? The purchase price doesn t tell the whole story. Apart from the reliability of the motor, Ruddell says it is important to consider the life cycle services offered by the motor manufacturer. Consulting, diagnostic and appraisal tools for preventive and predictive maintenance all contribute to a motor s longevity. These tools monitor the condition of motors either on-site or remotely and detect service needs at an early stage. This enables plant operators to replace worn components before they actually fail, helping to reduce and even eliminate downtime. In our personal lives we are all becoming quite astute at working out the true cost of owning something. Most notable, is our understanding of the costs associated with running a car. Not only do we consider the purchase price, but we also investigate the running costs such as fuel consumption, service, road tax and insurance. This allows us to understand the cost of owning the car and not just the cost of buying the car. So why should our approach to industrial goods be any different? Cost of ownership = + + ABB s formula for the cost of electric motor ownership. Purchase Cost of running Cost of not running 06 ABB energise 1 13

7 Motors Revolutionary motor takes efficiency to new heights ABB s revolutionary IE4 synchronous reluctance motor and drive package (SynRM) has completed a highly successful trial at a pumping station operated by South Staffs Water, resulting in an additional six percent energy saving. The SynRM package replaced a 20-year old, 115 kw induction motor with drive used to control a single vertical shaft driven borehole pump at the South Staffs Water s Somerford Pumping station. The existing motor was already using an ABB industrial drive, ACS800, to achieve maximum savings with the drive s flux optimization function. South Staffs Water was interested in trialling the synchronous reluctance motor to harness its benefits, which include higher efficiency, greater reliability, lower heat loss, less noise and reduced maintenance costs. During the trial, ABB removed the existing drive and replaced it with an ABB machinery drive, ACS850, featuring a more powerful core processor that enables operation with the synchronous reluctance motor. It also employs the next generation of ABB s direct torque control (DTC), which avoids the need for encoders and speed feedback devices. The biggest benefit is the six percent reduction in energy, explains Keith Marshall, Supply Director at South Staffs Water. Pumping water accounts for some 90 percent of our energy spend as we have one of the highest pumping head of any UK water utility because of the deep boreholes and hilly terrain within our area of supply. So a 6 percent reduction on one pump in a system that was already very efficient is massive news for us. Other benefits to South Staffs Water of using the SynRM include a 58 percent reduction in frame temperature compared to the previously used induction motor. As the rotor has effectively no losses, the bearing temperature is lowered dramatically, giving a reduced need for forced ventilation. Reduced temperatures mean the utility can either choose to extend the period between greasing or increase the bearing life expectancy. Traditional induction motors produce slip losses that can be as much as 35 percent of the entire losses produced by the motor. Eliminating these could increase motor efficiency by up to eight percent while giving a 20 percent to 40 percent increase in power for the same temperature class. ABB achieved this remarkable performance by using synchronous reluctance technology. A SynRM rotor has neither a conducting short circuit SynRM at Somerford Pumping station. cage as with the induction motor, nor permanent magnets, nor a field excitation winding. The streamlined rotor structure eliminates rotor cage losses, increasing efficiency and reducing size. ABB offers the new motor as part of two optional packages. Each complete with a variable-speed drive, one package is optimised for high output - up to 315 kw - while the other is optimised for super high efficiency, compliant with the IE4 efficiency class. ABB s synchronous reluctance motor and drive package rated IE4. ABB energise

8 Competition Win an ipod Touch Due to the popularity of last issue s competition here is another chance to get your hands on a 4th generation ipod Touch. Another chance to WIN As well as being a personal music player with space for over 1,000 songs, the device features two built-in cameras allowing you to take pictures and record videos. The winner will be able to surf the internet and customise their device by downloading Apps directly onto their ipod through the Apple store. For your chance to win one of two ipod Touches, circle the correct answers and fax this page back to with your contact details below, or scan and send via to energy@gb.abb.com, alternatively, you can enter online via our website The closing date for entries is the 29th March All answers can be found in the newsletter. Good luck. 1. How many UK households energy consumption was saved by ABB drives? A. 20 million B. 26 million C. 30 million D. 16 million 2. What is the name of the Eire town whose pumping station kept ragging? A. Dublin B. Mountrath C. Portlaoise D. Mountmellick Name: Company name: Telephone number: address: 3. How many tonnes of CO 2 did Medway Galvanising save? A. 25 tonnes of CO 2 B. 30 tonnes of CO 2 C. 60 tonnes of CO 2 D. 40 tonnes of CO 2 4. What was the payback time for United Utilities drives replacement? A. Over 3 years B. Less than 3 years C. 3 years D. Over 2 years Energise newsletter/february 2013 ABB Limited Daresbury Park Daresbury Warrington Cheshire WA4 4BT Tel: