Jukka Tolvanen Market manager Energy efficiency. ABB Day VSD and energy efficiency

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Erica Kelley Osborne
5 years ago
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1 Jukka Tolvanen Market manager Energy efficiency ABB Day VSD and energy efficiency ABB Singapore Sep

2 Finland country in northern Europe ABB EE kick off meeting - 2 -

3 Famous finns ABB EE kick off meeting - 3 -

4 My focus LV drives energy efficiency marketing Active co-operation with ABB teams, global and local customers, universities etc. 10+ years experience in ABB in several manager positions Father of 9 year old girl ABB EE kick off meeting - 4 -

5 ABB s vision As one of the world s leading engineering companies, we help our customers to use electrical power efficiently, to increase industrial productivity and to lower environmental impact in a sustainable way. Power and productivity for a better world ABB EE kick off meeting - 5 -

6 ABB energy efficiency certainly ABB EE kick off meeting - 6 -

7 Market shares according to IMS! ABB Siemens Mitsubishi Rockwell Yaskawa - Omron Schneider Toshiba Danfoss Emerson - Control Techniques Fuji (incl. GE) Lenze/AC Tech Vacon Others % ABB EE kick off meeting Source IMS Studies 2006, 2007

8 Contents VSD and Energy efficiency Why - Environmental background How VSD and Energy efficiency What next - Trends ABB EE kick off meeting - 8 -

CO 2 emissions -> temperature and sea level ABB EE kick off meeting - 9 - In 2100, worst case scenario shows +6

9 CO 2 emissions -> temperature and sea level ABB EE kick off meeting In 2100, worst case scenario shows +6 degrees temperature change and +1m sea level rise These two would lead to a massive global socioeconomical catastrophe

10 CO 2 emission reductions, IEA WEO 2008 ABB EE kick off meeting

11 Cost of CO 2 emissions reduction Source: IEA WEO 2008 ABB EE kick off meeting

12 Contents VSD and Energy efficiency Why - Environmental background How VSD and Energy efficiency What next - Trends ABB EE kick off meeting

13 Our offering LV AC drives ABB EE kick off meeting

14 Low voltage AC drives for... Building automation Industries Original equipment manufacturers ABB EE kick off meeting

What wastes energy? ABB EE kick off meeting - 15 - Oversized installations (motors, pumps, fans etc.

15 What wastes energy? ABB EE kick off meeting Oversized installations (motors, pumps, fans etc.) Inefficient motor applications Equipment running unnecessarily long hours Stirrers on empty tanks Deadheading pumps Ventilation fans running 24/7 and 1001 other applications

16 Comparing different control methods ABB EE kick off meeting

17 Control methods for pumps Throttling Bypassing ABB EE kick off meeting On/off control Variable speed

18 Study ABB EE kick off meeting Energy efficiency of parallel pumps Proof: Matlab computer simulation with four case studies Carried out by Lappeenranta University, Finland Master thesis - Ms. Hanna Värri

19 Comparisons 3 different control methods were studied Throttle control Standard pump control Optimized pump control ABB EE kick off meeting

20 Patent - new idea to run pumps with VSD ABB EE kick off meeting

21 Specific energy E s Formulas ABB EE kick off meeting f HS hydraulic system factor 3 system curves, A having small static head Low static head -> great saving potential

22 Optimized pump control, idea Optimal number of pumps are running with same speed. Animation ABB EE kick off meeting

23 Results, pulp and paper mill ABB EE kick off meeting

24 Your own carbon footprint To estimate your own carbon footprint try Carbon Calculator It gives you a number of ideas for reducing your carbon footprint through simple, everyday changes ABB EE kick off meeting

25 Carbon footprint with new Audi A4 Audi 3.2 FSI quattro CO2 emissions 219 g/km Driving annually km -> CO2 emission 4,4 tons ABB EE kick off meeting

Energy saving tips Bank s computer centre A British bank installed four ABB AC drives in a computer centre cooling system Controls speed of four pumps - total power

26 Energy saving tips Bank s computer centre A British bank installed four ABB AC drives in a computer centre cooling system Controls speed of four pumps - total power 240 kw Pumps previously running at constant speed Energy saving CO 2 reduction Segment and application About 1,000 MWh /year 500 tons/year HVAC, pumps ABB Group

Energy saving tips Sugar cane mill A sugar plant in Honduras replaced five steam turbines, which were driving the cane mill, with ABB AC drives and induction motors The steam produced on site can now

27 Energy saving tips Sugar cane mill A sugar plant in Honduras replaced five steam turbines, which were driving the cane mill, with ABB AC drives and induction motors The steam produced on site can now be used exclusively to generate electricity which will feed the whole plant and can even be sold to the grid Energy saving CO 2 reduction Segment and application About 24,366 MWh/year About 12,183 tons/year Food and beverage,sugar cane mill ABB Group

Energy saving tips Metal company A Taiwanese steel company used a mechanical return (bypass) valve, controlled by an external PID controller to regulate water pressure to the hot rolling mill

28 Energy saving tips Metal company A Taiwanese steel company used a mechanical return (bypass) valve, controlled by an external PID controller to regulate water pressure to the hot rolling mill descaling pumps Retrofitting ABB AC drives to the fixed speed booster pump motors reduced energy and water costs considerably Water use was reduced by about 65,000 tons per year Energy saving CO 2 reduction Segment and application About 3,000 MWh/year 1,500 tons/year Metal, water supply for descaling pumps ABB Group

Energy saving tips Metal company A Swedish steel company replaced a steam turbine, powering a blast furnace blower, with a 6 MW ABB AC drive The replacement resulted in

29 Energy saving tips Metal company A Swedish steel company replaced a steam turbine, powering a blast furnace blower, with a 6 MW ABB AC drive The replacement resulted in estimated energy savings of 16 GWh Energy saving CO 2 reduction Segment and application About 16,000 MWh/year 8,000 tons/year Metal, blast furnace blower ABB Group

Energy saving tips Petrochemical plant A refinery in Argentina replaced a steam turbine driving a blower, with an ABB AC drive and an induction motor The Energy Intensity

30 Energy saving tips Petrochemical plant A refinery in Argentina replaced a steam turbine driving a blower, with an ABB AC drive and an induction motor The Energy Intensity Index (EII) improved by 10.5% within one year Energy saving CO 2 reduction Segment and application About 7,560 MWh/year 3,780 tons/year Petrochemical, blower ABB Group

Energy saving tips Coal-fired power plant A German coal-fired power plant replaced the hydraulic couplings regulating two boiler feed-water pumps of 5.

31 Energy saving tips Coal-fired power plant A German coal-fired power plant replaced the hydraulic couplings regulating two boiler feed-water pumps of 5.8 MW each with ABB AC drives Energy consumption was reduced by about 30% Energy saving CO 2 reduction Segment and application About 6,000 MWh/year About 4,800 tons/year* Power, boiler feed-water pumps ABB Group * 0,8 kg/kwh for carbon power plants

Energy saving tips Refinery A refinery in Saudi Arabia was upgraded to meet the country s future demand for refined products Several ABB AC drives replaced the fixed

32 Energy saving tips Refinery A refinery in Saudi Arabia was upgraded to meet the country s future demand for refined products Several ABB AC drives replaced the fixed speed control of the shipping pumps Energy saving CO 2 reduction Segment and application About 18,700 MWh/year About 9,350 tons/year Petrochemical, pumps ABB Group

monitoring of energy consumed before and after the change to ABB drives ABB offers

33 Energy saving tips Energy audit To reduce energy costs, a company should evaluate its energy usage An energy audit is a systematic examination of applications It includes monitoring of energy consumed before and after the change to ABB drives ABB offers energy audits that rapidly determine where and how much energy can be saved ABB Group

walk through 3rd session: measurements 4 th session: results,

34 Energy audit on a shoestring Local marketing activities 1st meeting with customer: process, backround info 2nd session: walk through 3rd session: measurements 4 th session: results, investment plan 5 th session: check results ABB EE kick off meeting

Audit benefits play domino ABB EE kick off meeting - 35 - Once

temperature -> higher lifetime for components, less cooling, less

35 Audit benefits play domino ABB EE kick off meeting Once audit savings are achived, secondary benefits occure: Lower temperature -> higher lifetime for components, less cooling, less service needed Less noise Less losses of raw material Audit plays domino

36 ABB drives save energy Energy saved with ABB drives TWh ABB EE kick off meeting Y92 Y93 Y94 Y95 Y96 Y97 Y98 Y99 Y00 Y01 Y02 Y03 Y04 Y05 Y06 Y07 The installed base of ABB low voltage drives saved about 140 TWh in 2007, equivalent to the consumption per year of more than 36 million families. ABB s installed base of ABB low voltage drives reduced CO2 emissions in 2007 by 120 million ton, more than the yearly emission of Finland.

The shoemakers s children have no shoes ABB EE kick off meeting - 37 -

..6MW Installed drives base: 12MW in production 7MW in laboratories

37 The shoemakers s children have no shoes ABB EE kick off meeting Daily power consumption of Helsinki factory is 4...6MW Installed drives base: 12MW in production 7MW in laboratories 100kW in air conditioning In ABB drives we have - shoes and a lot of drives Energy audit done in 2001

38 Contents VSD and Energy efficiency Why - Environmental background How VSD and Energy efficiency What next - Trends ABB EE kick off meeting

39 ABB Drives - energy efficiency path marketing auditing monitoring Marketing tools help to clarify savings ABB auditing process helps to find the right applications Monitoring supports continuous improvement in this field ABB EE kick off meeting

Energy efficiency parameters ABB EE kick off meeting - 40 - Energy savings

efficiency Output - Total energy savings in kwh, currency and C0 2 Flux optimizer

40 Energy efficiency parameters ABB EE kick off meeting Energy savings calculation Benefit proof PumpSave calculation and help to monitor energy efficiency Output - Total energy savings in kwh, currency and C0 2 Flux optimizer Benefit reduces motor magnetizing current at low mechanical loads, specially uselful with pumps and fans

41 VSD & Energy efficiency future trends Drives able to fine tune automatically to optimal efficiency of the motor system Saved energy and reduced CO 2 more and more important parameters new business models for CO 2 trade Small scale power plants with wind mills and solar panels ABB EE kick off meeting

Energy efficiency solutions Simple steps to reduce fuel consumption and your environmental footprint

Energy efficiency solutions Simple steps to reduce fuel consumption and your environmental footprint A simple way to get started with green shipping... Energy efficiency has traditionally not been a key