Published on March 6, 2014
How to reduce energy consumption of your pumping systems by up 30% used in mining operations Jack Creamer Segment Manager – Pumping Equipment Schneider Electric
Topics ●Energy Challenge ●Energy and Pumping ●What is the World Doing? ●Passive and Active Energy Efficiency ●Where are the Savings Schneider Electric 2
Energy Dilemma The facts The need vs Energy demand by 2050 Electrical energy demand by CO2 emissions 2030 to avoid dramatic climate changes Source: IEA 2008 Source: IPCC 2007, figure (vs. 1990 level) Energy management is the key to address the dilemma
Energy Demand Renewable 2008 Non-renewable Schneider Electric 4
Legislation and Influencing Bodies Support Energy Efficiency ● Legislation texts ● Economic Stabilization Act ● Energy Independence and Security Act ● European Union Energy Directive ● Kyoto Protocol ● Non-governmental initiatives ● Clinton Climate initiative ● Energy Efficiency accreditation ● Utility Programs ● Alliance to Save Energy ● Other government initiatives ● State Policy and Incentives ● White certificates ●DOE ● Pump Energy Efficiency Standards under development Schneider Electric 5
Energy Use in Pumping Systems Pumps represent about 25% of industrial motor energy use. Source: DOE Office of Industrial Technology Schneider Electric 6
Pumping – Energy Savings Potential GWhr / Year 2,000 1,500 Pump Savings Motor Upgrades Air Compressor Savings 1,000 Other Savings Fan Savings Downsize Savings Rewind Savings 500 1000+ HP 501 - 1000 HP 201 - 500 HP 101 - 200 HP 51 - 100 HP 21 - 50 HP 6 - 20 HP 1 - 5 HP 0 Source: U.S. Industrial Motor Systems Market Opportunities Assessment, U.S. Department of Energy Schneider Electric 7
Pumping – Energy Savings Potential Pumping systems have the most to gain from energy savings efforts. Source: DOE Office of Industrial Technology Schneider Electric 8
Metals Mining Example Source – Sulzer Pumps Schneider Electric 9
Motor use in mining ● Typical Distribution of Motor Population by HP and Application
What is the World Doing? Schneider Electric 11
Lifecycle solutions for Energy Efficiency Energy Audit & Measure Passive Energy Efficiency Fix the basics Low consumption devices, insulation material, power factor correction Schneider Electric - Power NA Leadership Forum – January 2010 Active Energy Efficiency Optimise through automation & regulation Pump control, lighting control, variable speed drives… Monitor, maintain, improve Meters installation, monitoring services, EE analysis software 12
Passive Energy Savings – By Design Motor Starting Example ● Energy efficient design provides more features while using less energy than a standard starter and overload Contactor + MCP Starter + Circuit Breaker Self Protected Motor Starter SPMS versus IEC based solution -> 50.97% savings SPMS versus NEMA based solution -> 92.71% savings Schneider Electric 13
Active Energy Savings – VFD Example ● Variable Speed Drives ● On centrifugal loads such as pumps, VFD’s save energy because of the Affinity Laws ● Provide precise speed control of an AC motor ● Can generate full torque and low motor speed ● Protect a motor and wiring from overload currents ● Have inherent power factor correction increasing efficiency ● Limits inrush current to provide soft-start and soft-stop Schneider Electric 14
Active Energy Savings – By Design VFD Example ● Affinity Laws of Centrifugal Loads: ● FLOW is proportional to motor speed ● PRESSURE is proportional to the motor speed squared ● POWER is proportional to the motor speed cubed. Schneider Electric 15
Active Energy Savings – VFD Example A motor running at 90% of full speed requires 70% of the electricity of a motor running at full speed. Schneider Electric 16
Active Energy Savings – VFD Example ● Situation – Dewatering Application ● A 50hp centrifugal Pump ● Supply air 10 hours/day for 250 days ● Cost at full speed would be: 50 hp x 0.746 kW/hp x 2500hours x $0.08 /kWhr = $7,460 ● Assuming the Pump does not have to run at full speed all the time ● 25% of time at 100% speed = 625 hours ● 50% of time at 80% speed = 1250 hours ● 25% of time at 60% speed = 625 hours ● Cost running with an AC Drive: ● 50 x (1.0)3 x 0.746 x 625 x $0.08 ● 50 x (0.8)3 x 0.746 x1250 x $0.08 ● 50 x (0.6)3 x 0.746 x 625 x $0.08 = $ 1,865 = $ 1,910 = $ 428 Annual savings ($7,460.00 - $4,203.00) = $3,257 Potential Utility Rebate at $50 per HP = $2,500 Schneider Electric 17
Maximize the savings ●Efficient devices and installation (saves 10 to 15%) ●Optimized usage via automation (save 5 to 15%) ● Without regulation and control systems (up to 12 % lost) ●Without Monitoring and Maintenance (2 to 8% lost) Optimized usage via automation Energy Consumption 70% Efficient devices and installation 100% Lack of monitoring, maintenance programs, regulation and control systems Monitoring & Maintenance Time Schneider Electric - Power NA Leadership Forum – January 2010 18
Energy Savings – Through Monitoring System Level ● Power Monitoring Equipment ● Provides monitoring of facility’s power system ● Capture an record numerous parameters such as: ●Voltage ●Current ●Harmonics ●Power factor ●Transient Voltage ●Energy Consumption ●Peak Consumption ● Monitoring this data allows a facility manager to monitor, understand, and correct any power issues in order to maximize the energy usage of the facility Schneider Electric 19
Energy Savings – Through Monitoring Pump Specifics ● Motor Management System ● Allows control and power monitoring of individual devices ● Allows a user to monitor things such as a motor where it would be traditionally too expensive for an dedicated power monitoring device ● Predictive logic can alert a user to potential problems such as an increase in motor current over a period of time ● Built in communication macros drive integration into System Level systems allowing a facility to monitor all power aspects from distribution to device Schneider Electric 20
Conclusions ● Pumps are a primary consumer of energy in mining applications ● Solutions are available that will greatly reduce these costs ● Legislation is driving/incenting energy management Act NOW! Source - www.pumpschool.com Schneider Electric 21
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