Report on Energy-Saving Survey by medium … control (inverter) not applied to motors for pumps,...
Transcript of Report on Energy-Saving Survey by medium … control (inverter) not applied to motors for pumps,...
Report on EnergyReport on Energy--Saving SurveySaving Surveyby medium voltage inverterby medium voltage inverter
February 23, 2010 In SingaporeFebruary 23, 2010 In SingaporeFebruary 25, 2010 In ThailandFebruary 25, 2010 In Thailand
Copyright 2009, Green IT Promotion Council 2
1.Background and Objective2.Introduction of the Survey/Surveyed
Companies3.Survey Process4.Results
・Current Status and issues on Energy Efficiency
・Energy-saving plan and its effect5.Suggestions
Table of Contents
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Background and objective
Approx 70% of electric power consumption in a factory is used for motor operation ( for manufacturing, for air conditioning etc).
Therefore, energy saving in motor operation is important.
IM IM
PumpPump
IM
Pump
IM IM
Pump
IMIM
PumpPump
IM
Pump
Boiler IDF
IM
FAN
FAN
IM
Boiler
IMIM
FANFAN
FANFAN
IMIM
Boiler
Water pump
Motor speed control by inverter realizes energy saving !!
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Introduction of Surveyed Company 1 Rayong Olefins Co., Ltd. (ROC)
• One of the leading petrochemical company in Rayong Thailand who produces 1.2 million ton olefin product annually.
• Main energy consumer within the Siam Cement Group (SCG) Chemicals.
• Aggressively pursue ‘KAIZEN’ through quality management program and conscious of safety and environment issue.
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Introduction of Surveyed Company 2 Thai Acrylic Fibre Co., Ltd. (TAF)
• Top 3 quality fiber producers globally with 100,000 Ton annual acrylic fiber products in Saraburi Thailand.
• One of the top service providers of acrylic application development.
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Introduction of Survey Company
-Green Factory Innovation- TMEIC (the joint-venture of Toshiba & Mitsubishi-electric) strives to support customers to evolve towards “Green Factories” by following solutions and technologies. 1)Motor & Drive systems for Energy Saving
Medium voltage inverter, High speed drive, PMSG/M
2)Renewable energy systems Photovoltaic power, Wind power
3)Energy control & management systems
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Summary of the survey
November 30, 2009: ROCDecember 2, 2009: TAF
– Survey motor and other electrical equipment (Rating, characteristic and
operation data)
Survey Process
Xxx
Current Status
– Selected target item and recommend speed control by inverter
Energy-Saving Plan and Its Effect
Result of the Survey
Speed control (inverter) not applied to motors for pumps, especially medium voltage motors.
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Survey Process (Summary)
ProposalAnalysisField Survey
スケジュ
ール
スケジュ
ールDateDate
– Selection of survey target– Selection of inverter capacity– Confirmation of installation
space– Energy saving calculation
•Motor data review•Plant site survey•Electrical room survey•Power distribution equipment review
ActionAction
November 30, 2009: ROCDecember 2, 2009: TAF
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Survey Process (Detail)① Inverter system
<Drive Panel >
(4) Convert AC DC
SCR Diode
GTO/IGCT/SGCT
(2) Transformer(1) MainSupply
X
(3) FIlter
X
(6) FIlter
AC Motor
(8) MV MotorTransformer7) ((5) Convert DC AC
IGBT/IEGT
SCR
GTO/IGCT/SGCT
<< TMdrive-MVG>>
(5) Convert DC AC
AC+- AC+-
IGBT/IEGT
(4) Convert AC DC
DC +-
Diode AC Motor
(8) MVMotor
(1) MainSupply
X
(2) Transformer
<Drive Panel >
(4) Convert AC DC
SCR Diode
GTO/IGCT/SGCT
(2) Transformer(2) Transformer(1) MainSupply
X
(1) MainSupply
X
(3) FIlter
X
(3) FIlter(3) FIlter
X
(6) FIlter(6) FIlter
AC Motor
(8) MV Motor
AC Motor
(8) MV MotorTransformer7) ((5) Convert DC AC
IGBT/IEGT
SCR
GTO/IGCT/SGCT
(5) Convert DC AC
IGBT/IEGT
SCR
GTO/IGCT/SGCT
IGBT/IEGT
SCR
GTO/IGCT/SGCT
<< TMdrive-MVG>>
(5) Convert DC AC
AC+- AC+-
IGBT/IEGT
(4) Convert AC DC
DC +-
Diode AC Motor
(8) MVMotor
(1) MainSupply
X
(2) Transformer
<< TMdrive-MVG>> << TMdrive-MVG>>
(5) Convert DC AC
AC+- AC+-
IGBT/IEGTIGBT/IEGT
(4) Convert AC DC
DC +-
Diode AC Motor
(8) MVMotor
AC Motor
(8) MVMotor
(1) MainSupply
X
(1) MainSupply
X
(2) Transformer(2) Transformer
Conventional type
Desirable type
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Survey Process (Detail)② Panel outline
Inverter panel
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~ ~
~ ~
~ ~
~ ~
~ ~
~ ~
~ ~
~ ~
~ ~
~ ~
~ ~
~ ~
~ ~
~ ~
~ ~
M
~ ~
Input Transformer Control Panel
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Survey Process (Detail)③ PUMP Q-H Curve
Pum
p H
ead
; H
Pump Flow ; QQ1
H1
Flow loss CurveR = Q2
H = A-(A-1)Q2
REQUIRED MOTORPOWER
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Survey Process (Detail)④ Valve Control vs
Speed control
Pum
p H
ead
; H
Pump Flow ; QQ1
H1
Flow loss CurveR = Q2
H = A-(A-1)Q2
REQUIRED MOTORPOWER
A
0.7x Q1
Pum
p H
ead
; H
Pump Flow ; QQ1
H1
Flow loss CurveR = Q2
H = A-(A-1)Q2
REQUIRED MOTORPOWER
A
0.7x Q1
Valve Control Speed Control
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Current Status and issues of Energy Efficiency (Summary)
ROCCooling water pump etc
Item
Speed control (inverter) not applied to motors for pumps, especially medium voltage motors
Current Status and issues of Energy Efficiency
TAF
Water pump for chiller etcSpeed control (inverter) not applied to motors for pumps, especially medium voltage motors
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Current Status and issues of Energy Efficiency (Details)①
ROC
Motor data
Target item for
Inverter operation
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Current Status and issues of Energy Efficiency (Details)②
ROC
Detail of target item
Item No. : PM-2400CEquipment : Cooling water pumpMotor rating : 10P-1850kW-6600V-50Hz-F eG3
6.6kV-2600kVA TMdrive-MVG is applicable.(*The existing eG3 motor shall be replaced with a new explosion-proof motor (Exn) in order to get variable speed motor explosion- proof certificate.)
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Current Status and issues of Energy Efficiency (Details)③
ROC
Outline dimension
6.6kV-2600kVA
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Current Status and issues of Energy Efficiency (Details)④
ROC
Panel layout
Primarily selected Optional selected
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Current Status and issues of Energy Efficiency (Details)①
TAF
Motor data
Target item for
Inverter operation
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Current Status and issues of Energy Efficiency (Details)②
TAF
Detail of target item
Item No. : 3631-Ⅱ-BEquipment : Water pump for chillerMotor rating : 2P-450kW-6600V-50Hz-F Non-exp
6.6kV-600kVA TMdrive-MVGis applicable
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Current Status and issues of Energy Efficiency (Details)③
TAF
Outline dimension
6.6kV-600kVA
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Current Status and issues of Energy Efficiency (Details)④
TAF
Panel layout
INVERTER ROOM SUB-4
The height of the celing is 3.95 meter.
LP
C20I COM PLC PLC
C16I
C09I
C17I R R
C15I
SAMI STAR-III
C/OC10IC23IRRR
C14I
C08I
INV
INV
INV
960 CM
420 CM 980 CM
150CM
110CM
250CM
620 CM200 CM200 CM 200 CM75 75 70
120CM
190CM 190CM
180CM
150CM
155CM
980 CM190CM
190CM270 CM 200 CM240 CM
110 CM55 55
660 CM
140CM
120CM
30 CM
230 CM
180CM
140CM 110CM
65CM60CM
210CM
160CM
6.6kV-600kVATMdrive-MVG
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Energy-saving Plan and Its Effect (Summary)
Expected Total Effect Proposals
ROCApplication of inverter(2600kVA)
Energy-saving Plan
Electricity-- 60% savingCO2 reduction-- 4032t
Effect (per year)Application of inverter・Energy saving, CO2 reduction・Cost saving
TAFApplication of inverter(600kVA)
Electricity-- 57% savingCO2 reduction-- 668t
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Energy-saving Plan and Its Effect (Details)
①
ROC Cost comparison
Operation hour ( % ) of total operation hours
70 % Flow
Flow
100 % of totaloperation hours
Operation pattern
Estimated payback period: 1.0 Year *Cost of inverter and new Exn motor are included.*Cost of construction, modification of existing equipments are not included.
Condition1850kW Motor x 1 unit7483 hrs operationCost = 2.5 THB / kWh
30.4MTHB(100%)
12.2M THB(40%)
60% saving
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Energy-saving Plan and Its Effect (Details)
②
ROC CO2
Reduction
Energy Comparison
CO2 Reduction : 4032t per year(* 0.000555t – CO2/kWH)
12,159,875 kWH
Inverter control 4,893,882 kWH
Energy saved per year 7,265,993 kWH
Energy Comparison
CO2 Reduction : 4032t per year(* 0.000555t – CO2/kWH)
Valve control 12,159,875 kWH
Inverter control 4,893,882 kWH
Energy saved per year 7,265,993 kWH
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Energy-saving Plan and Its Effect (Details)
①
TAF Cost comparison
100 % Flow
50 % Flow
Flow
Operation hour ( % ) of total operation hours
20 % of total operat-ion hours
80 % of total operation hours
Operation pattern
Estimated payback period: 1.7 Year *Cost of construction, modification of existing equipments and temperature signal transmitter system are not included.
Condition450kW Motor x 1 unit6500 hrs operationCost = 2.5 THB / kWh
5.3M THB(100%)
2.3M THB(43%)
57% saving
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Energy-saving Plan and Its Effect (Details)
②
TAF CO2
Reduction
Energy Comparison
CO2 Reduction : 668t per year(* 0.000555t – CO2/kWH)
2,108,600 kWH
Inverter control 904,800 kWH
Energy saved per year 1,203,800 kWH
Energy Comparison
CO2 Reduction : 668t per year(* 0.000555t – CO2/kWH)
Valve control 2,108,600 kWH
Inverter control 904,800 kWH
Energy saved per year 1,203,800 kWH
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Suggestions
Application of inverter1) Friendly to motor, friendly to power source2) Energy saving, CO2 reduction3) Cost saving
Create green factory