Investigating ways to increase the efficient use of Electrical Energy in the Manufacturing Industry MALTA Energy Efficient Electric Motor Systems Key Experts: Prof. Ing. C. SpiteriStaines Co-Supervisors: Dr. Cedric Caruana Researcher: Industrial Partners : Playmobil Toly Products Andrews Feeds Mr. Peter Spiteri Department of Industrial Electrical Power Conversion Faculty of Engineering – University of Malta Introduction • It is estimated that motor driven systems account for around 65% of the electricity consumed by the European industry. • 1.5% improvement in the motors’ efficiency implies a reduction of around1% energy consumption in the European industry. • The more efficient use of energy in the manufacturing industry has become a key factor for the industrial organisations to maintain a competitive edge. Department of Industrial Electrical Power Conversion, University of Malta Aims of Project • The objective is to facilitate the adoption of energy saving measures on electric motors by the Maltese industry. • Carry out an extensive Data gathering exercise on Energy Usage and Patterns of Electrical Motor Systems in various local industries • Develop a user-friendly software tool to help organisations take intelligent decisions on the options available for reducing electric motors’ energy consumption. • Other benefits derived from project: – Knowledge on : • electrical motors used in selected manufacturing industries • energy savings mechanisms for manufacturing industry – Additional benefits: possibility for reduced heat dissipation and lower maintenance costs. Department of Industrial Electrical Power Conversion, University of Malta Increasing Efficiency in Motor Systems Department of Industrial Electrical Power Conversion, University of Malta Results • Experimental Tests were carried out : • In a laboratory set-up and • On-site in selected industries • Studies were carried out to quantify the energy savings that can be achieved by a Motor Energy Controller (MEC) or a High Efficient Motor (HEM). On-site Case Studies: Lab rig tests: • Profile of an Elevator load • Two different Injection Mould Machine profiles • Andrews Feeds (Malta) Ltd • Motor Energy Controller • High Efficient Motor • Toly Products (Malta) Ltd • Motor Energy Controller • FS Eng. & Plastics Ltd (Malta) • Motor Energy Controller 6 Department of Industrial Electrical Power Conversion, University of Malta Laboratory Test Rig schematic Department of Industrial Electrical Power Conversion, University of Malta Laboratory Test Rig Department of Industrial Electrical Power Conversion, University of Malta Lab test rig results • Motor (5.5kW) at no load No Load PowerBoss from OFF to ON Input power (kW) vs time(s) 600 35% Energy Savings 500 Active power (W) 471W 400 300 305W Motor Energy Controller switched ON 200 100 0 0 1 2 3 4 5 Time (sec) 6 7 8 9 10 Department of Industrial Electrical Power Conversion, University of Malta Lab test rig results • Comparison of efficiency with the MEC ‘on’ and ‘off’ for different operating points Efficiency (%) vs Output power (kW) 100 MEC OFF MEC ON 95 90 Efficiency (%) 85 80 75 High Load Low Savings 70 65 60 Low Load High Savings 55 50 0 1 2 3 Output power (kW) 4 5 6 Department of Industrial Electrical Power Conversion, University of Malta Elevator Profile (Lab Results) 5.3% overall energy savings Input power (W) vs Time (s) 3500 1% 3000 Input power (W) 2500 2000 1500 9.7% 1000 MEC OFF MEC ON 500 0 50 100 150 200 250 300 350 400 450 500 Time (s) Department of Industrial Electrical Power Conversion, University of Malta Injection Mould Machine (Lab Results) Profile 1 Input power (kW) vs time(s) 7000 MEC OFF (IMM profile) MEC OFF (ave. load) MEC ON (IMM profile) MEC ON (ave. load) 6000 Active power (W) 5000 4000 4.6% Energy Savings 3000 2000 1000 0 0 10 20 30 40 50 Time (sec) 60 70 80 90 100 12 Department of Industrial Electrical Power Conversion, University of Malta Injection Mould Machine (Lab Results) Profile 2 BOY profile (PowerBOSS OFF) Input power (kW) vs time(s) 6000 5000 Active power (W) MEC OFF 4000 3000 Average power = 1.20kW 2000 1000 0 0 20 40 60 80 100 Time (sec) BOY Profile (PowerBoss ON) 120 140 160 180 200 Input power (kW) vs time(s) 6000 Active power (W) 5000 4000 3.3% energy savings MEC ON 3000 Average Power = 1.16kW 2000 1000 0 0 20 40 60 80 100 Time (sec) 120 140 160 180 200 Department of Industrial Electrical Power Conversion, University of Malta Case Study 1 Motor Energy Controller (MEC) installed on elevator motor at Andrews Feeds Ltd Active power (W) vs Time (s) 8000 MEC OFF MEC ON 7000 6000 Active power (W) 5000 4000 3000 2000 1000 More than 20% energy savings were achieved at low load 0 -1000 2000 2200 2400 2600 2800 3000 Time (s) 3200 3400 3600 3800 Department of Industrial Electrical Power Conversion, University of Malta Case Study 2 Motor Energy Controller (MEC) installed IMM motor at Toly Products Ltd • Motor Energy Controller (MEC) was installed on an Injection Mould Machine at Toly Products (Malta) Ltd • Motor rating = 22kW • Average power with the MEC OFF = 7.12kW • Average power with the MEC ON = 6.89kW • Energy savings = 3.2% Department of Industrial Electrical Power Conversion, University of Malta Motor Energy Controller (MEC) installed on IMM at FS Engineering & Plastics Ltd Case Study 3 Active power (kW) vs Time (s) 9 MEC OFF: Average power = 3.18kW Average p.f. = 0.4129 8 MEC ON: Average power = 3.11kW Average p.f. = 0.4549 Active power (kW) 7 MEC OFF MEC ON 2.2% 2.2% energy Savings savings 6 5 4 3 2 0 20 40 60 Time (s) 80 100 120 Department of Industrial Electrical Power Conversion, University of Malta Case Study 4 High Efficient Motor (HEM) replaced ‘older’ elevator motor at Andrews Feeds Ltd. Active power (W) Active power (W) vs Time (s) 10000 Around 8000 25% 6000 overall energy savings Old Standard Motor High Efficient Motor 4000 2000 0 More than 35% energy savings at low load -2000 -4000 9.4 9.42 9.44 9.46 9.48 Time (s) 9.5 9.52 9.54 9.56 9.58 4 x 10 Department of Industrial Electrical Power Conversion, University of Malta Motor Energy Saving Tool (MEST) Screenshot of software tool developed to guide technical persons in industry to take right decisions in order to increase the efficiency in motor applications Department of Industrial Electrical Power Conversion, University of Malta Increasing Energy Efficiency during Testing of Equipment by novel Gridâconnected Load Units Key Experts: Dr. Maurice Apap Co-Supervisors: Prof. C. Spiteri Staines & Prof. J. Cilia Researchers: Industrial Partners : Abertax Delta (Malta) Mr. Francarl Galea Department of Industrial Electrical Power Conversion Faculty of Engineering – University of Malta Introduction • Manufacturing Cycle • Testing of each product must take place before reaching the market and the customer. • Testing of certain products leads to high energy consumption. • power supply full load burn-in test usually last for a minimum of 24 hours. (can exceed 400,000kWhr yearly.) • batteries testing is carried out by cycling. Department of Industrial Electrical Power Conversion, University of Malta Aims • This project is targeted at increasing the efficiency during testing of manufactured electrical equipment: namely, DC Power Supplies and Battery Banks. • Currently Electrical Energy consumed during testing is ‘wasted’ (as heat) in Active Loads. • The aim of this project is to REDIRECT the Electrical Energy used during testing back to the Electrical Supply. • 70% energy saving is predicted. Department of Industrial Electrical Power Conversion, University of Malta Case Study • Testing of a 70V 800W Power Supply with the Regenerative Load • The energy savings obtained in this test were 83% (excluding losses in the Power Supply). Department of Industrial Electrical Power Conversion, University of Malta Case Study • List of savings obtained when testing various models of Power Supplies Device under test Power consumed in resistive load Power consumed with Regenerative Load Percentage Decrease in Energy consumption (excluding losses from the Device under Test) 200V 800W 123W 84.6% 70V 800W 135W 83.1% 35V 800W 212W 73.5% 30V 300W 65.4W 78.2% 30V 150W 43W 71.5% 30V 1500W 418W 72.1% 70V 2000W 350W 83.5% 200V 2000W 255W 87.5% 300V 2000W 272W 86.4% 400V 2000W 261W 87% 600V 2000W 275W 86.3% Department of Industrial Electrical Power Conversion, University of Malta Thank you for your attention - next talk shall consider in detail one case study concerned with regenerative load testing MALTA Department of Industrial Electrical Power Conversion, University of Malta