Emerging Trends in Integrated Motor Systems

Transcription

1 Emerging Trends in Integrated Motor Systems Alex Fleming, P.Eng. Principal Demand Side Energy Consultant Inc. Markus Zeller, P.Eng. BC Hydro #psf11

2 Presentation Outline Integrated Motor Systems and Energy Use Trends and Opportunities Component Efficiency Premium Control Energy Engineering Application Engineering System Energy Performance Closing the Gap Innovators Early Adopters Early/Late Majority Laggards

3 Electric Motor Energy Usage 50% of total electricity consumed in BC is converted to shaft power in motor driven systems: 100% Small (< 1 hp), 9% 80% 60% 40% 20% 0% Medium (1-500 hp), 68% Large (>500 hp), 23% %-Energy Small (< 1 hp), 89% Medium (1-500 hp), 11% %-Units

4 Component Efficiency has an Impact Efficient conveyor components can boost system efficiency, but not improve the basis of design. η Conveyor system = η Motor X η Belt X η Reducer X η Chain X η dragchain Component 30% = x 0.95 x 0.55 x 0.90 x 0.70 EE Component 54% = x 0.97 x 0.94 x 0.90 x 0.70

5 Limits and Diminishing Returns in Motor Component Efficiency 100 Full Load Efficiency (%) Super Premium Rating (hp)

6 Premium Control Allows equipment to follow the load and maintain the Best Efficiency Point (BEP) over an operating range The load is a process and the motor system boundary is now crossed

7 Premium Control Complicates component efficiency predictions Chart courtesy of CEATI

8 Premium Control Requires motor, VFD & equipment efficiencies Torque (% Nominal) 25 Conveyors Speed (% Nominal) Pumps & Fans

9 Premium Control Plus any minimum pressure requirement needs modified Laws of Affinity 3 1 min min H H Q Q H H Power Power 2 1 min min H H Q Q H H Head Head 1 min min H H Q Q H H Speed Speed

10 Five Motor System Opportunities ACTIVITY APPROACH MOTOR SYSTEM OBJECTIVE Catalogue Engineering Go to E.E. Catalogue Premium Control Energy Engineering Application Engineering Remove and replace (R&R) Install energy efficient components Load match the supply side with process demands Optimize supply side efficiency with demand-side consideration Integrated Motor Systems OEM Industrial Appliances Low Distraction/Transaction Low Cost/Low Risk Improve Component Efficiency Achieve Best Efficiency Points Optimize Performance Reduce components Re-visit the Basis of Design Integrated Energy Mgt System Premium Control and EE Components comprise majority of present activity

11 Power Smart Pump Video

12 Five Motor System Opportunities ACTIVITY APPROACH MOTOR SYSTEM OBJECTIVE Catalogue Engineering Go to E.E. Catalogue Premium Control Energy Engineering Application Engineering Remove and replace (R&R) Install energy efficient components Load match the supply side with process demands Optimize supply side efficiency with demand-side consideration Integrated Motor Systems OEM Industrial Appliances Low Distraction/Transaction Low Cost/Low Risk Improve Component Efficiency Achieve Best Efficiency Points Optimize Performance Reduce components Re-visit the Basis of Design Integrated Energy Mgt System

13 Energy/Application Engineering Basis of Design Packaged unit with lowest risks and lowest total cost of ownership High speed motor with magnetic bearings Oil-free variable speed compressor Off-load power lowest in industry Half weight and size Low maintenance Low noise But what s in the box?

14 What is an Integrated Motor System? An electric motor driven system that serves the process application efficiently and effectively as well as addresses the design intent Integrated Fan Motor System (30 Watts) All-electric LNG Plant (4 motors, 260 MW)

15 The Trend is Toward the On-Demand Appliances OEM go back to basis of design. Variable capacity and intelligent control. Packaged system knowledge Other Benefits noise, footprint, reliability. + =

16 Application Engineering Commercial HVAC Appliance Variable Refrigeration Volume (VRV) is more than variable frequency drives on chillers & fans. Variable System output - tracks load profile and demand Volume regulated by electronic expansion valve Simultaneous heating/cooling Ductless heating and cooling Intelligent and Proprietary Controls

17 Application Engineering Industrial Wastewater Appliance High Speed Turbo Blower..Just add electricity and piping High-speed blower designed for wastewater High speed & variable speed motor Balanced design low noise, small footprint Intelligent & Proprietary Controls Energy performance metric is kwh per kg of BOD removed

18 High Speed Turbo Blowers Performance Price Bellows P.D. Multi Stage Turbo Induction Motor Geared Single Stage Turbo Induction Motor Magnetic Bearing Direct Drive Single Stage Turbo PM Motor Foil Bearing Direct Drive Stainless Steel Impeller Single Stage Turbo Photos courtesy of KTurbo Inc.

19 Industrial Appliance Design Starts with the process requirement and the basis of design, then considers the most appropriate integrated motor system options.

20 How to ID Application Engineering A renewed basis-of-design, fully integrated, definite purpose, plug & play. Re-engineered as an appliance package with embedded specific algorithms and controls. Energy performance is based upon its process function - not just efficiency. kwh per unit of process outcome

21 Examples: Integrated Motor Systems Energy Efficient Components Premium Control Energy Engineering Application Engineering Early Adopters Early/Late Majority Innovators Laggards

22 Gearless Mill Drives Basis of Design: very large (16MW), low-speed, variable speed VSD High Speed VSD Low Speed VSD GMD Transformer 99.1% 99.1% 99.1% Converter 98.6% 98.6% 99.2% Motor 97.2% 97.2% 96.8% Gear Reducer 98.5% n/a n/a Ring-gear 98.0% 98.0% n/a Overall Efficiency 91.7% 93.1% 95.2%

23 Motorized Pulleys Basis of Design: Integrated design Sealed unit Low maintenance

24 Constant Speed Direct Drive Coupling Basis of Design: Small speed reductions can result in large energy savings Fixed speed tuning for centrifugal loads (similar to sheaves) Reversed by removing shims (impeller trim is not reversible) Isolate pump from motor (alignment & vibration) Motor Shaft Load Shaft Photos courtesy of MagnaDrive Inc.

25 Integrated Fan Motor Systems Basis of Design: Greenhouse ventilation & control Energy savings (60-80%) Variable speed

26 Direct Drive Cooling Tower Fan?

27 Dust Extraction Technology Basis of Design: Eliminates baghouse filter system by encapsulating the dust particles into atomized water Removes abrasive dust particles out of air stream No reduction in performance under high dust loads High dust collection efficiencies Compact high volume design Low maintenance Self cleaning Photos courtesy of Engart Global.

28 Electro-Mechanical Actuators Basis of Design: Eliminate pneumatic or hydraulic completely Improved control & reliability

29 Fish Hatchery Raceway Recirc. Same Fish Growth with 60% less water Well pump energy reduced by 50% Site energy consumption reduced by 25%

30 Application Engineering for Dry Kilns Performance Conventional High Premium Progressive Kiln Efficiency Kiln Efficiency Kiln Kiln Electricity 0.16 kwh/kg 20-25% savings 30-50% savings >50% savings Thermal 5.0 MJ/kg 10-15% savings 20-30% savings >30% savings

31 Next Steps: Closing the Gap - System versus Components Standardized system boundaries of unit process function Baseline and benchmarking protocols

32 Next Steps: Closing the Gap - System versus Components Development of process specific energy performance metrics are critical: Ability of field measurement for energy performance verification and diagnostic:

33 Impacts on Codes & Standards Shift from the energy efficient components to system energy performance requires: Definitions: Efficiency versus Effectiveness Scope: System Boundaries and Load Profiles M&V: Process Specific Energy Performance EnMS: Energy Management System

34 Thank You! Alex Fleming, P.Eng. Principal Demand Side Energy Consultants #psf11