Investigating ways to increase the efficient use of Electrical Energy in the Manufacturing Industry MALTA.

Investigating ways to Investigating ways to increase the efficient use of increase the efficient use of

Electrical Energy in the Electrical Energy in the Manufacturing IndustryManufacturing Industry

MALTA

Department of Industrial Electrical Power ConversionFaculty of Engineering – University of Malta

Energy Efficient Electric Motor Energy Efficient Electric Motor SystemsSystems

Key Experts: Prof. Ing. C. Spiteri-

Staines

Co-Supervisors: Dr. Cedric Caruana

Researcher: Mr. Peter Spiteri

Industrial Partners : Playmobil

Toly Products

Andrews Feeds

Department of Industrial Electrical Power Conversion, University of Malta

IntroductionIntroduction

• 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 ProjectAims 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 Increasing Efficiency in Motor SystemsSystems

Department of Industrial Electrical Power Conversion, University of Malta

ResultsResults

6

• 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).

Lab rig tests:

• Profile of an Elevator load

• Two different Injection Mould Machine profiles

On-site Case Studies:

• 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

Department of Industrial Electrical Power Conversion, University of Malta

Laboratory Test Rig schematicLaboratory Test Rig schematic

Department of Industrial Electrical Power Conversion, University of Malta

Laboratory Test RigLaboratory Test Rig

Department of Industrial Electrical Power Conversion, University of Malta

Lab test rig resultsLab test rig results

• Motor (5.5kW) at no load

0 1 2 3 4 5 6 7 8 9 100

100

200

300

400

500

600

Time (sec)

Act

ive

pow

er (

W)

No LoadPowerBoss from OFF to ON

Input power (kW) vs time(s)

471W

305WMotor Energy Controller

switched ON

35% Energy Savings

Department of Industrial Electrical Power Conversion, University of Malta

Lab test rig resultsLab test rig results

• Comparison of efficiency with the MEC ‘on’ and ‘off’ for different operating points

0 1 2 3 4 5 650

55

60

65

70

75

80

85

90

95

100

Output power (kW)

Eff

icie

ncy

(%)

Efficiency (%) vs Output power (kW)

MEC OFF

MEC ON

Low LoadHigh Savings

High LoadLow Savings

Department of Industrial Electrical Power Conversion, University of Malta

Elevator Profile (Lab Results)Elevator Profile (Lab Results)

5.3% overall energy savings

0 50 100 150 200 250 300 350 400 450 500

500

1000

1500

2000

2500

3000

3500

Time (s)

Inp

ut p

ow

er

(W)

Input power (W) vs Time (s)

MEC OFF

MEC ON

9.7%

1%

Department of Industrial Electrical Power Conversion, University of Malta

Injection Mould Machine (Lab Results) Injection Mould Machine (Lab Results) Profile 1Profile 1

12

0 10 20 30 40 50 60 70 80 90 1000

1000

2000

3000

4000

5000

6000

7000

Time (sec)

Act

ive

pow

er (

W)

Input power (kW) vs time(s)

MEC OFF (IMM profile)

MEC OFF (ave. load)

MEC ON (IMM profile)

MEC ON (ave. load)

4.6%Energy Savings

Department of Industrial Electrical Power Conversion, University of Malta

0 20 40 60 80 100 120 140 160 180 2000

1000

2000

3000

4000

5000

6000

Time (sec)

Act

ive

pow

er (

W)

BOY Profile (PowerBoss ON)

Input power (kW) vs time(s)

Average Power = 1.16kW

0 20 40 60 80 100 120 140 160 180 2000

1000

2000

3000

4000

5000

6000

Time (sec)

Act

ive

pow

er (

W)

BOY profile (PowerBOSS OFF)

Input power (kW) vs time(s)

Average power = 1.20kW

MEC OFF

MEC ON3.3%

energy savings

Injection Mould Machine (Lab Results) Injection Mould Machine (Lab Results) Profile 2Profile 2

Department of Industrial Electrical Power Conversion, University of Malta

2000 2200 2400 2600 2800 3000 3200 3400 3600 3800

-1000

0

1000

2000

3000

4000

5000

6000

7000

8000

Time (s)

Act

ive

pow

er (

W)

Active power (W) vs Time (s)

MEC OFF

MEC ON

Case Study 1Case Study 1 Motor Energy Controller (MEC) installed on elevator motor at Andrews Feeds Ltd

More than 20% energy savings were achieved at low load

Department of Industrial Electrical Power Conversion, University of Malta

Case Study 2Case Study 2

• 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%

Motor Energy Controller (MEC) installed IMM motor at Toly Products Ltd

Department of Industrial Electrical Power Conversion, University of Malta

0 20 40 60 80 100 1202

3

4

5

6

7

8

9

Time (s)

Act

ive

pow

er (

kW)

Active power (kW) vs Time (s)

MEC OFF

MEC ON

2.2%Savings

MEC OFF:Average power =3.18kWAverage p.f. = 0.4129

MEC ON:Average power =3.11kWAverage p.f. = 0.4549

Case Study 3Case Study 3 Motor Energy Controller (MEC) installed on IMM at FS Engineering & Plastics Ltd

2.2% energy savings

Department of Industrial Electrical Power Conversion, University of Malta

9.4 9.42 9.44 9.46 9.48 9.5 9.52 9.54 9.56 9.58

x 104

-4000

-2000

0

2000

4000

6000

8000

10000

Time (s)

Act

ive

pow

er (

W)

Active power (W) vs Time (s)

Old Standard Motor

High Efficient Motor

Case Study 4Case Study 4High Efficient Motor (HEM) replaced ‘older’ elevator motor at Andrews Feeds Ltd.

More than 35% energy savings at low load

Around

25%

overall energy savings

Department of Industrial Electrical Power Conversion, University of Malta

Motor Energy Saving Tool (MEST)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 ConversionFaculty of Engineering – University of Malta

Increasing Energy Efficiency Increasing Energy Efficiency during Testing of Equipment during Testing of Equipment

by novel Grid‐connected Load by novel Grid‐connected Load UnitsUnits

Key Experts: Dr. Maurice Apap

Co-Supervisors: Prof. C. Spiteri Staines & Prof. J. Cilia

Researchers: Mr. Francarl Galea

Industrial Partners : Abertax

Delta (Malta)

Department of Industrial Electrical Power Conversion, University of Malta

IntroductionIntroduction

• 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

AimsAims

• 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 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 StudyCase 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 attentionThank you for your attention

- next talk shall consider in detail one - next talk shall consider in detail one case study concerned with regenerative case study concerned with regenerative load testingload testing

MALTA