Report on Energy-Saving Survey by medium … control (inverter) not applied to motors for pumps, especially medium voltage motors Current Status and issues of Energy Efficiency TAF

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


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 !!


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.


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.


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


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.


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


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


Survey Process （Detail）② Panel outline

Inverter panel

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～～

～～

～～

～～

～～

～～

～～

～～

～～

～～

～～

～～

～～

～～

～～

～～

Ｍ

～～

Input Transformer Control Panel


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


Survey Process （Detail）④ Valve Control vs

Speed control

Pum

p H

ead

; H

Pump Flow ; QQ1

H1


H = A-(A-1)Q2

REQUIRED MOTORPOWER

A

0.7x Q1

Pum

p H

ead

; H

Pump Flow ; QQ1

H1


H = A-(A-1)Q2

REQUIRED MOTORPOWER

A

0.7x Q1

Valve Control Speed Control


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


Current Status and issues of Energy Efficiency （Details）①

ROC

Motor data

Target item for

Inverter operation


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.)


Current Status and issues of Energy Efficiency （Details）③

ROC

Outline dimension

6.6kV-2600kVA


Current Status and issues of Energy Efficiency （Details）④

ROC

Panel layout

Primarily selected Optional selected


Current Status and issues of Energy Efficiency （Details）①

TAF

Motor data

Target item for

Inverter operation


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


Current Status and issues of Energy Efficiency （Details）③

TAF

Outline dimension

6.6kV-600kVA


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


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


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



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


Valve control 12,159,875 kWH

Inverter control 4,893,882 kWH




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



②

TAF CO2

Reduction

Energy Comparison


2,108,600 kWH

Inverter control 904,800 kWH


Energy Comparison


Valve control 2,108,600 kWH

Inverter control 904,800 kWH



Suggestions

Application of inverter1) Friendly to motor, friendly to power source2) Energy saving, CO2 reduction3) Cost saving

Create green factory

Report on Energy-Saving Survey by medium … control (inverter) not applied to motors for pumps, especially medium voltage motors Current Status and issues of Energy Efficiency TAF

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