DS-OCT24-PG43_Layout 1 15/10/2024 10:09 Page 1


DRIVES, CONTROLS & MOTORS FEATURE


CRAFTING ENERGY-SMART MOTOR DRIVEN SYSTEMS


ABB’s president of motion services, Erich Labuda, explores how audits can help operators design more energy efficient motor systems and develop targeted sustainability strategies


CERN, the European Laboratory for Particle Physics, also observed energy savings through a study with ABB. In 2022 and 2023, it conducted energy efficiency audits which revealed potential savings of 17.4% across 800 motors. It also developed a roadmap to reduce energy consumption in CERN’s cooling and ventilation systems. The identified annual savings were up to 31 GWh, potentially


avoiding 4 kilotons of CO2 emissions, equivalent to planting 420,000 trees. The CERN and ABB experts assessed


data from motors in cooling and ventilation applications, combining information from digitally connected motors, CERN’s SCADA system – designed to monitor, control and analyse their industrial processes – and pumps and instrumentation. The experts evaluated overall system performance, gaining insights to identify motors with the best case for increased energy efficiency. CERN aims to selectively upgrade the motors with the highest energy-saving potential.


I


ndustrial motors are the backbone of modern society. From powering manufacturing plants to driving essential infrastructure like water and energy systems, motors play a crucial role in keeping things running smoothly. According to the International Energy Agency (IEA), there are over 300 million industrial motors currently in use, consuming around 45% of the world’s total electricity. As the world pursues sustainability, there is a


growing demand for energy-efficient solutions. Coupled with a shift to renewable energy, these efforts are essential for meeting the 1.5˚C global warming target, set in 2015 at The Paris Agreement. This urgency is driven by rising energy costs, societal pressure, customer expectations, and stricter regulations. Enhancing the efficiency of motor driven


systems offers a practical solution to reduce energy consumption that aligns with climate goals and cost savings. The IEA notes that upgrading all motors to high-efficiency models could cut global electricity use by at least 10%.


UNLOCKING ENERGY EFFICIENCY POTENTIAL A recent ABB survey found that 97% of industry leaders want to invest in efficiency, but only 41% feel informed enough to act. Key challenges that impede the energy efficiency transformation include a lack of clarity, missing capabilities, misaligned incentives, and resistance to change. Energy audits offer a detailed analysis


across a fleet of industrial motors to pinpoint areas with significant energy-saving potential.


This invaluable information allows maintenance teams to make informed decisions, targeting motors with the highest savings potential, leading to reduced energy consumption and cost savings. Experts can collect data manually, on-site,


or digitally from regular updates. They then analyse motor performance to identify potential upgrades, helping businesses calculate energy savings, emissions reductions, and return on investment (ROI). Digital solutions, using big data and AI, can detect energy efficiency potentials, enabling new possibilities in automation and self-optimisation.


POWERING INNOVATIONS TOGETHER In 2023, ABB conducted audits on over 2,000 industrial motors across various sectors and applications to identify their potential for energy savings. Remarkably, the findings showed that upgrading the technology could offer 31% potential energy savings for each motor, especially for those currently operating without the benefit of a variable speed drive (VSD). By implementing the suggested upgrades, operators could achieve a return on investment (ROI) in as little as three months, depending on local energy costs. The audits uncovered a total savings of


2.1 terawatt-hours (TWh) over the 20-year lifespan of the 2,000 motors – equivalent to powering 1.25 million houses for a year. When extrapolated to the 300 million industrial motors worldwide, the potential impact of upgrading inefficient motors is staggering.


ACTIONABLE INSIGHTS FROM ENERGY AUDITS To improve motor energy efficiency, operators commonly add VSDs which allow a motor’s speed or torque to be adjusted continually to match task demands. For example, reducing a motor’s speed by 20% can halve energy use. Despite their benefits, only 25% of industrial motors currently use VSDs, though at least half could benefit from the technology. Design upgrades to more energy-efficient


motors offer another effective strategy. Many existing motors use IE1 or IE2 technology, but modern IE5 motors achieve 40% lower energy losses than IE3 models, reducing


energy use and CO2 emissions. Progress continues as ABB’s synchronous reluctance (SynRM) motors now offer the anticipated IE6-level hyper-efficiency. Energy audits frequently find that many motors


are oversized, as designers build in large safety margins for infrequent contingencies. Resizing them can optimise energy efficiency without sacrificing performance or reliability, especially as frequently it is possible to overrun motors during the rare periods of peak demand. Operators must evaluate not just motor efficiency, but the whole system. For example, in a heating, ventilation and air conditioning (HVAC) installation, operators must also assess the fans, condensers, and cooling towers. Now is the time to prioritise energy efficiency


to cut costs and emissions. Energy audits streamline this process by pinpointing top efficiency opportunities. This practical approach not only enhances operations but also brings industry closer to global Net Zero targets.


ABB www.abb.com


OCTOBER 2024 DESIGN SOLUTIONS 43


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60