The paper, presented by GAMBICA deputy director Steve Brambley, will show how the lifetime cost of efficient equipment is lower due to the high proportion of energy costs in motor driven systems. Brambley will explain that 97% of the lifetime costs of a motor come from the energy it consumes and that energy efficient systems can deliver significant, often double digit, savings. He will also compare two example lifetime costs, the first with investment in motor control, the second without it.

“Running old or inefficient equipment is a false economy,” explains Brambley. “The real barrier to investment is the understanding of the lifetime cost of a system at a corporate and financial level. In contrast, I think engineers readily accept the benefits of motor control.”

The 2012 one-day MDS Conference will still examine the significance of these areas but will focus sharply on drilling down into how they impinge on the all- important end users.
Because electric motors and motor driven systems in industry and commerce, together with pumps, fans and compressors still account for around 40% of the world’s total energy consumption, it was always intended that the MDS Conference would be an on-going process rather than a one-off event.

The Motor Driven Systems conference will take place on November 8 at St. John’s Hotel, Solihull. The event, which is supported by companies from the pump, compressed air, motors, drives, controls and fan industries, aims to bring together the varied strands of legislation, standardisation, system strategies and technological developments affecting motor driven systems.

In the context of the economic downturn and subsequent cuts, manufacturers are reluctant to invest in improving their systems. However, as time passes, inefficient industrial machines consume more and more expensive energy and begin eating away at profits. One solution to this problem is the installation of a variable speed drive (VSD) or alternative fixed speed form of motor control, as GAMBICA’s white paper illustrates.

“The American industrialist Henry Ford once said that, If you need a machine and don’t buy it, then you will ultimately find that you have paid for it, but don’t have it,” says Steve Brambley, deputy director of GAMBICA. “I believe that a century later, his assertion is more pertinent than ever for UK manufacturing. As our findings point out, VSDs can reduce the energy cost of most fixed speed motor driven systems by more than their own capital cost in a relatively short period – often less than a year. As energy prices continue to soar, the return on investment on a VSD application increases in proportion to the bill,” he concluded.

The price for delegates to attend the Motor Driven Systems event is £235 plus VAT. For more information, bookings and a conference programme, visit the Motor Driven Systems website at www.motordrivensystems.com.

The second MDS Conference will take place on 8^th November at St. John’s Hotel, Solihull.
The event is supported by the same five national trade associations that came together to ensure the successful launch of MDS 2011. BPMA, BCAS, BEAMA, Gambica and FETA represent the pumps, compressed air, motors, drives, controls and fan industries respectively, and are all vitally important conduits for getting across the message that a systems’ engineering approach to motor driven systems is critical in achieving energy efficiency.

The inaugural event was held over a two-day period enabling the organisers to bring together the many and varied strands of legislation, standardisation, system strategies and technological developments affecting motor driven systems.

The 2012 one-day MDS Conference will still examine the significance of these areas but will focus sharply on drilling down into how they impinge on the all- important end users.
Because electric motors and motor driven systems in industry and commerce, together with pumps, fans and compressors still account for around 40% of the world’s total energy consumption, it was always intended that the MDS Conference would be an on-going process rather than a one-off event.

Given that existing and future legislation and technological innovations can offer the potential to reduce the energy demand of motor systems across the global economy by 20% – 30%, it is in industry’s best interest to find out how it can benefit.

Decision makers, financial heads, energy managers, plant engineers and facilities managers within manufacturing and processing industries in end user companies will hear much to their advantage by attending the MDS Conference 2012.

The MDS Conference will take place at St. John’s Hotel, Solihull on Thursday 8th November 2012.

For further information and delegate booking details please contact Andrew Castle, Event Director at Touchwave Media on 07785 290034 or by email at andrew@touchwavemedia.co.uk.

Alternatively, visit the dedicated website at www.motordrivensystems.com.

ENDS

Editors’ Note: For further information contact Richard Burke, Marketing Communications, Touchwave Media on 01634 234050 or 07711 444 198  or by email at richardburke144@yahoo.co.uk.

Within the MDS Conference individual elements of a system – pumps, fans, motors, drives and compressors – will be addressed to highlight best practices, new technology and innovative ideas designed to achieve those enhanced energy savings.
 
Touchwave Media provides a synopsis of what will be discussed at the Conference within each product area, and having previously addressed Pumps, Motors and Fans we now look at both Drives and Compressors.
 
Co-ordinating motor drive systems for best efficiency
 
To achieve the best possible energy savings/efficiency from a fan or pump infrastructure, it is an absolute requirement that Variable Speed Drives (VSDs) are used. VSDs, combined with high efficiency motors, enable a fan or pump system to be optimised to the best operating speed for the Duty, rather than being restricted or compromised by the use of a fixed speed design.
 
This paper will show, by way of example, where the use of VSDs can enable the compromise of a fixed speed design to be avoided with subsequent energy efficiency benefits.
 
1. A fan design that has poor efficiency that will never benefit from variable speed operation
 
2. Multiple pump operation versus single pump
 
3. Higher operating speed than mains frequency nominal
 
The metric for these examples will be the ‘Cost of Energy’ in kWhr per cubic metre, using this metric,  the benefits, or detriment, of particular fan/pump scenarios will be demonstrated
 
From this it is hoped that the use of VSDs will be shown to assist in the complex interaction that is design, to arrive at an optimum solution to end user clients.
 

Optimisation of drive system energy efficiency
 
The global optimisation of energy efficiency of various processes in industry, building automation and civil engineering is a complex exercise involving a multitude of components. A global optimization is not easy, as the decisions on component selection in various parts of the energy flow (specifically electric energy) are undertaken by different actors, who do not necessarily communicate sufficiently. Thus it is easy to optimise some part of the total energy used, but create a globally suboptimal solution.
 
The components and devices involved in optimising electricity flow and usage start with the prime movers – generators , then transmission and distribution systems, power distribution , drives and motors and finally the actual working machine that change state or location of material for specific purposes. The final requirement is that this process should be as efficient and cheap as possible.
 
A typical drive system – from the final user’s point of view, – consists of a motor and a drive and the power supply for this. An analysis of the developments in terms of energy efficiency will be presented for the motor and the drives (introduction of new legislation for motors, efforts to create similar requirements for drives) as well as technical developments focused on energy consumption are presented. The relationships of various parameters to the energy efficiency and the cost of the product are examined – typically switching frequency and its relationship with the motor efficiency, the improvements in energy efficiency reached with new drive components and topologies etc.
 
Following up – the influence of harmonics on cable and transformer losses, stretching all the way to the generators will be discussed. A short discussion on optimal cable sizing will also be done – examining the different priorities in choosing cable size.
 
A presentation of the relative effects of various actions in optimising the energy use in comparison to the relative costs of the action rounds off the presentation.
 
Drive chain management as part of a best practice approach
 
It is becoming increasingly well known that motor driven systems account for around 2/3 of the electrical energy consumed by industry – and are the largest single consumers of electrical energy overall. Additionally, most end users have already engaged with energy efficiency programmes. However, very few users have adopted a truly systematic approach to energy and cost reduction which could dramatically multiply the cost savings – this paper therefore seeks to; 

• Provide a clear evaluation of complete “drive train management”
• Define the relative importance of motors, mechanical drives and electronic variable speed drives

• Highlight many of the most common mistakes
• Position “drive train management” within the context of a systematic approach to energy management and the recommendations of important standards such as BS EN 16001
• Provide clear technical and commercial benefits of a systematic approach
• Identify new technologies and strategies to maximise the benefits of complete “drive train management”

 
Energy optimisation in air compression
 
Electrical energy in Europe for Compression Air Systems (CAS) in Industry accounts for almost 100 TWh. Including leakage and the incorrect use of compressed air, the potential in terms of energy saving, has been estimated to be 30%. Using optimised compressors, specifically conceived for energy saving could offer potential energy savings estimated at close to 10%, which would represent 50% of the European Energy saving goal by 2020 (“20-20-20” EU Directive) if CAS is considered as a specific sector.
 
Sliding Vane Rotary Compressors (SVRC) show previously unforeseen potential in terms of energy saving due to some intrinsic features specifically related to the principles of the working conditions of the machine and which do not strictly apply to other types of rotary compressor.
 
As we strive for energy savings and CO₂ reduction the inherent efficiency advantages of these machines increases the importance of developing this SVRC technology,
 
A complex reconstruction of the pressure inside a cell was carried out using multiple piezoelectric pressure transducers positioned within an existing commercial SVRC. The data obtained represented an innovation in the sector and thanks to comprehensive mathematical modeling previously developed by the Authors; the theoretical handling of the pressure measured allowed a detailed examination of the thermodynamic aspects of the closed volume compression phase.
 
In this paper the Authors refine the mathematical modeling of a SVRC focusing on energy consumption:
 
Main issues of this advancement are.
 
a) Filling and emptying process of the cells made by a quasi-propagatory modeling, optimised for the discharge phase;
 
b) Blade settings which are not radial, so the blade motion moves according to a given angular inclination respecting the geometrical constraints;

c) A complete derivation of a new blade dynamics modeling was considered allowing a more precise value of energy lost due to friction to enhance the main SVRC design parameters.
 
The model has been used in order to deal with:
 
a) Maximisation of the air mass inducted by the machine, having fixed the stator and rotor geometry, as well as the inlet and exhaust ports. Leaving as free design parameters, the eccentricity, and the associated inclination of the blades (slots), taking into account the real slot and blade dimensions, and, so, the possible geometrical interferences;
 
b) The optimisation of the specific power required to compress the air (W/kg/s), having fixed a downstream pressure in the line.
 
A validation with actual experimental data is presented based on direct measurement of the indicated and mechanical power.
 
The MDS Conference will take place at St. John’s Hotel, Solihull, on 9^th & 10^th November 2011.
 
For further information and delegate booking details please contact Andrew Castle, Event Director at Touchwave Media on 07785 290034 or by email at andrew@touchwavemedia.co.uk.

 
Frank Holden, Drive & Coupling Solutions: Frank is Southern Manager for Drive & Coupling Solutions Ltd serving the Southern and Home Counties of England with a unique service for rotating equipment.

Frank’s mechanical engineering experience spans 30+ years in many industrial sectors from heavy power generation, paper and steel mills through water utilities and pharmaceutical to food preparation and production. Positions held cover training, general management, consultancy, technical sales and technical specialist.
 
His projects look to reduce total cost of ownership with low/zero maintenance products that reduce energy consumption and lower his clients’ carbon footprint. He will be looking at MagnaDrive technology.
 
 
Florent Violain, Sterling Fluid Systems UK: Florent is currently responsible for the Life Cycle Cost Development for Sterling Fluid Systems UK – a global leading supplier of pumping solutions – focusing on energy efficiency to address the complete life cycle costs of complete pumping systems.
 
After beginning with Sterling Fluid Systems, France, he held a position in Sterling Colombia to provide technical and commercial support to the South American distribution network. He is now based in the UK leading energy assessments for pumping systems and is a US Department of Energy Qualified PSAT (Pumping System Assessment Tool) Specialist.
 
He will be asking – ‘What is a Systems Approach to Pumping?’
 
 
Iain Lindsay, Rockwell Automation: Iain works for Rockwell Automation – a leading supplier of automation and industrial control products and services – where he represents Rockwell Automation’s interests on European Regulatory Affairs.
 
He has more than 20 years’ experience of European directives and regulations – both as a system integrator and a product supplier – across a wide range of Safety, EMC, and Environmental topics.
 
As part of his role, Iain is an active member of several National and European and industry associations (including GAMBICA (UK), CAPIEL, Orgalime, and TechAmerica Europe) focussing on European directives and regulations, and he also participates in standards development organisations including BSI (UK), CENELEC (Europe) and IEC/ISO (International).
 
Iain will ask the question – ‘Does Regulation 640-2009 Change The Way To Design A System?’
 
 
Jeremy Wilkinson, Siemens: Jeremy has 20 years’ experience in the variable speed drives industry. He has worked with several industry leading manufacturers, is a member of the IET, advised on energy efficiency and harmonics best practice and has extensive technical & applications support of AC & DC products.
Jeremy’s paper will examine the topic of ‘VSD & Direct Motor Technology For Cooling Tower Fans’.
 
The MDS Conference will take place at St. John’s Hotel, Solihull, on 9th & 10th November 2011.
For further information and delegate booking details please contact Andrew Castle, Event Director at Touchwave Media on 07785 290034 or by email at andrew@touchwavemedia.co.uk.

The Motor Driven Systems Conference, being staged on 9th& 10th November 2011 at the St. Johns Hotel in Solihull, will for the first time in the UK examine the legislative, technical and application developments within motor driven equipment whilst addressing the commercial and environmental benefits of adopting a systems’ based strategy for optimum energy efficiency.

The specially produced digital ‘Event Guide’ provides all the information you will need to know about the Motor Driven Systems Conference, including its speakers, sponsors and partners. It carries detailed technical articles on the core subject matter and references all those organisations involved in bringing this important event to market.

The Event Guide can be accessed via the home page on the event website or directly via the following link – http://motordrivensystems.com/event-guide.

We hope you find it of interest and that it further encourages you to attend the conference and to learn how you can improve the efficiency of your motor driven apparatus, be it pumps, compressors or fans.

For further information and delegate booking details please contact Andrew Castle, Event Director at Touchwave Media on 07785 290034 or by email at andrew@touchwavemedia.co.uk.

Alternatively, visit the dedicated website at www.motordrivensystems.com.

 
Regis Giraud, Leroy Somer: Regis has been employed by Moteurs Leroy Somer for 27 years and is the Commercial and Marketing Manager of the IHP Division of the company. He has been actively involved in the design and marketing of Permanent Magnet motors and their use with Electronic Drives for many years. He will be discussing Permanent Magnet technology.

 
Dan Hopkins, ebm-papst: Technical Manager at ebm-papst UK and with over 15 years in the industry, Dan has gained a wealth of experience in fan selection and air movement system design across domestic, commercial and industrial sectors. Leading a team of application engineers, he is focused on ensuring that appropriate fan selection, efficient system design and promotion of the latest energy saving technology are his top priorities when meeting clients’ needs.

Dan regularly contributes at the Residential Ventilation Association (RVA) meetings, is the acoustic consultant for ebm-papst UK and is an associate member of the Institute of Acoustics.

He will be asking the question – Total Or Static Efficiency – What Does It Mean?

Roberto Cipollone, Mattei Compressors: The co-founder of “Fucino Energia”, a new Consortium between eleven industries and University of L’Aquila to create synergies between industry and the University. He is also vice-Director of the Department of Mechanical Engineering, Energy & Management at the University of L’Aquila.

He sits on the Board of Directors of numerous companies, consortium and commissions and is involved in many strategic development projects in the research and development of new engines, pumps & compressors, sealing technology and energy saving issues.
His paper will address Energy Optimisation in Air Compression.

Ian Robinson, KSB: Ian has worked within the pump manufacturing business since his graduation in Mechanical Engineering in the early 70s. During his 30+ years at KSB, one of the world’s leading pump and valve manufacturers, he’s been involved in applications, technical support, QA and sales. This has included significant experience with users to establish solutions to pumping applications and assist in improving equipment operation.

 
He will discuss Improved Efficiencies by Pumps Operating in a System.

 
For further information and delegate booking details please contact Andrew Castle, Event Director at Touchwave Media on 07785 290034 or by email at andrew@touchwavemedia.co.uk.

The Motor Driven Systems (MDS) Conference being held at St. Johns Hotel, Solihull, on 9^th & 10^th November 2011, will examine how a systems engineering approach to designing motor driven systems will result in the achievement of greater energy savings.

Within the MDS Conference individual elements of a system – pumps, fans, motors, drives and compressors – will be addressed to highlight best practices, new technology and innovative ideas designed to achieve those enhanced energy savings.

Touchwave Media provides a synopsis of what will be discussed at the Conference within each product area, and having previously addressed both Pumps an Motors, we now look at Fans.

Improving fans in air handling units

This study will demonstrate how the correct application of alternative fans in an Air Handling Unit (AHU) can reduce energy consumption by 56% compared to the use of traditional fans and methods.

The study is based on three party development of an Air Handling Unit by the motor/fan manufacturer, the AHU manufacturer and the ends users Iceland Frozen Foods. It demonstrates how the overall efficiency can be improved when the motor driven system and overall product system is considered.

The design duty for a typical Iceland Food Store is 6 m³/s. The original AHU consumed 12.6 kW/h. The alternative motor, fan and revised AHU layout reduced this to 5.6 kW/h. Further savings were gained as a result of the lower heat dissipated into the mechanically cooled air stream from the more efficient fans.

The conclusion observes that changing to an alternative more efficient fan and motor does not provide the theoretical benefits unless the correct application of motor driven system and fan is considered. Further savings are also achieved by improved airflow through the AHU.

A Standard energy classification for fans

To maintain economic growth there is a need to promote energy efficiency. This requires better selection of equipment by users and therefore better design of this equipment by its manufacturers.

Fans of all types are used for ventilation and air conditioning, for process engineering – drying, pneumatic conveying, and combustion air supply and for agriculture etc. Indeed, the energy usage by fans has been calculated to be nearly 20% of the worldwide usage.

The fan industry is of a global nature, with a considerable degree of exporting and licensing. To ensure that the definition fan performance characteristics are common throughout the world a series of standards have been developed, it is the belief of the industry that there is now a need for minimum efficiency standards to be recognised. To encourage their implementation, a classification system is proposed which incorporates a series of efficiency bands. With improvements in technology and manufacturing processes the minimum efficiency levels may be reviewed and increased in time.

A review of existing product information was undertaken and fans were categorized in to two groups:-

• Bare shaft fans
• Driven fans

A system of efficiency grades has been developed for both groups, the bare shaft based on diameter, the driven based on input power.

The standard, ISO 12759: 2010, was published in December last year. It is now under the process of being adopted by CEN as an equivalent EN.

Minimum energy efficiency levels – a practicality?

The European Union Commission’s study and consultation to create legislation for fan efficiency revealed diverging views amongst stakeholders with regard to classifying fan efficiency. All had a common desire for simplicity, but some lobbied for abridged solutions that grouped fan types into just a few categories, or even just one minimum level for all fans types. Is this a practical objective and would it deliver the aim of reduced Carbon emissions?

The Lot 11 study of the European Union’s Energy using Product Directive to develop fan minimum efficiency standards is not unique around the world. Individual countries have existing regulations, for example the UK’s Building

Regulation sets a maximum specific fan power and China has developed standards setting minimum fan efficiency levels.

These varieties of current minimum fan standards show the complexity and the diversity of fans. The highest efficiency levels are achieved by backward curve centrifugal fans with high pole speed motors, but a number of fan types will never reach the heights of efficiency of a few that attain the highest level. The setting of one minimum efficiency level would ultimately ban the use of the lower efficiency types, but can backward curved fans and high pole speed motors deliver Carbon reductions in all applications? An analysis of some typical very common applications shows that the banning of perceived less efficient fans will lead to increased Carbon emissions.

Fan efficiency legislation needs to consider the full diversity of fan types and not be transfixed by simplicity if it is to deliver real Carbon reductions.

PM motor technology for fan applications

Permanent magnet (PM) motor technology, commonly referred to as EC technology in the fan industry, has revolutionised the industry since its introduction in the 1990’s. Small PM motors reduce motor energy consumption by as much as 80%. Whilst larger motors, >1.1 kW offer lesser energy saving opportunities compared to induction motors, when they are integrated in efficient fan technology case studies show that it can offer system savings of up to 78%.

There are a number of different PM motors; DC machines with separate drives, EC machines with integrated drives, 1-core and multi core motor windings that offer different solutions and features for a variety of applications. Understanding and using the range of solutions offers significant energy saving opportunities in many applications from domestic appliances, domestic houses, commercial buildings, retail, industrial engineering, IT and telecommunication industry.

There are potential issues with PM motor technology such as acoustic noise and harmonic distortion. An understanding of the potential issues and solution will mean that real energy savings can be achieved whilst maintaining a secure and reliable system.

This paper discusses PM motor technology from a fan perspective, how the technology works, is applied and with case studies gives examples of applications and potential energy savings. Potential issues are discussed explaining the cause and effect with explanations of mitigating measures.

VSD And Direct Drive Motor Technology For Cooling Tower Fans

Motor driven systems account for around 2/3 of the electrical energy consumed by industry. Fans and centrifugal pumps give the greatest energy saving potential of all variable speed motor driven applications. Cooling tower fans predominate in the power generation section as well as in large industrial process cooling systems. Traditionally these systems have been gearbox driven fixed low speed systems. The technology has not existed in the past for end users to fully maximise the overall cost and system benefits of variable speed direct drive technology. This paper therefore seeks to;

• Introduce the technologies behind cooling tower fans
• Provide a clear evaluation of estimating possible energy savings in fan applications.
• Assess the considerations that affect the sustainability of the process including operational efficiency, noise limitations, mechanical constraints, reducing downtime, water management, maintenance requirements as well as cost and carbon reduction.
• Highlight the technical parameters to take in to account when retrofitting to such a fan system, and discuss best practice installation techniques.
• Introduce the latest direct drive technology that can meet the system requirements.
• Summarise legislation surrounding energy efficiency technologies relating to the Carbon Trust, the Enhanced Capital Allowance scheme and the associated Energy Technology List.

The paper will use data based on real examples to illustrate the key learning points.

The Motor Driven Systems Conference, being held in Solihull, UK on 9^th & 10^th November will address this very issue.