“...Integrator Mobile Electrics completed the installation and commissioning while Control Logic measured the current draw after implementing the solution with amazing results.”

A leading global paints and coatings company and a major producer of specialty chemicals supply innovative and sustainable paints, coatings and specialty chemicals to customers around the world. Their products also play a vital role in the manufacturing process in many industries. To sustain manufacturing in Australia they have to keep their plant running at optimum/efficient level. Recent changes in electricity tariffs encourage a re-think in ways they could introduce efficient methods to cut energy costs.

Project Scope

Electricity charges plays crucial role for large manufacturing facilities. With recent VIC electricity distributors changing the electricity demand tariffs from KW to KVA demand, retailers have passed these demand tariffs to their respective clients. Based on these changes the power bill of this respective client increased dramatically adding huge operating costs to run the plant. They sourced Control Logic’s assistance, which is now an IPD business, to help reduce electricity costs through the use of new technologies to improve system efficiency and remove wasted power.

Collaborating with their Electrical engineer, Control Logic involved their system integrator to conduct power analysis onsite, providing a comprehensive report to address the critical areas needing immediate attention.

The Report highlighted a number of areas where the motor was operating at full speed even when it was not required. A new solution was proposed to improve system efficiency without compromising its capabilities with focus on their Dust Collector Fan.

Solution

Their current Dust Collector fan had an old induction motor that was around 15-20 years old with no speed control methods. It was operating at full speed even when manufacturing is not running at its full capacity. We offered the ABB SynRM motor and the ABB580 VSD package (55KW) based on its innovative technology and design. SynRM motors claim to have no Rotor losses when compared to standard induction motors. This Rotor losses gain is converted into mechanical gain and hence improves system efficiency.

Our integrator Mobile Electrics completed the installation and commissioning while Control Logic measured the current draw after implementing the solution with amazing results.

Benefits

The below is a list of successes as a direct result of this implementation:

• Dust collector main fan, with previous motor IE1 55kW 4 pole TEFC consuming 90Amps
• Stage 1 upgrade to IE4 SynRM package 75kW VSD/55kW 1500rpm TEFC IP56 motor – Now draws 50Amps from line
• Stage 1 upgrade to IE4 SynRM package 75kW VSD/55kW1500rpm TEFC IP56 motor - Now draws 50Amps from line
• Stage 2 Upgrade - speed was trimmed back to 45hz, now drawing 44Amps from line
• Stage 3 Upgrade - replaced blown suction seals at fan intake (which drew air locally from atmosphere instead of duct), now drawing 40Amps from line.

The excellent torque and speed characteristics of the SynRm motor allows for fantastic results across a wide speed range. This has been proven over and again in the incremental efficiencies at every stage above. The massive 55kW motor is now comfortably operating at less than 40% torque output saving energy and therefore saving costs on their power bills. With a payback time within 14 months (in this case), the project proved to be financially beneficial to them.

Contact
For more information on ABB’s range of SynRM motors, VSD equipment, or this case-study please contact us by clicking here.