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How to reduce energy consumption of
your pumping systems by up 30% used
in mining operations Jack Creamer
Segment Manager – Pumping Equipment
Schneider Electric
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2 Schneider Electric
Topics
●Energy Challenge
●Energy and Pumping
●What is the World Doing?
●Passive and Active Energy Efficiency
●Where are the Savings
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Energy Dilemma
vs Energy demand by 2050
Electrical energy demand by
2030
CO2 emissions to avoid dramatic
climate changes
The facts The need
Source: IEA 2008 Source: IPCC 2007, figure (vs. 1990 level)
Energy management is the key
to address the dilemma
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Energy Demand
2008
Re
ne
wa
ble
N
on
-ren
ew
ab
le
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5 Schneider Electric
Legislation and Influencing Bodies
Support Energy Efficiency
●Legislation texts
● Economic Stabilization Act
● Energy Independence and
Security Act
● European Union Energy Directive
● Kyoto Protocol
●Other government initiatives
● State Policy and Incentives
● White certificates
●DOE
● Pump Energy Efficiency
Standards under development
●Non-governmental initiatives
● Clinton Climate initiative
● Energy Efficiency accreditation
● Utility Programs
● Alliance to Save Energy
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Pumps represent about
25% of industrial motor
energy use.
Source: DOE Office of Industrial Technology
Energy Use in Pumping Systems
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0
500
1,000
1,500
2,000
1 -
5 H
P
6 -
20 H
P
21 -
50 H
P
51 -
100 H
P
101 -
200 H
P
201 -
500 H
P
501 -
1000 H
P
1000+
HP
Rewind Savings
Downsize Savings
Fan Savings
Other Savings
Air Compressor Savings
Motor Upgrades
Pump Savings
Source: U.S. Industrial Motor Systems
Market Opportunities Assessment,
U.S. Department of Energy
GWhr / Year
Pumping –
Energy Savings Potential
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Pumping –
Energy Savings Potential
Source: DOE Office of Industrial Technology
Pumping systems have
the most to gain from
energy savings efforts.
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9 Schneider Electric
Metals Mining Example
Source – Sulzer Pumps
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Motor use in mining
●Typical Distribution of Motor Population by HP and Application
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What is the World Doing?
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Schneider Electric 12 - Power NA Leadership Forum – January 2010
Lifecycle solutions for Energy Efficiency
Energy Audit
& Measure
Active Energy Efficiency Passive Energy Efficiency
Optimise through
automation &
regulation
Monitor,
maintain,
improve
Fix the basics
Low consumption devices,
insulation material, power
factor correction
Pump control, lighting control,
variable speed drives…
Meters installation, monitoring
services, EE analysis software
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Passive Energy Savings –
By Design Motor Starting Example
●Energy efficient design provides more features while using less
energy than a standard starter and overload
SPMS versus IEC based solution -> 50.97% savings
SPMS versus NEMA based solution -> 92.71% savings
Contactor + MCP
Starter + Circuit Breaker
Self Protected Motor Starter
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Active Energy Savings – VFD Example
●Variable Speed Drives
● On centrifugal loads such as pumps, VFD’s save energy because of the Affinity Laws
● Provide precise speed control of an AC motor
● Can generate full torque and low motor speed
● Protect a motor and wiring from overload currents
● Have inherent power factor correction increasing efficiency
● Limits inrush current to provide soft-start and soft-stop
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Active Energy Savings – By Design
VFD Example
●Affinity Laws of Centrifugal Loads:
● FLOW is proportional to motor speed
● PRESSURE is proportional to the motor speed squared
● POWER is proportional to the motor speed cubed.
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Active Energy Savings – VFD Example
A motor running at 90% of full speed requires 70% of the electricity
of a motor running at full speed.
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●Situation – Dewatering Application
● A 50hp centrifugal Pump
● Supply air 10 hours/day for 250 days
● Cost at full speed would be:
50 hp x 0.746 kW/hp x 2500hours x $0.08 /kWhr = $7,460
●Assuming the Pump does not have to run at full speed all the time
● 25% of time at 100% speed = 625 hours
● 50% of time at 80% speed = 1250 hours
● 25% of time at 60% speed = 625 hours
●Cost running with an AC Drive:
● 50 x (1.0)3 x 0.746 x 625 x $0.08 = $ 1,865
● 50 x (0.8)3 x 0.746 x1250 x $0.08 = $ 1,910
● 50 x (0.6)3 x 0.746 x 625 x $0.08 = $ 428
Annual savings ($7,460.00 - $4,203.00) = $3,257
Potential Utility Rebate at $50 per HP = $2,500
Active Energy Savings – VFD Example
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Schneider Electric 18 - Power NA Leadership Forum – January 2010
En
erg
y
Co
ns
um
pti
on
100%
70%
Eff
icie
nt
devic
es
an
d i
nsta
lla
tio
n
Op
tim
ized
usag
e
via
au
tom
ati
on
Monitoring & Maintenance
Time
Maximize the savings
Lack of monitoring,
maintenance programs,
regulation and control
systems
●Efficient devices and installation (saves 10 to 15%)
●Optimized usage via automation (save 5 to 15%)
● Without regulation and control systems (up to 12 % lost)
●Without Monitoring and Maintenance (2 to 8% lost)
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Energy Savings – Through Monitoring
System Level
●Power Monitoring Equipment
● Provides monitoring of facility’s power system
● Capture an record numerous parameters such as:
●Voltage
●Current
●Harmonics
●Power factor
●Transient Voltage
●Energy Consumption
●Peak Consumption
●Monitoring this data allows a facility manager to monitor,
understand, and correct any power issues in order to
maximize the energy usage of the facility
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Energy Savings – Through Monitoring
Pump Specifics
●Motor Management System
● Allows control and power monitoring of individual devices
● Allows a user to monitor things such as a motor where it
would be traditionally too expensive for an dedicated power
monitoring device
● Predictive logic can alert a user to potential problems such as an
increase in motor current over a period of time
● Built in communication macros drive integration into System Level
systems allowing a facility to monitor all power aspects from
distribution to device
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Conclusions
●Pumps are a primary consumer of energy in mining applications
●Solutions are available that will greatly reduce these costs
●Legislation is driving/incenting energy management
Source - www.pumpschool.com
Act NOW!
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Thank you!