How to reduce energy consumption of

your pumping systems by up 30% used

in mining operations Jack Creamer

Segment Manager – Pumping Equipment

Schneider Electric

2 Schneider Electric

Topics

●Energy Challenge

●Energy and Pumping

●What is the World Doing?

●Passive and Active Energy Efficiency

●Where are the Savings

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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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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Metals Mining Example

Source – Sulzer Pumps

Motor use in mining

●Typical Distribution of Motor Population by HP and Application

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What is the World Doing?

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

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!

Thank you!