6 Ways Refineries Can Save Energy with Electric Motors
Electric motors are a major source of energy consumption in most refineries, accounting for over 80% of electricity used. Pumping applications make up the majority of motor use, with air compressors, fans, and other applications making up the rest. In order to maximize efficiency and reduce energy use, it’s important to use a “systems approach” that looks at the entire motor system and optimizes supply and demand of energy services. Here are six ways refineries can save energy with electric motors.
- Sizing Motors Appropriately
Motors that are not sized correctly can lead to significant energy losses. Peak loads can be reduced by adjusting the size of the motor, resulting in a 1.2% reduction in electricity consumption.
- Using High Efficiency Motors
High efficiency motors are designed with better materials and tighter tolerances to reduce energy losses. When motors need to be replaced, using high efficiency motors is almost always economically feasible. In fact, the Copper Development Association found that energy efficient motors can result in payback of less than one year from energy savings alone.
- Motor Decisions Matter Campaign
The Motor Decisions Matter campaign is a marketing initiative from NEMA and other organizations to promote NEMA approved premium efficient motors. These motors often have a payback period of less than 15 months.
- Avoid Rewinding Motors
Rewinding motors currently has no quality or efficiency standards, and in most cases, it’s a better idea to buy a new high efficiency motor instead of trying to rewind an old one.
- Matching Speed and Load
Using adjustable speed drives to match the speed and load of electric motors helps to reduce energy consumption and maximize efficiency.
- System Optimization
Optimizing the entire motor system (pumps, compressors, motors, and fans) to reduce supply and demand of energy services can result in significant savings.
By following these six tips, refineries can save energy and reduce their electricity consumption. Investing in high efficiency motors, using adjustable speed drives, and optimizing the entire motor system can all help to reduce energy use and increase efficiency.
How to Improve Power Factor and Reduce Voltage Unbalance with Adjustable Speed Drives
Power factor and voltage unbalance can cause significant increases in energy costs. In order to reduce energy costs and ensure the longevity of equipment, it is important to understand how to improve power factor and reduce voltage unbalance. One of the most effective ways to do this is with the use of Adjustable Speed Drives (ASD) or Variable Speed Drives (VSDs). In this article, we will discuss the benefits of using ASD/VSDs to improve power factor and reduce voltage unbalance.
What is Power Factor?
Power Factor is a measure of how efficiently electrical energy is used by a device or system. A low power factor can lead to increased power consumption and higher electricity costs. In order to reduce electricity costs, it is important to improve power factor by minimizing idling of electric motors, avoiding operation of equipment over its rated voltage, replacing motors by energy efficient motors, and installing capacitors in the AC circuit to reduce the magnitude of reactive power in the system.
What is Voltage Unbalance?
Voltage unbalance is a condition where the voltage of the three phases of a three-phase power system are not equal. This condition can degrade the performance of three-phase motors and shorten their life. Voltage unbalance can be caused by faulty operation of power correction equipment, unbalanced transformer banks, or open circuits. It is recommended that voltage unbalance at the motor terminals does not exceed 1%. Even a 1% unbalance will reduce motor efficiency at part load operation, and if the unbalance increases to 2.5%, motor efficiency will decrease at full load operation.
How Can Adjustable Speed Drives Help?
Adjustable Speed Drives (ASD) or Variable Speed Drives (VSDs) can help improve power factor and reduce voltage unbalance. ASD/VSDs help match speed to load requirements for motor operations, which can result in significant energy savings. ASD/VSDs also improve overall productivity, control and product quality, and reduce wear on equipment, resulting in lower future maintenance costs. The installation of ASD/VSDs can have paybacks as low as 1.1 years.
Conclusion
Power factor and voltage unbalance can have a significant impact on energy costs. In order to improve power factor and reduce voltage unbalance, it is important to understand the causes and effects. One of the most effective ways to improve power factor and reduce voltage unbalance is with the use of Adjustable Speed Drives (ASD) or Variable Speed Drives (VSDs). ASD/VSDs help match speed to load requirements for motor operations, which can result in significant energy savings.