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energy savings & molding costs Energy Savings & Molding Costs 1 retrofit motor speed energy savings & molding costs Energy Savings & Molding Costs 1 retrofit motor speed control what can retrofit motor speed control achieve? Fred Pratt Business Development CCS Syncro. Speed

energy savings & molding costs 2 what to expect from this session retrofit motor energy savings & molding costs 2 what to expect from this session retrofit motor speed control how much savings to expect the cost of retrofit installations what makes a good system perform well how to avoid poor results & failed investment

energy savings & molding costs 3 retrofit motor speed control • relative and rising energy savings & molding costs 3 retrofit motor speed control • relative and rising costs of – – material labour energy maintenance, depreciation, overheads energy is not the greatest spend, but costs can be managed and reduced

energy savings & molding costs 4 retrofit motor speed control savings in perspective energy savings & molding costs 4 retrofit motor speed control savings in perspective

energy savings & molding costs energy savings in perspective 5 retrofit motor speed control energy savings & molding costs energy savings in perspective 5 retrofit motor speed control source energy for the molding machines is most of the utility bill

energy savings & molding costs energy savings in perspective 6 retrofit motor speed control energy savings & molding costs energy savings in perspective 6 retrofit motor speed control • • • power consumption operating hours savings potential cost of realisation risk

energy savings & molding costs savings index 7 retrofit motor speed control motors and energy savings & molding costs savings index 7 retrofit motor speed control motors and heaters offer the greatest potential but not the least risk

energy savings & molding costs 8 retrofit motor speed control hydraulic IMMs what’s not energy savings & molding costs 8 retrofit motor speed control hydraulic IMMs what’s not to like?

moulding machine hydraulic losses energy savings & molding costs 9 retrofit motor speed control moulding machine hydraulic losses energy savings & molding costs 9 retrofit motor speed control actual pump discharge Q true flow demand USEFUL POWER WASTED POWER true working pressure requirement actual discharge pressure p prime cause of losses is mismatch of power supplied to true demand

energy savings & molding costs how the savings are made 10 retrofit motor speed energy savings & molding costs how the savings are made 10 retrofit motor speed control • matching supply to demand – speed of movement – volume of oil from the pumps – regulation of required oil volumes • reducing pressure losses attack the over supply of oil volumes and pressures

energy savings & molding costs performance … what to expect 11 retrofit motor speed energy savings & molding costs performance … what to expect 11 retrofit motor speed control • reduction in motor energy consumption – 25% to 55% • reduced load on oil cooling system – additional 5% to 15% of above • machines to operate as normal • still working 10 years on a developing technology that delivers measurable results

energy savings & molding costs 12 retrofit motor speed control examples of savings energy savings & molding costs 12 retrofit motor speed control examples of savings

energy savings & molding costs Sandretto 1100 t machine study cooling plasticising injection hold energy savings & molding costs Sandretto 1100 t machine study cooling plasticising injection hold retrofit motor speed control injection 13 47 k. W 21 k. W estimate power reduction is 55%

energy savings & molding costs Husky EW 1150 ES ps 28 s 14 retrofit energy savings & molding costs Husky EW 1150 ES ps 28 s 14 retrofit motor speed control actual power reduction is 30%

energy savings & molding costs manufacturer tonnage total motor power k. W saving motor energy savings & molding costs manufacturer tonnage total motor power k. W saving motor loading Engel 1000 110 k. W 41. 1% LG 550 104 k. W 33. 3% Demag 500 55 k. W 36. 5% Meiki 850 110 k. W 35. 4% Van Dorn 3000 280 k. W 38. 2% Krauss Maffei 1000 110 k. W 44. 7% Oima 400 45 k. W 51. 7% Negri Bossi 330 30 k. W 66. 4% Mitsubishi 650 90 k. W 34. 0% MIR 200 30 k. W 60. 1% Stork 440 90 k. W 52. 4% 15 retrofit motor speed control

energy savings & molding costs annual savings by tonnage 16 retrofit motor speed control energy savings & molding costs annual savings by tonnage 16 retrofit motor speed control annual operating hours 6000 energy cost Euro 0. 10 / k. Wh oil cooling tower ♦ annual savings

energy savings & molding costs annual savings by motor size 17 retrofit motor speed energy savings & molding costs annual savings by motor size 17 retrofit motor speed control annual operating hours 6000 energy cost Euro 0. 10 / k. Wh oil cooling tower ♦ annual savings

energy savings & molding costs cost vs annual benefit 18 retrofit motor speed control energy savings & molding costs cost vs annual benefit 18 retrofit motor speed control annual operating hours 6000 energy cost Euro 0. 10 / k. Wh oil cooling tower ♦ annual savings ♦ system cost

energy savings & molding costs typical system 19 retrofit motor speed control • • energy savings & molding costs typical system 19 retrofit motor speed control • • • inverter to drive the motor controller to regulate the inverter signal interface with host machine user interface for information techniques & experience – installation design & specification – maximise energy savings – deal with host machine faults

energy savings & molding costs 20 retrofit motor speed control typical installation energy savings & molding costs 20 retrofit motor speed control typical installation

energy savings & molding costs main screen 21 retrofit motor speed control The main energy savings & molding costs main screen 21 retrofit motor speed control The main screen displays essential operational information; • drive (inverter) status • motor speed • motor power • averaged energy savings

energy savings & molding costs calculate power savings 22 retrofit motor speed control The energy savings & molding costs calculate power savings 22 retrofit motor speed control The ‘re-calculate’ button forces the motor to run at full speed for three cycles, then revert to speed control. The Full Power data is retained and the Syncro. Speed data refreshed every three cycles. Users can establish benchmarks of energy performance for every job. Setters have the vital information to refine the job setup to further optimise energy saving performance.

energy savings & molding costs power consumption 23 retrofit motor speed control This screen energy savings & molding costs power consumption 23 retrofit motor speed control This screen provides useful information for the user concerning power consumption and energy costs. The ‘energy cost per k. Wh’ is set by the user. The consumption and cost variables are automatically updated and displayed every 3 cycles of the machine.

energy savings & molding costs 24 retrofit motor speed control candidate machine factors to energy savings & molding costs 24 retrofit motor speed control candidate machine factors to consider when selecting machines

energy savings & molding costs candidate machine 25 retrofit motor speed control pumps all energy savings & molding costs candidate machine 25 retrofit motor speed control pumps all variable mixed all fixed hours 4000 6000 27/7 motor size single < 37 k. W job setup cycle < 20 s multiple > 55 k. W cycle > 40 s static time < 30% static time > 50% screw speed = 100% screw speed < 100% energy, k. Wh Euro 0. 06 incentives none material & form thin wall pp Euro 0. 10 soft loans abs, pa $$ per k. W or k. Wh thick sections, pvc, pc

energy savings & molding costs candidate retrofit system 26 retrofit motor speed control vsd energy savings & molding costs candidate retrofit system 26 retrofit motor speed control vsd specification it’s ok, it’ll take just a few weeks to put in a bigger one limited configurability inadequate overload capacity unknown performance configured for dynamic performance sized for massive overloads international reputation immunity to ‘nuisance trips’ installation standards oops, no-one told me to ground just one end of the braid guesswork focus on time & material costs engineered solutions focus on codes & good practice

energy savings & molding costs candidate retrofit system 27 retrofit motor speed control commitment energy savings & molding costs candidate retrofit system 27 retrofit motor speed control commitment how long have these energy savers been switched off? apathy project champion interest, understanding, authority lack of control or procedures methods commissioning knowledge I don’t know why it’s started to do that. . . does it matter? patchy process knowledge missed links understands IMMs in depth operation, control, malfunctions

energy savings & molding costs candidate retrofit system 28 retrofit motor speed control software energy savings & molding costs candidate retrofit system 28 retrofit motor speed control software just like the i. Phone 4 S – it’s all about the software manually set for each job fixed speeds no visual information ‘transparent’ to the user full speed-range response status & performance screens

energy savings & molding costs in summary 29 retrofit motor speed control • vsd energy savings & molding costs in summary 29 retrofit motor speed control • vsd retrofits can deliver great savings • management understanding and commitment is needed at the start • supplier knowledge and experience is the route to the desired result lost savings today are lost forever

energy savings & molding costs 30 retrofit motor speed control checklist for success energy savings & molding costs 30 retrofit motor speed control checklist for success

energy savings & molding costs 31 retrofit motor speed control success with retrofit MSC energy savings & molding costs 31 retrofit motor speed control success with retrofit MSC … planning ü select good candidate machines ü management commitment ü reliable assessment of energy savings ü accurate overall project cost

energy savings & molding costs 32 retrofit motor speed control success with retrofit MSC energy savings & molding costs 32 retrofit motor speed control success with retrofit MSC … project installation ü installation work to correct standards ü optimal delivery of savings

energy savings & molding costs 33 retrofit motor speed control success with retrofit MSC energy savings & molding costs 33 retrofit motor speed control success with retrofit MSC … delivery ü IMM productivity OK ü verify the results

energy savings & molding costs CCS Syncro. Speed 34 retrofit motor speed control centrally energy savings & molding costs CCS Syncro. Speed 34 retrofit motor speed control centrally based in the UK retrofit MSC installations around the world

energy savings & molding costs 35 retrofit motor speed control energy savings & molding energy savings & molding costs 35 retrofit motor speed control energy savings & molding costs Fred Pratt CCS Syncro. Speed, England Robert Knaster CCS Syncro. Speed, New York www. syncrospeed. com (914) 582 -1848 CPT CCS Syncro. Speed, Cincinnati