Calculation analysis of energy saving tools for fan and pump applications

This thesis analyses the calculation of FanSave and PumpSave energy saving tools calculation. With these programs energy consumption of variable speed drive control for fans and pumps can be compared to other control methods. With FanSave centrifugal and axial fans can be examined and PumpSave deals with centrifugal pumps. By means of these programs also suitable frequency converter can be chosen from the ABB collection. Programs need as initial values information about the appliances like amount of flow and efficiencies. Operation time is important factor when calculating the annual energy consumption and information about it are the length and profile. Basic theory related to fans and pumps is introduced without more precise instructions for dimensioning. FanSave and PumpSave contain various methods for flow control. These control methods are introduced in the thesis based on their operational principles and suitability. Also squirrel cage motor and frequency converter are introduced because of their close involvement to fans and pumps. Second part of the thesis contains comparison between results of FanSave’s and PumpSave’s calculation and performance curve based calculation. Also laboratory tests were made with centrifugal and axial fan and also with centrifugal pump. With the results from this thesis the calculation of these programs can be adjusted to be more accurate and also some new features can be added.

Energy saving potential in reservoir pumping

Pumping systems account for up to 22 % of the energy consumed by electrical motors in European industry. Many studies have shown that there is also a lot of potential for energy savings in these systems with the improvement of devices, flow control or surrounding sys-tem. The best method for more energy efficient pumping has to be found for each system separately. This thesis studies how energy saving potential in reservoir pumping system is affected by surrounding variables, such as the static head variation and friction factor. The objective is to create generally applicable graphs to quickly compare methods for reducing pumping system’s energy costs. The gained results are several graphs showcasing how the chosen variables affect energy saving potential of the pumping system in one specific case. To judge if these graphs are generally applicable, more testing with different pumps and environments are required.

Ohuiden päällystyskerrosten applikointi puukuitupohjaisille materiaaleille

Työn aiheena oli tutkia vaahdon soveltuvuutta ohuiden päällystyskerrosten applikointiin paperin tai kartongin pinnalle. Paperia ja kartonkia päällystetään teollisessa mittakaavassa eri menetelmillä, mutta niille kaikille yhteistä on päällystyspastan laimentaminen vedellä ennen applikointia ja laimennusveden haihduttaminen applikoinnin jälkeen päällysteen asettamiseksi. Laimennus on tärkeää pastan komponenttien tasaisen levittämisen vuoksi, mutta veden haihduttaminen kuluttaa valtavasti energiaa. Tekstiiliteollisuudessa on saavutettu merkittäviä säästöjä kuivausenergiassa korvaamalla laajalti vedellä laimentaminen vaahdottamisella. Diplomityön kirjallisessa osassa käytiin läpi vaahdon kemiallisia ja fysikaalisia ominaisuuksia sekä selvitettiin mitä kemikaaleja ja laitteita vaahdotukseen käytetään. Lisäksi luotiin katsaus vaahtoprosessien käyttöön tekstiiliteollisuudessa ja muilla aloilla. Kokeellinen osa koostui esikokeista, joissa selvitettiin pastan koostumuksen vaikutuksia vaahtoamiseen, ja pilot-mittakaavan koeajoista, joissa esikokeiden tuloksia hyödynnettiin. Esikokeissa huomiota kiinnitettiin varsinkin eri polyvinyylialkoholien (PVA) seosten erinomaiseen vaahtoavuuteen. Pilot-koeajoissa vaahtopäällystys vaikutti lupaavalta menetelmältä, joskaan täysin tyydyttävää päällystystulosta ei saavutettu. Suurimpana ongelmana esiintyi ilman pääseminen pohjapaperin ja päällysteen väliin ja siitä seuraava huono päällystejälki. Toisen ongelmakokonaisuuden muodostivat päällysteeseen jäävät reiät. Vaahtopäällystys vaikuttaa lupaavalta tekniikalta ohuiden päällystekerrosten applikointiin, mutta pastareseptejä tulee optimoida ja ratkaista päällysteen alle pääsevän ilman ongelma.

Distributed Energy Production in the North-West Region of Russia

The energy system of Russia is the world's fourth largest measured by installed power. The largest are that of the the United States of America, China and Japan. After 1990, the electricity consumption decreased as a result of the Russian industry crisis. The vivid economic growth during the latest few years explains the new increase in the demand for energy resources within the State. In 2005 the consumption of electricity achieved the maximum level of 1990 and continues to growth. In the 1980's, the renewal of power facilities was already very slow and practically stopped in the 1990's. At present, the energy system can be very much characterized as outdated, inefficient and uneconomic because of the old equipment, non-effective structure and large losses in the transmission lines. The aim of Russia's energy reform, which was started in 2001, is to achieve a market based energy policy by 2011. This would thus remove the significantly state-controlled monopoly in Russia's energy policy. The reform will stimulateto decrease losses, improve the energy system and employ energy-saving technologies. The Russian energy system today is still based on the use of fossil fuels, and it almost totally ignores the efficient use of renewable sources such as wind, solar, small hydro and biomass, despite of their significant resources in Russia. The main target of this project is to consider opportunities to apply renewable energy production in the North-West Federal Region of Russia to partly solve the above mentioned problems in the energy system.

Optimization of energy consumption in wastewater pumping

Pumppauksessa arvioidaan olevan niin teknisesti kuin taloudellisestikin huomattavia mahdollisuuksia säästää energiaa. Maailmanlaajuisesti pumppaus kuluttaa lähes 22 % sähkö-moottorien energiantarpeesta. Tietyillä teollisuudenaloilla jopa yli 50 % moottorien käyttämästä sähköenergiasta voi kulua pumppaukseen. Jäteveden pumppauksessa pumppujen toiminta perustuu tyypillisesti on-off käyntiin, jolloin pumpun ollessa päällä se käy täydellä teholla. Monissa tapauksissa pumput ovat myös ylimitoitettuja. Yhdessä nämä seikat johtavat kasvaneeseen energian kulutukseen. Työn teoriaosassa esitellään perusteet jätevesihuollosta ja jäteveden käsittelystä sekä pumppaussysteemin pääkomponentit: pumppu, putkisto, moottori ja taajuusmuuttaja. Työn empiirisessä osassa esitellään työn aikana kehitetty laskuri, jonka avulla voidaan arvioida energiansäästöpotentiaalia jäteveden pumppaussysteemeissä. Laskurilla on mandollista laskea energiansäästöpotentiaali käytettäessä pumpun tuoton ohjaustapana pyörimisnopeuden säätöä taajuusmuuttajalla on-off säädön sijasta. Laskuri ilmoittaa optimaalisimmanpumpun pyörimisnopeuden sekä ominaisenergiankulutuksen. Perustuen laskuriin, kolme kunnallista jätevedenpumppaamoa tutkittiin. Myös laboratorio-testitsuoritettiin laskurin simuloimiseksi sekä energiansäästöpotentiaalin arvioimiseksi. Tutkimukset osoittavat, että jätevedenpumppauksessa on huomattavia mandollisuuksia säästää energiaa pumpun pyörimisnopeutta pienentämällä. Geodeettisen nostokorkeuden ollessa pieni, voidaan energiaa säästää jopa 50 % ja pitkällä aikavälillä säästö voi olla merkittävä. Tulokset vahvistavat myös tarpeen jätevedenpumppaussysteemien toiminnan optimoimiseksi.

Supplier Energy Audits in Thermal Power Plants

This master’s thesis handles an operating model for an electric equipment supplier conducted sale oriented energy audit for pumping, fan and other motor applications at power plants. The study goes through the largest factors affecting internal electricity use at a power plant, finds an energy audit –like approach for the basis of information gathering and presents the information needed for conducting the analysis. The model is tested in practice at a kraft recovery boiler of a chemical pulping mill. Targets chosen represent some of the largest electric motor applications in the boiler itself and in its fuel handling. The energy saving potential of the chosen targets is calculated by simulating the energy consumption of the alternatives for controlling the targets, and thereafter combining the information with the volume flow duration curve. Results of the research are somewhat divaricated, as all the information needed is not available in the automation system. Some of the targets could be simulated and their energy saving potential calculated quite easily. At some of the targets chosen the monitoring was not sufficient enough for this and additional measurements would have been needed to base the calculations on. In traditional energy audits, energy efficiency of pump and fan applications is not necessarily examined. This means that there are good possibilities for developing the now presented targeted energy audit procedure basis further.

Energy efficiency parameters in variable speed drives

The main purpose of this thesis is to measure and evaluate how accurately the current energy saving calculation in ABB’s new variable speed drive ACS850 works. The main topic of this thesis is energy-efficiency parameters. At the beginning of this thesis centrifugal pump, squirrel cage motor and variable speed drive, including some equations related to them, are being introduced. Also methods of throttling control and variable speed drive control of centrifugal pumps are being introduced. These subjects are introduced because the energy saving calculation in ACS850 is related to the centrifugal pumps usually driven by squirrel cage motors. The theory also includes short section about specific energy of pumping. Before measurements the current energy saving calculation of ACS850 is being introduced and analyzed. The measurements part includes introduction of measuring equipment, measurement results, summary and analysis of the measurements. At the end of this thesis a proposal for an improvement to the current energy saving calculation is being introduced and few proposals are made for new energy-efficiency parameters, which could be added to variable speed drives. At the end are also thoughts

Energy storage in electric drive system

In recent years the environmental issues and the energy saving have become increasingly import in modern society where industry is the major emission factor and energy consumer. Generally, most of the total energy consumption is caused by electrical drives used in industrial applications and thus improving the performance of electrical drives give an opportunity to improve the energy efficiency. In this Master Thesis improving the energy efficiency in different electrical drives is clarified with different cases: regenerative braking in the electric grid or recovery of the braking energy into an energy storage. In addition, as an example, the energy consumption of an elevator is analyzed by measurements. From these measurement results it can be estimated how much the share of the standby energy consumption is from the total energy consumption and how much regenerative energy is available. The latter part of the thesis concentrates on determination of the properties of lithium iron phosphate battery with measurements.

On Energy Efficient Computing Platforms

In accordance with the Moore's law, the increasing number of on-chip integrated transistors has enabled modern computing platforms with not only higher processing power but also more affordable prices. As a result, these platforms, including portable devices, work stations and data centres, are becoming an inevitable part of the human society. However, with the demand for portability and raising cost of power, energy efficiency has emerged to be a major concern for modern computing platforms. As the complexity of on-chip systems increases, Network-on-Chip (NoC) has been proved as an efficient communication architecture which can further improve system performances and scalability while reducing the design cost. Therefore, in this thesis, we study and propose energy optimization approaches based on NoC architecture, with special focuses on the following aspects. As the architectural trend of future computing platforms, 3D systems have many bene ts including higher integration density, smaller footprint, heterogeneous integration, etc. Moreover, 3D technology can signi cantly improve the network communication and effectively avoid long wirings, and therefore, provide higher system performance and energy efficiency. With the dynamic nature of on-chip communication in large scale NoC based systems, run-time system optimization is of crucial importance in order to achieve higher system reliability and essentially energy efficiency. In this thesis, we propose an agent based system design approach where agents are on-chip components which monitor and control system parameters such as supply voltage, operating frequency, etc. With this approach, we have analysed the implementation alternatives for dynamic voltage and frequency scaling and power gating techniques at different granularity, which reduce both dynamic and leakage energy consumption. Topologies, being one of the key factors for NoCs, are also explored for energy saving purpose. A Honeycomb NoC architecture is proposed in this thesis with turn-model based deadlock-free routing algorithms. Our analysis and simulation based evaluation show that Honeycomb NoCs outperform their Mesh based counterparts in terms of network cost, system performance as well as energy efficiency.

Framework for Regional Heating Energy Efficiency Assessment

The aim of this project was to develop general framework for systematic assessment of energy efficiency of heating on regional level in Russia. The framework created during this project includes two main instruments, namely: general regional heating energy efficiency assessment model (REEMod) and general regional heating energy efficiency assessment criteria for housing areas (REECrit). Framework pays extreme attention to realization of energy saving, overall cost efficiency and comfortable indoor climate. Life-cycle ideology was applied during creation of the framework. Application of the framework can provide decision-making process with systematically collected and processed information on current state of areas energy efficiency. Such information will help decision makers to evaluate current situation of the whole energy chain, to compare different development scenarios and to identify the most efficient improvement methods, thus supporting realization of regions efficient energy management. Simultaneous pursuit of energy savings, cost efficiency and indoor air quality can contribute to development of sustainable community. Presented instruments should be continuously developed further as an iterative process based on knew experience, development of technology and overall understanding of energy efficiency issues.

Modelling Energy Consumption of a Switch using Fuzzy-Rule Classifier

The energy consumption of IT equipments is becoming an issue of increasing importance. In particular, network equipments such as routers and switches are major contributors to the energy consumption of internet. Therefore it is important to understand how the relationship between input parameters such as bandwidth, number of active ports, traffic-load, hibernation-mode and their impact on energy consumption of a switch. In this paper, the energy consumption of a switch is analyzed in extensive experiments. A fuzzy rule-based model of energy consumption of a switch is proposed based on the result of experiments. The model can be used to predict the energy saving when deploying new switches by controlling the parameters to achieve desired energy consumption and subsequent performance. Furthermore, the model can also be used for further researches on energy saving techniques such as energy-efficient routing protocol, dynamic link shutdown, etc.

Towards a better energy efficiency through a systems approach in an industrial forklift

The purpose of this study is to improve the potential energy recovery to electric energy in an electrohydraulic forklift system. The initial achieved result for energy saving ratio after structural optimization is 40 %. Component optimization is applied to the tested drive which consists of a DTC controlled electric servo motor directly running a reversible hydraulic pump. According to the study the energy efficiency and the energy recovery from the electro-hydraulic forklift system can be increased by 11 % units. New ideas and directions of further research were obtained during the study.

Energy efficiency of glassmaking production

Master’s thesis Energy efficiency of glassmaking production gives description of glassmaking production and possible energy saving measures. Due to the high electricity and fuel prices the problem of rational energy utilization rises sharply. In addition the environmental issues also require a great attention. This work represented the feasible increasing of the furnace efficiency as the most productive activity. Thesis also provides a detail description of utilizing waste heat boiler. Also possible boiler characteristics are calculated and represented at the end of the thesis. As well as brief description of the feasibility of using this method of energy saving. The solution of this problem has a huge importance. Due to the increasing of energy costs and limits of raw materials, glassmaking industry should overcome on high efficiency operation mode. Especially, if such measures is making a significant contribution in the safety of environment.

Ilmanvaihtokoneen ohjauksen taloudellisuusvaikutukset

Tämän insinöörityön tarkoituksena oli luoda Insinööritoimisto Olof Granlund Oy:lle malliprojekti ilmanvaihtokoneen ohjauksen mahdollisesta sähköenergian säästöpotentiaalista. Insinöörityötä voidaan myöhemmin käyttää referenssinä tarjottaessa yrityksen palvelua asiakkaille energiakatselmointityössä kiinteistöihin, joissa on suuria ilmanvaihtokone-yksiköitä. Ensin työssä esitellään käytössä olevat, tutkittavat ilmanvaihtokoneet ja niiden toiminta. Sitten selvitetään ilmanvaihtolaitteiden ja niiden ohjauksen eri osien toiminta, sekä ohjausinformaatio, joka välittyy eri laitteiden välillä. Seuraavaksi työssä tutkitaan rakennusautomaation osuutta, sen hyötyä ja rakennetta kiinteistössä. Tämän jälkeen selvitetään hankkeen viranomaismääräykset. Sitten selvitetään, mistä koostuvat kustannukset ilmanvaihtokoneen ohjauksen uusimisessa. Lopuksi vielä tutkitaan, kuinka pitkä on tehtävän investoinnin takaisinmaksuaika, sekä mitkä ovat saneerauksen hiilidioksidi-päästövaikutukset. insinöörityön Lopputuloksena syntyi yrityksen sisäinen kansio. Kansion esimerkkilaskelmia ja laskentamenetelmiä on tarkoitus käyttää jatkossa referenssinä kiinteistönpito-osastolla sähkö- ja lvi-ryhmissä, niiden henkilöiden käytössä, jotka ovat tekemisissä energiakatselmointien kanssa.

Energiansäästökohteiden kartoitus konepajateollisuuden yrityksessä

Tämän diplomityön tavoitteena on kartoittaa Vaahto Oy:n Hollolan tehtaan energiankulutus ja energiansäästökohteet. Ensin tutkittiin tehtaan energiankulutus ja energiankulutuksen jakautuminen. Tutkimuksessa käytettiin saatavilla olevia kulutustietoja, luettiin konekirjoja sekä haastateltiin tehtaan työntekijöitä. Lisäksi tehdashallien lämmityslaitteiden hyötysuhteet mitattiin. Tutkimuksen päätavoite oli selvittää, miksi tehtaan lämmitysenergiankulutus on kasvanut ja kannattaisiko rakennusten lämmittämiseen käyttää vaihtoehtoista lämmitysmuotoa öljylämmitykselle. Potentiaalisista energiansäästökohteista tehtiin investointilaskelmat ja toimenpide-ehdotukset. Kannattaviksi toimenpiteiksi tutkimuksessa todettiin: lämmityspolttoaineen vaihtaminen maakaasuun, nosto-ovien hankkiminen, paineilmaverkon huolto, paineilmakompressorin lämmöntalteenotto, tehdastilojen sisälämpötilan tarkastus ja työnjohtotilojen ilmanvaihdon käyntiaikojen muutos. Toimenpiteillä arvioidaan vuotuisten energiakustannusten pienenevän noin 34 000 euroa. Toimenpiteiden toteuttamisen arvioidaan maksavan 135 000 ¤, mistä lämmitysjärjestelmän vaihdon osuus on 100 000 ¤.