Energy Management

Adrian Langford is General Manager of the Process Burner Division at Lanemark International Ltd. who have been at the forefront of process gas burner design and installation since the early 1980s. He believes there are a number of steps that could be considered and taken – either via converting existing ‘point of use’ systems or replacing centralised facilities – which can help to mitigate against the new energy cost environment in which, he says, UK manufacturing must now operate. The rapid increase in energy prices is exercising minds both in the home and in the factory. On the domestic front the consistent suggestion from the media is to ‘shop around’ to ensure that the price paid for each kW of gas and electricity consumed is reduced to the minimum possible. Sensible advice, but while this pursuit of the best energy deal can lead to reductions in the amount of money that has to be spent, in industry it is only part of the story. Here, the real key is to reduce the total number of kWh that are used in manufacturing applications by critically appraising existing process heating methods in order to maximise operating efficiencies while, at the same time, identifying the optimum energy source for each process.

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Unified worldwide efficiency classifications for low voltage three-phase asynchronous motors are being introduced as part of a concerted international effort to increase energy efficiency and, unsurprisingly, HPC KAESER screw compressors are already being equipped with premium efficiency motors in accordance with these newest standards.

Defining Energy Efficient Motors
The efficiency of an electric motor is de-fined as the ratio of usable mechanical power to electric input power. In Europe, low-voltage three-phase motors were previously divided into EFF3, EFF2 and EFF1 efficiency classifications. Differences among various national systems with regard to scope and classification prompted the International Electrotechnical Commission (IEC) to develop a unified standard. In parallel, the IEC’s improved methods for determining efficiency were revised and standardised. The new IEC 60034-30 standard de-fines and harmonises IE1, IE2 und IE3 efficiency classifications for low-voltage three-phase motors worldwide.

Former European Motor Efficiency Classifications and Previous Measuring Methods
The voluntary agreement between the European Committee of Manufacturers of Electrical Machines and Power Systems (CEMEP) and the European Commission, in effect since 1998, defined three efficiency classifications:

• EFF3 = Standard efficiency motors
• EFF2 = Improved efficiency motors
• EFF1 = High efficiency motors

The minimum values for the various classifications were based on efficiency measurements in accordance with EN60034-2:1996.

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Titan Enterprises supplies innovative flow measurement solutions into a broad range of sectors, including medical, industrial, food & drink, laboratory and pharmaceutical. Its latest innovation, the Atrato flowmeter range, is set to challenge conventional flowmeter thinking the world over.
 

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The Ultraflo is a transit time ultrasonic flow meter designed to work with clamp-on transducers, to provide accurate measurement of liquid flowing within a closed pipe, without the need for any mechanical parts to be inserted through the pipe wall or to protrude into the flow system. It takes just a few minutes to install and there is no need to shut down flow or drain the system!

Programming the unit is carried out by selecting the options displayed in the main menu and by following the simple instructions in any of the user selectable languages. Signal strength, time and date, as well as flow information are all continuously displayed, keeping the user fully aware of the measurement process.

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The new PF330/220 portable range of clamp-on flow meters from Micronics.

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Want to improve industrial processes, energy efficiency and end-product quality with accurate, stable and reliable measurements combined with excellent services?

At MTEC 2010 Vaisala will be launching their new HMP110 & HMP60 Humidity, Temperature OEM Modules,  in addition to showcasing their range of industrial transmitters which monitor relative humidity, dewpoint, moisture in oil, carbon dioxide, oxygen and barometric pressure in extreme conditions.

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At the beginning of September 2008 we were approached by two companies regarding the rental of an O&G unit for a small platform in the North Sea called Varg A. The generator was to run the Fire Pump onboard for any emergency situations, so it is basically a standby unit. We offered a budget rate for renting one of our new Oil & Gas units.

After several discussions and clarifications Teekay Norway took over the project at the beginning of 2009, and the ball really started rolling. We not only had to place our Oil & Gas unit on the platform, it also needed some modifications. Together with our Technical Manager, Kjell Olsen Øen, Teekay decided that they needed some very special arrangements onboard the platform. This meant that we had to rebuild certain parts of the unit, and also install an extra long piping construction for the air intake and also for removal of the exhaust gases. See pictures. The container also needed overpressure, because of the danger of gas.

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http://www.engineeringmaintenance.info/images/stories/energyst%20PR2.jpgIn line with a further expansion of its growth in the International Power Projects business, Energyst B.V. has establised in close cooperation with Finning International  in Chili as stepping stone for South America a new business foothold.

As of late last year a new subsidiary Energyst Rental Solutions Chili Ltda has been incorporated and is fully operational. Mr.Jose Rodgriguez Monje former senior manager of Finning  with extensive experience in the rental business is the General Manager of Energyst Rental Solutions Chili Ltda.

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Flu AceThermal Energy International Inc., which recently acquired the Bristol based steam trap manufacturer GEM Ltd, is launching its highly acclaimed FLU-ACE technology to the UK and European market.  Greatly improving the fuel efficiency of boiler operations, FLU-ACE provides a significant return on investment, and reduces environmental emissions.

FLU-ACE effectively converts an Industrial boiler into a condensing boiler and, in so doing, effectively recovers up to 90% of the heat normally lost. This is possible because FLU-ACE

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Energy surveys from ERIKSWith the continuing increase in energy costs and with many fixed price deals currently coming to an end there has never been a greater emphasis on reducing energy bills in the FM sector. Facilities managers and facilities management (FM) companies can now cut costs and increase efficiency by making use of the new and comprehensive support package being offered by ERIKS Electro-Mechanical Services, part of ERIKS UK, a corporate member of the British Institute of Facilities Management.

Specifically designed to complement facilities management operations, the package draws on the enormous product portfolio, resources and expertise of ERIKS to go far beyond the simple repair services offered by other support companies.

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EFF1 Electric MotorDeritend has completed the commissioning of over 70 individual EFF1 high efficiency electric motors coupled with matched variable speed drives at the Hammersmith Hospital

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“Gelpack Industrial Ltd has made an annual saving of over 45% on energy used to generate compressed air using a retro-fit Variable Speed Drive package from EnergAir”

A compressed air audit conducted at Gelpack Industrial Ltd revealed that 40.18% of the input energy used to power the compressors was not productive, and that system pressure was higher than required. This was due to the inefficient operation of two fixed speed, 75kW, Worthington Rollair compressors, which were used on a rotating basis to provide compressed air to the factory. The audit highlighted the potential savings that could be made by retro-fitting a variable speed drive (VSD) to reduce offload running and match air generation more closely to system demand.

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Corus’s Trostre Steel Works in Llanelli, South Wales has installed Thermal Energy International’s GEM

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Energy costs.  In industry it is a subject that has never commanded so much attention or commitment to increasing efficiencies and reducing consumption.  

Adrian Langford is General Manager of the Process Burner Division at Lanemark International who have been at the forefront of process gas burner design and installation since the early 1980’s.  He believes there are a number of steps that could be considered and taken – either via converting existing ‘point of use’ systems or replacing centralised facilities – which can help to mitigate against the new energy cost environment in which, he says, UK manufacturing must now operate.     

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Even on a rough sea, a crane has to be able to lower loads of up to 120 tons into the water, accurate to the tenth of a metre

She was ready earlier this year: the Seven Atlantic, an ultra modern support vessel for divers in the North Sea. Responsible for the electrical wiring is Croon-Bakker Sliedrecht, who during the test phase could rely on the services of Energyst CAT ® Rental Power.

The recent delivery of the Seven Atlantic Subsea 7 to its owner meant the next step in a truly epic project for IHC Merwede Shipyard in Hardinxveld-Giessendam. In a relatively short time the company has produced two so-called pipe laying vessels – the Seven Oceans and the Seven Seas - and has completed project number three with the transfer of the Seven Atlantic. They are currently already working on the fourth ship, which as of yet remains nameless. Starting this year, the ships will perform their duties in the deep oil fields in the North Sea.

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http://www.engineeringmaintenance.info/images/stories/energyst%20PR3.jpgVehicles can be rented, so can tents and even Santa Claus outfits. It's probably less well known that when air-conditioning or power-supply units are required, they too can be hired rather than purchased outright. One of Europe's biggest providers in this area is Energyst B.V., with their head office in Breda, the Netherlands.

Energyst B.V. always have the right solution available when it comes to equipment for generating electricity, refrigeration, air conditioning, or heating and ventilation. Caterpillar electricity generators start at 20 kVA and go right up to complete installations for power stations. Besides electrical generating sets, Energyst also supplies uninterruptible power supplies (UPS), transformers, load banks, switch over panels, distribution panels, and cables.

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3 West north3 West North (3WN) is one of the newest buildings on the campus, built in 2005 to house a number of research laboratories as part of the Department of Physics. It includes drawing towers for making photonic crystal fibres, a 200-seater lecture theatre and two general teaching classrooms for 100 and 30 people, as well as various labs with equipment including lasers, lathes and furnaces. This vital research, however, is energy intensive, and the building has an annual electricity bill of £70,000.

Within the Department of Estates, significant investment has been made in improving the energy monitoring of buildings such as this, and through the Our Big Energy Challenge project, a departmental energy champion has been trained and now acts as a point of contact for the Energy & Environment team.

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Motor MaintenanceThe imperative in industry to cut energy costs and reduce green house gases is good news for suppliers of high efficiency motors. However, the projected efficiency gains from using EFF1 or 2 type machines will not be achieved if motor system and supply problems that existed before they were installed are not resolved. One of the most common of these is low power factor.

Motors operated with low power factors are expensive and inefficient. In the worst cases this can result in utility supply companies having to increase their generation and transmission capacity to handle the reactive power component caused by inductive loads. There is a price for this: in the UK, the threshold value for power factor is 0.85, below this figure industrial users are generally charged more by their suppliers.

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