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JULY 2024

Energy Efficiency – A key towards sustainable future

Raja Sekhar M
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Agenda

→ What is energy efficiency?

→ India – Power Industry facts & figures
→ Where to emphasize on EE?
Raja Sekhar M
→ Why adding VFD matters? Product Sales Manager
MODP India
→ Packaging efficiency – improvement of total
system efficiency
→ Tools we can use to engage customers to
Energy efficiency
→ EE - Regulatory requirement
→ EE - Regulatory incentives

© 2024 ABB. All rights reserved. Slide 2

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Energy efficiency &
sustainability
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What is Energy Efficiency

Energy efficiency means using less energy to

get the same job done – and in the process,
cutting energy bills and reducing pollution

Energy efficiency is the lowest hanging fruit with a

win-win approach to reduce power consumption,
save money and reduce carbon emissions

All types of manufacturing plants and utilities can

boost their productivity with energy efficiency.

© 2024 ABB. All rights reserved. Slide 4

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India – Contrasting facts & figures

Total Power produced 1,884TWH

& installed capacity – 442GW Per capita Consumption
CO2 /kwh

Global 480 Global 12000

43%
57%
India 713
India 1372
0 200 400 600 800
0 5000 10000 15000
CO2 /kwh
Fossil fuel Renewable Per capita Consumption

© 2024 ABB. All rights reserved. Slide 5 Under the govt. 2023-27 national electricity plan, no new fossil fuel plants will be built in utility
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Making the case for energy efficiency

→ India set’s itself a target of 44% of total → Higher energy efficiency means reduced stress on
electricity to be renewable by FY2030. But it is the grid & availability of quality power
faraway from IEA target of 60% globally
High-efficiency motors combined with VFDs have a
→ With an electricity consumption growth rate ~8%,
there will be a shortfall of power availability & → crucial role to play in reducing energy costs and
meeting environmental targets.
power outages due to maximum demand issues,
resulting in power quality issues This combination also immensely help in reducing
the peak time maximum load demands & increases
→ Energy efficiency is the only way forward to tackle
these issues
→ the optimum utilization of resources & saving
environment.

© 2024 ABB. All rights reserved. Slide 6

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The journey towards energy efficiency

1
Making better decisions
Making customer aware of
the energy saving avenues in
their plants & explaining how
2
Implementing change
Prioritize “quick win” projects along
side your modernization plan
Transition to newest technology
3
Mitigating risks
Continual engagement &
support on their install
base & new projects
our drives can enhance the with minimal interruptions
total plant efficiency

© 2024 ABB. All rights reserved. Slide 7

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Investment payback
Which offers best in class return on investment

On average, one dollar invested in energy efficiency will payback three times in energy saved
over the lifetime of the equipment

© 2024 ABB. All rights reserved. Slide 8

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Where to emphasize on Energy efficiency
Targeted sectors

Consumption of Electricity by sectors in India

✓ Industry consumes >40% of the total Commercial ,
Traction &
electricity and growing at an average of 8% 8%
Railway, 1%
Others, 6%

✓ Domestic consumption expected to grow Industry, 41%

exponentially due to urbanization & climate
change. Domestic,
26%

✓ Commercial building to consume around

25-30% in the coming few decades, but Agriculture,
with energy efficiency improvement we can 18%
Industry Agriculture Domestic
add 60% more building space Others Commercial Traction & Railway

© 2024 ABB. All rights reserved. Slide 9

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Where to emphasize on Energy efficiency – Heavy Industry
Highly electricity intensive industries

✓ Integrated Steel plants energy consumption per ton Energy intensive industry consumption
of crude steel – 6-6.5 Vs 4.5-5 Giga calories (global Pulp &
Paper, 2%
Avg)
Aluminum, 1%
Others, 32% Iron & Steel,
✓ Iron & Steel industry contributes 7% of global carbon 26%
emissions

✓ Cement plants in India consume 110kWh/ton Vs

91kWh/ton (global avg)
Automotive,
✓ Tier 2 &3 industries have more potential for energy 8%
efficiency
Textile, 6% Chemicals ,
16%
✓ Technologically advanced and sustainably managed F&B, 8%
plants with support of ABB motion portfolio to
enhance energy efficiency

© 2024 ABB. All rights reserved. Slide 10

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Where to emphasize on energy efficiency – Heavy Industry
Targeted applications

Utilities, HVACR

Oxygen plants Boiler auxiliaries

Conveyors Pollution control

Equipments
Value selling emphasizing
Energy efficiency
Air Compressors Pumps & Fans

Energy walks or sustainability tours

© 2024 ABB. All rights reserved. Slide 11
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Where to emphasize on energy efficiency – Light Industry

• Light industry verticals like Food & beverage, Pharma, Plastic, ceramic etc have huge potential
Light Industry for energy saving as most application are variable torque loads.
• F&B is growing ~15% CAGR & Ceramic / Plastic are growing ~ 8% CAGR

• F&B industry to consume 25-30% of the total industrial power consumption by FY2040.
Facts on Light
• >80% applications in Light industry are variable torque loads
Industry EE • >20% efficiency can be achieved in general in these industries

• All process pumps, fans, compressors, Boiler auxiliaries, Cookers, Extruders, Filter presses,
Mixers, Agitators, conveyors and other allied equipment etc.
Applications • Energy walks / Sustainability observation tours
• Show the benefits monetarily & explain the total savings with ROI wherever possible

• Early engagement & promote energy efficiency as core design criteria

Our • Promote superior value add products like ULH, PDR, Cooling compressor variant, H / Q variants
responsibility • Understand their pain points and offer our solutions around those issues

ABB Motion • Specific features like multi pump, fan control / Anti cavity / Temperature vs pressure graphs /
helps enabling Skid mounted PDRs / Panel less installations / higher ingress drives for harsh environments etc

© 2024 ABB. All rights reserved. Slide 12

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Efficiency standards
– IEC categorizes Low voltage motor
efficiency up to 1000KW : IE1 to IE5
– Motors categorized as IE1 or IE2
are comparatively low in efficiency
– The IE4 standard specifies energy losses

1 2 3 4 5
about 15% lower than IE3
– IE5 “ultra-premium efficiency” is the
highest level of motor efficiency
– IS 12615 categorizes efficiency IE2 to IE4
— — — — —
IE1 IE2 IE3 IE4 IE51
Standard High Premium Super Ultra
Efficiency Efficiency Efficiency Premium Premium
Efficiency Efficiency

Rewound motors have efficiency drop of 1 to 4%

IE2 minimum IE3 minimum From 2023, IE4 will be the
standard in India standard in minimum standard in Europe
Europe for motors between 75-200kW

1. The IE5 class has not been specified in the standard yet, but some
manufacturers have already developed motors that will be compliant
© 2024 ABB. All rights reserved. Slide 13
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Do larger motor ratings have better Energy Savings potential ?

• 75KW 4P 50Hz motor • 15KW 4P 50Hz motor

IE1 92.7%, IE2 94%, IE3 – 95% IE1 88.7%, IE2 90.6%, IE3 – 91.5%

Savings IE1 to IE3 - 17040KWHr/Yr Savings IE1 to IE3 - 5430KWHr/Yr

5 Nos of 15KW – 21720 KWHr/Yr

IE classes, 4-pole motors

© 2024 ABB. All rights reserved. Slide 14

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Why adding a drive matters
Drive can make a huge impact to your energy consumption even up to 25%

Just under 1 in 4 of the The number of motors

world’s industrial motors equipped with a drive is
are equipped with a drive expected to only increase
by 3% over the next five years

Experts suggest that around When added to the fan, pump

50% of industrial motors or compressor motor, a drive
would benefit from being can typically reduce power
paired with a drive consumption by 25%

Our ultra-premium efficiency Drives allow better start-ups

synchronous motors paired and lifetime optimization of
with a drive substantially the motor-driven system
maximize efficiency

© 2024 ABB. All rights reserved. Slide 15

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Intelligent motor control methods can help
in solving the energy challenges we all face

Running at 80% of the

nominal speed brings
Pumps, fans and compressors are the most used industrial 50% energy saving
applications and therefore have the greatest potential
for energy savings.

By installing a drive to your application, you can reduce energy

Power
consumption up to 25% by varying the motor speed. Even a small
reduction in speed can give significant savings.

This is due the Affinity Laws, when we reduce the speed

of pumps or fans by 20%, they consume 50% less power.

This means that the global energy savings potential is enormous 50%
as in many applications, there’s no need to run the application
with 100 % of speed all the time.

80% Speed

© 2024 ABB. All rights reserved. Slide 16

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Energy Efficiency
Conventional Vs Energy Efficient

Input power
359
Conventional pumping
Output flow
system
System Efficiency = 28% 100

Standard Motor Coupling Pump Throttle

Efficiency Efficiency Efficiency Efficiency
91% 98% 78% 40%

Input power

Energy Efficient pumping 122

system
Output flow
System Efficiency = 82%
100

Variable speed Energy- efficient Coupling Efficient pump

drive efficiency motor efficiency Efficiency Efficiency
98% 96% 99% 88%

© 2024 ABB. All rights reserved. Slide 17

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Energy efficiency pays back quickly By far, the largest cost in the
life cycle for motors and drives
is the cost of energy used.

The additional purchase price The main life cycle costs for a
of ABB high efficiency motors mechanically controlled pumping system
and variable speed drives is just
a few percent compared to the
energy spent to run the
equipment over its lifetime.
Energy savings with variable
speed drives and high efficiency
motors typically pay for 92% Energy
themselves in 1-3 years. In some 3% Maintenance
cases, the payback time is just a
5% Purchase
few months.
We offer a great saving You can save
potential of the life cycle energy money and reduce
consumption! your CO2 footprint by
using a drive to control
your motor.
© 2024 ABB. All rights reserved. Slide 18
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Software tools
Smooth selection and
advanced customization
ABB software tools
for drives enhance
the performance
and ease of use
of ABB drives
DRIVE AND MOTOR SELECTOR

DRIVESIZE

ENERGYSAVE CALCULATOR

ECODESIGN CALCULATOR

DRIVE COMPOSER

© 2024 ABB. All rights reserved. Slide 19

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EnergySave Calculator
Progressive Web Application progressing all the time

EnergySave calculator is a web application which renders well

on a variety of devices and window and screen sizes. It works in
your laptop, mobile phone and tablet and supports all web
browsers.
• You are always using the latest official version.
• Has got two modes: Basic and Advanced.
• The Basic mode lets you quickly see potential savings and
does not require a lot of technical details of a system.
• The Advanced mode gives you the opportunity to include
more technical details for a calculation.
• Can be used as a sales tool by calculating savings of pumps,
Fans & air compressors
• Has built-in calculators guiding on the motor sizing,
transformer sizing and showing the derating factor for
harmonic current impact on transformers etc
• Encourage customer maintenance engineers to use this tool to
gain their confidence and they can corelate the current method
power consumption with actual power consumption

© 2024 ABB. All rights reserved. Slide 20

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EnergySave Calculator
Fan, pump & air compressor

Basic Mode:
• useful for giving an idea to customer
whether the application worth upgraded
with Drive
• Only basic data like BKW, control method,
operating hours needed to calculate
expected energy savings
Advanced Mode:
• Offers clear understand of the sizing of the
motor for the operating point and also give
more detailed report with ROI
• Detailed application data needed to
execute this mode
• Results will be more closer to actual power
consumption & energy savings

© 2024 ABB. All rights reserved. Slide 21

 Yearly energy use
with 50 kW pump
Energy efficiency pays back quickly
= 300 MWh
with valve control
method*
ABB EnergySave
22.3% calculator

energy savings with a drive

= 86.3 MWh
The purchase price of ABB
high efficiency motors and CO2 savings
variable speed drives is just
Energy
= 60.4 t/y
a few percent vs. the energy
spent to run the equipment 92% Savings in INR

= ~600,000
over its lifetime.
Life cycle
Energy savings with variable costs for a
speed drives and high pump without
efficiency motors typically a drive
3% Maintenance
pay off in 1-3 years. In some
5% Purchase
cases, in just a few months.

*8760 h annual run, 90% flow 75% of the time, 80% flow 25% of the time, pump nominal flow 362 m3/h, head 30 m,
IE3 motor, valve control method, energy price INR 7.00/kWh.
© 2024 ABB. All rights reserved. Slide 22 May 8, 2023
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Software tools
Smooth selection and
advanced customization
ABB software tools
for drives enhance
the performance
and ease of use
of ABB drives
DRIVE AND MOTOR SELECTOR

DRIVESIZE

ENERGYSAVE CALCULATOR

ECODESIGN CALCULATOR

DRIVE COMPOSER

© 2024 ABB. All rights reserved. Slide 23

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DriveSize as a sales tool, not just an Engineering tool
DriveSize can be used to

• to select optimal drive system components

• Line supply unit
• Inverter
• Motor
• Transformer

• to calculate
• system harmonics
• efficiencies and power losses
• inverter load currents
• the loads of supply unit

• to have results
• in graphical and numerical format
• print and save the results to be used as part of drives offer

© 2024 ABB. All rights reserved. Slide 24

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DriveSize as a sales tool, not just an Engineering tool
Step-by-step process for dimensioning a Drive

1. Define the network 2. Define the motor 3. Dimension the Drive 4. Select the Transformer

5.Overload Cycles 6. Motor Loadability 7. Losses & Efficiency 7. Network Harmonics

© 2024 ABB. All rights reserved. Slide 25

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Ultra-low harmonic drives
Features & Benefits

Low Harmonic content, <3% THDi Unity Power Factor, at all loads Reactive Power Control
The drive produces exceptionally low harmonic content and ABB’s ultra-low harmonic drives have been designed to be ABB’s ultra-low Before compensation After compensation

exceeds the requirements of harmonic recommendations, neutral from the network point of view. Drive reaches unity harmonic drives
such as IEEE 519 and G5/4. The total harmonic current power factor. This high power-factor indicates that electrical have the built-in Active power
Active power
distortion is typically <3% in nominal situation and energy is used efficiently. feature for
undistorted network. reactive power
compensation, Reactive power
Reactive power
Diode supply Active supply 0,7 1 without any Q Q
additional
components
P P
Standard 6-pulse drive ABB ultra-low harmonnic drive
cosφ = 0,80 cosφ = 0,95
without input choke

Reduced Demand ~25% Immunity to network variations Improve System Efficiency

ABB’s ultra-low The voltage
Harmonic drives kills stabilization feature in U
+
the cause for the the ultra-low harmonic 100 %
harmonics at the source 1,35 MVA 6-pulse drive drives can boost the
and hence the demand output voltage more Supply voltage < 100 %
for the network also than the source voltage. t
U
reduces by 25% + And ensures 100%
Motor voltage ≥ 100 %
voltage at motor
1,1 MVA Ultra-low terminals consistently 100 %
harmonic despite of input
drive
J fluctuations. t
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DriveSize as a sales tool, not just an Engineering tool
Analysing the results

Transformer derating and selection details

6 pulse standard drive selection

Ultra Low Harmonic drive selection

• 250kW - 4 Nos on a transformer with standard drive Vs ULH Drive transformer selection data
© 2024 ABB. All rights reserved. Slide 27
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Software tools
Smooth selection and
advanced customization
ABB software tools
for drives enhance
the performance
and ease of use
of ABB drives
DRIVE AND MOTOR SELECTOR

DRIVESIZE

ENERGYSAVE CALCULATOR

ECODESIGN CALCULATOR

DRIVE COMPOSER

© 2024 ABB. All rights reserved. Slide 28

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EcoDesign tool
Progressive web application

The ABB EcoDesign tool

• Absolute and relative losses and efficiency data at
standard and user-defined operating points according
to EU regulation 2019/1781 for complete drive module
(CDM), LV motors with VSD supply, and power drive
system (PDS)
• Losses and efficiency data at operating points in
graphical and table format
• Printable efficiency report with possibility to
customize title and additional details
• Report can be converted to PDF or CSV format and
shared via email

© 2024 ABB. All rights reserved. Slide 29

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EcoDesign tool
Overview of PDS section

• The PDS section of the tool provides PDS power

loss and efficiency data at eight standard
operating points: (0;25), (0;50), (0;100), (50;25),
(50;50), (50;100), (90;50), and (90;100), as well as
losses at standby point.
• The motor selection includes ABB motor,
reference motor, and user-defined motor.
• The CDM selection includes ABB CDM, reference
CDM, and user-defined CDM.
• The CDM recommendation is based on the voltage
and current of the selected motor.
• The tool also calculates PDS power losses and
efficiency at user-defined operating points. A
maximum of eight user-defined operating points
can be added. Three types of user-defined load
points are available for PDS: custom points,
predefined NEMA index points, and predefined
quadratic load curve points.

Complete drive module Motor Power drive system

Drive efficiency (CDM) Motor efficiency System efficiency (PDS)
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EcoDesign tool
Overview of PDS section

Complete drive module Motor Power drive system

Drive efficiency (CDM) Motor efficiency System efficiency (PDS)
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Combined efficiency (PDS) utilization example
Enabling customers take cautious approach in sizing

Combined
efficiency (PDS)

90% 50% Absolute

Motor speed & speed losses
Motor Model VFD kW VFD Model
kW 100% & 50% @90/100
torque torque
(Watt)
ND / 132 ACS580-01-246A-4 92.80% 90.00% 9252
132 M2BAX 315SMC4 HD / 160 ACS580-01-293A-4 92.10% 89.30% 10192
UHD / 200 ACS580-01-363A-4 91.60% 88.40% 10960

Additional losses ND to HD – 940Watt = ~INR 55,272 PA

Additional Losses ND to UHD – 1708 watt = ~ INR 100,430 PA

At partial loads saving potential may be higher in different scenarios

© 2024 ABB. All rights reserved. Slide 32

Heat dissipation / Thermal losses
– Ecodesign
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Drive power losses / Heat Dissipation – hidden facts
Schneider: ATV630 Yaskawa: GA700
Model: ATV630D90N4 Model: GA70C4168BBA
Usage in Normal Duty Overload – 90kW Usage in Normal Duty Overload – 90kW
Power dissipated at nominal current (W) : 1781W Typical heat dissipation(W) as per catalogue: 1760W
(as per Installation manual & Efficiency Calculators) Efficiency: 98%
Efficiency: 98%

Losses as per Eco-design (Altivar efficiency calculator) Losses as per Eco-design standards

90% (frequency) : 100% (Current) – 1.77% - 2013W 90% (frequency) : 100% (Current) – 1.8% - 1981W
50% (frequency) : 100% (Current) – 1.5% - 1708W 50% (frequency) : 100% (Current) – 1.5% - 1715W
50% (frequency) : 50% (Current) – 0.76% - 862W 50% (frequency) : 50% (Current) – 0.8% - 848W

Difference: 11% Difference: 11%

Read between lines and expose the lies

© 2024 ABB. All rights reserved. Slide 34

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Drive power losses / Heat Dissipation – hidden facts
Danfoss: FC302 ABB: ACS580
Model: FC-302P75KT5E21H1 Model: ACS580-01-0169A-4
Usage in Normal Duty Overload – 90kW Usage in Normal Duty Overload – 90kW
Estimated power loss at rated max. load (W) : 1474W Typical heat dissipation(W) as per catalogue: 2021W
as per catalogue Efficiency: 98%
Efficiency: 99%

Losses as per Eco-design (Danfoss - Ecosmart) Losses as per ABB - Eco-design results

90% (frequency) : 100% (Current) – 1.89% - 2325W 90% (frequency) : 100% (Current) – 1.7% - 2021W
50% (frequency) : 100% (Current) – 1.59% - 1953W 50% (frequency) : 100% (Current) – 1.3% - 1547W
50% (frequency) : 50% (Current) – 0.74% - 915W 50% (frequency) : 50% (Current) – 0.7% - 860W

Difference: 36% Difference: 0%

Reduced losses: 304W at nominal load and more than 400W at
partial loads

ABB - The most transparent among peers

© 2024 ABB. All rights reserved. Slide 35

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Drive power losses / Heat dissipation – Analysis

Assuming 10 Nos of 90kW systems under one MCC:

ATV630 Vs ACS580:
PDS losses @90% speed / 100% load = -8 watt (2013-2021) - No difference
PDS losses @50% speed / 50% load = 2 watt (862-860) - No difference

FC302 Vs ACS580:
PDS losses @90% speed / 100% load = 204 watt (2325-2021) - Major additional losses
PDS losses @50% speed / 50% load = 55 watt (915-860) – Major additional difference

FC302 will consume 17,870 KWH (90,100) = ~INR 125,000 or 4642kWH (50,50) = ~INR 32,500 PA

© 2024 ABB. All rights reserved. Slide 36

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Power quality
regulatory requirements
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Power Quality – Regulatory requirements

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Power Quality – Regulatory requirements

Harmonics

To abide by IEEE-519
POWER FACTOR COMPENSATION

KVAH Billing & Peak Hour charges

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Energy efficiency
Regulatory incentives
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Energy Efficiency – regulatory incentives

• National Mission for Enhanced Energy Efficiency (NMEEE) under NAPCC

NMEEE
• one of the eight missions under the National Action Plan on Climate Change (NAPCC).

Perform, Achieve, • A market-based mechanism to enhance the cost-effectiveness in improving Energy Efficiency
in Energy Intensive industries and they receive energy saving certificates (Escert)
and Trade Scheme • The ESCerts could be traded on the Power Exchanges and bought by other units under PAT
(PAT): who can use them to meet their compliance requirements.
• Under MTEE, two programs have been developed i.e. Bachat Lamp Yojana(BLY) and Super-
Market Efficient Equipment Programme (SEEP).
Trasnformation • BEE promotes the use of LED lights using the institutional structure of the BLY Programme
for EE (MTTE): possible
• This is a platform for the creation of mechanisms that would help finance demand-side
EE Financing management programs in all sectors by capturing future energy savings.
platform (EEPF): • FI’s to work together for the development of the energy efficiency market and the identification
of issues related to this market development.

Framework for EE • Partial Risk Guarantee Fund for Energy Efficiency (PRGFEE)
economic • The Venture Capital Fund for Energy Efficiency (VCFEE)
development (FEEED):

© 2024 ABB. All rights reserved. Slide 41

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Let’s write the future.
Together.
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Q&A

© 2024 ABB. All rights reserved. Slide 43