Rachel Urquhart
ABB Authorised Value Provider A1 Electric Motors was recently engaged to conduct an in-depth performance analysis on the HVAC systems serving a multi-tenancy building in the heart of Hobart’s CBD.
The Sypkes Group’s property at 85 Macquarie Street is a commercial building with corporate office spaces, with tenants including government and parliamentary officials. The building’s 10 floors are occupied by about 250 workers each day, and the bottom two levels of the building date back almost 200 years.
Initially, Director of Property of the building Stuart Davey-Sypkes identified problems with the ageing HVAC plant. He consulted Enginuity Power Solutions, which collectively engaged ABB Authorised Value Provider A1 Electric Motors to conduct an in-depth analysis of the existing system’s process performance.
According to ABB, the aim of the analysis was to identify strategies for increasing the reliability of HVAC operations using modernised technology, and to identify areas where energy demand could be reduced, and energy efficiency increased.
The analysis looked at the HVAC motors and drives responsible for powering and managing the building’s chilled water, and those that powered the supply air fan for the entire building.
Solutions identified
Tom Green, Managing Director at Enginuity Power Solutions, together with Chris Cheong, Director at A1 Electric Motors, decided ABB motor and drive solutions were the best fit for the building infrastructure upgrade.
Their analysis also recognised that the building could bring its existent motor selection down a size. The supply air fan was originally powered by a 15kW motor; however, it was determined that only an 11kW motor was required. According to the analysts, this would enhance the system, reduce operating costs and increase energy efficiency.
The analysts say that the chosen ABB drive was also optimally matched to the motor’s required power rating, increasing the return on investment overall. ABB synchronous reluctance motors (SynRM) and ACH580 variable speed drives (VSD) were selected for the project.
Upgrading to high efficiency
HVAC systems worldwide rely on millions of low-voltage (LV) electric motors to run pumps, fans and compressors. ABB says that on average, these motors consume around 50 per cent of the energy used in buildings, and most motors fall into efficiency class IE1 or IE2.
Upgrading 85 Macquarie Street to IE5 SynRM motors saved significatn energy, says the company.
“Even when compared to an IE3 energy efficiency class induction motor, it offers up to 40 per cent reduced energy losses, delivering ultra-premium energy efficiency – a new level of efficiency defined by the International Electrotechnical Commission,” says ABB. “This attribute makes SynRMs the first choice to meet the global demand for environmental impact reduction when it comes to motor technology.
“When it comes to the innovative design, the rotor in a SynRM motor runs without magnets or windings and suffers virtually no power losses. This makes it as service-friendly as traditional induction motors. SynRMs are also made from reduced quantities of material for manufacturing versus a traditional motor.”
According to Rory Paltridge, Division Manager for Motors at ABB Australia, the SynRM motors offer industrial users a great opportunity to reduce their electricity usage and CO₂ emissions while also benefiting from increased productivity and lower life-cycle costs.
“Climate change and environmental responsibility are propelling changes across all industries and there’s a clear synergy with A1 Electric Motors and Enginuity Power Solutions to support this drive towards net zero,” says Paltridge.
Efficiency and effectiveness without compromise
ABB says the ACH580 is a drive that stands out for its ability to guarantee air quality in the most energy-efficient and cost-effective way in both normal and critical situations.
“Because HVAC systems run at partial loads close to 99 per cent of the time, VSDs can save energy by an average of 20–60 per cent compared to traditional damper or valve control methods,” says the company. “Such massive energy savings are possible because drives can adjust the motor speed of equipment directly to meet the current building needs.
“Variable speed control delivers the full benefit of running HVAC applications at partial load, allowing accurate control of ambient CO₂ levels, temperature, and humidity for the best indoor air quality and occupant comfort, health and safety, while optimising energy use.”
Davey-Sypkes says the asset replacement at 85 Macquarie Street “just made sense”.
“Reducing energy consumption in the building by upgrading the foundation that underpinned the plant and where equipment played a pivotal role, was the logical first step in a broader strategy to reduce the running costs of our building,” says Davey-Sypkes. “The ROI calculations looked compelling and it was backed with sound logic, which resulted in an easy ‘yes’ to undertake these upgrades.”
One year later
A full 12 months of post-upgrade data is now available to confirm the impacts. According to ABB, the equipment upgrade provided a 5.1 tonne reduction in annual CO₂ emissions, the equivalent of planting approximately 2.5 hectares of trees every year for the life of the asset.
“A look at the supply air fan application shows energy consumption was reduced by around 40 per cent, with a reduction in line current of approximately 9 per cent,” says the company. “Thanks to the implementation of the ABB ACH580 VSD, inrush currents have been reduced by more than 140A per phase and kVA demand has been reduced by over 100kVA. This has the potential to further reduce the energy costs at 85 Macquarie Street by over $12,000 annually.
“When it comes to the chilled water pump application, energy consumption was reduced by around 35 per cent, with a reduction in line current of approximately 43 per cent. Owing to the new VSD, inrush currents have been reduced by over 92A per phase and kVA demand has been reduced by over 65kVA. This has the potential to further reduce the energy costs by over $8,400 annually, giving the project’s capital investment an ROI of approximately 18 months.”
Reflecting on surprising results
Green says the project aligned with Enginuity Power Solutions’ focus on supporting industry and bridging the gap between intangible ideas and delivering evidence-backed, innovative, future-proof solutions.
“Our partnership with Chris and his team at A1 Electric Motors and our collaborative approach cements our ability to consult, design and deliver on projects such as these,” says Green. “The hope is that we can continue to specify engineered solutions to build a more energy-efficient tomorrow.”
Cheong says he was surprised, in a positive way, when he reviewed the energy charges after three months.
“We’re always thrilled when we’re able to see potential energy savings from equipment upgrades with the use of the ABB EnergySave calculator, coupled with ROI data such as that provided by Enginuity Power Solutions,” says Cheong. “It always makes a huge difference to the offering we’re able to give to our customers and Sypkes Group was no different.”
A year after project completion, Davey-Sypkes says he was also surprised by the outcomes.
“The reduction in energy charges and its direct beneficial impact on our bottom line was unmistakable,” says Davey-Sypkes. “Our team immediately started thinking about other opportunities that existed across our assets to replicate the process. We also communicated the results to our tenants who report on the environmental impacts of their office accommodation, and they were naturally happy to be occupying a more environmentally friendly establishment. So, a good news story all-round.”
Image shows (L-R) Stuart Davey Sypkes, Tom Green, and Chris Cheong in the lobby of the 85 Macquarie Street building.
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