Voltage optimisation is a highly effective energy saving technique that has an excellent payback period and can provide savings on machinery maintenance.

The technology has a significant impact on the amount of energy used because it brings the voltage supplied by the grid in line with what is actually required, making it ideally suitable for the manufacturing and processing industries and heavy power users.

According to operations director Australasia of Powerstar Sam Czyczelis,  companies can reduce annual energy consumption by 12-15% and even more in some installations.

“Voltage optimisation is an innovative technology dedicated to matching power demands to the needs of electrical equipment and machinery. It works best on inductive loads — motors, drives and lighting for example, especially if these are not loaded at 100% of their capacity for 100% of the time.

“As each site is different, with its own unique infrastructure and specific load requirements, a voltage optimisation strategy should be customised to ensure that savings are maximised,” he says.

The technology

Voltage optimisation is an electrical energy-saving technique in which a device is installed in series with the mains electricity supply to provide an optimum supply voltage for the site’s equipment.

The statutory electricity supply range for Australia is 230V +10% to -6%, which means that electricity suppliers are required to provide a voltage level that is between 253V and 216V. Therefore, the supplier will distribute electricity at 253V and over distances the voltage will decrease. On average, it is received from the grid at 247V.

Because most electrical equipment and machinery manufactured for Australia is designed to work most efficiently at 220V to 230V, site engineers and managers would therefore realise any incoming power that is higher than this level is wasted energy and means organisations are paying for power that is not required and not used.

Voltage optimisation deals with this over supply and brings incoming mains supply into line with what equipment needs to run at its most efficient level, thus saving money, lowering carbon emissions, helping equipment last longer and reducing maintenance costs.

The advantages of voltage optimisers include:

* Benefits all loads within a building

* Minimal, non-disruptive downtime for installation

* Reduces energy consumption

* Reduces CO2 emissions

* Reduces harmonics

* Improves power factor by up to 20%

* Improves the life expectancy of equipment

* Provides absolute voltage phase balancing

* Lowers the operating temperature of motors

* Helps protect against damaging transients (power spikes) of up to 25,000V

Over-voltage means that energy consumption is not only higher, but as a result, the lifespan of equipment is shortened. Installing a voltage optimisation unit leads to reduced maintenance costs as less demand is placed on electrical equipment.

Higher frequency harmonic currents can cause overheating and hardware damage including:

* Equipment malfunctions due to excessive voltage distortion

* False tripping of branch circuit breakers

* Metering errors

* Increased internal energy losses in connected equipment, causing component failure and shortened lifespan

* Fires in wiring and distribution systems

VO technology presents an excellent opportunity for savings without compromising the supply to a building’s electrical equipment.

The savings

Generally, voltage optimisers will deliver between 12-15% savings. However, the most efficient voltage optimisation solutions can save up to 26% of total electricity consumption and related CO₂ emissions, all without compromising the supply to electrical equipment and machinery.

Virtually all sites can benefit from reducing and controlling their voltage, but as conditions and loads differ from site to site, the size of the benefit will vary ─ savings will be determined by the type of system used, as well as site specifications.To ensure optimum savings and performance, a comprehensive analysis of a building or site’s power conditions should be completed before installation.

An additional benefit of VO systems is an integrated intelligent interface that allows site engineers/managers to track product and site performance in real time, enabling them to identify where emissions stand compared with the usage and spend of previous months and years. This data can be used to not only set a benchmark for the future, but also to evaluate the efficiency of various green measures that have been taken within the organisation.

“Saving energy and money begins with information and knowledge. It is about understanding where, when, and how much energy is being consumed, and having the ability to effectively act on that knowledge,” Powerstar’s Czyczelis says.

“The reality is that it doesn’t have to cost more to make a building more efficient. With an array of technologies, tools, and expertise available, engineers and managers have never been in a better position to take control of their energy costs and reap the financial returns that high performance solutions can deliver.”

The cost

The cost of a voltage optimisation system will differ depending on a site’s unique requirements. All installations should be provided with 100% guaranteed savings for the life of the equipment and equipment should have a minimum warranty of 10 years and up to 15 years.

The payback period after installation (despite the size of the installation) is typically between 0.8 and 2.5 years. Users should expect voltage optimisation equipment to offer a 50-year life expectancy with 100% reliability.

The market

Sam Czyczelis says there are various types of equipment that are misleadingly touted as ‘voltage optimisation’ technology, so beware.

“Most sites require a genuine, dynamic voltage optimisation solution supplied by an experienced and reputable company to maximise energy savings and carbon reductions,” he says. “Installing the right type of system is essential to ensure that machinery and electrical equipment never receives more or less than the required minimum voltage for correct operation ─ important during power dips and surges.”

“By opting for a true voltage optimisation solution, equipment will operate as efficiently as possible at all times, the lifetime of equipment will be maximised, and maintenance costs will be significantly reduced. Ultimately, if a company’s power is not optimised, it is paying much more for electricity than needed, and at the same time, emitting excessive amounts of CO₂,” Czyczelis says.

As voltage optimisation is one of the simplest and most cost effective ways to reduce electricity use and cut carbon emissions, it should be regarded by all organisations as the cornerstone of their energy efficiency agendas.