Electric motors and the systems they drive consume electrical energy more than twice as much as lighting, while lighting is typically considered a major low-lying fruit for energy reduction in a factory. It is estimated that motors account for between 43% and 46% of all global electricity consumption particularly from the manufacturing sector. The presentation will cover topics like the effort to ensure the motor efficiency in manufacturing sector; the application of variable speed drives and other factors which affect the motor efficiency such as power quality; and good maintenance regimes for energy reduction

1. Manufacturing Energy Efficiency – Process,
Technology and Mind-Set
Industrial Motors Case
Colin Koh
colinkoh@precicon.com.sg
Lim Kim Hai Electric – Precicon
D&C Pte Ltd – Lim Kim Hai Power Distribution

4. Table of Content
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•
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Manufacturing Energy Efficiency
Process, Technology
Industrial Motor Efficiency
Culture & Mind-Set : Energy Management
System
Precicon D&C Pte Ltd

5. Energy Use in A Manufacturing Business
Energy Use
Distribution
Generation
Purchase
User 1
Electricity
electrical Substation
User 2
Steam
Boiler House
Electricity
Natural Gas
User 3
Hot Water
Hot Water Plant
Fuel Oil
User 4
Process Water
CHP Plant
Diesel
User 5
Cooling Water
Cooling Tower
Renewable
User 6
Refrigeration
Regeneration Plant
Water
User…
Compressed Air
Industrial Gas
Utility Export
Process Gases
Vaporiser
HVAC
Air Compressors
Lighting
Renewable Energy Plant
Waste Water
Waste
Source: Energy Management in Business kit Oung 2013
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Effluent Treatment
Effluent
Disposal/Reuse

6. Visualisation and Optimisation
Source: www.EnMS-doc.com
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7. Industrial Energy Efficiency Measures
Source: envision
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8. Residential
Residential
Electric Motors
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Commercial
Industrial

9. Low Hanging Fruits
•
•
•
•
•
•
Insulation
Efficient Lighting
Plugging Air-Leak
Boiler Tuning
ASD (VSD)
Efficiency Motor
Source: NEEC 2013: 3M
Precicon D&C Pte Ltd

10. Lighting Energy Saving Solution
ROI
Best Value
Budget
TCOO
Initial Investment
Operating Hours
Energy Saving
Customer for customer who focuses on
initial investment and specific payback
Customer who focuses on product life
span, energy and money saving
Quality of Light
Product Quality
Ave Illuminance (Lux)
Uniformity
Lumen Maintenance
Colour Temp. (K)
Instant Start
LED Technology
IEC / Energy Star
Efficacy lm/W
Beam Angle
CRI
No IR & UV
Lifetime
Instant Start
Best Lighting
Best Product
Ease of Maintenance
Customer who focuses on product
specification, application and
replacement
Precicon D&C Pte Ltd
Best ROI
Fitting Design
LED Design
Cost of Replacement
Customer who wants best lighting
specification and performance
LESS
LESS

11. Energy Efficiency – Electric Motor and Drive System (EMDS)
Total Motor System
With Transmission, Gears and Motor
Large Saving
Good Saving
Core Motor
System
Electric
Motor
Small Saving
Motor + Pump
+ VSD
Entire System with Pipe Pump
and Motor, VSD
Source: A+B International, 2008.

12. Motor O&M Best Practice
Global Electric Motor & Drive System
Motor Size (KW) Energy Consumption (%) Volume (Pcs)
0.75
9
2 Billion
0.75-375
68
230 Million
above 350
13
600,000
Application
Appliances, Fan, Pump
Pump, Fan, Conveying, Compressors, Process
Industrial & Infrastructure
IEA: 2011
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•
•
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Right Sizing & High Efficiency Motors
Right Application of VSD
Power Quality: Balance Three Phase Voltage
Ventilation, Bearing, Thermal Scanning, Vibration
Analysis
• Consider TCO rather then first cost
Precicon D&C Pte Ltd

13. System Approach for EMDS

14. Right Sizing:
Factors That Leads to Over Design of Motors
• Process Pump Required 20KW motor
• Designer: 10% add for head and flow
• Design Checker: 10% add to ensure pump work
when install
• Procurement Department: Purchase the next
available frame size
• Pump original design: 10-20% add for safety
margin
• Final Motor size: 30-40KW
(OEM, system specifier, plant manager, energy manager and senior manager, executive)
Precicon D&C Pte Ltd

15. Understanding Motor Size and Energy Consumption
Data Logger @
less than
S$200.00*
per motor !
(Logger & 100A CTs)

16. VSD Can Reduce Energy 30%-50%
Motor systems that are likely to be appropriate
for VSDs are those with the following
characteristics:
• Drive a centrifugal fan, pump, or blower and
operate long hours (> 2000 hours/yr.)
• Fluid or air flow varies over time and control
systems such as valves, throttles, or dampers
are used to regulate the flow and pressure
Precicon D&C Pte Ltd

17. Motor Loads and ASDs:
Common Applications and Energy Considerations
Motor Load Type
Variable Torque Load
• Power [hp] varies as the cube of the
rotational speed
• Torque varies as the square of the
rotational speed
Common Applications
• Centrifugal fans
• Centrifugal pumps
• Blowers
• Axial fans
• HVAC systems
Energy Considerations
Lower speed operation results in significant
energy savings as shaft power of the motor
drops with the cube of the rotational speed
Constant Torque Load
• Torque remain constant at all
rotational speeds
• Power [hp] varies in direct
• Mixers
• Conveyors
• Compressors
• Printing presses
Lower speed operation saves energy in
direct proportion to the rotational speed
reduction.
Constant Power [hp] Load
• Develops the same power [hp] at all
rotational speeds
• Torque varies in inverse proportion
to the speed
• Machine tools
• Lathes
• Milling machines
• Punch presses
No energy savings at reduced speeds;
however, energy savings can be realized by
attaining the optimized cutting and
machining speeds for the part being
produced. A time limiting switch device
controlling no-load operating time saves
energy, too.
Source: CEE
Precicon D&C Pte Ltd

18. Energy savings with speed control for a centrifugal pump
without static pressure head
By-Pass Control
Power Input (%)
Throttle Control
On-Off Control
Speed Control
With VSD
Pump Power
Required
Speed Control
With Magnetic Coupling
Source: Ferreira, 2009
Full Speed (%)
Pumping System without
Static Pressure Head

19. Fan & Pump Loads
The basic Affinity laws can be converted for use with
centrifugal fans and pumps.
Flow is directly proportional
to speed.
No need for valves & dampers
FLOW = RPM’s
Horsepower is directly
proportional to the cube of
the speed.
HP= (RPM’s)³
1 HP = 746 watts (How do we pay for power?)
A 10% reduction in speed = 27% reduction in power!
Precicon D&C Pte Ltd

20. Case Study of VSD Energy Saving
A 50hp centrifugal pump operating 4,067 hours annually, with a 75% load factor, a
throttling valve to regulate flow to 70% on average, and primarily frictional losses and
negligible static head.
VSD reduces
Motor speed
By 30%
Annual Energy Cost (Without ASD) = 50hp/0.93 x 0.75 x 0.746kw x (1.0)2 x 4,067hr x S$0.2 = S$24,467
VSD)
VSD
Annual Energy Cost (With ASD) = 50hp/0.93 x 0.75 x 0.746kw x (0.7)2 x 4,067hr x S$0.2 = S$11,989
(VSD Cost approximate S$6,000) = Pay Back in 6 Months
Annual Saving = S$12,478 (50%)
Precicon D&C Pte Ltd

21. Power Quality: Unbalance Voltage
I2R
Winding
% voltage
losses
temp.
unbalance
(%of
(Degree C)
Total)
0
120
30%
1
130
33%
2
140
35%
3
150
38%
4
160
40%
5
180
45%
Precicon D&C Pte Ltd
Efficiency
reduction
Expected winding life
(Years)
—
Up to 1/2%
1-2%
2-3%
3-4%
5% or more
20 years
10
5
2.5
1.25
Less than 1

22. Motor Life Cycle Cost
Life Cycle Cost = C + E(t) + M
Where:
C = initial capital cost plus installation
E(t) = total energy cost = Hr/yr x $/kWh x avg. kW x years
M = total maintenance cost = annual $ x years
For example, a 10 HP motor operates 50% of the time at an average output of 7.5
HP. Its efficiency is 88%. Purchase price is $1,000 and installation is $200. The
motor is expected to last 10 years and cost $50/year to maintain. Electricity price
is $0.25/kWh
C = $1000 + $200
E(t) = 8760 x 0.5 x {(7.5 x 746)/0.88} x 0.25 x 10
M = $50 x 10
Life Cycle Cost: $1,200 + $69,619 + $500 = $71,319
Cost of Motor against Life Cycle Cost = 1.7%

23. High Efficiency Motors
(From Standard to High/Premium/Super Premium Motors)

24. Singapore Energy Efficiency Market Size
Frost & Sullivan

25. Best Practices: ISO 50001 Make Easy
Source: www.EnMS-doc.com
Precicon D&C Pte Ltd

26. Thank You
Colin Koh
colinkoh@precicon.com.sg
http://www.linkedin.com/in/colinkoh
Lim Kim Hai Electric – Precicon
D&C Pte Ltd – Lim Kim Hai Power Distribution