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Electric Motor Systems: targeting and implementing efficiency improvements

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Energy savings of 20% to 30% in industrial electric motor systems are economically viable but can only be achieved through system optimization. This includes the electrical side as well as the mechanical side and its operation condition. Depending on the individual context of the industrial end user (e.g. regulation, energy price, management structure, capacities, available support, supply services, etc.), the end user can follow a sequence of steps in order to improve the efficiency of its running stock and thus ‘harvest’ the savings on a cost-effective and sustainable base.

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Electric Motor Systems: targeting and implementing efficiency improvements

  1. 1. Electric Motor Systems: targeting and implementing efficiency improvements 8 October 2015 Maarten van Werkhoven Low Carbon Economy Webinar
  2. 2. 2 Contents 1.  Introduction 2.  Efficient motor systems 3.  Standards and policies for motor systems 4.  Steps for end users to optimize their motor systems 5.  Some successful programs, tools and further information sources Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  3. 3. 3 Webinar Electric Motor Systems targeting and implementing efficiency improvements Maarten van Werkhoven (mvanwerkhoven@tpabv.nl) n  TPA advisors n  Consultant energy, sustainability and management n  Multiple projects on Energy Efficient production, building and policies. n  Electric Motor Systems: o  Operating Agent Electric Motor Systems Annex, IEA IA 4E EMSA o  Projects, programs in the Netherlands: o  Program Green Deal on efficient motor systems (Dutch) o  Knowledge Network efficient electric motor systems (Dutch) Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  4. 4. 4 EMSA Electric Motor Systems Annex n  6 countries n  2009 – 2017, 3rd phase 2014 - 2017 n  EMSA overview Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  5. 5. 5 EMSA for market transformation Global National Company Personal …harmonized global standards …successful policies …energy management & audits …tools & information Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  6. 6. 6 Contents 1.  Introduction 2.  Efficient motor systems 3.  Standards and policies for motor systems 4.  Steps for end users to optimize their motor systems 5.  Some successful programs, tools and further information sources Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  7. 7. 7 Global Electricity Demand Electric motors 46% Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015 Light 19% Electronics 10% Electrolysis 3% Heat 19% Standby 3% Motors 46% Paul Waide & Conrad U. Brunner et al., IEA Energy Efficiency Series, Working Paper, 2011
  8. 8. Energy and motor systems Electric Motor Systems - Low Carbon aandrijvi ng; 69% Heat, others; 15% ICT, lighting; 15% Motors in industry: = 69% of industrial electricity use Pump   21%   Air   compressor   18%   Cooling   compressor   7%   Fan   16%   Conveyor   2%   Processes,   other   36%   motors 69% Motor systems in industry: applications Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015 Source: P. Waide & C.U. Brunner et al., IEA Energy Efficiency Series, 2011
  9. 9. Scenarios of global electricity consumption 0 2'000 4'000 6'000 8'000 10'000 12'000 14'000 16'000 2005 2010 2015 2020 2025 2030 M o to r s ys te m e le ctricity c o n s u m p tio n (T W h ) Policy scenario Reference scenario LLCC scenario 20% 30% Source: Paul Waide & Conrad U. Brunner et al., IEA Energy Efficiency Series, Working Paper, 2011 Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  10. 10. 10 Electric Motor Systems n  Motor systems drive pumps, fans, compressors, transportation systems, processes. n  They can be improved in new and existing industrial applications, in infrastructure and building systems. Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015 20% - 30% savings
  11. 11. 11Electric Motor System s - Low Carbon Econom y Webina r 8 October 2015 Ventilation system: motor, transmission, fan Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  12. 12. 12 Contents 1.  Introduction 2.  Efficient motor systems 3.  Standards and policies for motor systems 4.  Steps for end users to optimize their motor systems 5.  Some successful programs, tools and further information sources Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  13. 13. 13 Why globally harmonized standards? Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  14. 14. 14 Group of motor standards line operated AC motors Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  15. 15. 15 Standards: Motor efficiency (IE-Code) Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  16. 16. 16 Interaction of stakeholders Standards are the basis for minimum energy performance standards (MEPS) Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  17. 17. 17Motor MEPS* worldwide *Minimum Energy Performance Standards Efficiency Levels Efficiency Classes Testing Standard Performance Standard 3-phase induction motors IEC 60034-30-1, 2014 IEC 60034-2-1, 2014 Mandatory MEPS *** (Low Voltage < 1000 V) Global classes IE-Code * incl. stray load losses National Policy Requirement Super Premium Efficiency IE4 Preferred Method ** Premium Efficiency IE3 Canada (< 150 kW) Mexico (< 150 kW) USA (< 150 kW) South Korea Switzerland Japan (Toprunner) EU 28**** (> 7.5 kW) China****** (> 7.5 kW; 2016) High Efficiency IE2 Australia***** Brazil Canada (> 150 kW) China Mexico (> 150 kW) South Korea New Zealand Turkey USA (> 150 kW) Standard Efficiency IE1 Costa Rica Israel Taiwan Below Standard "italic" means in effect in 2016 17 08 2015 *) Output power: 0.12 kW - 1000 kW, **) for 3-phase machines, ****) European Union: IE3 or IE2 + VFD; Impact EnergyInc. 50 and 60 Hz, line operated rated output power < 1000 kW 2017 above 0.75 kW © EMSA2015 2-, 4-, 6- and 8-poles ***) Minimum EnergyPerformance Standard *****) Australia adoption of IE Standards ******) China: 2017 IE3 also < 7.5 kW Summation of losses with load test: Additional losses PLL determined from residual loss Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  18. 18. 18 Global motor sales Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015 Source: IHS, 2015
  19. 19. 19 European Union Motor systems MEPS Motors n  Revision of existing regulation no 640/2009 n  Technical study completed, draft 2015, decision expected in 2016 n  MEPS for motors 0.12 kW – 1000 kW, plus new VFD losses Fans n  Revision of existing regulation no 327/2011 n  draft 2015, MEPS with increased efficiency tier effective from 2020 Compressors n  Technical study completed, MEPS draft pending Water pumps n  Plan for revision of existing regulation no 547/2012, start in 2016 Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  20. 20. 20Key Stakeholders Most effective policies stimulate action Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015 Source: Policy Guidelines For Electric Motor Systems, Part 2, EMSA October 2014
  21. 21. 21Successful policy implementation EMSA publications Upcoming n  Roadmap for Electric Motors & Variable Frequency Drives (2015) n  Policy Guidelines for Motor Driven Units (2016/17) Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015Download: www.motorsystems.org
  22. 22. 22 Programs – policy instruments 1.  Mandatory audits o  regular audits with standard protocol o  European Energy Efficiency Directive 2012/27/EU 2.  Financial incentives o  pay for system analysis (not for motor exchange) 3.  Efficiency targets o  negotiated target setting for 5 - 10 years ahead 4.  Training programs o  in-house factory personnel o  energy efficiency experts for industry Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  23. 23. 23 Contents 1.  Introduction 2.  Efficient motor systems 3.  Standards and policies for motor systems 4.  Steps for end users to optimize their motor systems 5.  Some successful programs, tools and further information sources Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  24. 24. 24 Steps to optimise motor systems End user n  System improvement with: o  Motor o  Variable Frequency Drive for load control o  Transmission o  Application o  System integration Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  25. 25. 25System optimization BAT: Best Available Technology •  motor replacement = only small savings BATpump,fan,compressor nothrottle,efficient transmission IE3orIE4 Controlfor variableload necessaryflowrate, pressure,time,etc. Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  26. 26. 26 Load control: VFD instead of throttle pumps and fans Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015 Saving potential VFD
  27. 27. 27 Analysis of motor system n  Motor / Energy audit 1.  Motor list – inventory + characteristics 2.  First analysis 3.  Measurements 4.  Business cases: cost-efficient improvements 5.  Implementation n  Energy management, motor management 1.  Management commitment 2.  Involving procurement, design, maintenance, suppliers Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  28. 28. 28 Stock analysis Swiss research 2010-14 n  Age: Never touch a running system o  56% of motors are older then their operating life expectancy; these older motors are in average 99% too old n  Sizing: Load factor o  2/3 have average load factor < 60% n  Control o  20% have VFD Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  29. 29. 29 Motors: efficiency and age >2020 >2015 >2012 >2000 >1990 >1980 -> IE4 (95.4) -> IE3 (94.2) -> IE2 (93.1) -> IE1 (91.7) -> Eff3 (90.0) -> Eff4 (88.3) Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015 45 kW
  30. 30. 30 Never touch a running system Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015 56% of motors are older than their operating life expectancy; these older motors are 99% too old.
  31. 31. 31 Only 20% have a VFD Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  32. 32. 32 Load factor
  33. 33. 33 Contents 1.  Introduction 2.  Efficient motor systems 3.  Standards and policies for motor systems 4.  Steps for end users to optimize their motor systems 5.  Some successful programs, tools and further information sources Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  34. 34. 34 Programs on Motor Systems some examples n  Swiss Easy program o  Financial incentives on 4 analysis steps – tools! o  Remove barriers Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015 Motor-Systems-Check
  35. 35. 35 Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015 Calculations Effective consumption of electricity of the electrical drives 9.707 [GWh/a] Fraction of effective consumption of electricity of electrical 69.3 [%] Percentage of motors to be replaced 64.0 [%] Numbers of motors with VFD 40.0 [%] Improved consumption of electricity of the electrical drives 8.238 [GWh/a] Potential of energy efficiency (electric energy) 1.469 [GWh/a] Potential of energy efficiency (in currency) 0.157 [Mio CHF/a] Potential of energy efficiency (in percentage) 15.1 [%] Additional investments for realisation of the potential of energy efficiency 0.205 [Mio CHF] Payback-time for realisation of efficiency potential 1.3 [a] 0.177493766 1.45 Release 1 Copyright ©: topmotors 2010 9.707 8.238 1.469 0.000 2.000 4.000 6.000 8.000 10.000 12.000 Effective consumption of electricity of the electrical drives Improved consumption of electricity of the electrical drives Potential of energy efficiency (electric energy) 1 3 2 4 SOTEA Efficiency Potential ILI Intelligent List STR Standard Test Report MST Motor Systems Tool
  36. 36. 36Package of measures Life Cycle: 10 – 20 years Payback: Package 2.4 years 0 200 400 600 800 1,000 1,200 1,400 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 532 555 600 601 364 575B 490 320 289 374B 362 374A 428 374C 514A 520A 405 494B 363 425A 374E 463A 293 389B 575C 425B 508 156 520D 514B 520B 463B 453D 453A 494A 520C 575A 555V 184 Electricenergysavings[MWh/a] Payback[years] Machine identification number Machine factory Pay back Pay back (cumulated) Energy savings (right scale) Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  37. 37. 37 Programs on Motor Systems some examples n  Netherlands: Green Deal o  Audits o  Awareness o  Incentive on motors, and program management n  By motivated members of supply chain, and end users Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  38. 38. 38 Projects - examples savings, client demand, follow up Savings Maintenance/ Follow up/ replacement EE extension P1: 20% x yes, motormanagement P2: 40% x x yes, all production lines P3: 6% x yes, motormanagement P4: 30% x yes, other motor systems Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  39. 39. 39 Available tools n  Motor Systems Tool: www.motorsystems.org n  Easy tools: www.topmotors.ch n  EMSA Policy Guidelines: www.motorsystems.org n  Webinars Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015 15  Oct  15   Op#miza#on  of  Motor  Systems:  the  Motor  Systems  Tool   Sandie  B.   Nielsen   EMSA  /  Danish   Technological   Ins#tute   22  Oct  15   Electric  Motor  Systems:  the  Motor  Policy  Toolkit   Konstan#n   Kulterer   EMSA  /   Austrian   Energy  Agency   26  Nov  15       Op#miza#on  of  Cooling  Systems:  compressors  and  other  power   consumers   Lasse  Søe   Danish   Technological   Ins#tute   03  Dec  15   Pumps  &  circulators:  ecodesign  and  op#miza#on  of  pump  systems   Sandie  B.   Nielsen   Danish   Technological   Ins#tute   17  Dec  15   Fans:  ecodesign  and  op#miza#on  of  fan  systems   Morten   Sandholm   Madsen   Danish   Technological   Ins#tute  
  40. 40. 40 Save the date! Zurich, 11-12 Oct Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  41. 41. 41 Conclusions 1.  Electric motors use 46% of global electricity 2.  20% - 30% can be saved 3.  Rolling stock is too old 4.  Payback typically 3 – 5 years 5.  Big savings only with improved systems 6.  Load control with Variable Frequency Drives 7.  Motors are globally traded 8.  Harmonized standards basis for Minimum Energy Performance Standards There is still much more to be saved by using best available technology in matched systems! Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015
  42. 42. 42 Contact Maarten van Werkhoven Operating Agent, Electric Motor Systems Annex EMSA TPA advisors Generaal Winkelmanlaan 31 2111 WV Aerdenhout, Netherlands +31 23 536 8090 mvanwerkhoven@tpabv.nl Rita Werle Program Coordinator, Electric Motor Systems Annex EMSA Impact Energy Gessnerallee 38a, CH-8001 Zurich, Switzerland +41 44 226 30 70 rita.werle@impact-energy.ch www.motorsystems.org Electric Motor Systems - Low Carbon Economy Webinar 8 October 2015

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