SandeepSandeep GargGargBureau of Energy EfficiencyBureau of Energy Efficiency

Standards & labeling Program for motors Standards & labeling Program for motors

in in

IndiaIndia

MEPSA 2009 , 4MEPSA 2009 , 4--5th February 2009, Sydney5th February 2009, Sydney

Bureau of Energy Efficiency

Established in 2002, under the Energy Conservation Act, 2001.Improve energy efficiency through various regulatory and promotional instruments

Plan, manage and implement provisions the EC ActAppliance standards and labelingIndustrial energy benchmarksEnergy Conservation Building CodesMonitor energy use in high energy‐consumption unitsCertify and accredit energy auditors and energy managers

Provide a policy framework and direction to national energy conservation activitiesDisseminate information and knowledge, and facilitate pilot and demonstration projectsEstablish  EE  delivery  systems  through  Public‐Private Partnerships (PPP).

2

3

Action Plans of BEE

(S&L)-12 Projects (ECBC) NBC

Energy consumptionnorms for

Designated Consumers (15)Schedule-Section 2(s)-ECA

EA/EMNational Certification Exam

BEE created as a nodal statutory body to improve energy –efficiency through:

Bachat Lamp Yojna

EE delivery systems through Public-Private Partnerships (PPP)

State Designated Agencies(30-SDAs)

Fund Req.

983.3 In Rs.Mn

Collectively Save 308 MW ofEnergy

Rs.1843 Cr. Per yr.By implementation of

Energy Efficiency measures.

SDC (9)Required Auditing

& by BEE certified Auditor ESCOs

Installed Capacity India (as on 31st August, 2008)

TOTAL IC-1,45,627 MW

HYDRO, 36198, 24.8

%

THERMAL 9311564%

NUCLEAR 41202.8%

R.E.S., 121958.4%

Per Capita Consumption of Electricity in India

Source: CEA

176348

559632 672 704

1000

613

1980-81

1990-91

2000-01

2004-05

2005-06

2006-07

2007-08

2011-12

kWh/year

(Projected)

As per UN Methodology (Gross Electrical Energy Availability / Population)

Growth Pattern

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Up to 30

Up to 20

Up to 30

Up to 25

Conservation potential (%)

20-25%

Commercial Sector

Domestic Sector

Agriculture Sector

Industrial Sector

Sector

Sector wise Energy Saving potential

Energy Handled by Motors (%)

70-75%

2-3%

4-5%

Source : AFF report

Products covered under Indian S&L Program

Current List 1. Frost-free Refrigerators2. Tubular Fluorescent Lamps (TFL)3. Air-conditioners 4. Direct cool /Frost Free Refrigerators5. Distribution Transformers6. Motors7. Pump sets 8. Ceiling fans9. LPG Stoves10.Colour TVs11.Storage Water Geysers

Launched on 18th May 2006 , for 4 products by BEE

Future Products under Indian S&L Program

•Compact Fluorescent Lamps ( CFLs)•Transport Sector

•Passenger Cars•2 & 4 Wheelers•Heavy Commercial Vehicles.

•Office Equipments ( Monitors, Fax, Copiers etc)•Washing Machines•Consumer Electronics

•Set-Top Boxes, Microwaves etc•Invertors •Uninterrupted Power Supply (UPS)•External Power Supplies (EPS)•Battery Chargers (BCs)•Compressors•Industrial Fans & Blowers

100%

70%

40%

3%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

TheoroticalPotential

Technicallyfeasible

Economicallyviable

Marketpenetration

9

Barriers to penetration of HEM s1. Lack of knowledge/ awareness with users2. Non availability of EE motors3. Confusion – EE motor definition4. Need to have focused market transformation

• Higher initial cost• Low demand; high price• Lesser working hours• Lack of technology

1. Poor power quality in rural sector2. Application limitations

10

Regulation:

•Policies & its framework •Standards & Labels to be made mandatory at appropriate time

Supply Push

•Design & technology developments•Align with international trends•Handholding of some segments of manufacturers

Demand Pull

•Awareness & dissemination•Demand for the EE products

Energy Efficiency

Institutional frame work for regulation

BIS – National Standards BodyFormulation & Implementation of National Standards 

Production certification, Quality system certification, EMS 

certification etc.

Bureau of Energy Efficiency (BEE)BEE is established to implement & monitor the Energy 

Conservation Act, 2001

One of the key thrust areas of EC Act, 2001 is Standards & 

Labeling Programme

Formulation of Energy Efficiency Standards.

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Impact of S&L ProgramS.No. Particulars Motors (<15kW)

1. No. of products currently in use (Million) (31 December 2005) 1.68

2. Total energy use by the products (Million kWh/Year) (2005-06) 24988

3. Contribution to demand (MW) (2005-06) 5112

4. Current Annual Sales (Million/Year) 0.36

Energy Savings Potential

5. 2009 (MUs/Yr) 314

6. 2011 (MUs/Yr) 974

7. 2015 (MUs/Yr) 3051

8. 2020 (MUs/Yr) 6455

Demand Saving Potential (MW)

9. 2009 64

10. 2011 199

11. 2015 624

12. 2020 1320

Market Transformation Potential : Induction Motors

EFF3

EFF2

EFF 1

IEEMA members

Small MM

Focus area

Minimum Benchmark Crompton Greaves 40%

Bharat Bijlee& Others 7%

ABB 16%

Siemens 37%

Source: Primary Survey, AFF Estimates

Market Share - EFF1 Motors (Nos.)

EE Motors: Current Market Status

Market growth CAGR of 2 % , with 50 % unorganized sector

Policy interventions

•Designated consumers, which are basically energy intensive industry, commercial buildings and establishments.

•Energy consumption standards and labeling program for equipment and appliances.

•Energy conservation building codes for efficient use of energy and its conservation in the buildings and building complex.

•Promotion of R&D, energy efficiency in buildings and establishments, awareness creation among educational institutions etc.

Methodology used for formulating the scheme

Market SurveySelect Sample ratings & make of motorsPurchase of Standard motorsTest for performance in NABL accredited laboratories.Assess constructional features, quantity & quality of active materials Techno‐commercial analysis Finalize recommendations with all the stakeholders Launch of scheme after due approvals

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Motor Market Segments

Fractional HP motors9.32 Million Units

DC Motors6,500 Units

0.75-7.5 kW1.18 Million Units

11-37.5 kW0.13Million Units

+37.5 kW10,000 Units

Low TensionSquirrel Cage

1.31 Million Units

Low TensionSlip Ring

4,000 Units

ACLow Tension Motors

1.31 Million Units

ACHigh Tension Motors

1,000 Units

Motors10.64 Million Units

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•Domestic Appliances•Light Loading

•60% Agricultural Pumps•30% Industrial•10% Domestic

•90% Industrial•10% Agricultural

•Industrial

Source: AFF Estimates, IEEMA Statistics, Primary Survey

0.75-7.5kW89%

11-37kW10%

>37kW1%

National players

54%

regional /Local

players46%

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Source: AFF Estimates, IEEMA Statistics, Primary Survey

89%

Market Size & break up

Rating wise break up for 3 ph sq cage Induction motors (2003-04)

Manufacturing sector break up Induction motors (2003-04)

Sample Plan for techno commercial study

3‐phase 4 pole squirrel cage induction motor: 2.2 kW (26 motors), 3.7 kW (27 motors)

8 national manufacturers 

18 regional/local manufacturers

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Distribution by Efficiency Class

2.2 kW                                                  3.7 kW2.2 kW                                                  3.7 kW

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38.5 38.5

23.1

05

101520253035404550

Eff2 Eff2(-) non-Eff2

Shar

e,%

48.1

22.2

29.6

05

101520253035404550

Eff2 Eff2(-) non-Eff2

Shar

e,%

Source: AFF Estimates, Primary Survey

Efficiency Improvement Analysis

Efficiency improvement will involve

motor design changes / redesign

manufacturing practices changes

manufacturing equipment changes.

Material optimization

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3 HP ( 2.2 kW ) Induction Motors - Efficiency, Material Used & Price

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

100.00

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Samples

Effic

ienc

y (

% )

/

Wat

t Los

s : W

15/

50 (

W/k

g )

2,000

3,000

4,000

5,000

6,000

7,000

100 % loadW 15/50 ( W/kg @ 1.5 tesla )Weight of steelCu WeightPrice ( INR )

EFF1 : 86.40 ~ 84.36 %

EFF2 : 81.00 ~ 78.15 %

Electrical Steel : < 8 W/kg / 5.3 W/Kg

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Analysis background

Source: AFF Report

Classification of MotorsMotors were classified into efficiency classes depending on full load 

efficiency:Following options were considered

Eff 1 and Eff 2 for motors having efficiency as per efficiency class in IS 12615 but without the allowed lower toleranceEff 1(‐) and Eff 2(‐) for motors having efficiency up to the allowed lower toleranceNon‐Eff 2 for motors having efficiency lower than the Eff 2 value with allowed tolerance.

It was agreed that Eff 2 is well‐established efficiency levels by virtue of being specified in IS 12615.

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Benefits of Eff2Benefits of Eff2

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Eff 2(-) Eff 2 Savings, GWh/yr 30.6 102.2 Savings, Rs crores 15.29 51.11 Affected Production, % 18.9 53.7

Source: AFF Report

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Scope of motors covered

•General purpose, S1 duty, 3 phase squirrel cage

induction motors

•Motors up to 15kW, 4 & 2 pole considered

•Governing standard-

– IS 12615: 2004

– IS 325: 1996

MOTOR EFFICIENCY LEVELS(qualitative comparison)

Vision & Choice

Prepared for ICA by Peter Liu, E&E, May 2008

75

80

85

90

95

100

1 5 10 20 40 75 150

Induction Motor Kilowatt rating - 3 phase - 4 pole, general purpose

% E

ffic

ienc

y(a

t ful

l loa

d)

NEMA Premium

Standard Eff.High Efficiency

Super Premium

EFF 1 ~ EPAct=JIS 4212

EFF 2

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Final labeling plan

•MEPS to be at Eff2 level and qualify for energy efficient endorsement label. •Eff1 would be a High energy efficient endorsement label

–Consider efficiency at 100% loading –Include 2 pole motors also on addition to 4 pole motors

•Label contents –

–Parameters spelt out in clause 20.1a of IS 325 : 1996–BEE logo, license number & Efficiency class marking

•Mandatory process to be initiated after positive market transformation.

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Future plans

•Undertake DSM initiatives with the end users. •Develop CDM framework to instigate new buisness models.•Review the plan after periodically to up grade & align with international standards & norms.•Align National Programs such as APDRP and RGGVY schemes to trigger market pull and transformation.

Manufacturing of energy efficient motors

EPACT (NEMA MG1-2006)motors already being exported to north & south America.

EPACT motors are tested as per IEEE 112 (method B) standard for efficiency determination.

Project Objective

Overall objective:

Transfer high pressure die casting technology & Energy Efficient Motor

(EEM) design capabilities to motor industry in order to achieve energy

savings

Project Components:

1. Establish Centre of Excellence (C o E) with skills & technology

2. Enhance Energy efficiency Motor design competence to support SME’s

3. Transfer technology to at least two manufacturers

4. Technology commercialization

Component 1: Manufacturing capabilitySpecific objective:

Establish physical & operational facility

Sub components

Launch project, constitute team

Select the site

Finalize equipment specifications

Procure & install the equipments

Make the manufacturing facility operational

Die casting trials

UNDP- BEE and ICA Joint Project on the technology development of Die Casting Copper

Rotors

Component 2: Design CompetenceSpecific objective:

Enhance EEM design competency to support SME’s

Sub components

Procure design software

Engage consultants to train design engineers of C o E

Select motor types / Applications for design optimizations

Vetting of designs & guidance from industry experts

Prototype EEM manufacture & testing

Component 3 : Technology Transfer

Specific objective:

To transfer the technology to at least two Indian motor manufacturers

Sub components

Identify potential partners

Enter in to agreement

Conduct design optimizations & die casting trials for them

Component 4: Tech. Commercialization

Specific objective: To disseminate technology to industry

Sub components

Dissemination workshops

Technology demonstration to motor industry

Training to motor manufacturers & die casters

Thank you for your attention,

Contact information:

Sandeep Garg (sgarg@beenet.in)Bureau of Energy Efficiency

(Ministry of Power, Govt. of India)4th Floor, Sewa Bhawan

R.K.PuramNew Delhi - 110066

www.bee-india.nic.in