Motor Energy Management

8/11/2019 Motor Energy Management

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Motor Energy Management:Opportunities for Energy and

Cost Savings

John MalinowskiBaldor Electric Company

Bob Zaragoza

Xcel EnergyEnergy Star WebExMarch 4, 20092:00pm Eastern


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Presentation Outline

Estimating Lifetime Motor Costs

Motor Management and Planning Use MDM tools for motor management and

communicating lifetime costs Partner with efficiency programs

Motor System Opportunities

Next Steps


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Why Energy-Efficient Electric Motors?

Electric motors consume

63% of the electricityused by Americanindustry

Source: U.S. Department of Energy, 2002


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Savings Opportunity

U.S. DOE estimated annual savings: 62 104 billion kWh in electricity 15.3 26 million metric tons of carbon CO 2 Remove 3.2 5.4 million cars from the road $3 5 billion savings


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Motor Electricity Usage

All of the electricitythat enters a motor iseither lost as heat orconverted intomechanical energy(torque).

The heat producedmust be removed.


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Compare Auto Life Cycle Costs

Less than 17 months to pay back additional cost of moreexpensive hybrid auto.

$6,660$17,6405 year operating cost

$1,332$3,528Annual operating cost$4.00/gal.$4.00/gal.Fuel/Energy Cost

45 MPG17 MPGEfficiency

15,000 mi.15,000mi.Annual use$20,500-$22,075$18,995Net purchase price

$525-$2,100$0Less federal rebate

$22,600$18,995Purchase PriceHybrid AutoPickup


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Compare Auto Costs to Motor Costs

~11.2 times~6.0-6.5%Annual operating cost asa % of purchase price

$25,932$1,332Annual operating cost

$0.08/kWh$4.00/gal.Fuel/Energy Cost

0.93645 MPGEfficiency

8760 hrs.15,000 mi.Annual use

$2,330$20,500-$22,075Net purchase price

$0$525-$2100Less federal rebate

$2,280$22,600Purchase Price

50 HP motorHybrid Auto


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Life Cycle Cost Energy Savings

$78,460$44,140Est. Savings overmotor life (20yrs.)

$3,923$2,207Est. AnnualSavings

$135,862$137,578$139,785Est. Op. Cost/Yr.:Continuous op. at

$0.10/kWh

96.295.093.5Efficiency

NEMAPremium

Efficiencymotor

EPActefficiency

motor

Pre-EPActefficiency(average)

200 HP, 4 poleoperating

costs


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Motor Management &Planning: Use MDM Tools


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Motor Decisions MatterSM

A national campaign to:

Encourage motor planning and management Highlight financial and performance benefits Improve repair/replace decision-making Promote NEMA Premium & best practice repair

Collaborate nationally to enhance localeffectiveness


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MDM SponsorsMotor Manufacturers ABB Inc. A.O. Smith Electrical Products

Company Baldor Electric Company

Emerson Motors GE Industrial Systems Regal-Beloit Corporation Siemens Energy & Automation TECO-Westinghouse Motor

Company Toshiba International WEG Electric Motor Corp.

Other Organizations

CDA, Inc. EASA NEMA Advanced Energy

Efficiency Program Administrators Alliant Energy Austin Energy BC Hydro ComEd, a division of Exelon Corporation LIPA MidAmerican Energy Company National Grid USA NYSERDA NW Alliance NSTAR Electric & Gas PG&E SMUD SCE Xcel Energy

Supporting Organizations U.S. Department of Energy Consortium for Energy Efficiency (CEE)


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Motor Management Is

a set of ongoing policies and practicesthat help commercial and industrial facilitymanagers proactively plan and effectively

manage their motor populationreducing equipment downtime

and energy costs .


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MDM Resources: www.motorsmatter.org MDM Tools

Motor Planning Kit MotorSlide Calculator Simple Savings Chart 1*2*3 Spreadsheet & Users Guide

MDM Events: Webcasts, Conferences

Other resources: DOE, EPA


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Proactive Planning


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The Building Blocks of aMotor Management Plan

Policies Based onLife Cycle Costing

- Purchasing- Best-Practice Repair


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1*2*3 ProcessInput

Company InformationCompany Name ContactLocation Date Evaluated (mm/dd/yy)

Input: Representative Motor 1 * Required fields

Motor ID * Year motor installedManufacturer Motor locationModel ApplicationSize (hp) * Total yearly operating hours *RPM * Actual load (amps) (optional)Enclosure type Repairs/RewindsFull-load efficiency(%) * Quantity of similar motors *

Frame s ize and typeVoltage ratingFull-load am ps

Cost of Electricity (note 1) *Desired Payback Period (yrs)Horsepower breakpoint (hp)

% of Full Load (if available)Annual Energy CostCapital Investment N/AIncremental Investment Cost N/A N/AAnnual Energy Savings N/A N/ANet Present Value N/A N/AReturn on Investment N/A N/ASimple Payback Period N/A N/A

Act Now

ReplaceImmediatelywith NEMAPremium

RewindUsing Best

Practice

Replace withEPAct

Replace withNEMA

Premium

Motor Management: Input Page

Replace withEPAct

Act Upon Motor Failure

Motor Nameplate Data Motor Application Information

EPAct Motor Cos t *EPAct Motor Efficiency *

All values represent results forone motor. To see cumulativeresults for the full quantity of

similar m otors, go to theSummary page.

Financial Information

Motor Installation Cost *

Decision: Representative Motor 1Review the results with your customer. Decideon the appropriate course o f action. Then, clickthe corresponding bu tton and the 123software will generate label(s) that you can useto tag this repres entative group of motors. Itwill also enter the decision in the 123 MotorInventory.

Best Practice Rewind Cost *

Current

Costs(Base Case)


NEMA Premium Motor Cost *NEMA Premiu m Efficiency *

Rewind UsingBest

Practice(Base Case)

Act Upon Motor Failure

New Motor &Best Practice Rew ind Costs

The 123 Approach to

Results: Representative Motor 1Act Now

Replace with

NEMAPremium

Replace withNEMA

Premium

Replace withEPAct

RewindUsing Best

Practice


Decision

Results


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Partner withEfficiency Programs


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Consortium for Energy Efficiency Includes

Utility EfficiencyPrograms

National Labs No private interests

Covers 35 states 5 provinces

Motors Program Info:www.cee1.org/ind/mot-sys/mtr-ms-main.php3


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Utility Offered Efficiency Programs Education and Training

Technical Expertise Financial Assistance

Custom Programs: New Construction, Retrofit Prescriptive Programs: motors, drives

Financial Incentives Rebates to the customer Rebates to the motor service provider


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CEE Member Programs

20Fan Systems

22Pump Systems

40Compressed Air Systems

58Industrial Motors (above 200hp)

Dedicated Programs for Equipment and Systems

50Variable Speed Drives

58 (5 offer 1-500 hp)Industrial Motors (1-200 hp)

Prescriptive Programs for Equipment

No. of ProgramsDedicated Program Area

2009 Preliminary CEE Member Profile


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Motor SystemOpportunities


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Conduct Plant Surveys Level 1 - Basic

Survey your facility and inventory all motors

Tag action on failure Level 2 - Advanced

Measure current draw on each motor todetermine sizing

Level 3 - Systems Add adjustable speed drives on fans and

pumps to control flow and save energy


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Level 1 Plant Surveys

Survey facility and inventory motors Decide what to do for each motor before it fails

and tag motor 2+ shifts - Replace immediately with Premium

1+ shifts - Replace on failure with Premium Intermittent use - Replace on failure withEPAct

Special motors not available from distributor -Rewind on failure


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Additional Energy Savings Replace single phase motors with three phase

Typical Single Phase 80.0%

Premium Single Phase 86.5% Typical Three Phase 87.5% NEMA Premium Three Phase 90.2%

Always use three phase motors when possible If only single phase is available consider use

of inverter and three-phase motor

When repairing motors, always use BestPractices


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A more extensive survey making currentmeasurements during operation

Allows to right size motors for eachapplication

Increase efficiency and power factor Reduce purchase price

Consider adjustable speed drive here orin Level 3 system analysis


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Identify the Correct Motorfor the Application

Determine failure mode for motor Upgrade enclosure Upgrade level of environmental protection

Cast Iron - Severe duty or IEEE 841 Steel band - Washdown duty

Correct bearings for application

Right-size motor for load


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Right-size the Motor Choose the correct rating for the application

Oversized motors have lower efficiency and power factor Highest efficiency 75 - 100% of rated load Service factor is for short-term operation

Motor Efficiency vs Load

89

90

91

92

93

94

95

96

97

25 50 75 100 115 125 150

Percent Load

EPAct

NEMA Premium

Motor Power Factor vs Load

60

65

70

75

80

85

90

95

25 50 75 100 115 125 150

Percent Load

P e r c e n t

P F

EPAct

NEMA Premium


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Look beyond the motor at the application duringthe survey

Add adjustable speed drives on pump and fanapplications Process control can increase productivity

Increased efficiency gear reducers Add servos for increased throughput


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Plant Surveys

Surveys may be performed by plant personnel Training and Audits:

Industry representatives and utilities offer motorsurvey training and audits of installed base

EASA Motor repair shops

National Distributors Energy Service Companies - ESCO Local resources


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Considerations at Repair TimeDeduct repair cost from new motor price on

replacement

Establish a motor repair policy Establish repair / replace guidelines Immediate replacement of non-premium

motors 2+ shifts operation Replace other motors on failure Repair Premium motors if cost is < ?% of new

price (Horsepower break point)


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Additional Energy Savings

The most efficient motor is one that is notrunning Turn off motors when not needed Sensors on conveyors PID for pumps and compressors Watch number of starts on large motors Soft start can reduce voltage and improve

power factor


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Controlling Flow to Achieve Savings

Change Motor and/orEquipment

Fan belts Motor base speed Pump Impeller Blade pitch

Inlet Guide Vanes Pump Valves Variable Frequency Drive

(VFD)


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Motor Systems Tips: Pumps & Fans Few applications require 100% continuous flow

Greatest savings are available when less than100% flow or pressure is required Systems are designed for worst case

Emergency conditions require higher volumes Systems are sized up to next rating (to multiply

safety margins

Demand changes: weekend, nighttime havelower needs


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Typical Duty Cycle: Centrifugal Fan

% Flow Volume% Flow Volume1010 2020 3030 4040 5050 6060 7070 8080 9090 100100

100100

8080

6060

4040

2020

00 % T

o t a l O

p e r a

t i n g

T i m e

% T

o t a l O

p e r a

t i n g

T i m e

Source: Electric Power Research Institute


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Electrical Energy CostsElectrical Energy Costs

100% Speed, 100% Load100% Speed, 100% Load

100 HP Induction Motor

$27,139 per year!(100 HP)x (1/95%eff.) x(.746 kw/HP )x(.08 $/kWh)x(12 h/Day)x(360 D/Year) =


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Electrical Energy CostsElectrical Energy Costs

$5,970 per year!

60% Speed, 22% HP60% Speed, 22% HP

100 HP Induction Motor

(100 HP)x(0.22) ( 1/95%eff. )x(.746 kw/ HP)x(.08 $/kWh)x(12 h/Day)x(360 D/Year) =


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Annual Electrical Energy Savings Annual Electrical Energy Savings

$21,169 per year!

100% Speed: $27,13960% Speed: $5,970


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Systems Best Suited for Drives

All friction system (No static head) System where control valve is constantly

modulated Pumps in parallel or series operation Pumping system with multiple design points System with modulating bypass valve

Cooling towers that start and stop frequently


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Input Power Necessary

0.0

20.0

40.0

60.080.0

100.0

40 60 80 100

Percent Motor Load

K W

Motor w/Throttle valve Motor With ASDMotor W/Bypass Valve


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Motor Drive Compatibility Standard Efficiency

Not well suited to ASD/VFD use

NEMA High Efficiency May work on variable torque applications

NEMA Premium ASD/VFD suitable: VT & CT applications

Optimized for ASD/VFD use Pole optimized Not suitable for line start


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Next Steps


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Make the Business Case forMotor Management


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Motors: ~40% of Building Energy Use

Commercial Buildings Other: 9% Cooling: 8%

Ventilation: 7% Refrigeration: 6%Total: 30%

Office Buildings Space Heating: 13% Space Cooling: 11%

Other: 10% Refrigeration: 6% Ventilation: 6%

Total: 46%Source: www.eia.doe.gov


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Motor Energy Costs Can Be Managed Over 90% of motor decisions are made at the

facility level Only 11% of companies have written motorspecifications

Only 12% of companies have written motorrewind specifications 24% of facilities have not addressed energy


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Change the Purchasing Paradigm

Management empowers purchasing to use life

cycle costs, not lowest initial cost Maintenance selects equipment for lowest life

cycle costs

Benchmark processes to establish energy costper item produced


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Most Important to Facility Managers &Engineers

Keep plant running increase uptime Reduce plant operating costs

Often heard - Keep the facility running butdont spend a nickel more than you need to..


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Change the Purchasing Paradigm

Commitment

Set goals Make action plan Implement plan

Verification Recognize

achievements Repeat cycle


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Conclusions Consider life cycle cost not initial cost Use MDM Tools to develop a motor

management plan Know what to do on failure

Replace with NEMA Premium motors Seek Best Practice Repair

Consider drives where appropriate

Partner with service shops & distributors,and electric utility provider


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U.S. DOE Best Practices

Choose NEMA Premium Best Practice Rewinds Motor right sizing Reduce system load: 5 60% savings

Control motor speed ASD: 30-80% savings Match equipment to load: 5 30% savings Upgrade component efficiency: 2 10% savings

Maintenance: 2 30% savings

Dont Forget Rebates


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Don t Forget Rebates

CEE 2009 Motor & Systems Program Summary Rebates, audits and surveys, custom incentives

Rebate Examples Xcel Energy (MN) prescriptive rebates:

$4/hp for new motors 1-500hp

$16.50/hp for upgrade 1-500 hp $30/hp for drives

Xcel Energy (MN) dedicated custom: Compressed Air System


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Thank you. Any questions?

John [email protected]

Kellem [email protected]

Bob [email protected]

www.motorsmatter.org

Documents

Motor Energy Management