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Training programme on Energy Efficient technologies for climate change mitigation in Southeast Asia

Case Studies on Electric Motors

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Objectives of Case Studies


Demonstrate the technical and financial viability of installing HEM To conduct an actual energy use comparison between standard motor and HEM installed at site under local conditions. To assess the potential energy and cost saving for the entire plant if all the relevant standard motors with continuous loading were replaces by equivalent HEMs

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Why are Motor Systems Important


Some 300 million existing systems are in use in industry, infrastructure, & large buildings 20-30 million new systems installed each year Repair 60-90 million old systems per year Load factor 60% average CO2 emissions 4,300 M t per year Energy saving potential 20% - 30% Energy cost saving US$100 146 billion per year

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Typical Applications
Fans Pumps Compressors Conveyers Machine tools

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Motors as Part of the System

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Why High Efficiency Motors?


Electric motors responsible for 40% of global electricity usage
Drive pumps, fans, compressors, and many other mechanical traction equipment

International Energy Agency estimates 7% of global electricity demand could be saved by higher energy efficiency motors HEMs are cost effective solutions

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Standards
Diverging standards and different classification schemes have been used

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A New International Standard


Proposed in 2007 by IEC and introduced in 2008 for energy classes for electricity motors
IEC 60034-30 (Ed.1.0): 2008-10 has been published in October 2008 3 commercial levels of energy efficiency are defined in IEC 60034-30

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Comparison of MEPS

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2009 Global development of electric motor standards

(Source: A+B International 2009)

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Standards

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Standards

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Barriers to HEM Penetration


Lack of awareness Energy expenses are invisible to management hidden in general overhead Small cost items for enterprise Low priority among capital investment and operating objectives Subsidies on electricity price First cost vs. long term operating costs Reluctance to change a working process due to lack of experience
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Overcoming Barriers
Mandatory minimum energy performance standards (MEPS) Improve access to information and market transparency
Labeling schemes, standard harmonization

Financial and non-financial incentives Training and education Introduction of energy management systems/requirements
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An Example of Market Transformation

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A Short Video

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Case Study 1
Second largest oil field in China The total power consumption in the oil field ~ 7 billion kWh
3.11 billion kWh goes to motors

Total quantity of motors with high power consumption and low efficiency is 14,000 Operating hours 7,200 per year Average price for power 0.45 Yuan per kWH Replacement of standards motors
2 x 22KW, 1 x 30KW, 2 x 37KW, 2 x 45KW, 1 x 55KW
25% Motors >200kW each The rest Motors <200kW each

60%

15%

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Case Study 1
Power consumption before and after the replacement
Before the replacement Output (m3) 12,296.8 Unit consumption by calculation Power (kWh) 44,779 Unit consumption by calculation After the replacement Output (m3) 12,400
Power (kWh) 38,869

Total

Total

3.64kWh/m3

3.13kWh/m3

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Case Study 1
The output variation is very small (0.83%) The average power saving rate
4477938869 13.2 44779

Monthly saved power: 5,910 kWh Annually saved power: 5910 * 1270,920 kWh

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Case Study 1
Total investment for motor replacement: 52,500 yuan (US$7,600) Annually saved power (0.46 yuan/kWh) 32,600 yuan (US$4,700) Recovery for investment: 5.25/3.261.61 years The service life of high efficiency motor is 15 years => total gain is 486,000 yuan Total electricity saving potential over 400 million kWh per annum
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Case Study 2
Manufactures medium density fireboard and related products in Malaysia Estimated annual electricity cost of the manufacturing facilities is about RM14 million A 10 year old 37 kW rated motor driving the boiler feed water pump for the manufacturing process

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Case Study 2 Results


Based on operating hours of 4,380 hours per year The HEM reduced energy consumption by 3.8%
Annual energy savings = 6,933 kWh => RM1,456

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Case Study 2 - Results

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Case Study 2 - Results

Based on RM 0.21/kWh and operating 5000 hours per year

4 years for RM 6750 ( Without Tax Relief )


2.4 year for RM 3922 ( With Tax relieve )

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Case Study 2 - Results

Based on life span of 15 years ROI on the motor premium 30% per year with tax relief 15% per year without tax relief.

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Case Study 2 Savings


Different types of motors installed and with different efficiencies Using an average of 3 % increment in HEM efficiency Annual savings is ~ 420,000kWh if standard motors (medium size range) are replaced with equivalent HEMs. This equal to a saving of RM88,200 per annum at RM0.21 per kWh.
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Case Study 3
A leading provider of technology and products enabling people to store, access, and manage information (Thailand) To increase the reliability of the temperature control system through the redundant operation of Chilled water Pump and Cooling Water Pump to their central air conditioning system. Two additional 3- phase induction motors, 55kW and 75kW, along with pumps were installed in parallel with the existing systems

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Case Study 3

Application

Standard Motor Full Load Efficiency Purchasing Price ( US $ ) USD1,575 USD2,250 Full Load Efficiency 93.6% 94.3%

HEM Purchasing Price ( US $ ) USD2,075 USD3,850

Cooling Water Pump ( 55kW ) Chilled Water Pump ( 75kW)

91.5% 91.8%

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Case Study 3
Application
Cooling Water Pump (55kW)

Model
Standard Motor High Efficiency Motor

kW consumed
62.7 57

Electricity Cost / Month


USD 2,257.20 USD 2,052.00

Application Chilled Water Pump (75kW)

Model Standard Motor High Efficiency Motor

kW consumed 73.8 71.5

Electricity Cost / Month USD 2,656.80 USD 2,574.00

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Case Study 3
Application Additional Investments for HEMs (USD) USD1,600 USD 500 Electricity Cost Payback Period Saving Per Month for additional (USD ) investment for HEMs USD 82.8 USD 205.2 19.3 months 2.4 months

Chilled Water Pump Cooling Water Pump

Cooling Water Pump were overloaded Chilled water pump motors 95% of rated capacity Monthly operation 720 hours (8,640 per year) Energy cost = US$ 0.05/kWh
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Conclusion

In most cases, the investment cost of HEMs, in relation to standard motors, can be recovered within a short period

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For further inquiries Contact


bek.cheejin@copper.org.sg

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