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.

1. Electric Motor Systems:
targeting and implementing
efficiency improvements
8 October 2015
Maarten van Werkhoven
Low Carbon Economy Webinar

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
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
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
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
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
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. 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. 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
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. 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
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
Why globally harmonized standards?
Electric Motor Systems - Low Carbon
Economy Webinar 8 October 2015

14. 14
Group of motor standards
line operated AC motors
Electric Motor Systems - Low Carbon Economy Webinar
8 October 2015

15. 15
Standards: Motor efficiency (IE-Code)
Electric Motor Systems - Low Carbon Economy Webinar
8 October 2015

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. 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
Global motor sales
Electric Motor Systems - Low Carbon Economy Webinar
8 October 2015
Source: IHS, 2015

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. 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. 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
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
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
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. 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
Load control: VFD instead of throttle
pumps and fans
Electric Motor Systems - Low Carbon Economy Webinar 8 October
2015
Saving potential VFD

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
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
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
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
Only 20% have a VFD
Electric Motor Systems - Low Carbon Economy Webinar
8 October 2015

32. 32
Load factor

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
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
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. 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
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
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
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
Save the date! Zurich, 11-12 Oct
Electric Motor Systems - Low Carbon Economy Webinar
8 October 2015

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
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