Cost Savings John Malinowski Baldor Electric Company Bob Zaragoza Xcel Energy Energy Star WebEx March 4, 2009 2:00pm Eastern 2 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 3 Why Energy-Efficient Electric Motors? Electric motors consume 63% of the electricity used by American industry Source: U.S. Department of Energy, 2002 4 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 5 Motor Electricity Usage All of the electricity that enters a motor is either lost as heat or converted into mechanical energy (torque). The heat produced must be removed. 6 Compare Auto Life Cycle Costs Less than 17 months to pay back additional cost of more expensive hybrid auto. $6,660 $17,640 5 year operating cost $1,332 $3,528 Annual operating cost $4.00/gal. $4.00/gal. Fuel/Energy Cost 45 MPG 17 MPG Efficiency 15,000 mi. 15,000mi. Annual use $20,500-$22,075 $18,995 Net purchase price $525-$2,100 $0 Less federal rebate $22,600 $18,995 Purchase Price Hybrid Auto Pickup 7 Compare Auto Costs to Motor Costs ~11.2 times ~6.0-6.5% Annual operating cost as a % of purchase price $25,932 $1,332 Annual operating cost $0.08/kWh $4.00/gal. Fuel/Energy Cost 0.936 45 MPG Efficiency 8760 hrs. 15,000 mi. Annual use $2,330 $20,500-$22,075 Net purchase price $0 $525-$2100 Less federal rebate $2,280 $22,600 Purchase Price 50 HP motor Hybrid Auto 8 Life Cycle Cost Energy Savings $78,460 $44,140 Est. Savings over motor life (20yrs.) $3,923 $2,207 Est. Annual Savings $135,862 $137,578 $139,785 Est. Op. Cost/Yr.: Continuous op. at $0.10/kWh 96.2 95.0 93.5 Efficiency NEMA Premium Efficiency motor EPAct efficiency motor Pre-EPAct efficiency (average) 200 HP, 4 pole operating costs Motor Management & Planning: Use MDM Tools 10 Motor Decisions Matter SM 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 local effectiveness 11 MDM Sponsors Motor 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) 12 Motor Management Is a set of ongoing policies and practices that help commercial and industrial facility managers proactively plan and effectively manage their motor population reducing equipment downtime and energy costs. 13 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 14 Proactive Planning 15 The Building Blocks of a Motor Management Plan Policies Based on Life Cycle Costing - Purchasing - Best-Practice Repair 16 1*2*3 Process Input Company Information Company Name Contact Location Date Evaluated (mm/dd/yy) Input: Representative Motor 1 * Required fields Motor ID * Year motor installed Manufacturer Motor location Model Application Size (hp) * Total yearly operating hours * RPM * Actual load (amps) (optional) Enclosure type Repairs/Rewinds Full-load efficiency(%) * Quantity of similar motors * Frame size and type Voltage rating Full-load amps Cost of Electricity (note 1) * Desired Payback Period (yrs) Horsepower breakpoint (hp) % of Full Load (if available) Annual Energy Cost Capital Investment N/A Incremental Investment Cost N/A N/A Annual Energy Savings N/A N/A Net Present Value N/A N/A Return on Investment N/A N/A Simple Payback Period N/A N/A Act Now Replace Immediately with NEMA Premium Rewind Using Best Practice Replace with EPAct Replace with NEMA Premium Motor Management: Input Page Replace with EPAct Act Upon Motor Failure Motor Nameplate Data Motor Application Information EPAct Motor Cost * EPAct Motor Efficiency * All values represent results for one motor. To see cumulative results for the full quantity of similar motors, go to the Summary page. Financial Information Motor Installation Cost * Decision: Representative Motor 1 Review the results with your customer. Decide on the appropriate course of action. Then, click the corresponding button and the 123 software will generate label(s) that you can use to tag this representative group of motors. It will also enter the decision in the 123 Motor Inventory. Best Practice Rewind Cost * Current Costs (Base Case) Replace Immediately with NEMA Premium NEMA Premium Motor Cost * NEMA Premium Efficiency * Rewind Using Best Practice (Base Case) Act Upon Motor Failure New Motor & Best Practice Rewind Costs The 123 Approach to Results: Representative Motor 1 Act Now Replace with NEMA Premium Replace with NEMA Premium Replace with EPAct Rewind Using Best Practice Replace Immediately with NEMA Premium Decision Results Partner with Efficiency Programs 18 Consortium for Energy Efficiency Includes Utility Efficiency Programs National Labs No private interests Covers 35 states 5 provinces Motors Program Info: www.cee1.org/ind/mot-sys/mtr-ms-main.php3 19 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 20 CEE Member Programs 20 Fan Systems 22 Pump Systems 40 Compressed Air Systems 58 Industrial Motors (above 200hp) Dedicated Programs for Equipment and Systems 50 Variable Speed Drives 58 (5 offer 1-500 hp) Industrial Motors (1-200 hp) Prescriptive Programs for Equipment No. of Programs Dedicated Program Area 2009 Preliminary CEE Member Profile Motor System Opportunities 22 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 to determine sizing Level 3 - Systems Add adjustable speed drives on fans and pumps to control flow and save energy 23 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 with EPAct Special motors not available from distributor - Rewind on failure 24 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 Best Practices 25 Level 2 Plant Surveys A more extensive survey making current measurements during operation Allows to right size motors for each application Increase efficiency and power factor Reduce purchase price Consider adjustable speed drive here or in Level 3 system analysis 26 Identify the Correct Motor for 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 27 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 28 Level 3 Plant Surveys Look beyond the motor at the application during the survey Add adjustable speed drives on pump and fan applications Process control can increase productivity Increased efficiency gear reducers Add servos for increased throughput 29 Plant Surveys Surveys may be performed by plant personnel Training and Audits: Industry representatives and utilities offer motor survey training and audits of installed base EASA Motor repair shops National Distributors Energy Service Companies - ESCO Local resources 30 Considerations at Repair Time Deduct 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) 31 Additional Energy Savings The most efficient motor is one that is not running 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 32 Controlling Flow to Achieve Savings Change Motor and/or Equipment Fan belts Motor base speed Pump Impeller Blade pitch Inlet Guide Vanes Pump Valves Variable Frequency Drive (VFD) 33 Motor Systems Tips: Pumps & Fans Few applications require 100% continuous flow Greatest savings are available when less than 100% 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 have lower needs 34 Typical Duty Cycle: Centrifugal Fan % Flow Volume % Flow Volume 10 10 20 20 30 30 40 40 50 50 60 60 70 70 80 80 90 90 100 100 100 100 80 80 60 60 40 40 20 20 0 0 %
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T i m e Source: Electric Power Research Institute 35 Electrical Energy Costs Electrical Energy Costs 100% Speed, 100% Load 100% 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) = 36 Electrical Energy Costs Electrical Energy Costs $5,970 per year! 60% Speed, 22% HP 60% 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) = 37 Annual Electrical Energy Savings Annual Electrical Energy Savings $21,169 per year! 100% Speed: $27,139 60% Speed: $5,970 38 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 39 Input Power Necessary 0.0 20.0 40.0 60.0 80.0 100.0 40 60 80 100 Percent Motor Load K W Motor w/Throttle valve Motor With ASD Motor W/Bypass Valve 40 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 Next Steps 42 Make the Business Case for Motor Management 43 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 44 Motor Energy Costs Can Be Managed Over 90% of motor decisions are made at the facility level Only 11% of companies have written motor specifications Only 12% of companies have written motor rewind specifications 24% of facilities have not addressed energy 45 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 cost per item produced 46 Most Important to Facility Managers & Engineers Keep plant running increase uptime Reduce plant operating costs Often heard - Keep the facility running but dont spend a nickel more than you need to.. 47 Change the Purchasing Paradigm Commitment Set goals Make action plan Implement plan Verification Recognize achievements Repeat cycle 48 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 49 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 50 Dont 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 Thank you. Any questions? John Malinowski JMalinowski@baldor.com Kellem Emanuele kemanuele@cee1.org Bob Zaragoza Bob.Zaragoza@xcelenergy.com www.motorsmatter.org
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