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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5
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%
60%
15%
Motors >200kW each
The rest
Motors <200kW each
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Case Study 1
• Power consumption before and after the
replacement
Before the replacement
Total
Unit
consumption
by
calculation
Output
(m3)
Power
(kWh)
12,296.8
44,779
3.64kWh/m3
After the replacement
Total
Unit
consumption
by calculation
Output
(m3)
Power
(kWh)
12,400
38,869
3.13kWh/m3
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Case Study 1
• The output variation is very small (0.83%)
• The average power saving rate：
44779－38869 ＝ 13.2％
44779
• Monthly saved power: 5,910 kWh
• Annually saved power: 5910 * 12＝70,920 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: 5.25/3.26＝1.61
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
HEM
Full Load
Efficiency
Purchasing
Price ( US $ )
Full Load
Efficiency
Purchasing
Price ( US $ )
Cooling Water Pump
( 55kW )
91.5%
USD1,575
93.6%
USD2,075
Chilled Water Pump
( 75kW)
91.8%
USD2,250
94.3%
USD3,850
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Case Study 3
Application
Model
kW
consumed
Cooling Water
Pump (55kW)
Standard Motor
62.7
USD 2,257.20
High Efficiency
Motor
57
USD 2,052.00
Application
Model
Chilled Water
Pump (75kW)
Standard Motor
73.8
USD 2,656.80
High Efficiency
Motor
71.5
USD 2,574.00
kW
consumed
Electricity Cost /
Month
Electricity Cost /
Month
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Case Study 3
Application
Additional
Investments for
HEMs (USD)
Electricity Cost
Payback Period
Saving Per Month for additional
(USD )
investment for
HEMs
Chilled Water
Pump
USD1,600
USD 82.8
19.3 months
Cooling Water
Pump
USD 500
USD 205.2
2.4 months
•
•
•
•
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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