EUP Lot 30 Task 5
Definition of Base Case
Prof de Almeida (for Hugh Falkner
Feb 2014, Brussels)
Date (if applicable)
Presentation Title
Objectives of Task 5
• Selection of the base cases
• Assessment of the environmental impacts, at both product
and EU level
• Assessment of LCC, both at product and EU level
Date (if applicable)
Presentation Title
Base case selection
• A total of 22 base cases have been selected to ensure that
the key characteristics of each group of products are
adequately captured.
• If differences between base cases are found to be
negligible, then it is possible that at a later stage some base
cases might be merged.
• The base case models are based closely on real products,
but care must be taken in interpretation of the whole stock
results
Date (if applicable)
Presentation Title
Base case 1 – 12, 16 - 17 Motors
and VSDs
Date (if applicable)
Presentation Title
Base case 13 – 15 soft starters
Basecase Description
Ref
13 Soft Starter - Small
14 Soft Starter - Medium
15 Soft Starter - Large
Power Range
Basecase Loss/cycle Cycle time No. starts
corresponding to basecase Size (kW)
kW
secs
pa
0.25 - 7.5kW
1.1
0.05
5
2250
7.5 - 75kW
11
0.5
10
3000
75 - 750kW
110
5
20
6000
Date (if applicable)
Presentation Title
Base case 18 – 22 Motors + VSDs
The energy consumption is calculated from the sum of the VSD +
motor losses, with an additional 20% increase in motor losses to
take account of the impact on motor losses of the VSD.
Date (if applicable)
Presentation Title
Other motor and VSD input data
• Motor and VSD
Product
Motor
VSD
100%
0.2
0.25
75%
0.3
0.5
50%
0.3
0.2
25%
0.2
0.05
• The selection of 25, 20, 75 and 100% load points is in line
with published motor data. However, for the purposes of
this study, note that these load points are best considered
as the mid-point of a load range, ie87.5% - 112.% etc, not
everything between the load point and next lowest load
point (which would have been 75% – 100% etc).
Date (if applicable)
Presentation Title
Other motor and VSD input data
Date (if applicable)
Presentation Title
Motor and VSD Bill of Material input
data
Basecases: Motors & VSDs
Basecase Electrical Other
Ref
Steel
Steel
1
5550
925
2
3885
777
3
9922
1804
4
67210
11550
5
440000
84700
6
1000000 200000
7
1300000 200000
8
0
0
9
0
550
10
0
1760
11
0
5500
12
0
24750
16
19844
3608
17
148000
28490
18
3885
777
19
9922
2354
20
67210
13310
21
440000
90200
22
1000000 224750
Bill of materials (kg)
Cast Aluminium Copper Insulation Packing Impregn
Iron
Resin
1221
962
1387.5
370
481
222
1221
962
925
24.05
481
148
2750
2332
2486
55
1100
330
14300 1221000
11880
220
9900
1100
330000
27500
77000
1100
55000
5500
800000
100000 150000
2750 137500
13750
800000
100000 195000
2750 137500
13750
0
481
0
0
0
0
0
1100
0
0
0
0
0
2420
0
0
0
0
0
1100
0
0
0
0
0
4950
0
0
0
0
5500
4664
4972
110
2200
660
111000
9250
25900
370
18500
1850
1221
1443
925
24.05
481
148
2750
3432
2486
55
1100
330
14300 1223420
11880
220
9900
1100
330000
28600
77000
1100
55000
5500
800000
104950 150000
2750 137500
13750
Paint
48.1
51.8
110
550
1100
2750
2750
0
0
0
0
0
220
370
51.8
110
550
1100
2750
PVC
Plastic
PWB
0
0
0
0
0
0
0
148
330
550
3300
14850
0
0
0
0
0
0
0
96.2
220
330
1100
4950
148
330
550
3300
14850
96.2
220
330
1100
4950
Electronics Electronics
Small
Large
0
0
0
0
0
0
0
0
0
0
0
0
0
0
96.2
24.05
220
55
770
220
4400
3300
19800
14850
96.2
220
770
4400
19800
24.05
55
220
3300
14850
Date (if applicable)
Presentation Title
Soft starter input data
Soft Starter energy use inputs
Basecase Description
Ref
13 Soft Starter - Small
14 Soft Starter - Medium
15 Soft Starter - Large
Power Range
Basecase Loss/cycle Cycle time No. starts
corresponding to basecase Size (kW)
kW
secs
pa
0.25 - 7.5kW
1.1
0.05
5
2250
7.5 - 75kW
11
0.5
10
3000
75 - 750kW
110
5
20
6000
Soft starter cost and miscellaneous data
Basecase Ref
Annual Energy
Costs (euros)
losses (kWhpa) Installation Repair
Unit
13
0.2
50
0
14
4.2
100
100
15
166.7
150
250
Repair
EU Sales pa Lifetime
Distance (km)
(Years)
100
0
1
15
250
75
0.4
15
900
100
0.4
15
Stock
Units
Total Energy use of Total Energy Losses of Elec price Volume
euros/kWh m3
Stock (TWhpa)
Stock (GWhpa)
15
0.0
0.1
0.3
6
0.0
0.1
0.3
6
1.0
0.1
0.3
Soft starter Bill of Materials
Bill of materials (kg)
Basecase Ref
Electrical Other
Steel
Steel
13
0
0
14
0
0
15
0
0
Cast
Iron
Aluminium Copper Insulation Packing Impregn
Resin
0
715
0
0
0
0
0
5500
0
0
0
0
0
12100
0
0
0
0
Paint
PVC
Plastic
0
220
0
1650
0
2750
PWB
Electronics Electronics
Small
Large
143
143
35.75
1100
1100
275
1650
3850
1100
Date (if applicable)
Presentation Title
Submersible borehole pump motor
input data
Assumed proportion of the time spent at each flow
Flow
Relative Time
100%
0.3
75%
0.5
50%
0.2
25%
0
• The material content and costs are based on that for
conventional induction motors. This is small source of
inaccuracy due to the different dimensional constraints,
casing and cooling mechanisms.
Date (if applicable)
Presentation Title
Submersible borehole pump motor
input data continued
Submersible Borehole Pump motor energy use inputs
Basecase Description
Ref
16 Submersible borehole motor - Small
17 Submersible borehole motor - Large
Power Range
Basecase
corresponding to basecase Size (kW)
0.22 - 22kW
2.2
22 - 550kW
37
Efficiency (%) at load points
Running
Annual Energy
100%
75%
50%
25%
Hours pa Consumption kWhpa
75.0
75.0
71.0
65.0
1000
1,300
88.0
88.0
86.0
80.0
4000
73,971
Submersible Borehole pump motor costs and other data
Basecase Description
Ref
16 Submersible borehole motor - Small
17 Submersible borehole motor - Large
Costs (euros)
Repair
Installation Repair
Unit
Distance (km)
20
250
400
200
40
8000
12000
200
EU Sales
Lifetime
Mln pa
(Years)
0.5
10
0.01
15
Stock
Total Energy Use of
Units (Mln)
Stock (TWhpa)
5
6.5
0.15
11.1
Total Energy Losses of Elec price Volume
euros/kWh
m3
Stock (TWhpa)
2.9
0.1
0.03
2.4
0.1
0.2
Submersible Borehole Pump motor material content
Basecase Description
Ref
16 Submersible borehole motor - Small
17 Submersible borehole motor - Large
Electrical Other
Steel
Steel
19844
3608
148000
28490
Cast Aluminium Copper Insulation Packing Impregn
Iron
Resin
5500
4664
4972
110
2200
660
111000
9250
25900
370
18500
1850
Paint
220
370
PVC
Plastic
PWB
Electronics Electronics
Small
Large
Date (if applicable)
Presentation Title
Motor + VSD input data continued
Motor + VSD costs and other data
Motor + VSD material content
Bill of materials (kg)
Basecase Description
Ref
18 Motor + VSD - Very Small
19 Motor + VSD - Small
20 Motor + VSD - Medium
21 Motor + VSD - Large
22 Motor + VSD - Very Large
Electrical Other
Steel
Steel
3885
777
9922
2354
67210
13310
440000
90200
1000000 224750
Cast Aluminium Copper Insulation Packing Impregn
Iron
Resin
1221
1443
925
24.05
481
148
2750
3432
2486
55
1100
330
14300 1223420
11880
220
9900
1100
330000
28600
77000
1100
55000
5500
800000
104950 150000
2750 137500
13750
Paint
51.8
110
550
1100
2750
PVC
Plastic
148
330
550
3300
14850
PWB
Electronics Electronics
Small
Large
96.2
96.2
24.05
220
220
55
330
770
220
1100
4400
3300
4950
19800
14850
Date (if applicable)
Presentation Title
Environmental analysis of base cases
Breakdown of energy losses, by product
Date (if applicable)
Presentation Title
Environmental analysis of base cases
• Soft starters
•
only very short running hours, due to the fact that these are incurred only during start /
stop instances.
•
Their energy use is extremely small.
•
Technically there is negligible scope for reducing losses, with the possible exception
of standby losses, on which there is little data.
There is little scope for measures to reduce the energy losses of soft starters,
except for standby losses.
Date (if applicable)
Presentation Title
Environmental analysis of base cases
• Induction motors
•
Small induction motors have relatively high energy losses due to their
proportionately high (kW loss/ kW rated) energy losses. However, the economic
potential for energy saving is limited by their low running hours.
•
Medium induction motors have already been regulated, and so despite their large
losses, the scope for further improvement is limited because of the higher (IE2 or IE3)
efficiency levels already assumed for the basecase.
•
Large induction motors use less energy than the small and large segments, but the
cost effectiveness of energy savings will be determined by later analysis.
Date (if applicable)
Presentation Title
Environmental analysis of base cases
• Induction motors continued
•
The Small induction motor segment appears to have a good energy saving potential.
•
Later analysis will show whether it is technically and economically justifiable to
introduce measures to promote medium sized motors at efficiency levels beyond
those already included in the” Lot11” regulations.
•
Similarly it is not yet clear what energy saving potential there is in the Large induction
motor segment.
Date (if applicable)
Presentation Title
Environmental analysis of base cases
• Variable speed drives
•
Small internal losses means that the total losses are only a very small proportion of
the total motor energy use.
•
Only on those below 10kVA is there any room for energy saving, and this may relate
more to power management and ancillaries rather than losses in the power converter
itself.
VSDs are efficient devices with proportionately little energy losses. Later analysis
will show the technical and economic potential for energy savings.
Date (if applicable)
Presentation Title
Environmental analysis of base cases
• Multistage submersible borehole pump motors
•
The low energy use and modest energy saving potential mean that Multistage
submersible borehole pump motors are a lower priority for regulation, but it may still
be practical to regulate them as part of an “Extended Product Approach” for Multistage
submersible borehole pumps.
• Combine motor + VSD
•
This base case has been introduced in order that other new technologies requiring a
controller for operation can be compared on a like for like basis. The base case of this
combination of parts becomes relevant in the context of tasks 6 & 7
Date (if applicable)
Presentation Title
Results
• For motors and VSD the use phase dominates, then comes
the production phase.
• For small soft starters the production phase dominates.
• For medium and large soft starters the use and production
phases are relatively evenly split.
• Distribution phase’s main contribution comes through
particulate matter
• End of life phase is predominately hazardous waste and
particulate matter
Date (if applicable)
Presentation Title
Results – Examples
Base case 5 Medium Induction motor (l)
Base case 14 Soft Starter Medium
Thank You!