PRESENTED BY
Toshiba International:
Mike Tharp
Hupp Electric Motors:
Dave Patterson
What are we going to talk about
today?
Do you know how much Electric Motors Cost
you?
Why is improving Motor Efficiency Important?
When is an Energy Efficient Motor Cost
Effective?
How to size an Energy Efficient Motor?
Should I rewind a failed Motor?
How to begin a Motor Efficiency Program?
Do you know how much Electric
Motors cost you?
200Hp 1800Rpm TEFC
Hours of Operation 7,200
Cost K/H $.068
Annual Power Cost $70,669
Initial Purchase Price of Motor $6,350
20 Year Life Cycle Cost
90%
Power Costs
Downtime
Costs
5%
Rebuild Costs
4%
Initial Costs
1%
0%
20%
40%
60%
(Total Life Cycle Costs as Percentage of
Net Present Value)
80%
100%
Horsepower Vs Energy Usage
70.0%
18.0%
Population
60.0%
16.0%
Energy Use
58.8%
Percent of Population
50.0%
12.0%
40.0%
10.0%
8.0%
30.0%
26.4%
6.0%
20.0%
4.0%
9.1%
10.0%
2.0%
2.9%
1.8%
0.7%
0.2%
0.1%
0.0%
0.0%
1-5
6-20
21-50
51-100
101-200
Horsepower Range
Epact coverage 1-200 HP
NEMA Premium coverage 1-500 HP
201-500
501-1000
1000+
Percentage of Energy Usage
14.0%
Motor Construction
Each Motor is 10 HP, 1200 RPM
Standard
efficiency
84%
Epact
efficiency
87.5%
Premium
Efficiency 90.2%
Why is Improving Motor
Efficiency Important?
Over 50% of all Electrical Energy consumed is
used by Electric Motors. Do you know how
many Motors you have in your Home?
82% of the Electrical Energy consumed in the
USA is used by Electric Motors. Improving the
efficiency of Electric Motors and the
equipment they drive can save energy,
reduce operating costs, and improve the EndUser Profitability.
What is an Energy Efficient
Motor?
Motor efficiency is the ratio of mechanical
power output to the electrical power input.
Improved design, materials, and
manufacturing techniques enable energyefficient motors to accomplish more work per
unit.
Energy efficient motors offer other benefits.
Energy efficient motors usually have higher
service factors, longer insulation and bearing
lives, lower waste heat output, and less
vibration. Better Built Motors!
Efficiency Comparison
Low Voltage Motors
97
95
Efficiency
93
91
Standard
EPAct
Premium
89
87
85
83
81
0
100
200
300
Horsepower
400
500
When should you consider
buying a NEMA Premium Motor?
NEMA Premium Motors should be considered
in the following cases:
For all new installations
Purchasing new equipment packages, Air
Compressors, HVAC Systems, and Pumps
Major modifications made to facilities or
processes
Instead of rewinding older Motors
Replace oversized and under loaded Motors
Part of a Preventive Maintenance or Energy
Conservation Program
Guide to select an Energy
Efficient Motor if it will be used
more than numbers of
Hours/Year.
.02K/hr
.04K/hr
.06K/hr
.08K/hr
2 Years
8,750
6,000
4,000
3,000
3 Years
7,000
4,000
3,000
2,000
4 Years
6,000
3,000
2,000
1,500
Should I rewind a failed Motor?
Failed Motor usually can be rewound, it is
often worthwhile to replace a damaged motor
with anew NEMA Premium Motor to save
energy and improve reliability.
Motor is less than 40Hp.
Cost to rewound exceeds 65% of the price of
a new Motor.
Motor was rewound before 1980.
Repair / Replace Decision Tree
Failed Motor
75HP or Less
100 HP or Greater
Replace with New
Previously Rewound?
No
Premium
Efficiency
Repair Cost
below 50%
of New?
Yes »
Rewind
No »
Replace
Yes
< 2 Times
Standard
Efficiency
Review Repair Costs
& Energy Savings vs. New
Rewind
Replace
with New
EQP III
How should you begin a Motor
Efficiency Improvement
Program?
Survey your Motors. Gather nameplate information
(Hp, RPM, Enclosure, voltage, amps) Initially focus on
Motors that exceed minimum size and operating
hours:
Survey three phase NEMA Design B. Collect Motor
Nameplate Data.
50Hp and above.
2,000 hours/year of operation.
Constant load (not intermittent, cycle or fluctuating)
Older or rewound Standard Efficiency Motor.
Easy access.
How should you begin a Motor
Energy Improvement Program?
Conduct Motor Replacement Analyses by the
following three categories:
Motors Offering Rapid Payback through
Energy Savings. Motors that run continuously
(8,000 or more hours/year.
Improved Reliability - Oversized Motors
Utility Rebate Program - utility pays End-User
to replace older inefficient motor with new
NEMA Premium Motor.
How should you begin a Motor
Efficiency Improvement
Program?
Replace Motor at time of Failure – Motors
with Intermediate Payback, when these
motors fail, you will want to replace them a
NEMA Premium Motor. Plan this decision out
with End-User. Motor must be available from
stock.
Leave Present Situation as is – Motors with
Extended Payback. These motors are used
less than 2,000 hours each year. They can be
replaced with an Epact Motor.
Where did I get the information?
This Presentation was based on the US
Department of Energy. (DOE) Energy
Efficiency and Renewable Energy.
THANK YOU