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Motor Systems
Energy Management
Best Practices
A Webinar Sponsored by:
Natural Resources Canada
Canadian Industry Program for
Energy Conservation (CIPEC)
January 15th, 2014
Instructor: Gilbert McCoy, PE
WSU Energy Program
Big Picture Perspectives:
Industrial Motor Systems
Industrial motor systems:
 Are the single largest electrical end use
category in the North American
economy
 Account for 28% of Canada/s total
electrical energy use. (17% in U.S.).
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Motor Systems Management Training
Motor Systems Energy Use
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Motor Systems Management Training
Industrial Motor System Savings
Potential
Industrial motor system energy use can
be decreased by 11% to 18% if industries
deploy all mature/proven and costeffective energy efficiency technologies
Source: 1999 Xenergy Study
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Motor Systems Management Training
A motor SYSTEM is the entire energy delivery
process, from electric feed to finished product
Utility
feed
Ultimate
goal
Transformer
?
Breaker/
starter
ASD
(maybe)
Motor
Driven Load
Mechanical Work
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Motor Systems Management Training
What is efficiency?
Efficiency = Output / Input
Efficiency = (Input - Losses) / Input
Efficiency = Output / (Output + Losses)
They’re all mathematically equivalent.
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Motor Systems Management Training
Overall Efficiency
ηsystem = ηeqpt x ηGear/Belt x ηMotor x ηVFD x
ηIn-plant distribution system x ηTransformer
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Motor Systems Management Training
Typical Motor System Losses
Useful
Work
Controller losses
<1 to ~5% for ASD
Electrical distribution
system losses
<1 to 5%
Coupling device losses
<1 to >10% for large
speed reduction
Motor losses
3.5 to >10%
Load modulation
devices
0 to 50%
Driven load losses
30 to 50%
for pumps and fans
Basic Motor Improvements
(Component Substitution)
Motor Management Training
Typical Motor System Losses
Useful
Work
Controller losses
<1 to ~5% for ASD
Electrical distribution
system losses
<1 to 5%
Coupling device losses
<1 to >10% for large
speed reduction
Motor losses
3.5 to >10%
Load modulation
devices
0 to 50%
Driven load losses
30 to 50%
for pumps and fans
Advanced Motor Improvements
(Systems Optimization)
Motor Management Training
Motor Efficiency Definitions
“Energy Efficient”
 This covers 3-phase induction motors with efficiencies equal to
or exceeding that in table 12-11 of NEMA’s MG 1 standard. It
pertains to low voltage (<600V) motors from 2-poles to 8-poles
and 1-500 HP.
“NEMA Premium™ Efficient”
 This covers 3-phase induction motors from 2-poles to 6-poles. It
pertains to low voltage motors from 1-500 HP and medium
voltage motors (>600 & <5000V) from 250 HP to 500 HP. See
http://www.nema.org/premiummotors
To Compare all the motor efficiency
standards, see http://www.energy.wsu.edu/ftpep/pubs/engineering/motors/EfficiencyStandards.pdf
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Motor Systems Management Training
Standard, EE, PE Motors – Amount
of Copper, Size of Rotor
Courtesy: Toshiba
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Motor Systems Management Training
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Canada’s Motor Efficiency
Regulations
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Motor Systems Management Training
Premium Efficiency Motors Required
Require that all General Purpose 1-200 hp motors attain NEMA
Premium levels (MG1 12-12) as of January 1, 2011
Seven categories of motors must be designed to meet Energy
Efficient levels (MG1 12-11)
U-Frame Motors
Design C motors
Closed couple pump motors
Footless motors
Vertical solid shaft normal thrust (tested horizontally)
8 Pole motors (900 rpm)
All poly-phase motors with voltages up to 600 volts
These standards Apply to New Motor Sales Including Imports
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Motor Systems Management Training
Additional Minimum Motor Performance
Levels
201 to 500 Horsepower low voltage General
Purpose Design B motors must be rated at
Energy Efficient (MG1 12-11) levels.
The U.S. DOE has proposed increasing the U.S.
standards for 201 to 500 hp motors to Premium
Efficiency levels plus requiring Premium
Efficiency performance from Brake Motors (to 30
hp) and NEMA Design C Motors (to 200 hp). 900
RPM motors would also be covered by these
proposed standards.
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Motor Systems Management Training
Basic Motor Management Planning
Motor Survey and Savings Opportunities
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Motor Systems Management Training
Motor Management Planning
Goals and Benefits:
Provide dollar savings through reduced energy
costs Efficiency = More Profit
Minimize energy consumption
(energy cost per unit of product)
Maximize efficiency while reducing downtime
Improve system reliability and productivity
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Motor Systems Management Training
Motor Management Planning Actions
Develop a motor inventory and tracking system
Replace critical motors with histories of frequent
failures immediately
Develop a new motor purchase policy
Identify which motors should be replaced with
Premium Efficiency units when they fail
Establish a PEM-Ready spares inventory
Adopt model motor repair standards
Consider Life Cycle Cost Analysis
Motor Systems Management Training
Information Requirements for Motor
Management Planning
 Understand Utility Rates and Incentives
 Gather Motor Nameplate Data
 Establish Motor Operating Profiles
 Tune Your Electrical Distribution System
 Obtain Measurements at Connected
Loads
 Know Your Load Requirements
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Motor Systems Management Training
Understand your Utility Rate
Schedule
Decatur Utilities
General Power Rate (Schedule GSA) Code 54, 55, 59
Demand Charge = $10.45/kW-mo
Energy Charge = $0.06028/kWh
Single Shift
DC
EC
DC%
$12,540
$14,105
47.1%
Two Shifts
Three Shifts
$12,540
$12,540
$26,644
$52,805
32.0%
19.2%
Assumes: Annual energy costs for a 100 kW load
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Motor Systems Management Training
Gather Nameplate
Information
Frame Type/Size
Voltage
Rated Horsepower
Amps, Rated Load
Time Rating, i.e. Duty
Maximum ambient
Temperature
RPM at Rated Load
Insulation Class
Design Letter
Service Factor
Frequency
Number of Phases
Locked Rotor Code, MG1
Part 10.37 (kVA/hp)
Efficiency, Rated Load
Other Optional Information
Motor Systems Management Training
Develop Inventory of Significant
Motor-Driven Systems
Include Nameplate Data on:
 Motor
 Coupling
 Driven Equipment
 Load Requirements
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Motor Systems Management Training
Focus on High
Priority Motors
Larger motors (60 hp or 45 kW and above)
Motors driving centrifugal loads
Production critical process (reliability issue)
“Bad Actor” systems
Over 2000 hours per year utilization
Implement predictive and preventive
maintenance.
Non special purpose motors
Include spares
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Motor Systems Management Training
Estimating Operating Hours
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Motor Systems Management Training
Repair versus Replace:
You Need to Consider...
First cost of repair and new motor purchase.
Efficiency of existing and proposed new
motor at their operating points.
Urgency and availability of each alternative.
Possible modifications to the mounting.
Annual hours of operation.
Cost of down time.
Utility incentives
Available Warranties
CanMOST can
help
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Motor Systems Management Training
Replace Motors Less than 25 hp (18.5 kW)
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Motor Systems Management Training
Replace versus Repair Existing
Standard Efficiency Motors
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Motor Systems Management Training
-----------------------------------------------------------------------------------------------------------------------------
Over a 20-year life, the energy
savings from a PEM are enough to
buy OVER THREE more motors
--------------------------------
--------------------------------
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Motor Systems Management Training
Coverage Charts tell a Story
(for 200 hp or 150 kW 1200 RPM Motors)
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Count of Frame
9
1
8
7
status
efficiency_level
HP
RPM_Sync
Voltage
Spare - Std - 200 - 1200 - 575
Spare - PE - 200 - 1200 - 575
InPlant - Std - 200 - 1200 - 575
InPlant - PE - 200 - 1200 - 575
InPlant - EE - 200 - 1200 - 575
6
5
4
8
3
2
1
1
1
1
0
447T
449T
Frame
449TC
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Motor Systems Management Training
A Strategic Spares Inventory
( for 75 hp or 55 kW 1800 RPM Motors)
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18
16
Count of Frame
2
1
14
12
10
8
15
status
efficiency_level
HP
RPM_Sync
voltage_rating
Spare - Std - 75 - 1800 - 8
Spare - PE - 75 - 1800 - 8
InPlant - Std - 75 - 1800 - 8
InPlant - PE - 75 - 1800 - 8
6
4
2
0
1
365T
30
Frame
Motor Systems Management Training
Motor Action Plan
Old Motor
New Motor
Motor # 1
Replace W / EE When Failed
Motor # 2
Downsize / Replace W / EE When
Failed
Motor # 3
Immediate Replacement W / EE
Motor # 4
Replace W/Standard or Repair When
Failed
Motor # 5
Investigate ASD Potential
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Motor Systems Management Training
Sample Motor Tags
(Courtesy Advanced Energy)
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Motor Systems Management Training
Advanced Motor Management Planning
System Optimization Techniques
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Motor Systems Management Training
Tune Your In-Plant Distribution
System
Over/Under voltage improvement
Reduce or eliminate voltage unbalance
Use voltage drop or infrared survey to
identify and eliminate hot spots due
to loose, pitted, or worn contacts,
fuse clips or terminations
Correct for poor power factor
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Motor Systems Management Training
Operation Under Abnormal
Conditions
Voltage unbalance shortens the life of a three-phase
motor.
Unbalance is defined as 100 times the maximum
deviation of the line voltage from the average
voltage, divided by the average voltage. For
example, if the measured line voltages are 462,
463, and 455 volts, the average is 460 volts.
Unbalance is
100% x (460 - 455)/460 = 1.1%
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Motor Systems Management Training
Undervoltage with Unbalance
Source: Advanced Energy, 2013
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Motor Systems Management Training
Power Transmission Systems
V-belts have a peak efficiency of 95
to 98% at the time of installation.
Efficiency deteriorates by as
much as 5% over time if slippage
occurs and the belt is not
properly tensioned.
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Motor Systems Management Training
Consider Notched Belts
Notched belts have slots that
run perpendicular to the belt’s
length and can be used in the
same smooth pulleys as
equivalent rated V-belts. Their
efficiency is about 2% higher
than for a standard V-belt.
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Motor Systems Management Training
….or Synchronous Belts
Synchronous belts (also called
cogged, timing or high-torque
belts) are toothed and require the
installation of toothed drive
sprockets. Their efficiency is 98%
over a wide load range.
Synchronous belts require less
maintenance and re-tensioning,
operate in wet and oily
environments, and run slip-free.
However, they are noisy, transfer
vibrations and are unsuitable for
shock loads.
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Motor Systems Management Training
Efficiency Range versus Gear Type
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Motor Systems Management Training
Match Equipment to Load
Requirements
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Motor Systems Management Training
Overall Efficiency (Baseline)
ηsystem = ηPump x ηGear/Belt x ηMotor x ηLine
x ηTransformer
= (0.48) x (0.95) x (0.919) x (0.98) x (0.99)
= 0.406 x 100% or 40.6%
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Motor Systems Management Training
Pump Replacement Results
---250 hp MV motor and pump replaced by 125 hp
LV motor-driven pump
---Motor efficiency improves from 91.9% to 96.2%
---Pump efficiency improves from 48.2% to 73.9%
---Annual energy savings of 712,150 kWh,
equivalent to 50.8% of baseline energy use.
Original Pump Operating Power = 167.7 kW
Final Pump Operating Power = 82.4 kW
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Motor Systems Management Training
Electronic Adjustable Speed Drives
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Motor Systems Management Training
Good Candidates for ASDs
Any fluid mover that is currently controlled by throttling
valves, dampers or bypass flows much of the time
Any fixed flow fluid mover that provides greater than
needed flow much of the time
Existing applications with less efficient speed control
devices, especially where there is considerable
operating time below 90% load or where high to
moderate torque is required at reduced speed
Where older less efficient and high maintenance DC
drive systems are currently being used
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Motor Systems Management Training
Pump Operating Point
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Motor Systems Management Training
ASD Flow Control
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Motor Systems Management Training
Water Power at Operating Point
60.0
Head Pressure, Feet
50.0
40.0
30.0
20.0
10.0
0.0
0
100
200
300 400 500 600 700
Flow, Gallons Per Minute
800
900 1000
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Motor Systems Management Training
Water Power with Flow Reduced by
Throttling
60.0
Head Pressure, Feet
50.0
40.0
30.0
20.0
10.0
0.0
0
100
200
300 400 500 600 700
Flow, Gallons Per Minute
800
900 1000
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Motor Systems Management Training
Water Power with Flow Reduced by VSD
60.0
Head Pressure, Feet
50.0
40.0
30.0
20.0
10.0
0.0
0
100
200
300 400 500 600 700
Flow, Gallons Per Minute
800
900 1000
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Motor Systems Management Training
Water Power Reduction with Variable Speed
Operation
60.0
Head Pressure, Feet
50.0
40.0
30.0
20.0
10.0
0.0
0
100
200
300 400 500 600 700
Flow, Gallons Per Minute
800
900 1000
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Motor Systems Management Training
Constant Pump Efficiency is Maintained for
Systems Dominated by Friction Losses
200
Head, ft
30
150
40 50
60
100
70
75
80.5
(BEP)
75
50
0
0
1000
2000 3000 4000
Flow rate, gpm
5000
Motor Systems Management Training
Pump Efficiency does not Remain Constant
in a System with Static Head
200
Head, ft
30
150
40 50
60
100
70
75
80.5
(BEP)
75
50
0
0
1000
2000 3000 4000
Flow rate, gpm
5000
Motor Systems Management Training
Motor and Drive Efficiency
Constant and Variable Torque Loads
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Motor Systems Management Training
Ideal Load Profile for ASDs
High Operating Hours at Low Flows
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Motor Systems Management Training
Conducting a “Bin” Energy Savings
Analysis
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Motor Systems Management Training
Inherent ASD Benefits
• Controls speed
variations
• Provides process
control
• Eliminates startup
impacts causing
system vibration
• Provides fault tolerance
• Supports low current
soft starts
• Restarts spinning load
• Controls speed swings
• Enhances product
quality
• Power Factor
Improvement
• Conserves more energy
than any other option at
speed turn-downs
below about 90%.
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Motor Systems Management Training
Advanced Super Premium
Efficiency Motor Designs
Permanent Magnet and Switched Reluctance
Motors:
---Require an electronic power converter or
controller to control both torque and speed
(inherent variable speed capability)
---Compact/high power density (not available in
NEMA T-Frame sizes so difficult to use as retrofits)
---Above Premium Efficiency performance but with
high cost. Suitable for niche applications.
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Motor Systems Management Training
For Additional Information
CanMOST Technical Fact Sheet:
http://oee.nrcan.gc.ca/industrial/equipment/software/FactSheet.pdf
CanMOST download site:
http://oee.nrcan.gc.ca/industrial/equipment/software/intro.cfm
BC Hydro Industrial Success Stories:
http://www.bchydro.com/powersmart/business/industrial/success_stori
es/quesnel_river_pulp.html
Copper Development Association (CDA) Case Studies on Energy
Efficiency:
http://www.copper.org/publications/pub_list/energy_efficiency.html
U.S. DOE Motor Energy Tip Sheets:
http://www1.eere.energy.gov/manufacturing/tech_assistance/technical_
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publications.html
Motor Systems Management Training
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Motor Systems Management Training