2015-05-06 ecn nama ee motors third presentation_arrows removed
TRANSCRIPT
www.ecn.nl
Energy efficient electric motors
and their driven systems
Jeffrey Sipma, Himsar Ambarita
Jakarta
05/05/15
Content
1. General overview electric motors and their driven systems
2. Quantifying the Indonesian project
3. Barriers: literature and interviews
4. Policy instruments to reduce barriers
2
10.30 – 11.00 : Presentation of ECN; saving potentials, barrier analyses, results of
the interviews, policy options, examples from other countries
11.00 – 11.30 : Discussion of ‘electric motor driven systems’ – beyond MEPS,
what systems are we talking about, what potential is there in Indonesia?
5. Which industrial sector should
we look at in the next phase, as
a pilot project?
3
11.45 – 12.45: Discussion on next steps
Pilot: which industrial sector (10min)
Pilot: what has been done in that sector so far (running programmes) (10min)
Pilot: which of the presented policy options do we want to link with that sector (10min)
Feedback each group: 3 * 5 min
1. General overview electric
motors and their driven
systems
4
Global and Indonesian electricity
demand 2006
Where this electricity goes to?
5
19 % is used to light our world
6
46% flows to electric motor-
driven systems (EMDS)!
• 2,5 times electricity
consumption of light
• To keep things turning
• To keep things moving
7
Small motors,
up to 0,75 kW
• Residential sector, electrical appliances
• Often integrated in a ‘packaged machine’
• Refrigerators, mixers, DVD-players, PC hard disks
• Account for 90% of all electric motors
• Only 9% of total electricity used by motors8
Medium size motors,
between 0.75 kW and 375 kW
• Commercial and industrial sector
• Ordered from catalogues: stand alone or ‘specific device’
• Pumps, compressors, fans, conveyers, industrial handling and
processing applications
• Account for 10% of all electric motors
• But 68% of total electricity used by motors! 9
Large size motors,
above 375 kW, until 100.000 kW
• Industrial sector and infrastructure
• Custom designed for a special application, assembled on site,
often integrated with other functions (cooling, heating, etc)
• Examples: waste water treatment plant, oil industry
• Account for 0,03% of all electric motors
• But 23% of total electricity used by motors! 10
Priority for size of electric motor
Prioritas pada ukuran motor listrik
11
Priority for type of electric motor
• 80% of global
stock!
• Fixed speed
• Clear
international
testing
standard
12
Priority for sector and application
Pumps + Fans + Compressors: 62% Pumps + Fans + Compressors: 82%
Motors industrial sector: 70% Motors commercial sector: 35%
13
Energy efficient electric motors:
IE-classes
14
• 5 international
classes
• IE0 ‘unbranded and
cheap Chinese
motors’
• 1 kW motors:
10% efficiency
improvement IE1-IE3
• 400 kW:
3% efficiency
improvement IE1-IE3
MEPS programs around the
world
15
Contribution to life-cycle cost
literature
• 97 % of total cost is
electricity usage
• Higher efficient motor
could be twice the price of
standard motor (but less
repair and maintenance
cost)
• Only a few % efficiency
improvement is enough to
earn addition investment
back over lifetime
Life-cycle cost with 4000 operating hours per year
16
Contribution to life-cycle cost
Indonesia
Purchase prices:
• Cheap Chinese 1 kW electric motor: 800,000 IDR
• IE2 East European 1kW electric motor: 1,600,000 IDR
Electricity tariffs:
• Industrial sector: 796 IDR/kWh
• Commercial sector: 1,073 IDR/kWh
• Average for Indonesia: 818 IDR/kWh
• Government subsidy: 540 IDR/kWh
17
IE2 purchase costs during life
cycle
18
0%
1%
2%
3%
4%
5%
6%
7%
8%
9%
10%
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
% p
urc
ha
se c
ost
s o
ve
r li
fe t
ime
Running hours a year
Industry IE2 (757 Rp/kWh)
Commercial sector IE2 (1073 Pr/kWh)
Avarage without subsidy IE2 (1358 Rp/kWh)
Conclusion:
At 4000 h:
2% - 3.3%
Payback period: replacement of
broken down IE0, by IE2 instead IE0
19
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
ye
ars
Running hours a year
Industry (757 Rp/kWh)
Commercial sector (1073 Pr/kWh)
Avarage without subsidy (1358 Rp/kWh)
Conclusion:
Industry: 3 years at
minimum 1500 h
Comm: 3 years at
minimum 1200 h
No sub: 3 years at
minimum 900 h
Earlier IE2
placement:
[h replacement x 2]
It is about Energy Efficient Electric
Motor-Driven Systems (EE-EMDS)
20
It is about Electric Motor-Driven
Systems (EMDS)
MEPS = Minimum Energy Performance Standard
Maka bukan sebaiknya tidak hanya fokus pada motor, tetapi sistem secara
keseluruhan
21
Conclusion priorities
22
Many success stories
23
2. Quantifying the Indonesian
project
24
• Electricity consumption
• Electricity savings
• Financial savings sector and government
• Other benefits
Consumption electric motor systems
2014: Bottom-up versus Top-down
25
Consumption electric motor systems:
BAU projection towards 2035
26
BAU: Present market share IE-
classes Indonesia
27
Savings: by IE-class and for optimizing
electric-motor driven systems (EMDS)
28
Electricity savings: effect MEPS
29
0
20
40
60
80
100
120
140
160
2014 2016 2018 2020 2022 2024 2026 2028 2030 2032 2034
Mil
lio
n B
OE
BAU total consumption
IE1 total consumption
IE2 total consumption
IE3 total consumption
IE4 total consumption
EE-EMDS total
consumption
30
Other benefits
31
• Jobs
• Education
• International cooperation (motor conferences)
• Indonesia as a motor producing country again?
3. Barriers: literature and
interviews
But is doesn't go by itself….
32
Barriers at the level of
international trade
• Differences in grid voltage and frequency
• Different measuring systems (horsepower versus kW, motor frame size)
• Non-harmonised standards for Minimum Energy Performance Standards
(MEPS)
• Non-harmonised standards for efficiency tests
33
Barriers at the level of
manufactures and wholesale
• Customers demand for low investment cost, not life-cycle cost
• Manufacturers tendency to discourage energy-efficient EDMS
• Inability to effectively explain the economy of energy-efficient EDMS and
customer loyalty
• Inadequate assessment of actual use for EDMS
• Fear of EDMS failure that will disrupt production
• Lack of incentive to innovate
34
Barriers at the level of planning
and engineering
• Limited types of motors and components to minimise capital costs
• Outdated engineering skills
35
Barriers at the level of investors
and energy managers
• Complexity of EDSM
• Sales generally not the end-user
• Large stock of old inefficient replacement motors
• Purchasing decisions typically based on lowest investment cost
• Limited knowledge of energy-efficient options
• Inadequate understanding of how to avoid energy losses
36
Interviewed markets and users
Market
2015-01-27 Glodok Plaza (lower market)
2014-11-25 Teco wholesale and manufacturer (normal market)
2014-11-26 ABB wholesale (normal market)
2014-11-25 Grainger sales (upper market)
2014-11-26 Nidec sales (upper market)
2015-01-26 Persero PT EMI (market survey)
2015-01-29 PT Citra Solvindo (market survey)
Users Industry
2014-11-26 Indorama industrial
37
Interviewed organisations
Governmental stakeholders:
2015-01-28 Ministry of Trade
2015-02-03 Badan Standarisasi Nasional (BSN)
38
Some additional barriers found
in Indonesia
• Cheap (unbranded) import of bad quality Chinese electric motors, can this
really be stopped? And should it actually be stopped for all situations (e.g.
only little running hours a year)?
• Changing name plates to make the performance of a motor look better
• Brochures and catalogue with electric motor specifications can not always
be trusted
• Low electricity costs due to subsidizing program � although we have seen
that even then a payback period of three years can often be achieved
• Own electricity production with own generators
• Rewinding industry, including low quality rewinding (but fast)
• Large stock old ‘bad’ motors, often rewinded and oversized
• The employees working with motors and pumps, are not trained to
operate the system in an efficient way (e.g. keeping it running at night). 39
4. Policy instruments to reduce
barriers
Luckily there are is a lot of information available to face these challenges!
40
Interviewed organisations with
running programmes
2014-11-27 ADB (Audits)
2015-01-28 UNIDO (ISO 50001 Energy management, voluntary agreements)
2015-01-30 GIZ (Energy awareness trainings, incl workshops on electric
motors textile industry)
2015-01-29 UNDP BRESL (MEPS, testing facility)
2015-02-02 International Copper Association (MEPS, including other
countries)
41
Policy instruments to reduce
barriers
42
Stakeholders involved
43
Technical lifetime versus actual
motor age
44
Stakeholders versus policy
instrument
45
How does all of this works in
practice (see hand out)?
46
Support:
Target: Manufacturer
Importer
Sales
EE motor,
pumps,
fans...
Purchaser Industrial sectors
Individual businesses
Tool: MEPS high 3-5 years high
low quick varies
high 1-2 years low
medium quick varies
Energy Audit medium quick varies
Energy Management medium 1-2 years varies
Motor Policy medium quick low
Voluntary Agreements medium quick low
Speed CostsGovernment, PLN, Power Utilities and Associations
Financial Incentives
Labels
Awareness and Information
Direct
impact
5. Which industrial sector should
we look at in the next phase, as
a pilot project?
47
11.45 – 12.45: Discussion on next steps
Pilot: which industrial sector (10min)
Pilot: what has been done in that sector so far (running programmes) (10min)
Pilot: which of the presented policy options do we want to link with that sector (10min)
Feedback each group: 3 * 5 min
48
Electric savings potentials
sectors Indonesia
Thank you
Jeffrey Sipma; [email protected]
Himsar Ambarita
ECN
Westerduinweg 3 P.O. Box 1
1755 LE Petten 1755 ZG Petten
The Netherlands The Netherlands
T +31 88 515 49 49 [email protected]
F +31 88 515 44 80 www.ecn.nl49
Other available information
(examples)
• Policy guidelines, best practices,
• Several conferences, e.g. ,
• Technical support, e.g. energy saving / optimization calculators, as the
IEA4E :
50
How strong is 0,75 kW?
• Lift a person of 75 kg 1 meter
high, within 1 second
• The energy that you consume is
about 1 horse power, is about
0,75 kW
• A motor of 0,75 kW could do
the same
51