energy efficiency in motor driven...

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EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)

Peter Radgen, Dr., STEFraunhofer Institute System and Innovation Research, Karlsruhe

Ljubljana, 13 -15 March 2006

Mission 6.2: Energy Efficiency

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Energy Efficiency

in Motor Driven

Systems





2

Shares of electricity consumptionin industry (EU-15)

Electric motors andapplications69% = 800 TWh

Pumps30%

Fans14%

Refrigeratingmachines 14%

Other applications:mixing, stirring,transporting: 32%

Air compres-sors 10%

Motor systems account for about 65 % of electricity consumption in industry in the European Union

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Overview of saving potentials in motor driven systems

Measures economic saving

potential Improvement of drive by - use of high efficiency motors 3 % - use of variable speed drives 11 % Improvement of the system - for compressed air supply 33 % - for pump systems 30 % - for refrigeration systems 18 % - for HVAC and fan systems 25 % Motorsystems Total 25-30 %





4

81%

14%5%

Energy Costs

Investment

Maintance

Life Cycle Costs of Motor Driven Systems

Example Compressed Air System• Power 110 kW• Lifetime 15 a• Operating hours 4000 h/a• Energy price 6 ct/kWh

• Many measures are highly economic, as energy costs account for about 80% of the life cycle cost.

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Electric Motors





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Saving Potentials for drives

Measures Saving Potential

Systeminstalllation or Replacementhigh efficiency motors (HEM) 2-8 %correct sizing 1-3 %energy efficient motor repair 0,5-2%variable speed drives 10-50 %efficient gear boxes 2-10 %quality of power supply 0,5-3 %System operation and maintenancegreacing, adjusting and fine tuning 1-5 %

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Improved efficiency of motors

70%

75%

80%

85%

90%

95%

100%

1,1 kW 5,5 kW 11 kW 90 kW

high efficiency motors

standard motors

+ 8,7%+ 8,7%

+ 1,2%+ 1,2%

Cost Savings 11 kW 69 €/a 90 kW 266 €/a

– As smaller the power of the motor as worse is the efficiency of it and hence as larger the saving potential

– Also small improvements for large motors could deliver significant total savings





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High Efficiency Motors (HEM)

75

80

85

90

95

1 10 100

1

2

3

4

5

6

7

eff3-Motor (2 pol and 4 pol)eff2-Motor (2 pol)eff1-Motor (4 pol)∆ (eff1-eff3) (2 pol)

Effic

ienc

y(%

)

Efficiency requirements for motors

Effic

ienc

ydi

ffere

nce

(%)

Power (kW)

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Share of efficiency classes on motor sales in Europe

2%

30%

68%

3%

44%

53%

3%

54%

43%

4%

80%

16%

5%

83%

12%

6%

84%

10%

7%

85%

8%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

1998 1999 2000 2001 2002 2003 2004

Total motor-sales in the scope of the Voluntary Agreement of CEMEP

EFF3EFF2EFF1

Quelle: CEMEP, EEMODS Konferenz, Heidelberg, 2005.





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Comparison of EFF 1 and EFF 2-motors by infrared photographs

EFF 1 EFF2

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Pumps





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Energy efficiency of pump systems

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Energy Saving Potentials in Pump Systems

Measure Energy Saving Potential Sys-tems (EEP)i

Possible Mar-ket uptake

(MDD)i

Efficiencyfactor(1 - EEP*MDD)i

speed control 70 % 20 % 86,0 % operating hours 10 % 15 % 98,5 % high efficiency motors 4 % 40 % 98,4 % system design 15 % 4 % 99,4 % reduced pressure losses in the pipework

8 % 15 % 98,8 %

( )ii

n

iMDDEEP ⋅−Π

=

11

81,9 %

Energy Saving Potential ( )ii

n

iMDDEEP ⋅−−= Π

=

111

18,1 %

Measure Saving potential [%-points]

Reduction of surface roughness 10 % Reduction of internal leakage (gap losses) 6 % Optimised geometry of impellers 3%

Pump

Pumpsystem





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Energy Saving with Pumpsystems• Pumps often work away from their best

efficiency Point (BEP) based on – Over dimensioning during planning– Changes compared to design conditions– Significant reduction of efficiency of

the pump– Changed volume flows

• Aging of pumps: – Loss of efficiency by 10 to 15 %-points

based on poor maintenance

Effiz

ienz

head

Volume flow

Working line throttling

efficiency

Power

Effic

ienc

yPo

wer

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Maximum efficiency improvement by surface smoothening

whole pump: ... < 20%

volute: ... < 5% casing: ... < 5%

inner surface: ... < 5%outer surface: ... < 7%

whole impeller

Surface roughnessbefore smoothing:(kS = 0,4 mm)

The specifiedvalues of efficiencygain are per centpoints





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Fans

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Industrial FansFan for steel works

Mine ventilation fan

Induced draught fanfor 600 MW Power station

Fan forsinterplant





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Building Ventilation

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Distribution of energy consumption for fans by fan size in the US

Distribution of electricity consumption for fans by motor size(SIC 20-39 Overall Manufacturing)

1-5 hp5,2% 6-20 hp

13,9%

21- 50 hp13,5%

51 -100 hp10,8%101 -200 hp

17,9%

201 -500 hp8,2%

501-1000 hp11,1%

1000+ hp19,3%

Source: United States Industrial Electric Motor Systems Market Opportunities Assessment, OIT; US DOE, December 1998.





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Energy flow in a fan system

% 54inputenergy energyfan useful

==η

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Fan Electricity Consumption in the European Union (EU-15)

05

10

152025303540

45

Elec

tric

ity C

onsu

mpt

ion

[TW

h]

A BE DK FI F D GRE IRE I LU NL P ES S GB

Total consumption 197 TWh





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Fan Electricity Consumption by Sector

0102030405060708090

100

Elec

tric

ity c

onsu

mpt

ion

[TW

h]

Transport Industry Service SectorTertiary (excl.Servicesector)

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Emission and Cost Savings

– Electricity saving potential totals 43.2 TWh per year

– Overall emission reduction is 18.8 Million Tones of CO2per year

– Overall cost savings are about 1.7 to 3.5 Billion Euro per year0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

Elec

tric

ity s

avin

g po

tent

ial [

GW

h] a

nd C

O2 s

avin

g po

tent

ial [

kt]

Aus

tria

Bel

gium

Den

mar

k

Finl

and

Fran

ce

Ger

man

y

Gre

ece

Irela

nd

Italy

Luxe

mbo

urg

Net

herla

nds

Port

ugal

Spai

n

Swed

en

Uni

ted

Kin

gdom

Electricity saving potential in fans all sectors [GWh] FansCO2 Saving Potential in Fans all sectors [kt CO2] Fans





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Electricity consumption for fan systems in the EU-15 by sector up to 2020

•BAU (Business As Usual) no measures and improvements are implemented•IA (Improved Awareness) only technical improvements at fan will be implemented

•GT (Global Thinking) technical measures and system measures will be fully implemented

99953127727 120288

99842

93717

151007143457

117786

3418

67306461

5250

0

50000

100000

150000

200000

250000

300000

Base1997

BAU2020

IA2020

GT2020

Elec

tric

ity c

onsu

mpt

ion

for F

an S

yste

ms

[GW

h]

Industry Tertiary Transport

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Factors Influencing Fan System Efficiency•Difference between peak and low efficiency of a fan can be up to 30 %.•Small differences in fan peak efficiency are of much less importance than the poor matching between the fan and the system. •The fan has to be correctly designed, but all the effort in correctly designing a fan can be wasted, if all the other steps of the choice/design procedure are not carefully examined. Specifically:

– The fan operating point must be properly selected on its characteristic curve

– The fan and the system have to be properly matched– The system has to be correctly designed to reduce as much as possible

energy requirements and energy losses– The system has to be properly installed– The regulation system should be selected to limit energy losses





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Energy saving potentials and additional costs for fansFan type Efficiency gain Additional cost Propeller fans 15 – 20 % 2 – 12 % Tube-axial 2 – 10 % 4 – 10 % Jet fans 4 – 8 % 5 – 7 % Forward curved 5 – 15 % 7 – 10 % Radial tip 10 % 6 – 10 % Backward curved 2 – 5 % 8 – 12 % Radial fans 5 % 4 – 7 % Other fans 5 – 10 % 8 – 10 %

For each Euro spent about 4 Euro will be saved (based on LCC)

Each point of efficiency gain will increase fans first cost by about 1 %.

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Efficiency Measures for Fan Systems and their Improvement Potential

Management Action

Efficiency Gain Factor (EGF)

System

Market Penetration

Factor (MPF)

1-EGF*MPF

Operation Schedule 30 % 20 % 94.0 % HEM 5 % 20 % 99.0 % Correct Sizing of Motor 15 % 5 % 99.3 % Optimising Transmission 8 % 60 % 95.2 % Optimising Ducting 15 % 30 % 95.5 % Additional Savings 12 % 15 % 98.2 %

Product of (1-EGF*MPF) factors 82.5 % Energy Savings 17.5 %





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Energy savings depending on control system

Quelle: LfU, Stuttgart, 2002

Pow

er c

onsu

mpt

ion

[%]

Volume flow [%]

Bypass

Throttle

Rotational

Speed control

Theoretical

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Strategy for Improving the Energy Efficiencyof a Fan Installation

Carry out a performance test

Carry out a performance test to determine the actual flow rate, fan pressure and power absorbed. Many fans are not working at the speci-fied duty point, often the pressure requirement is overestimated. It may be possible to alter the fan speed to a lower value and still achieve the required flow. This in any case should be reviewed as the design flow may only be required 3 or 4 days per year.

Check the vee belt drive

Vee belt drives are frequently 'over-engineered'. Maintenance en-gineers often specify more belts than necessary as this extends their life. It is however at the expense of drive efficiency and con-sequent power consumption. Remove a belt at a time and re-check the amperage.

Check the motor selection

Many motors are oversized to give a margin. Check the new power ab-sorbed by means of voltage, amperage and power factor readings. De-termine if a new motor (possibly of higher efficiency) will give reduced energy consumption, and if power factor correction is warranted. HEM have typically a much broader high efficiency operating range.

Check if an impeller change is warranted

Many fan manufacturers have a range of impellers to suit a par-ticular fan casing / drive assembly. It may be that a change of im-peller and /or inlet cone will reduce the energy consumption e. g. changing a forward curved bladed impeller for a backward airfoil bladed impeller on a centrifugal fan or changing the solidity (num-ber and chord of blades) or hub to tip ratio on an axial fan.

Check if a complete change of fan is warranted

For best efficiency backward bladed fans are larger than forward curved fans for the same duty. The additional first cost may however be more than recovered over the life of the fan. Sometimes fans are found to be oversized for the duty and a smaller fan will then be more effi-cient. A change in width may also be beneficial.

Check the control type of the fan

Where the fan is fitted to a constant orifice system, an inverter speed control is preferred for varying the flow rate. If the system requires constant pressure, a variable geometry fan is suggested. A soft start should be incorporated wherever possible.





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Pay back time for fan replacements depending on power and number of operating hours

0

1000

2000

3000

4000

5000

6000

7000

8000

1 10 100 1000

Nominal motor power [kW]

oper

atin

g ho

urs

[h/a

]

1 year2 years3 years4 years5 years6 years

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Compressed Air





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Motor driven systems - much more than a motor(the compressed air example)

Compressor ControlReceiver Treatment

- Dryer- Filter- Condensate Technology

Distribution

VerbraucherEnd use devices

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Refrigeration SystemsRefrigeration compressor Ab-/Adsorption cooling





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Often refrigeration systems are responsible for peak power demand

0

100

200

300

400

500

600

700

800

01.07.96 02.07.96 03.07.96 04.07.96 05.07.96 06.07.96 07.07.96

WirkleistungGesamt

Wirkleistungohne Kälte

Summe Kälte

Power Total

Power w/o cooling

Power cooling

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The European Motor Challenge-Program

– Program of the European Commission with voluntary participation

– Target: Improvement of energy efficiency of motor driven systems in industry

– Aim of the Programme:• Reliability• Quality• Costs

of system to be improved





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Structure of the MCP-Program

Partner Guidelines

User of Motor Systems

Compressed Air Module

Pump Module

Fans Module

RefrigerationModule

EnergyManagement

Endorser Guidelines

Manufactureres, ESCO's and other supporting institutions

Drives Module

Distribution ModuleIn preparation

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Module-Guidelines•The module descriptions helps the partners to identify possible measures for the participation in the MCP Program.•Basic description of the system. (simple data collection of type, power and use).– Required measurements (e.g. Electricity

consumption, load distribution)– Basic data– Planned efficiency measures





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How to become an MCP Partner

• Partner– Company starts with a motor

system inventory.– Company proposes action plan ,

which contains type and size of the commitment and the list of measures to be undertaken

– EU-Commission approves action plan and grants Partner Status.

– Partner follows the Action plan and reports annually to the Commission

– EU-Commission checks annual report and renew the „Partner“-Status.

• Endorser– Company starts with an inventory of 's

energy saving activities. – Company proposes action plan , which

contains type and size of the commitment and the list of measures to be undertaken

– EU-Commission approves action plan and grants Endorser Status.

– Endorser follows the Action plan and reports annually to the Commission

– EU-Commission checks annual report and renew „Endorser“-Status.

A 5 Step Proceedure

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ProMot ww.eu-promot.org





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ProMot Toolbox (Refrigeration, Pumps)

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EuroDEEM International / IMSAA (Motors)





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Barriers and Resistance

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Killer phrases instead of killer applicationsWe´ve never made it that way.We´ve tried that already in the past.This may be right in theory, but...Others have tried already and failed.If it was that easy, the concurrence would have done it before.Therefore we haven´t got the funds.It´s not worth to do it.We know exactly what our customers want.Draw up all the details first before we do anything.





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Not only one but many reasons for investing in energy efficient motor driven systems

Decrease(energy)

costs

Reduce polluti-on of the envi-

ronment

FacilitateRepairs

obtain a generalidea

Reduce personalcost

ImproveQuality

Prepare for inc-reasing energy

cost

Stabilization ofcompanysituation

reducemaintenance

cost

Guaranteejobs

AchievePR-effects

Simplify regula-tion/ manipula-

tion

Increase/stabilizeturnover

Increaseefficiency

Improveservice

Improve indus-trial safety

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Why energy efficiency is a difficult task ?

Multiple Actors with multiple reasons for investing have to select

between multiple different technologiesfrom multiple suppliers

need to get an integrated energy efficient solution





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Market barriers to energy efficiency

Major Barriers

• Reluctance to change a working process

• Pay back time required below two years

• Investment and operation cost are not dealt equally at same time (split budgets)

Major BarriersMajor Barriers

• Reluctance to change a working process

• Pay back time required below two years

• Investment and operation cost are not dealt equally at same time (split budgets)

Moderate Barriers

• Other functional specifications conflict with energy efficiency

• Shortage of capital

Moderate BarriersModerate Barriers

• Other functional specifications conflict with energy efficiency

• Shortage of capital

Medium Barriers

• Missing motivation• Energy efficiency not seen as

priority at the management level

• missing definition of motor system efficiency

• Oversizing of equipment due to unknown load characteristics

Medium BarriersMedium Barriers

• Missing motivation• Energy efficiency not seen as

priority at the management level

• missing definition of motor system efficiency

• Oversizing of equipment due to unknown load characteristics

TechnicalFinancialManagement

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Interpreting Barriers

Many barriers of all types show up often due to a lack of informationPay back time seen as a tool for profit analysis and not as an risk indicator. (Note: Investments with a payback time of 4 years can have easily internal rates of return above 15 %)First cost seems to dominate the total cost(Note: Typically energy costs of motor driven systems make up more than 2/3 of the life cycle cost.) Efficiency improvements are related to single components(Note: The component with the lowest efficiency in the system limits the maximum efficiency)





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The key to efficiency are the people behind it

If you want to build a ship then do not gather men to- collect wood,- divide tasks- and to arrange the work.

Teach them the desire for the endless oceans.

Antoine de Saint-Exupéry

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Helpful resources on the web

http://europa.eu.int/comm/energy/index_de.htmlhttp://energyefficiency.jrc.cec.eu.int (Energy)www.motor-challenge.de (Motor systems)www.druckluft-effizient.de (Compressed Air)www.druckluft.ch (Compressed Air)www.eu-promot.org (ProMot; Pumps, Motors, ASD)www.energy.wsu.edu/software/imssa/ (EURODEEM Int.)www.bayern.de/lfu/bestell/index.html (Energy efficiency)

energy efficiency in motor driven...

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