need of escalating energy efficiency standards of...

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NEED OF ESCALATING ENERGY EFFICIENCY STANDARDS

OF MOTORS IN INDUSTRIAL SECTOR OF PAKISTAN

Mahesh Kumar*, Mazhar Hussain**,Ghulam Sarwar**, Muhammad Aslam Uqaili*

*Department of Electrical Engineering, Mehran UET Jamshoro, Pakistan

**Department of Electrical Engineering, Islamia University Bahawalpur, Pakistan

Corresponding Author: Mahesh Kumar Email: [email protected]

Abstract: Electricity shortage is one the major issues in Pakistan. Increasing power generation to meet required

demand will take 4-8 years time period and a huge amount of capital. The next feasible option is energy saving.

Electrical motors consume more than 40% of Pakistan‟s national power. The penetration of high efficiency motors

remains low in Pakistan‟s industrial and agriculture sector, whereas the use of Eff3 or below Eff2 motors have a

substantial market share. Harmonization of recent Pakistan standard with IEC 60034-30 (2007)requires

promulgation of labeling Eff1 or IE2/IE3 and complete removal of Eff3 motors. This paper presents the idea of

labeling and the Minimum Energy Performance Standard (MEPS) schemes of different motors. Moreover, a

methodology is presented for calculating efficiency of older motors being used in on-going industry, aiming at

energy conservation for reducing maximum demand and introducing new standards and regulations in Pakistan.

Keywords: Energy Efficiency, Energy Efficient Motors, Energy Efficiency Standards.

1. Introduction

The increased awareness of global warming and depletion of fossil fuels brings several

challenges for optimum use of energy throughout the world. Considering the case of Pakistan,

electricity crisis has slow down the wheel of socio economic development. Table 1 shows the

electricity generation and the demand for a typical period of 2003 to 2010 [1]. Load shedding of

8-10 hours in urban areas and 12-16 hours in rural areas has resulted in many problems

especially in industrial sector. In recent days the power generation is even not maintained and

further increase in load shedding will cause more energy crisis. Electrical motors are the major

load in any industry which consumes about 30%-80% of total energy [2]. A huge amount of

energy saving is possible with the adoption of high efficient motors.

Year Electricity Supply (MW) Electricity Demand (MW)

2003 14336 13071

2004 15046 13831

2005 15082 14642

2006 15072 15483

2007 15091 16548

2008 15055 17689

2009 15055 19080

2010 15055 20584

Table 1: Electricity production and demand

First International Conference on Modern Communication & Computing Technologies (MCCT'14) (Full Paper)

26-28 February, 2014, Nawabshah, Pakistan

mailto:[email protected]

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2. Electricity Consumption of Different Sectors in Pakistan

Figure 1 shows electricity consumption of all sectors of Pakistan [3].It can be observed that the

domestic sector is the largest consumer of electricity, consuming 46.2% of total power, whereas

industrial, agriculture, and commercial sectors consume 27.7%, 11.8%, and 7.5%of total power

respectively. Other remaining sectors consume a total of 6.8% of power.

Figure 1: Electricity Consumption of Different Sectors in Pakistan

3. Motors Load in Industrial Sector

In any industrialized nation about 70% of total power is consumed by electrical motors.In

Malaysia, UK, US, Turkey, India, Jordon, and Canada electrical motors used in industrial sector

consume 48%, 50%, 75%, 65%, 70%, 31%, and 80%of total industry power respectively [4].This

is because in an industry motors are mainly used in different process machines, pumps,

compressors, fans and blowers etc.

Pakistan‟s industrial sector‟s potential savings in electricity sector is expected to reach 11.2% for

ten years in a forecasted period from 2009 to 2019 with an investment of 1850 million US dollar

[5].According International Energy Agency (IEA), about 15 TWh/year power is consumed in

motors in Paksitan‟s all sectors inculding, industry, agriculture, resedential and transport that is

about 40% of toal demand of electricity of the country[6]. Figure2 shows the electrical energy

consumption of motors with respect to total electricity demand in different sectors of Pakistan. A

huge amount of energy can be saved by adopting high efficiency motors.

46.2

27.7

11.8

7.5 4.6 2.20

5

10

15

20

25

30

35

40

45

50

Domestic Industrial Agriculture Commercial Bulk Supplies

Others

Consumption (%)



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Figure 2: Motors Load for Different Sectors in Pakistan

4. Energy Saving And Energy Efficiency Standards In Developed Countries

According to [6],it is estimated that electric motors account 43% to 46% of total global

electricity consumption and hence causing 6040 Mt of CO2 emission. To overcome this problem,

many countries have adopted Minimum Energy Performance Standard (MEPS) for the main

class of industrial motors. Further, a number of countries are in process for use of these

standards. The use of the best practice MEPS for industrial motors will save about 322 TWh of

annual electricity and reduce 206 Mt of CO2emission. Table 2 depicts different energy efficiency

standards of three phase induction motors, energy efficiency levels and countries who have

achieved these levels. Further a summary of different phases of these standards achieved by

different countries is shown in table 3 [7]. Some of these countries have already achieved these

standards however others are in process of achieving them in near future.

IEC 60034-30 EU (MEPS) CEMPS US EPACT Other Regulation

Premium Efficiency

IE3 IE3 NEMA Premium

High Efficiency IE2 IE2 EFF 1 NEMA Efficiency

Canada, Mexico,

Australia, New

Zealand, Brazil,

China, Switzerland,

Standard Efficiency

IE1 EFF 2 Below Standard

China, Brazil, Israel,

Taiwan, Switzerland

2010.

EFF3

Below Standard

Table 2: Different Standards Used For Three Phase Induction Motor Efficiency Calculation.

0

5

10

15

20

25

30

Domestic Industrial Commercial Agriculture others

TWh

/ y

ear

Electricity Demand

Electricity use by motors



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Countries IE1 IE2 IE3

Phase-I Phase-II Phase-I Phase-II Phase-I Phase-II/III

EU 2011 2015/2017

US 2002 2011

Canada 2011

Australia 2006

New

Zealand

2006

Mexico 2004

South Korea 2008 2010 2015

China 2007 2012

Brazil 2010 2012

Turkish 2012 Table 3: Use of MEPS by Different Countries.

5. Mathematical Model

Saidur at el,2010 [2] has worked for energy economic and environmental benefits for using for

high efficiency motors to replace with standard motors for Malaysian industry., M.

Hasanuzzaman at el, 2011[8] has worked for energy saving and emission reduction for rewinding

and replacement of standard industrial motor, Garcia et al et [9] has carried out his research in

Brazilin industry on energy efficiency of motors, M Rathi at el [10] carried out his research in

energy efficient motors in Pakistan industrial sector.

To compare operating cost of existing motors with energy efficient motors, this paper considers

three phase induction motors, which are mainly used for different processes in industrial sector.

The efficiency of older motors can be determined by measuring electrical parameters such as real

measured current, power factor, nominal current from manufacturer, no load current from

manufacturer, and operating hours and subsequently substituting them in a mathematical model

suggested by [11].The real load γ of existing motor can be calculated as:

γ = 1 + 1

α × ln

IR

IN (1)

WhereIR and IN are real measured current and nominal current respectively [11].The load current

parameter α is given by

α = −ln I0

IN (2)

Where I0 is no load current



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The electrical efficiency of a motor is ratio of the output power Pout to the input power Pin and

can be calculated as

ηL = Pout

Pin=

(0.746×PHP ×γ)

PR (3)

Where PHP and PR are nominal output power and real input power in horse power.The rated load

γ is in percentage and ηL represents low efficiency.

According to [11], The Improvement in energy efficiency (IEE) is percentile energy saving by

replacing a low efficiency ηL motor with a new energy efficient motor η . It is given by:

IEE = 1 −ηL

η × 100% (4)

5.1 Motors Investment Value (MIV)

Motor investment value is price plus installation charges. Actually high efficient motors are

about 20% more expensive than ordinary motors as they use a higher amount of copper and

consider other mechanical parameters to increase the efficiency.

5.2 Energy Saving (KWh/year)

Energy saved is the electrical units saved. Therefore the quantity of energy saved QES per year

is given by:

QES = 0.746 × PHP × γ × t × 1

ηL−

1

η (5)

Wheret is operating time (h/year) [11].

5.3 Energy Saved Values (in Rs.)

Energy saving in Pakistan rupees is obtained by multiplying the energy unit saved with current

tariff per kWh. As the cost of electricity is different for peak and off-peak demands, thus a

particular motor having same rating operating at different times will consumes same electricity

units but with different electricity charges (in rupees). In this study, the cost for B3 industrial

sector is taken form Hyderabad Electric Supply Corporation (HESCO) Pakistan.

The energy save values per year is given by following equation:

ESV = QES × C (Rupees/year) (6)

where C is cost per unit.



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5.4 Payback Period

The payback period is the time taken by an industry to return the invested money utilized to

install the new energy efficient motors. The payback can be calculated as:

SPB = MIV

ESV 𝑦𝑒𝑎𝑟 (7)

6. Technical Data Analysis for Motors

In this research paper 15three phase induction motors are considered with ratings 7.5KW,

11KW, 15KW, 18.5KW and 22KW.These motors are ten years old and operate for 8760 hours in

a year. The electrical quantities such as nominal power, nominal current, no load current and

actual power are measured using power analyzer meter. The average cost for electricity per KWh

for B3 type industrial users is 10 rupees.

Table4: Different types of motors with rated, calculated and proposed values

By analyzing data from table 4, it is observed that the efficiency of existing motors is very low.

The efficiency of new motors is determined from manufacturer„s table of motor-driven system

[6] when the existing motors were replaced with energy efficient ones. The results are further

explained with help of illustrations in figures 4, 5 and 6.

Motors Motors

Rating

(Kw)

Pout

(kw)

Pin

(kw)

Measured

Eff (%)

New Eff

(%)

QES

(Kw)

ESV

(Rs)

MIV

(Rs)

SPB

(years)

M1 7.5 6.75 7.8 0.865 0.905 2991 29910 80000 2.6

M2 7.5 5.82 6.72 0.866 0.905 2475 24751 80000 3.2

M3 7.5 6.33 7.2 0.879 0.905 1787 17872 80000 4.4

M4 7.5 6.16 7.1 0.86 0.905 2549 25494 80000 3.1

M5 11 5.56 6.44 0.86 0.918 3263 32632 125000 3.8

M6 11 9.8 11.21 0.87 0.918 4631 46317 125000 2.6

M7 11 6.8 7.83 0.86 0.918 3661 36619 125000 3.4

M8 11 5.4 6.36 0.85 0.918 3652 36526 125000 3.4

M9 15 8.9 10.1 0.88 0.923 3975 39757 150000 3.7

M10 15 8.7 9.9 0.88 0.923 3874 38743 150000 3.8

M11 18.5 8.21 9.3 0.88 0.926 3786 37867 200000 5.2

M12 18.5 9.59 10.84 0.88 0.926 4190 41904 200000 4.7

M13 22 9.95 11.27 0.883 0.928 4739 47395 225000 4.7

M14 22 11.14 12.45 0.894 0.928 3878 38789 225000 5.8

M15 22 9.79 11.12 0.87 0.928 4918 49189 225000 4.5



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Figure 4: Power Saved in MWh per year by Different Three phase induction motors.

Figure 5: Rupees saved per year from individual three phase motor by replacing it with energy efficient motors.

Figure 6: Pay Back period for different motors.

0

1000

2000

3000

4000

5000

6000

M1

M2

M3

M4

M5

M6

M7

M8

M9

M1

0

M1

1

M1

2

M1

3

M1

4

M1

5

Power Saved (MWh/year)

0

10000

20000

30000

40000

50000

60000

M1

M2

M3

M4

M5

M6

M7

M8

M9

M1

0

M1

1

M1

2

M1

3

M1

4

M1

5

Rupees Saved (Rs.)

0

1

2

3

4

5

6

7

Pay Back (year)



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The variation in results for motors of same rating can be because of different materials used and

different type of loads they are connected with. The results reveal that the replacement of old

motors with new energy efficient motors not only saves electricity units, rupees but an increased

efficiency is also achieved.

7. Conclusion

The penetration of energy efficient motors is low in Pakistan. If we audit the motors installed in

industrial as well in other sectors then it can be analyzed that a huge amount of electricity can be

saved by replacing old motors with new energy efficient motors. However this requires a huge

amount of capital. Therefore in this paper we analyze the performance of old motors in industrial

sector and compare their performance with energy efficient motors. It can be observed from

measurements that a huge amount of energy can be saved by using motors which follow new

energy efficient standards. Hence, the efforts should be taken for regulatory measures, and

harmonization of Pakistan‟s standards with global trends. It is expected that such measures not

only fulfill the demand supply gap but also increase the industrial competitiveness.

Acknowledgement

The authors acknowledge the Mehran university of Engineering and Technology, Jamshoro,

Pakistan for providing laboratory and research facilities.

References

[1] I. Ullah, M.G. Rasul, A.Sohail, M.U.Islam and M.Ibrar, “Feasibility of a Solar Thermal

Power Plant in Pakistan,” Thermal Power Plants - Advanced Applications, InTech , 2013.

[2] R. Saidur, T.M.I. Mahlia, Energy, “Economic and Environmental Benefits of Using High-

Efficiency Motors to Replace Standard Motors for the Malaysian Industries, ”Energy Policy, vol.

38, no.8, pp. 4617-4625, August, 2010.

[3] “Pakistan Energy Year Book”, published by Ministry of Petroleum and Natural Gas.

Hydrocarbon Development institute of Pakistan, 2011.

[4] R. Saidur, “A Review on Electrical Motors Energy Use and Energy Savings,” Renewable and

Sustainable Energy Reviews, vol. 14, no. 3, pp. 877-898, April, 2010.

[5] Asian Development Bank, “Pakistan Sustainable Energy Efficiency Development Program,”

Financed by the Asian Development Bank (ADB), Project Number: ADB TA 7060-PAK, 2009.

[6] P. Waide, and C.U. Brunner, “Energy-Efficiency Policy Opportunities for Electric Motor-

Driven Systems,” Working paper, Energy Efficiency Series, Paris: IEA, 2011.



http://www.intechopen.com/books/thermal-power-plants-advanced-applications

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[7] “Global MEPS: Energy efficiency regulations for low voltage motors around the world,”

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http://www05.abb.com/global/scot/scot234.nsf/veritydisplay/dd9452aadd82f799c1257a8000367

061/$file/GloMeps_brochure_20120921.pdf

[8] M. Hasanuzzaman, N.A Rahim, R. Saidur, S.N Kazi, “Energy savings and emissions

reductions for rewinding and replacement of industrial motor,” Energy, vol. 36, no.1, pp. 233-

240, 2011.

[9] Garcia, A.G.Pinto, Szklo, S. Alexandere, Schaeffer, Roberto and McNeil, M.A. McNeil,

“Energy efficiency standards for electric motors in Brazilian industry,” Energy Policy Vol.35

no.6 pp.3424-3439, 2007.

[10] M. Rathi, P. H. Shaikh, F. Shaikh, M.A. Uqaili “Energy Conservation through Motors in

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Computer Applications vol.54 no.5 pp. 1-7, 2012.

[11] A. V. H. Sola, C. M. M. Mota, J. L. Kovaleski, “A model for improving energy efficiency in

industrial motor system using multi criteria analysis,” Energy Policy, vol. 39, no.6, pp. 3645-

3654, 2011.



http://www05.abb.com/global/scot/scot234.nsf/veritydisplay/dd9452aadd82f799c1257a8000367061/$file/GloMeps_brochure_20120921.pdf

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