High Efficiency Motor Application Slide 1 HEM application - - - PowerPoint PPT Presentation

Slide 1

HEM application - Industrial sector

International Copper Promotion Council (India)

High Efficiency Motor Application

Welcomes The Delegates For Work Shop for UNDP / GEF PROJECT

(4th April 2009 at Nagpur)

Presentation By

SHASHIBHUSHAN S AGRAWAL

BEE Certified Energy Auditor (R.No.EA-1090)

Consultant To ICPCI for EE Motor Project

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HEM application - Industrial sector

ICPCI-International Copper Promotion Council (India)

Indian centre of ICA to promote Copper applications in India.

ICA-INTERNATIONAL COPPER ASSOCIATION

• A Not -for- profit Global Organization
• Registered in New York, USA. 31 Offices in 24 countries.
• Members Account for Over 80% of World Copper

Production. Basic Objective: Promotion of Beneficial consumption of Copper.

ICA-India liaison office started in January 1998.

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HEM application - Industrial sector

Presentation Structure

1. Why HEM s 2. HEM implementation 3. Policies & Regulation 4. Supply chain involvement 5. End Users involvement 6. Conclusion

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HEM application - Industrial sector

Sector wise energy consumption

Industrial 41% Agri 26% Domestic 19% Commercial 4% Others 10%

Industry consumes the most Energy

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HEM application - Industrial sector

Up to 30 Up to 20 Up to 30 Up to 25 Conservation potential (%) 20-25% Commercial Sector Domestic Sector Agriculture Sector Industrial Sector Sector

Sector wise Energy Saving potential

Energy Handled by Motors (%) 70-75% 2-3% 4-5%

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HEM application - Industrial sector

• On Average Basis Almost 70% of the electricity is consumed

by motors in Industry.

• Though Electric Motors Consume Major energy in Industry

proportional attention is not paid to Motor audit and its efficiency.

• It has been accepted by all Government, Semi Government,

Private agencies & NGO’s that lot of scope for energy saving in electric motors.

• Modest improvement in the energy consumption in motor will

result in substantial energy savings.

Why HEM Project ?

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HEM application - Industrial sector

Equipment Energy Saving Potential per year Distribution Transformer 463 Motors & Pumps 39,500 Others 200

• Total

40,163 Million KWH

• Estimated Energy Saving Potential by

Improving Energy Efficiency

So if we conserve this energy we may not need additional generation capacity to meet the shortage.Also saving one unit is much cheaper than generating one unit.

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HEM application - Industrial sector

Presentation Structure

1. Introduction & Why HEM s 2. HEM implementation 3. Policies & Regulation 4. Supply chain involvement 5. End Users involvement 6. Conclusion

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HEM application - Industrial sector

100% 70% 40% 3%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Theorotical Potential Technically feasible Economically viable Market penetration

Barriers to penetration of HEM s

1. Lack of knowledge/ awareness with users 2. Non availability of EE motors 3. Confusion – EE motor definition 4. Need to have focused market transformation

• Higher initial cost
• Low demand; high price
• Lesser working hours
• Lack of technology

1. Poor power quality in rural sector 2. Application limitations

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HEM application - Industrial sector

Towards increasing penetration of HEM s

Policies Regulation Standards Supply Chain Marketing Promotion

HEM Implementation

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HEM application - Industrial sector

Presentation Structure

1. Introduction & Why HEM s 2. HEM implementation 3. Policies & Regulation 4. Supply chain involvement 5. End Users involvement 6. Conclusion

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HEM application - Industrial sector

Standards

Standard

• Prescribes Energy performance of manufactured products (Minimum

Energy Performance Standards, MEPS).

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HEM application - Industrial sector

Standards scenario - International

• Legislation
• Three-phase induction
• motors
• 0.75 to 150kW
• 60Hz
• 2, 4, and 6 pole
• Specifies minimum
• efficiencies
• Testing to IEEE-112b
• Voluntary
• Three-phase induction
• motors
• 1.1 to 90kW
• 50 Hz
• 2 and 4 pole
• Efficiency labelling
• Testing to IEC60034-2

EPACT CEMEP Agreement

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HEM application - Industrial sector

Indian Standards scenario

• IS 8789 : Standard motor

– all small manufacturers “follow” specification – most large manufacturers provide higher efficiency than “specified” 8789.

• IS 12615(2004) : Standard for EE motors based on

CEMEP/EPACT

– applicable up to 160 kW motors – minimum efficiency values specified in two levels, Eff1 & Eff2

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HEM application - Industrial sector

Labels

Label

• Information on product’s energy performance

(usually in the form of energy use, efficiency, or energy cost)

• Give consumers the data necessary to make

informed purchases

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HEM application - Industrial sector

Labeling Recommendations

• MEPS should be at Eff2(-) level
• Eff1 would be an endorsement label

–Consider efficiency at 100% loading –Include 2 pole motors & 4 pole motors

• Label contents –

–Parameters spelt out in clause 20.1a of IS 325 : 1996 –BEE logo, license number & Efficiency class marking

• Mandatory from one year of notification

Source: BEE

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HEM application - Industrial sector

Presentation Structure

1. Introduction & Why HEM s 2. HEM implementation 3. Policies & Regulation 4. Supply chain involvement 5. End Users involvement 6. Conclusion

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HEM application - Industrial sector

Efficiency Improvement

Efficiency = Output Input = Output + Losses Output

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HEM application - Industrial sector

Loss reduction

Core length has to be increased to maintain starting torque

Reduce Stator Cu Loss Reduce Rotor Cu Loss

Reduce Iron Loss Reduce Copper Loss

Low Loss Magnetic matl.

Reduce Flux Density Increased Starting current

Increase Copper Section

Stator slot area Increase Rotor bar section

Reduced S t a r t i n g T o r q u e

Increase Reduce Stator Yoke Rotor Diam

Source: Bharat Bijlee

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HEM application - Industrial sector

Energy Efficient motor costs more

• EFF 1 motors are generally priced 20-

25 % higher than eff 2 motors.

• More laminations - longer core length

and/or

• High Grade (low loss) laminations
• More Copper

Rs

Source: Bharat Bijlee

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HEM application - Industrial sector

Presentation Structure

1. Introduction & Why HEM s 2. HEM implementation 3. Policies & Regulation 4. Supply chain involvement 5. End Users involvement 6. Conclusion

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HEM application - Industrial sector

End User involvement

Awareness creation Conviction Adoption

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HEM application - Industrial sector

Awareness Willing to Change - Conviction Yes No Yes How – Adoption Identify key implementers Help them

Structured program on Energy Management through motors

Why? Barriers /issues Price premium, availability, Claims Vs savings actual,

• Tech. Support, rewinding issues

No finance,Not decision maker Solutions Remove doubts Reasons? Barriers /issues Lack of info. (tech. /general) Corporate culture, Individual mindsets no interest in Energy Cons. Know –all attitude Solutions Provide information No

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HEM application - Industrial sector

Opportunities to adopt HEM

• 1. First purchases

Existing motors New Project

• 3. Retrofit
• 2. Replacement

Expansion Projects / Consultants Plant Personnel Top Management/Financers

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HEM application - Industrial sector

Lowest Cost purchases can be deceptive

• Purchase decisions are normally dependent on -
• 1. Reliability
• 2. Price
• 3. Brand
• 4. Service

Rarely attention given to the Life Cycle Cost in capital purchases

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HEM application - Industrial sector

Economic Analysis

15 kW (4-pole) Standard Energy Efficient Price (Rs): 17700 (393 USD) 21420(476 USD) % Efficiency: 89.0% 91.8% Price premium 4000 Operation-Hours 8000 8000 Energy Rate per kWh Rs.4 (8.8 cents) Rs.4 (8.8 cents) Energy Cost (Rs/Yr): 5,39,326 (11985USD) 5,22,876(11619USD) Annual Savings: Nil Rs.16,450.(365 USD) Payback for premium: 2.5 months Recovery of Entire cost of EE Motor: 1.25 years

Payback Reduced with Longer Hours, Greater Load

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HEM application - Industrial sector

The operating costs are what count ! ! !

12 yrs 15 yrs 20 yrs

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HEM application - Industrial sector

Retrofitting of existing motors

n Statistical Approach n Analytical Approach

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HEM application - Industrial sector

Values measured using a Power Meter LocationTag No Applica tion Pur.date kW Rpm Volts AmpsEff% Volts Amps Hz PF kW Rpm Temp ºC Identification No.of rewinds Name Plate data

Motor data & initial load survey

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HEM application - Industrial sector

Statistical Approach

• List the ratings of motors in terms of output

under three frame groups

• Up to 132 frame- 0.25-7.5 kW
• 160-225 frame - 9.3 to 45 kW
• 250- 355 frame - 55 –315 kW
• Framed policies for replacements of motors in

a phased manner

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HEM application - Industrial sector

• Classify on the basis of
• perating hours
• Repair/rewind history
• Load factor
• Age
• Identify critical motors for field study/payback calculations
• Make investment proposals for motor replacements

Analytical Approach

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HEM application - Industrial sector

Presentation Structure

1. Introduction & Why HEM s 2. HEM implementation 3. Policies & Regulation 4. Supply chain involvement 5. End Users involvement 6. Conclusion

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HEM application - Industrial sector

We all have our personal doomsday scenarios with respect to an extremely “energy hungry” world

Year 1800 Year 2050 Year 2020, LED Year 2000 CFL Year 1900

Source- Gtz

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HEM application - Industrial sector

Thank you !!

E Mail – shashi@charteredvaluer.com Mobile - +91 9422161638

Presentation By

SHASHIBHUSHAN S AGRAWAL

BEE Certified Energy Auditor (R.No.EA-1090)

Consultant To ICPCI for EE Motor Project