MotorUp 2004

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Energy SavingsthroughMotor Management
Bruce Benkhart - Director
Rev. 08/19/04
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What is MotorUp

• Sponsored by all New England Utilities
• Promote the purchase of NEMA Premium
• Provide End User Dealer Support
• Program brochures and applications
• Technical and reference materials
• Program training and support
• Rebates on NEMA Premium motors
• Motor Master software and training
• Industry presentations outreach

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EPAct Motors

• Energy Policy Act of 1992
• General Purpose
• 1-200 horsepower
• 3 Phase (220 / 460 / 575 volt)
• NEMA design A B
• ODP and TEFC
• 1200 - 1800 - 3600 RPM
• NEMA Premium Efficient motors (0.6 - 4 more
  efficient)

3 Phase electric motor
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Industrial Motor Efficiencies
Source Emerson Motors
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Motor Energy Usage Facts

• There are millions of 3 phase, 1-200 HP motors
  sold annually.
• HVAC, compressed air, process, pumping, conveyor
  systems, etc.
• These motors annually consume 679 billion kWh
  nationally (23).
• Consume 60 of the Northeasts CI electric
  energy resources.
• HVAC motors can account for up to 50 of
  Commercial energy use
• Motors can account for up to 70 of Industrial
  energy use
• 1 efficiency gain 6.7 Tera Watt hours saved
• 670 Million Dollars annually in electric costs
• and eliminate 80 million tons of carbon

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Repair or Replace?
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Company Policy

• Establish a Company Policy for sound motor
  management
• Motor Decisions Matter resources
• DOE Best Practices MotorMaster
• Use MotorUp Motor Repair Purchasing Specification
• Always consider Operating cost when choosing a
  motor

Motor Management Plan
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Motor Failure

• Over 2,000 Annual Run hours?
• Is the motor over 10 years old?
• Has the motor been repaired before? How many
  times?
• What is the efficiency of the motor?
• What are your energy costs?

Motor Failure
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Motor Replacement

• Replace if repair will cost over 60 of
  replacement.
• Motor has experienced high temperatures (enough
  to blister paint)
• Motor with bent or broken shaft, cracked rotor
  bar, hole in stator.
• Motor is 5 less efficient than a new NEMA
  Premium motor

Replace
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Replace

• Lower purchase price
• Lower efficiency
• Higher operating costs
• Often runs hotter, can reduce life.
• Do not buy on first cost alone.
• Higher operating costs can cost you more than the
  total price of a new NEMA Premium motor

Standard EPAct Motor
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Replace

• Higher initial cost (offset by Rebate)
• .5 to 4 more efficient
• Runs cooler, lower maintenance, less downtime,
  extended warranties.
• Can save thousands of dollars in energy costs.
• Simple payback in as little a 1/2 year.

NEMA Premium Motor
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Motor Repair

• Is this a specialized motor?
• Is the motor over 10 years old?
• Has the motor been repaired before?
• What is the efficiency of the motor?
• What are your energy costs?
• What is the life cycle cost

Repair
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Repair

• Rush the repair - no backup on hand
• Dont know shop quality
• No expectations or quality verification of the
  repaired motor
• No documentation of test results
• Could lose efficiency
• Could miss real problem

Standard Practice
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Repair

• Be prepared! Dont rush the repair
• Know your Motor Repair shop
• Make sure they understand the motors history and
  purpose
• Expect before and after analysis
• Use the MotorUp Motor Repair Purchasing
  Specification

Best Practice
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Where do I begin?

• Understand your motor inventory
• Develop Policies Procedures
• Implementation

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1 - Inventory motors

• Collect information for high annual run hour
  motors
• Location function
• Make, model, HP, annual run hours
• Age
• NEMA nominal efficiency
• Critical application?
• Service history (if known)

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2 - Develop a Plan

• Develop Policies Procedures
• Assign an individual - we can help train
• Life cycle costing
• NEMA Premium procurement policy
• Repair/replace plan for each motor in advance
• Analyze population for possible retrofits
• Spares on hand for critical applications

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3 - Identify Action

• Rewind (or replace) at failure (Green)
• Replace with EPAct Standard at failure (Blue)
• Replace with NEMA Premium at failure (Yellow)
• Retrofit with NEMA Premium as soon as
  possible! (Red)

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Question?

• How much does it cost in electricity to run
• 40 hp motor
• 8,000 hours per year (3 shifts)
• 0.10 per kWh
• A. 1,500
• B. 6,000
• C. 14,000

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Answer

• 19,252.00
• every year

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What tools are available?
MDM Motor Planning Kit
MotorMaster 4.0 Software
MotoRater Energy Calculator
Repair Purchasing Specification
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Examples

• Purchase new 40 hp NEMA Premium vs. EPAct
  standard
• Saves 3,060 in energy costs over life of motor
• New NEMA Premium vs. Rewind
• Saves 8,550 in energy costs over life of motor
• Retrofit old, inefficient motor with NEMA Premium
• Saves 13,030 in energy costs over life of motor
• based on 0.10/kWh - 10 yr motor life - 8000
  hrs/yr operation

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Case Studies

• Clariant Swiss pigments Dyes (RI)
• 80 of 3.7 mW load
• 250 hp _at_ 102.4 load (Eff 95.3)
• 300 hp _at_ 85.3 (Eff 96.3)
• 1,500 / year savings
• Marthas Vineyard Arena (MA)
• Retrofit 2 - 125 hp (82 - 95.8)
• Save 61,400 kWh / year
• 9,200 / year savings
• 0.3 year payback

• SESD (MA)
• 2,000 motors
• 30-100 million gallons
• Spares, MM, repair/replace policy, inventory
• 100 motor retrofit planned
• Franklin Mushroom Farm (CT)
• 80,000 mushrooms daily
• 5-50 hp fans VFD
• 568,000 kWh saved first 5 months

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Case Studies

• Corning (NY)
• 82 motor sample audit
• 30 NEMA already
• 32 no opportunity
• 1 - 1.8 yr. Payback
• 24,725 / year savings
• Seneca/Niagara Casino
• 47 new motors
• 28,000 / year savings
• 10 month payback

• Eastman Kodak (NY)
• 70-90,000 motors (65 load)
• 44 motors in 1 small area - Replaced w/ NEMA
• Saved 17,250 / yr. (250,000 kWh)
• 200,000 / year in other area
• Kraft Food (NY)
• 1,000 motors
• Just now embarking on Audit.

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[phone] www.MotorUpOnline.com
Always specify Qualifying NEMA Premium
Efficiency motors