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Energy Saving Opportunities

Potential energy-efficiency improvements:


1.
Motor management plan
2.
Maintenance program
3.
Using of energy-efficient motors
4.
Rewinding of motors
5.
Proper motor sizing
6.
Using Adjustable speed drives (ASDs)
7.
Power factor correction
8.
Minimizing voltage unbalances

1. Motor management plan


A motor management plan is an essential part of a plants energy management strategy. Having
a motor management plan in place can help companies realize long-term motor system energy
savings and will ensure that motor failures are handled in a quick and cost effective manner.
The Motor Decisions MatterSM Campaign suggests the following key elements for a sound
motor management plan (CEE, 2007):
1.
Creation of a motor survey and tracking program.
2.
Development of guidelines for proactive repair/replace decisions.
3.
Preparation for motor failure by creating a spares inventory.
4.
Development of a purchasing specification.
5.
Development of a repair specification.
6.
Development and implementation of a predictive and preventive maintenance program.
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2. Maintenance
The purposes of motor maintenance are to prolong motor life and to foresee a motor failure. Motor
maintenance measures can therefore be categorized as either preventative or predictive.
Preventative measures, include voltage imbalance minimization, load consideration, motor
alignment, lubrication and motor ventilation.
Some of these measures are further discussed below. Note that some of them aim to prevent
increased motor temperature which leads to increased winding resistance, shortened motor life,
and increased energy consumption.

The purpose of predictive motor maintenance is to observe ongoing motor temperature, vibration,
and other operating data to identify when it becomes necessary to overhaul or replace a motor
before failure occurs.
The savings associated with an ongoing motor maintenance program could range from 2% to 30%
of total motor system energy use.
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3. Energy-efficient motors

An example of energy-efficient motor


Energy-efficient motors reduce energy losses through improved design, better materials, tighter
tolerances, and improved manufacturing techniques. With proper installation, energy- efficient
motors can also stay cooler, may help reduce facility heating loads, and have higher service factors,
longer bearing life, longer insulation life, and less vibration.
The choice of installing a premium efficiency motor strongly depends on motor operating
conditions and the life cycle costs associated with the investment.
In general, premium efficiency motors are most economically attractive when replacing motors with
annual operation exceeding 2,000 hours/year. Sometimes, even replacing an operating motor with
a premium efficiency model may have a low payback period.
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4. Rewinding of motors

Electric motor being rewound (photo credit:


soco.co.nz)
In some cases, it may be cost-effective to rewind an existing energy-efficient motor , instead
of purchasing a new motor. As a rule of thumb, when rewinding costs exceed 60% of the costs of a
new motor, purchasing the new motor may be a better choice (CEE, 2007).
When repairing or rewinding a motor, it is important to choose a motor service center that follows
best practice motor rewinding standards in order to minimize potential efficiency losses. Such
standards have been offered by the Electric Apparatus Service Association (EASA) .
When best rewinding practices are implemented, efficiency losses are typically less than
1% (EASA, 2003). Software tools such as MotorMaster+ can help identify attractive applications of
premium efficiency motors based on the specific conditions at a given plant.
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5. Proper motor sizing


It is a persistent myth that oversized motors, especially motors operating below 50% of rated load ,
are not efficient and should be immediately replaced with appropriately sized energy-efficient units.
In actuality, several pieces of information are required to complete an accurate assessment of
energy savings.
They are the load on the motor, the operating efficiency of the motor at that load point, the full-load
speed (in revolutions per minute [rpm]) of the motor to be replaced, and the full-load speed of the
downsized replacement motor.
The efficiency of both standard and energy-efficient motors typically peaks near 75% of full load and
is relatively flat down to the 50% load point. Motors in the larger size ranges can operate with
reasonably high efficiency at loads down to 25% of rated load.
There are two additional trends: larger motors exhibit both higher full- and partial-load efficiency
values, and the efficiency decline below the 50% load point occurs more rapidly for the smaller size
motors.
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6. Using Adjustable speed drives (ASDs)

AC Variable Speed Drive


and IE2 Motor Kit 1.5kW (2.0HP) 230V Single Phase (photo credit: inverterdrive.com)
Adjustable-speed drives better match speed to load requirements for motor operations, and
therefore ensure that motor energy use is optimized to a given application. As the energy use of
motors is approximately proportional to the cube of the flow rate, relatively small reductions in flow,
which are proportional to pump speed, already yield significant energy savings.
Adjustable-speed drive systems are offered by many suppliers and are available worldwide. Worrell
et al. (1997) provides an overview of savings achieved with ASDs in a wide array of applications;
typical energy savings were shown to vary between 7% and 60% with estimated simple payback
periods for ranging from 0.8 to 2.8 years (Hackett et al., 2005).
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7. Power factor correction


Power factor is the ratio of working power to apparent power. It measures how effectively electrical
power is being used. A high power factor signals efficient utilization of electrical power, while
a low power factor indicates poor utilization of electrical power.
Inductive loads like transformers, electric motors, and HID lighting may cause a low power factor.

The power factor can be corrected by minimizing idling of electric motors (a motor that is turned
off consumes no energy), replacing motors with premium-efficient motors, and installing capacitors
in the AC circuit to reduce the magnitude of reactive power in the system.
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8. Minimizing voltage unbalances


A voltage unbalance degrades the performance and shortens the life of three-phase motors.
A voltage unbalance causes a current unbalance, which will result in torque pulsations, increased
vibration and mechanical stress, increased losses, and motor overheating, which can reduce the
life of a motors winding insulation.
An example of Effects of voltage unbalance on 5 hp motor:
Characteristic

Performance

Average voltage

230

230

230

Percent unbalanced voltage

0.3

2.3

5.4

Percent unbalanced current

2.4

17.7

40

Increased temperature (C)


<1
11
60
Voltage unbalances may be caused by faulty operation of power factor correction equipment, an
unbalanced transformer bank, or an open circuit. A rule of thumb is that the voltage unbalance at
the motor terminals should not exceed 1% although even a 1% unbalance will reduce motor
efficiency at part load operation. A 2.5% unbalance will reduce motor efficiency at full load
operation.
By regularly monitoring the voltages at the motor terminal and through regular thermographic
inspections of motors, voltage unbalances may be identified. It is also recommended to verify that
single-phase loads are uniformly distributed and to install ground fault indicators as required.
Another indicator for voltage unbalance is a 120 Hz vibration, which should prompt an immediate
check of voltage balance (U.S. DOE-OIT, 2005b).
The typical payback period for voltage controller installation on lightly loaded motors in the U.S. is
2.6 years (U.S. DOE-IAC, 2006).

Use lighting controls to automatically turn lights on and off as needed, and save energy. Of course you can save energy
by turning off lights when they're not needed, but sometimes we forget or don't notice that we've left them on.
The most common types of lighting controls include:

Dimmers
Motion, occupancy, and photosensors
Timers.

Before purchasing and using any lighting controls, it's a good idea to understand basic lighting terms and principles.
Also, it helps to explore your indoor and outdoor lighting design options if you haven't already. This will help narrow your
selection.

DIMMER CONTROLS
Dimmer controls provide variable indoor lighting. When you dim lightbulbs, it reduces their wattage and output, which
helps save energy.

Dimmers are inexpensive and provide some energy savings when lights are used at a reduced level. They also increase
the service life of lightbulbs significantly. However, dimming reduces an incandescent bulb's lumen output more than its
wattage. This makes the bulbs less efficient as they are dimmed.

DIMMERS AND CFLS


Unlike incandescents, compact fluorescent lamps (CFLs) do not lose their efficiency with dimming. Some CFLs are
compatible with standard dimmers, which will be indicated on the package. Others require special dimming ballasts and
bulb holders. Fluorescent dimmers are dedicated fixtures and bulbs that provide even greater energy savings than a
regular fluorescent bulb. Dimming a CFL that is not designed to work with a dimmer switch is not recommended, as this
can shorten its life significantly.
You can change the lightbulbs and ballasts in fluorescent lighting fixtures rather than replace them.

DIMMERS AND LEDS


Some light-emitting diode (LED) lightbulbs can be used with dimmers. LED bulbs and fixtures must be designed for
dimming, and you may need to replace existing dimmer switches with ones that are compatible with an LED lighting
product. The packaging or accompanying instructions will indicate if the product is dimmable and which dimmer products
are compatible. Fully compatible LED dimmers are expected to become more common as the LED industry expands.

MOTION SENSOR CONTROLS


Motion sensors automatically turn outdoor lights on when they detect motion and turn them off a short while later. They
are very useful for outdoor security and utility lighting.

Because utility lights and some security lights are needed only when it is dark and people are present, the best way to
control might be a combination of a motion sensor and photosensor.
Incandescent flood lights with a photosensor and motion sensor may actually use less energy than pole-mounted highintensity discharge (HID) security lights controlled by a photosensor. Even though HID lights are more efficient than
incandescents, they are turned on for a much longer period of time than incandescents using these dual controls.
HID lightbulbs don't work well with just a motion sensor, as they can take up to ten minutes to produce light.

OCCUPANCY SENSOR CONTROLS


Occupancy sensors detect indoor activity within a certain area. They provide convenience by turning lights on
automatically when someone enters a room, and save energy by turning lights off soon after the last occupant has left the
room. Occupancy sensors must be located where they will detect occupants or occupant activity in all parts of the room.
There are two types of occupancy sensors: ultrasonic and infrared. Ultrasonic sensors detect sound, while infrared
sensors detect heat and motion. In addition to controlling ambient lighting in a room, they are useful for task lighting
applications such as over kitchen counters. In such applications, task lights are turned on by the motion of a person
washing dishes, for instance, and automatically turn off a few minutes after the person leaves the area.

PHOTOSENSOR CONTROLS
You can use photosensors to prevent outdoor lights from operating during daylight hours. This can help save energy
because you don't have to remember to turn off your outdoor lights.

Photosensors sense ambient light conditions, making them useful for all types of outdoor lighting. These light-sensitive
controls are less effective inside the home because lighting needs vary with occupant activity rather than ambient lighting
levels. Many LED nightlights, however, have this feature built in which makes them effective and easy to use.

TIMER CONTROLS
Timers can be used to turn on and off outdoor and indoor lights at specific times. There are two types of timers: manual
timers, which plug into an electrical outlet for controlling objects such as lamps or light strings; and in-wall programmable
digital timers (which look like digital thermostats), which automate indoor or outdoor lighting.
Programmable timers are not often used alone for outdoor lighting because the timer may have to be reset often with the
seasonal variation in the length of night. However, they can be used effectively in combinations with other controls. For
example, the best combination for aesthetic lighting may be a photosensor that turns lights on in the evening and a timer
that turns the lights off at a certain hour of the night (such as 11 p.m.).

For indoor lighting, timers are useful to give an unoccupied house a lived-in look. However, they are ineffective for an
occupied home because they do not respond to changes in occupant behavior, like occupancy sensors.
Using timers with CFL and LED Lighting
Timing controls work well with CFL and LED lightbulbs, as they do not interrupt the circuitry. This is especially true with
manual timers that use pins for setting the on and off times.

Manual timers: compatible with LED, CFL, and incandescent lighting


Programmable digital timers: check the package label to be sure it is compatible with the type of lighting you want
to use.

Improvements in motor efficiency can be achieved without compromising motor performance - at higher cost within the limits of existing design and manufacturing technology.
Motor efficiency is the ratio of mechanical power output to the electrical power input, usually

expressed as a percentage.
Considerable variation exists between the performance of standard and energy-efficient motors.
Energy-efficient motors reduce energy losses through Improved design, better materials, tighter
tolerances and improved manufacturing techniques and accomplishes more work per unit of electricity

consumed.
Energy-efficient

motors

offer

other

benefits.

Because

they

are

constructed

with

improved

manufacturing techniques and superior materials, energy-efficient motors usually have higher service
factors, longer insulation and bearing lives, lower waste heat output, and less vibration, all of which

increase reliability. With proper installation, energy- efficient motors can also stay cooler Most motor

manufacturers offer longer warranties for their most efficient models.


To be considered energy efficient, a motors performance must equal or exceed the nominal full-load

efficiency values provided by the National Electrical Manufacturers Association (NEMA).


The choice of installing a premium efficiency motor strongly depends on motor operating

conditions and the life cycle costs associated with the investment.
In general, premium efficiency motors are most economically attractive when replacing motors with
annual operation exceeding 2,000 hours/year. Sometimes, even replacing an operating motor with

a premium efficiency model may have a low payback period.


Replacing a motor may be justifiable solely on the electricity cost savings derived from an energy-

efficient replacement.
This is true if the motor runs continuously, power rates are high, the motor is oversized for the

application, or its nominal efficiency has been reduced by damage or previous rewinds.
Efficiency comparison for standard and high efficiency motors is shown in Figure

Simply Stated:

REDUCED LOSSES = IMPROVED EFFICIENCY

Technical aspects of Energy Efficient Motors


(or)
design factors to be considered while choosing an energy efficient motor
1. Energy-efficient motors last longer, and may require less maintenance. At lower
temperatures, bearing grease lasts longer; required time between re-greasing increases. Lower
temperatures translate to long lasting insulation. Generally, motor life doubles for each 10C
reduction in operating temperature.
2. Select energy-efficient motors with a 1.15 service factor, and design for operation at 85% of
the rated motor load.
3. Electrical power problems, especially poor incoming power quality can affect the operation
of energy-efficient motors.
4. Speed control is crucial in some applications. In polyphase induction motors, slip is a
measure of motor winding losses. The lower the slip, the higher the efficiency. Less slippage
in energy efficient motors results in speeds about 1% faster than in standard counterparts.
5. Starting torque for efficient motors may be lower than for standard motors. Facility
managers should be careful when applying efficient motors to high torque applications.
6. Motor Size. Motors should be sized to operate with a load factor between 65% and 100%.
The common practice of oversizing results in less efficient motor operation. For example, a

motor operating at a 35% load is less efficient than a smaller motor that is matched to the
same load . Of course, some situations may require oversizing for peak loads, but in such
cases alternative strategies should be considered, such as a correctly sized motor backed up
with a pony motor.
7. Operating Speed. Select replacement energy-efficient motors with a comparable full-load
speed for centrifugal load applications (pumps and fans). Induction motors have an operating
speed that is slightly lower than their rated synchronous speed. For example, a motor with a
synchronous speed of 1800 rpm will typically operate under full load at about 1750 rpm.
Operating speed (full-load rpm) is stamped on motor nameplates. The difference between the
synchronous speed and the operating speed is called slip. Slip varies with load and the
particular motor model. Every pump and fan has a design speed. Centrifugal pump and fan
loads are extremely sensitive to speed variations; an increase of just 5 rpm can significantly
affect the pump or fan operation, leading to increased flow, reduced efficiency, and increased
energy consumption. Whenever a pump or fan motor is replaced, be sure to select a model
with a full-load rpm rating equal to or less than that of the motor being replaced.
8. Inrush Current. Avoid overloading circuits. Energy-efficient motors feature low electrical
resistance and thus exhibit higher inrush currents than standard models. The inrush
current duration is too short to trip thermal protection devices, but energy-efficient motors
equipped with magnetic circuit protectors can sometimes experience nuisance starting trips.

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