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Motor Conversion For Reduced Energy Consumption In Compressor

Applications

Melissa R. Dale David Carichner

Sales Engineer, Pneumatic Transport Chief Mechanical Engineer
FLSmidth Inc. CalPortland
2040 Avenue C 2025 E Financial Way
Bethlehem, PA 18017, USA Glendora, CA 91741, USA
Melissa.Dale@flsmidth.com dcarichner@calportland.com

Abstract - A significant energy savings can be achieved by converting inefficient direct-driven rotary vane compressor
applications to belt-driven applications.

Index Terms Cement Industry, Compressors, Energy Conservation, Motor Drives, Motor Economics, Motors.

I. INTRODUCTION

Compressor applications utilizing rotary vane technology typically consume more energy than applications
utilizing newer technologies. Much of the reason for the higher energy consumption associated with rotary vane
compressors is the motor utilized. Motors that are inefficient, under/oversized, or have not been properly
maintained reduce motor efficiency, increase power utilization and thus, increase operating costs.
To reduce power consumption and cost of operation, while increasing motor efficiency, an Arizona cement plant
installed motor conversion technology in 2008. The following study is focused on two installations converting
direct drive motors to high efficiency TEFC motors.

A. Motor Efficiency

A correctly-sized motor is crucial to the continued operation and maintenance of a rotary vane compressor. The
motor provides the power to turn the compressor rotor and provide a powerful source of compressed air (or gas) for
plant operations.
A motor, at most basic terms, converts electrical energy to mechanical power. The measure of total energy used
by the motor related to the amount of energy delivered to the shaft (rotor) is motor efficiency.

Output Output
Efficiency = --------------- = ----------------------
. Input Output + Losses

Fig. 1. Determining motor efficiency

Motor efficiency is influenced by function and design of the motor. Efficiency standards in the United States
were established in 1990 with the National Electrical Manufacturers Association (NEMA) MG1-1987 guidelines.
These guidelines became the basis for the Energy Policy Act of 1994 (EPAct) which established more strict
guidelines on motor construction and efficiency. EPAct took effect in 1997, mandating minimum motor efficiency
requirements. In 2001, the basis for NEMA premium motors was established. NEMA premium efficiencies are the
standard for most motor manufacturers today[2].

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A large percentage of rotary vane installations in the United States utilize motors which pre-date these standards.
A typical direct-driven motor application has less than 85% efficiency, depending on the age and maintenance of the
motor.

B. Motor Conversion

In utilizing a modern high efficiency, high speed motor in rotary vane compressor technology, the user must
convert the existing direct-driven application to a cog-belt driven application to adjust for the increase in motor
speed. The motor must be installed at a greater height to allow for the installation of the correct belting.
In converting a direct drive motor application to a cog-belt driven motor application, there are two common
conversion methods. The first method, a motor conversion frame, is installed in the footprint of the former direct
drive motor. The frame allows for the high efficiency motor to be installed and adjusted to the proper height of the
belt. The frame may also incorporate lubrication and control systems.

Fig. 2. Motor conversion frame (view of belt and coupling)

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Fig. 3. Motor conversion frame (view of motor)

The second method of motor conversion is the installation of the motor directly atop the compressor.
In both applications, a cog belt (synchronous) belt provides the drive to the compressor. Cog belts offer superior
efficiency and require no retensioning or lubrication.

C. Installation Results

The cement plant installed two motor conversions in 2008 utilizing high-efficiency motor conversion frames in
the footprints of the former direct drive motors. In both applications, an 1800 RPM, 200 HP TEFC high efficiency
motor replaced a 590 RPM direct drive motor. Both existing direct drive motors were over 20 years of age.
Prior to motor conversion, measurements were taken for a 24 hour period with the operation of the direct-drive
motor under normal circumstances in 2007.

With existing motor With upgraded motor

RPM 590 1800
Average kW over 24 hours 181 kW 116 kW
Average production in tph 63.8 tph 67.0 tph
Average kW/ Ton 2.84 kW/ton 1.74 kW/ton
Cost per kWh 6.5 cents
Annual average run hours 7756 hours
Energy costs USD 84,436.40 USD 31,189.30

Fig. 4. Measurement of motor energy consumption, before and after installation of high efficiency motor

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After installation of the belt-driven motor was complete, measurements were taken for a 24 hour period under
normal circumstances in 2008. A slight increase in production (tph) occurred during this timeframe.
Upon the installation, compressor energy consumption (kW) dropped 36% and provided a yearly savings of
$53,247 USD. The return on investment for the installations was well under one year. The large decrease in energy
usage in this application and others at the plant have earned the installation site an EPA Energy Star designation
each year since 2005. [3]

D. Conclusion

The applications above have continued to provide consistent energy savings and efficient operation. The plant
has since added motor conversions to additional rotary vane compressors. Additional data recorded has shown that
increases in production may yield even greater energy savings in compressors with belt-driven motors.

REFERENCES

[1] Paul Waide and Conrad U. Brunner, Energy-Efficiency Policy Opportunities for Electric Motor-Driven
Systems International Energy Agency, 2011.
[2] Motors and Generators, NEMA MG 1-2003
[3] CalPortland, Environmental Awards fact sheet - http://www.calportland.com/environmental_awards.aspx

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