Siemens Corporate Design PowerPoint-Templates · less than allowed by law. ... Project reference...

Motor Efficiency Andy Wahmhoff Manufacturing in America │ 02/22-23/2017

Unrestricted © Siemens 2017 All rights reserved.

Agenda

• Introduction

• Why is efficiency so important?

• DOE Requirements

• History

• Current

• Future Trends

• Solution Examples

• Open Discussion

Why is motor efficiency so important?


Why electric motor efficiency is so important?

The purchase price of a motor is less than 3% of the total cost of ownership Over 96% of the cost of a motor is the energy it consumes over its operational life Electric motors use ~ 55% of the available electricity globally


Countries with energy efficiency certification for electric motors

USA, Canada (NEMA)

DoE, CSA-E

Mexico NOM (NEMA)

Brasil ABNT

Chile Energy Label Eff.

Australian MEPS

Korea KEMCO

JAPAN MEPS

China CEL

Vietnam VNEEP

Thai MEPS

India BEE

Europe (EU) 2009/125/EG

ECA

Saudi Arabia SEEC

Columbia (RETIQ)

Department of Energy Requirements – Past & Present


Motor Efficiency Regulations


New DOE Efficiency Requirements - Integral HP (IHP) Motor Rule – June 2016


Motors Covered Under the IHP Rule (EISA Subtype I)


Additional Motor Designs Covered (Subtype II)


Motor Designs Not Covered


Progression of Active Material


What is next?

System Efficiency (Pump, fan, compressor, conveyor) Pumps will be first Efficiency standards and definitions established Implementation dates need to be confirmed Links to additional information: http://www.pumps.org/DOE_Pumps.aspx

http://www.pumps.org/DOE_Pumps.aspx




Energy Policy Act Of 1992—where it all started…

Defined a minimum motor efficiency level > NEMA MG1, table 12-11

Defined “covered product”

> 1-200HP 2/4/6pole General purpose 230/460volt

Established a test method using IEEE/CSA standards Required manufacturers to use accredited test labs Created a labeling standard Implemented a product compliance procedure Enforcement begain in October, 1997


NEMA Premium® Efficient Motors…a step up in energy savings

Established a national motor efficiency standard significantly above the federal mandated efficiencies (EPAct 1992)

Expanded scope of product to include a much greater number of potential units

Created a testing and labeling standard that is consistent with existing federal energy legislation (EPAct)

Added NEMA Premium® to NEMA MG1 in two new tables NEMA tables 12-12 & 12-13

Coordinated with CEE to revise utility rebate programs to use NEMA Premium®

Required a participating manufacturer to sign a memo of understanding before using the NEMA Premium®

registered trademark and to report sales


Motors and Applications 1 HP to 500 HP

>HVAC >Pumps >Fans >Material Handling >Compressors

http://www.google.com/imgres?imgurl=http://www.parkmechanical.com/com/img/side/Cooling Tower.jpg&imgrefurl=http://www.parkmechanical.com/com/hvac.htm&h=1536&w=2048&sz=631&tbnid=Zr1-2MaKikVVqM::&tbnh=113&tbnw=150&prev=/images?q=cooling+tower+photo&hl=en&usg=__Wh3sDPxkFf8uTUoKxtJJovT8fQk=&sa=X&oi=image_result&resnum=2&ct=image&cd=1


Motor Facts

Industrial motors can have up to 30 year service life

The average integral HP motor is repaired 3 or more times in its lifetime

The average IHP motor can use 4 to 6 times it’s original cost in electricity per year

Lots of opportunities to save energy and lower total operating costs


What Is the Difference Between EPAct & NEMA Premium®

EPAct covers a broad spectrum of motors from 1 – 200 hp.: Federal regulation mandates efficiency levels as well as labeling and testing standards Efficiency levels defined by NEMA MG1 table 12-11 Some ratings not covered (design C, P-base, etc.)

NEMA Premium® expands product scope & efficiency levels: 1- 500 hp Efficiency levels defined by NEMA MG1 table 12-12

NEMA Premium® efficiencies not a regulation or law today

It is strictly a voluntary program (except government purchases…must be NEMA Premium®) This changes with the Energy Independence & Security Act (EISI) signed into law in December, 2007

& became effective December, 2010.


Are NEMA Premium® Motors a Direct Replacement for Old Std or EPACT Motors?

Motors are normally built in one of four design categories A,B,C, or D The most universally used design is design B

Commercial and industrial electrical systems are designed to use NEMA design B motors at either 230, 460 or 575 volts NEMA Premium® motors are intended to be direct replacements to existing motors Is there a risk of miss application using NEMA Premium® motors to replace failed motors?

NEMA Premium® motors are built as design “B” or “A” only. High torque design “C” or “D” applications would be effected.


Efficiency Quality EPAct NEMA Premium®

Motor Failure

Repair or Used

Replace

Decision to replace failed Motors with NEMA Premium® can save thousands of dollars in unnecessary operating costs


Cost Savings Opportunities Are Driven by Energy Use Reductions

Replace motors as they fail with NEMA Premium®

Implement a motor survey & replace low efficient units with NEMA Premium® before they fail based on projected savings

Avoid repairing motors or replacing with used or spares…paying higher energy bills!

Evaluate and refine motor selection and purchasing guidelines to improve TCO situation

Siemens – Maximize Efficiency


Department of Energy - Estimated Impact of NEMA Premium® Over a Ten Year Period

Reduction of 80 million tons of carbon

Reduction of 5,800 gigawatt-hours

The equivalent of removing 16 million cars from American highways

Unrestricted © Siemens 2017 All rights reserved. Potential 10 Year Savings with SIEMENS = $47, 312

SIEMENS Motor Efficiency is Better Than Required by DOE

Installed Motor Profile Energy loss with Siemens motors is guaranteed to be 10% less than allowed by law.

Cumulative savings $4,689 $9,483 $14,219 $17,313 $23,692 $28,426 $33,100 $37,849 $42,583 $47,312

Motor Size Qty 1 HP 60

30 HP 15 100 HP 5 200 HP 2

Energy cost: $0.105/kWh

Continuous duty: Full load

Run period: 10 years @ 18 hour / day


SIEMENS CO2 Emissions Savings

Motor Qty

1 HP 1530 HP 5

100 HP 3200 HP 2

Installed Motor Profile

*C02 calculated at 632g/kWh per SINASAVE

Continuous duty: Full load

5 years 18 hour / day

*


Copper Rotor NEMA Motors Efficiency Levels (4-Pole, TEFC Motors)

Siemens Copper Rotor

All efficiency levels exceed NEMA Premium requirements!

Available for severe duty and general purpose products 1-20HP

Efficiencies 5-7% above premium efficient

Unrestricted © Siemens 2017 All rights reserved. March 17, 2010 Si I d t

75

80

85

90

95

100

1 5 7.5 10 20 25 30 40 50 75 100 125 150 200

Horsepower

Effic

iency STD

EE

Premium

Energy Policy Act of 1992

Three Levels of Motor Efficiency


Motor technologies for high efficient systems Higher efficiency classes require new technologies

“IE4”

SYN

IE2

IE3

IE1

Efficiency

Technology

Standard asynchronous motors

Synchronous motors with permanent magnets/ in reluctance technology

IE4

New technologies


Motor Technologies for High Efficient Systems Selection of the system with the lowest costs

PD LD P/DF MC GMC

Costs

Performance / Efficiency

DC drive

Asynchronous motor +

Frequency converter

Permanent magnetized synchronous motor

+ Frequency converter

Synchronous reluctance motor

+ Frequency converter + efficient

+ highest dynamic - intensiv in costs for special applications

+ efficient + high dynamic + low costs for standard drive systems

+ robust + low costs for standard drive systems

+ robust inverter + simple control - intensiv in costs and maintenance for special applications

2016 04 Page 34


Looking Beyond the Motor and VFD IDS – Integrated Drive System

Belt conveyor

What is IDS?

Optimizing system efficiency

Efficient Motor +

VFD +

Efficient Gearbox +

Coupling =

Optimized system for application


IDS Examples Conveyor Belt Drive

Design Bevel Gear Unit

Sizes 8

Gear stages 3-stages

Power ratings Up to 1176 kW

Transmission ratios i = 12,5 … 40

Nominal torques Up to 113 kNm

Design horizontal


Example: Vattenfall Mining Project reference with measurable customer benefit

Customer Vattenfall Europe Mining AG Reichwalde, Lausitz region, Germany Order Construction of a 13- km-long belt conveyor system with a coal output capacity of 6,000 t/h Solution • Complete engineering, manufacture, delivery,

and assembly of the drive stations and installation of the conveyor system

• Drive systems with SINAMICS S120 converters in six stations

• Construction of a control center with SIMATIC WinCC • SIMATIC S7-400 controls Customer benefit • 98% availability • Energy savings of up to 15% • Maintenance cost savings of up to 15%


Type and size P2DA 38

Power ratings 500 kW

Transmission ratio i = 80

Nominal torque 3.00,000 Nm

In group grinding : Kiln Drives with Planetary gears


Bucket Wheel Drive

Type and size PBUC 42

Power ratings 1,150 kW

Transmission ratio i = 250

Nominal torque 2,750,000 Nm


Questions?

Andy Wahmhoff Siemens – Low Voltage Motors Houston, TX USA Phone: (832) 335-9677 E-mail: [email protected]

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