International Copper Promotion Council (India) Welcomes The Delegates For Work Shop for UNDP / GEF PROJECT (4 th April 2009 at Nagpur) Presentation By SHASHIBHUSHAN S AGRAWAL BEE Certified Energy Auditor (R.No.EA-1090) Consultant To ICPCI for EE Motor Project High Efficiency Motor Application Slide 1 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 . Slide 2 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 Slide 3 HEM application - Industrial sector
Sector wise energy consumption Others 10% Commercial 4% Industrial 41% Domestic 19% Agri 26% Industry consumes the most Energy Slide 4 HEM application - Industrial sector
Sector wise Energy Saving potential Energy Handled Conservation Sector by Motors (%) potential (%) 70-75% Industrial Sector Up to 25 Agriculture Sector Up to 30 20-25% 2-3% Domestic Sector Up to 20 4-5% Commercial Sector Up to 30 Slide 5 HEM application - Industrial sector
Why HEM Project ? • 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. Slide 6 HEM application - Industrial sector
Estimated Energy Saving Potential by Improving Energy Efficiency Equipment Energy Saving Potential per year Distribution Transformer 463 Motors & Pumps 39,500 Others 200 ------------------------------------------------------------------------- Total 40,163 Million KWH ------------------------------------------------------------------------- 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. Slide 7 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 Slide 8 HEM application - Industrial sector
Barriers to penetration of HEM s 1. Lack of knowledge/ awareness with users 2. Non availability of EE motors Market 3. Confusion – EE motor definition 3% 4. Need to have focused market transformation penetration • Higher initial cost Economically • Low demand; high price 40% • Lesser working hours viable • Lack of technology Technically 1. Poor power quality in rural sector 70% 2. Application limitations feasible Theorotical 100% Potential 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Slide 9 HEM application - Industrial sector
HEM Implementation Towards increasing penetration of HEM s Policies Marketing Supply Regulation Promotion Chain Standards Slide 10 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 Slide 11 HEM application - Industrial sector
Standards Standard •Prescribes Energy performance of manufactured products (Minimum Energy Performance Standards, MEPS). Slide 12 HEM application - Industrial sector
Standards scenario - International EPACT CEMEP Agreement • Legislation • Voluntary • Three-phase induction • Three-phase induction • motors • motors • 0.75 to 150kW • 1.1 to 90kW • 60Hz • 50 Hz • 2, 4, and 6 pole • 2 and 4 pole • Specifies minimum • Efficiency labelling • efficiencies • Testing to IEEE-112b • Testing to IEC60034-2 Slide 13 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 Slide 14 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 Slide 15 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 Slide 16 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 Slide 17 HEM application - Industrial sector
Efficiency Improvement Efficiency = Output Input = Output Output + Losses Slide 18 HEM application - Industrial sector
Loss reduction Reduce Iron Loss Reduce Copper Loss Reduce Reduce Stator Cu Loss Rotor Cu Loss Increase Reduce Increase Copper Section Flux Density Rotor bar section Stator slot area Increase Reduce Increased Low Loss Stator Yoke Rotor Diam Starting current Magnetic matl . Source: Bharat Bijlee Reduced S t a r t i n g T o r q u e Core length has to be increased to maintain starting torque Slide 19 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 Rs � High Grade (low loss) laminations � More Copper Source: Bharat Bijlee Slide 20 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 Slide 21 HEM application - Industrial sector
End User involvement Awareness creation Conviction Adoption Slide 22 HEM application - Industrial sector
Awareness Yes No Willing to Change - Conviction Reasons? Barriers /issues Lack of info. (tech. /general) Corporate culture, Individual mindsets Yes No no interest in Energy Cons. Know –all attitude How – Adoption Why? Identify key implementers Barriers /issues Price premium, availability, Claims Vs savings actual, Solutions Tech. Support, rewinding issues Provide information No finance,Not decision maker Help them Solutions Remove doubts Structured program on Energy Management through motors Slide 23 HEM application - Industrial sector
Opportunities to adopt HEM 1. First purchases Existing motors New Project Expansion 2. Replacement 3. Retrofit Projects / Consultants Plant Personnel Top Management/Financers Slide 24 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 Slide 25 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 Slide 26 HEM application - Industrial sector
The operating costs are what count ! ! ! 12 yrs 15 yrs 20 yrs Slide 27 HEM application - Industrial sector
Retrofitting of existing motors n Statistical Approach n Analytical Approach Slide 28 HEM application - Industrial sector
Motor data & initial load survey Identification Name Plate data Values measured using a Power Meter No.of Applica rewinds LocationTag No tion Pur.date kW Rpm Volts AmpsEff% Volts Amps Hz PF kW Rpm Temp ºC Slide 29 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 Slide 30 HEM application - Industrial sector
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