Energy Efficient Drives en

1
EU-Twinning Project SL04/EN/01

Integrated Pollution Prevention and Control (IPPC)
Peter Radgen, Dr., STE
Fraunhofer Institute System and Innovation Research, Karlsruhe
Ljubljana, 13 -15 March 2006
Mission 6.2: Energy Efficiency
1
Energy Efficiency
in Motor Driven
Systems
2
Shares of electricity consumption
in industry (EU-15)
Electric motors and
applications
69% = 800 TWh
Pumps
30%
Fans
14%
Refrigerating
machines 14%
Other applications:
mixing, stirring,
transporting: 32%
Air compres-
sors 10%
Motor systems account for about 65 % of electricity consumption in
industry in the European Union
2
3
Overview of saving potentials in
motor driven systems
Measures
economic saving
potential
Improvement of drive by
- use of high efficiency motors 3 %
- use of variable speed drives 11 %
Improvement of the system
- for compressed air supply 33 %
- for pump systems 30 %
- for refrigeration systems 18 %
- for HVAC and fan systems 25 %
Motorsystems Total 25-30 %

4
81%
14%
5%
Energy Costs
Investment
Maintance
Life Cycle Costs of Motor Driven Systems
Example Compressed Air
System
Power 110 kW
Lifetime 15 a
Operating hours 4000 h/a
Energy price 6 ct/kWh
Many measures are highly economic, as energy costs account for
about 80% of the life cycle cost.
3
5
Electric Motors
6
Saving Potentials for drives
Measures
Saving
Potential
Systeminstalllation or Replacement
high efficiency motors (HEM) 2-8 %
correct sizing 1-3 %
energy efficient motor repair 0,5-2%
variable speed drives 10-50 %
efficient gear boxes 2-10 %
quality of power supply 0,5-3 %
System operation and maintenance
greacing, adjusting and fine tuning 1-5 %
4
7
Improved efficiency of motors
70%
75%
80%
85%
90%
95%
100%
1,1 kW 5,5 kW 11 kW 90 kW
high efficiency motors
standard motors
+ 8,7% + 8,7%
+ 1,2% + 1,2%
Cost Savings
11 kW 69 /a
90 kW 266 /a

As smaller the power of the
motor as worse is the
efficiency of it and hence as
larger the saving potential
Also small improvements for
large motors could deliver
significant total savings
8
High Efficiency Motors (HEM)
75
80
85
90
95
1 10 100
1
2
3
4
5
6
7
eff3-Motor (2 pol and 4 pol)
eff2-Motor (2 pol)
eff1-Motor (4 pol)
(eff1-eff3) (2 pol)
E
f
f
i
c
i
e
n
c
y
(
%
)
Efficiency requirements for motors
E
f
f
i
c
i
e
n
c
y
d
i
f
f
e
r
e
n
c
e
(
%
)
Power (kW)
5
9
Share of efficiency classes on motor sales in Europe
2%
30%
68%
3%
44%
53%
3%
54%
43%
4%
80%
16%
5%
83%
12%
6%
84%
10%
7%
85%
8%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
1998 1999 2000 2001 2002 2003 2004
Total motor-sales in the scope of the Voluntary Agreement of CEMEP
EFF3
EFF2
EFF1
Quelle: CEMEP, EEMODS Konferenz, Heidelberg, 2005.
10
Comparison of EFF 1 and EFF 2-motors
by infrared photographs
EFF 1 EFF2
6
11
Pumps
12
Energy efficiency of pump systems
7
13
Energy Saving Potentials in Pump Systems
Measure Energy Saving
Potential Sys-
tems (EEP)i
Possible Mar-
ket uptake
(MDD)i
Efficiencyfactor
(1 - EEP*MDD)i
speed control 70 % 20 % 86,0 %
operating hours 10 % 15 % 98,5 %
high efficiency motors 4 % 40 % 98,4 %
system design 15 % 4 % 99,4 %
reduced pressure losses
in the pipework
8 % 15 % 98,8 %
( )
i i
n
i
MDD EEP
=
1
1
81,9 %
Energy Saving Potential ( )
i i
n
i
MDD EEP =

=
1 1
1
18,1 %

Measure Saving potential
[%-points]
Reduction of surface roughness 10 %
Reduction of internal leakage (gap losses) 6 %
Optimised geometry of impellers 3%

Pump
Pumpsystem
14
Energy Saving with Pumpsystems
Pumps often work away from their best
efficiency Point (BEP) based on
Over dimensioning during planning
Changes compared to design conditions
Significant reduction of efficiency of
the pump
Changed volume flows
Aging of pumps:
Loss of efficiency by 10 to 15 %-points
based on poor maintenance
E
f
f
i
z
i
e
n
z
h
e
a
d
Volume flow
Working line
throttling
efficiency
Power
E
f
f
i
c
i
e
n
c
y
P
o
w
e
r
8
15
Maximum efficiency improvement
by surface smoothening
whole pump: ... < 20%
volute: ... < 5% casing: ... < 5%
inner surface: ... < 5% outer surface: ... < 7%
whole impeller
Surface roughness
before smoothing:
(k
S
= 0,4 mm)
The specified
values of efficiency
gain are per cent
points
16
Fans
9
17
Industrial Fans
Fan for steel works
Mine ventilation fan
Induced draught fan
for 600 MW
Power station
Fan for
sinter
plant
18
Building Ventilation
10
19
Distribution of energy consumption for fans by fan size in the US
Distribution of electricity consumption for fans by motor size
(SIC 20-39 Overall Manufacturing)
1-5 hp
5,2%
6-20 hp
13,9%
21- 50 hp
13,5%
51 -100 hp
10,8%
101 -200 hp
17,9%
201 -500 hp
8,2%
501-1000 hp
11,1%
1000+ hp
19,3%
Source: United States Industrial Electric Motor Systems Market Opportunities Assessment, OIT; US DOE, December 1998.
20
Energy flow in a fan system
% 54
input energy
energy fan useful
= =
11
21
Fan Electricity Consumption in the European Union
(EU-15)
0
5
10
15
20
25
30
35
40
45
E
l
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t
r
i
c
i
t
y

C
o
n
s
u
m
p
t
i
o
n

[
T
W
h
]
A BE DK FI F D GRE IRE I LU NL P ES S GB
Total consumption
197 TWh
22
Fan Electricity Consumption by Sector
0
10
20
30
40
50
60
70
80
90
100
E
l
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r
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i
t
y

c
o
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s
u
m
p
t
i
o
n

[
T
W
h
]
Transport Industry Service SectorTertiary (excl.
Service
sector)
12
23
Emission and Cost Savings
Electricity saving
potential totals 43.2
TWh per year
Overall emission
reduction is 18.8
Million Tones of CO
2
per year
Overall cost savings
are about 1.7 to 3.5
Billion Euro per year
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
E
l
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K
i
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o
m
Electricity saving potential in fans all sectors [GWh] Fans
CO2 Saving Potential in Fans all sectors [kt CO2] Fans
24
Electricity consumption for fan systems
in the EU-15 by sector up to 2020
BAU (Business As
Usual) no measures
and improvements are
implemented
IA (Improved
Awareness) only
technical
improvements at fan
will be implemented
GT (Global Thinking)
technical measures and
system measures will
be fully implemented
99953
127727
120288
99842
93717
151007
143457
117786
3418
6730
6461
5250
0
50000
100000
150000
200000
250000
300000
Base
1997
BAU
2020
IA
2020
GT
2020
E
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y

c
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f
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[
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]
Industry Tertiary Transport
13
25
Factors Influencing Fan System Efficiency
Difference between peak and low efficiency of a fan can be up to 30 %.
Small differences in fan peak efficiency are of much less importance than the
poor matching between the fan and the system.
The fan has to be correctly designed, but all the effort in correctly designing a
fan can be wasted, if all the other steps of the choice/design procedure are not
carefully examined. Specifically:
The fan operating point must be properly selected on its characteristic
curve
The fan and the system have to be properly matched
The system has to be correctly designed to reduce as much as possible
energy requirements and energy losses
The system has to be properly installed
The regulation system should be selected to limit energy losses
26
Energy saving potentials and additional costs for fans
Fan type Efficiency gain Additional cost
Propeller fans 15 20 % 2 12 %
Tube-axial 2 10 % 4 10 %
Jet fans 4 8 % 5 7 %
Forward curved 5 15 % 7 10 %
Radial tip 10 % 6 10 %
Backward curved 2 5 % 8 12 %
Radial fans 5 % 4 7 %
Other fans 5 10 % 8 10 %

For each Euro spent about 4 Euro will be saved (based on LCC)
Each point of efficiency gain will increase fans first cost by about 1 %.
14
27
Efficiency Measures for Fan Systems
and their Improvement Potential
Management
Action
Efficiency Gain
Factor (EGF)
System
Market
Penetration
Factor (MPF)
1-EGF*MPF
Operation Schedule 30 % 20 % 94.0 %
HEM 5 % 20 % 99.0 %
Correct Sizing of Motor 15 % 5 % 99.3 %
Optimising Transmission 8 % 60 % 95.2 %
Optimising Ducting 15 % 30 % 95.5 %
Additional Savings 12 % 15 % 98.2 %
Product of (1-EGF*MPF) factors 82.5 %
Energy Savings 17.5 %

28
Energy savings depending on control system
Quelle: LfU, Stuttgart, 2002
P
o
w
e
r

c
o
n
s
u
m
p
t
i
o
n

[
%
]
Volume flow [%]
Bypass
Throttle
Rotational
Speed control
Theoretical
15
29
Strategy for Improving the Energy Efficiency
of a Fan Installation
Carry out a performance test
Carry out a performance test to determine the actual flow rate, fan
pressure and power absorbed. Many fans are not working at the speci-
fied duty point, often the pressure requirement is overestimated. It may
be possible to alter the fan speed to a lower value and still achieve the
required flow. This in any case should be reviewed as the design flow
may only be required 3 or 4 days per year.
Check the vee belt drive
Vee belt drives are frequently 'over-engineered'. Maintenance en-
gineers often specify more belts than necessary as this extends
their life. It is however at the expense of drive efficiency and con-
sequent power consumption. Remove a belt at a time and re-
check the amperage.
Check the motor selection
Many motors are oversized to give a margin. Check the new power ab-
sorbed by means of voltage, amperage and power factor readings. De-
termine if a new motor (possibly of higher efficiency) will give reduced
energy consumption, and if power factor correction is warranted. HEM
have typically a much broader high efficiency operating range.
Check if an impeller change is warranted
Many fan manufacturers have a range of impellers to suit a par-
ticular fan casing / drive assembly. It may be that a change of im-
peller and /or inlet cone will reduce the energy consumption e. g.
changing a forward curved bladed impeller for a backward airfoil
bladed impeller on a centrifugal fan or changing the solidity (num-
ber and chord of blades) or hub to tip ratio on an axial fan.
Check if a complete change of fan is warranted
For best efficiency backward bladed fans are larger than forward
curved fans for the same duty. The additional first cost may however be
more than recovered over the life of the fan. Sometimes fans are found
to be oversized for the duty and a smaller fan will then be more effi-
cient. A change in width may also be beneficial.
Check the control type of the fan
Where the fan is fitted to a constant orifice system, an inverter
speed control is preferred for varying the flow rate. If the system
requires constant pressure, a variable geometry fan is suggested.
A soft start should be incorporated wherever possible.

30
Pay back time for fan replacements
depending on power and number of operating hours
0
1000
2000
3000
4000
5000
6000
7000
8000
1 10 100 1000
Nominal motor power [kW]
o
p
e
r
a
t
i
n
g

h
o
u
r
s

[
h
/
a
]
1 year
2 years
3 years
4 years
5 years
6 years
16
31
Compressed Air
32
Motor driven systems - much more than a motor
(the compressed air example)
Compressor Control
Receiver Treatment
- Dryer
- Filter
- Condensate
Technology
Distribution
Verbraucher End use devices
17
33
Refrigeration Systems
Refrigeration compressor Ab-/Adsorption cooling
34
Often refrigeration systems
are responsible for peak power demand
0
100
200
300
400
500
600
700
800
01.07.96 02.07.96 03.07.96 04.07.96 05.07.96 06.07.96 07.07.96
Wirkleistung
Gesamt
Wirkleistung
ohne Klte
Summe Klte
Power Total
Power w/o cooling
Power cooling
18
35
The European Motor Challenge-Program
Program of the European
Commission with voluntary
participation
Target: Improvement of energy
efficiency of motor driven
systems in industry
Aim of the Programme:
Reliability
Quality
Costs
of system to
be improved
36
Structure of the MCP-Program
Partner Guidelines
User of Motor Systems
Compressed
Air Module
Pump
Module
Fans Module
Refrigeration
Module
Energy
Management
Endorser Guidelines
Manufactureres, ESCO's and
other supporting institutions
Drives
Module
Distribution Module
In preparation
19
37
Module-Guidelines
The module descriptions helps the partners to identify
possible measures for the participation in the MCP
Program.
Basic description of the system. (simple data collection
of type, power and use).
Required measurements (e.g. Electricity
consumption, load distribution)
Basic data
Planned efficiency measures
38
How to become an MCP Partner
Partner
Company starts with a motor
system inventory.
Company proposes action plan ,
which contains type and size of the
commitment and the list of measures
to be undertaken
EU-Commission approves action
plan and grants Partner Status.
Partner follows the Action plan and
reports annually to the Commission
EU-Commission checks annual
report and renew the Partner-
Status.
Endorser
Company starts with an inventory of 's
energy saving activities.
Company proposes action plan , which
contains type and size of the commitment and
the list of measures to be undertaken
EU-Commission approves action plan and
grants Endorser Status.
Endorser follows the Action plan and reports
annually to the Commission
EU-Commission checks annual report and
renew Endorser-Status.
A 5 Step Proceedure
20
39
ProMot ww.eu-promot.org
40
ProMot Toolbox (Refrigeration, Pumps)
21
41
EuroDEEMInternational / IMSAA (Motors)
42
Barriers and Resistance
22
43
Killer phrases instead of killer applications
Weve never made it that way.
Weve tried that already in the past.
This may be right in theory, but...
Others have tried already and failed.
If it was that easy, the concurrence would have
done it before.
Therefore we havent got the funds.
Its not worth to do it.
We know exactly what our customers want.
Draw up all the details first before we do anything.
44
Not only one but many reasons for investing in energy
efficient motor driven systems
Decrease
(energy)
costs
Reduce polluti-
on of the envi-
ronment
Facilitate
Repairs
obtain a general
idea
Reduce personal
cost
Improve
Quality
Prepare for inc-
reasing energy
cost
Stabilization of
company
situation
reduce
maintenance
cost
Guarantee
jobs
Achieve
PR-effects
Simplify regula-
tion/ manipula-
tion
Increase/
stabilize
turnover
Increase
efficiency
Improve
service
Improve indus-
trial safety
23
45
Why energy efficiency is a difficult task ?
Multiple Actors
with multiple reasons for investing have to select
between multiple different technologies
from multiple suppliers
need to get an integrated energy efficient solution
46
Market barriers to energy efficiency
Major Barriers
Reluctance to change a
working process
Pay back time required
below two years
Investment and
operation cost are not
dealt equally at same
time (split budgets)
Major Barriers Major Barriers
Reluctance to change a
working process
Pay back time required
below two years
Investment and
operation cost are not
dealt equally at same
time (split budgets)
Moderate Barriers
Other functional
specifications conflict with
energy efficiency
Shortage of capital
Moderate Barriers Moderate Barriers
Other functional
specifications conflict with
energy efficiency
Shortage of capital
Medium Barriers
Missing motivation
Energy efficiency not seen as
priority at the management
level
missing definition of motor
system efficiency
Oversizing of equipment due
to unknown load
characteristics
Medium Barriers Medium Barriers
Missing motivation
Energy efficiency not seen as
priority at the management
level
missing definition of motor
system efficiency
Oversizing of equipment due
to unknown load
characteristics
Technical Financial Management
24
47
Interpreting Barriers
Many barriers of all types show up often due to a lack of information
Pay back time seen as a tool for profit analysis and not as an
risk indicator.
(Note: Investments with a payback time of 4 years can have
easily internal rates of return above 15 %)
First cost seems to dominate the total cost
(Note: Typically energy costs of motor driven systems make up
more than 2/3 of the life cycle cost.)
Efficiency improvements are related to single components
(Note: The component with the lowest efficiency in the system
limits the maximum efficiency)
48
The key to efficiency are the people behind it
If you want to build a ship then do not gather men to
- collect wood,
- divide tasks
- and to arrange the work.
Teach them the desire for the endless oceans.
Antoine de Saint-Exupry
25
49
Helpful resources on the web
http://europa.eu.int/comm/energy/index_de.html
http://energyefficiency.jrc.cec.eu.int (Energy)
www.motor-challenge.de (Motor systems)
www.druckluft-effizient.de (Compressed Air)
www.druckluft.ch (Compressed Air)
www.eu-promot.org (ProMot; Pumps, Motors, ASD)
www.energy.wsu.edu/software/imssa/ (EURODEEM Int.)
www.bayern.de/lfu/bestell/index.html (Energy efficiency)

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EU-Twinning Project SL04/EN/01

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