Best practice in motor management

THE TRUE COST OF ELECTRIC MOTORS

In Australia more than 1.7 million three-phase electric motors run in industrial and commercial facilities,
and account for nearly half of the energy used across all types of industry.

Organisations can cut the

energy a motor requires

Every organisation runs at least one motor, if not hundreds or thousands, to drive pumps, conveyors,
refrigeration equipment and other processes requiring motive force. In a typical organisation, running
costs can be up to 100 times the purchase price of a motor over its service life. The electricity consumed
can account for more than half an organisations energy costs. Inefficient and poorly maintained systems

by between 10 and
25 per cent through
better management and

can also lead to reduced profits, unnecessary downtime, and even safety risks.
Best practice leads to improved motor system reliability and efficiency, significant and cost-effective
savings, higher profits, and lower energy costs and greenhouse gas emissions.
Now, an innovative initiativeMotor Solutions Onlineis supporting industry to achieve best practice
in motor selection and management. Energy Efficiency Best Practice (EEBP), in the Commonwealth

selection practices.

Department of Industry, Science and Resources, is partnering with industry and other government bodies
on the initiative, encouraging a non-traditional, holistic and strategic approach to motors
which focuses on total life costs and links motor management to business systems.

SAVING THROUGH BEST PRACTICE

The savings opportunities are enormous considering that the energy consumed by electric motors
costs industry close to $3 billion a year and produces 37 million tonnes of carbon dioxide through
burning fossil fuels.
For example, organisations can cut the energy a motor requires by between 10 and 25 per cent
through better selection and management practices. For Australian industry, each percentage point
improvement in motor system efficiency translates to savings of nearly 370 000 MWh of electricity
and an associated 380 000 tonnes of greenhouse gas emissions. This is like taking 9 000 cars
off the road.
Total operating costs are also reduced through careful selection. A motor bought for $1 600 may cost
as much as $13 000 a year to run and amount to a total operating cost of $195 000 over a 15-year
lifetime. Best practice selection can reduce the total operating cost by as much as $16 000, or ten times
the initial purchase price.

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A U G U S T

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MOTOR SOLUTIONS ONLINE

Key to the initiative is Motor Solutions Online (www.isr.gov.au/motors), a comprehensive but easy-to-use
resource that provides practical advice and assistance.
Motor Solutions Online includes a checklist, an interactive self assessment tool, a reference manual,
case studies and techguides. In addition, free Motor Selector software, which can be downloaded, helps
organisations make the right choices about selecting and repairing electric motors. The software
simplifies analysing complex factors such as purchase price, life cycle costs, financial risk and
CO2 emissions.
How selecting the right motor results in large and cost-effective savings and how whole-of-system design
and management can achieve even greater savings are two of the issues discussed in a series of
well-received workshops held across Australia.
The workshop I attended provided great insight into practical actions that can help reduce business
costs through increasing energy efficiency and improving motor reliability, said Keith Jones, Environment
Program Manager, South Australian Wine and Brandy Industry Association. It demonstrated the
potential losses associated with poor motor management. It showed how the wine industry can benefit
from a systematic approach to motor management and how we can improve our bottom line and
enhance our environmental performance through greenhouse gas reductions.

STANDARDS AND CODES

It demonstrated how we

Motor Solutions Online also deals with various standards and codes that support better practice in motor
management and will help Australian industry save energy and reduce greenhouse gas emissions.

can improve our bottom

line and enhance our
environmental

For example, from 1 October 2001 all three-phase electric motors from 0.73 kW to 185 kW supplied
throughout Australia must meet minimum energy performance and high efficiency standards (MEPS).
Also explained is the Code of Rewinding Practice, which aims to improve the efficiency of repaired
electric motors by one per cent overall, equivalent to the amount of greenhouse gases emitted by
15 000 homes per year.

performance.
Keith Jones,
South Australian Wine

ENERGY EFFICIENCY BEST PRACTICE

The Motor Solutions Online initiative is managed by the Energy Efficiency Best Practice Program
of the Department of Industry Science and Resources, and was developed in partnership with the
Australian Greenhouse Office.
EEBP supports industry sectors to identify and implement cost-effective solutions for a more
sustainable and competitive future. The program has a combined focus on innovation, training
and benchmarking and also offers practical tools, information and assistance. EEBP is working
with a growing list of industry sectors, which includes aluminium production, beverage and
containers manufacturing, bread baking and milling, dairy processing, vehicle and fleet
management and hotel management.

ENERGY EFFICIENCY BEST PRACTICE

Energy and Environment Division
Department of Industry, Science and Resources
GPO Box 9839, Canberra City ACT 2601
Telephone: 02 6213 7878 Facsimile: 02 6213 7902

Web site: www.isr.gov.au/energybestpractice

Email: energy.bestpractice@isr.gov.au

COMCO/CLARITY COMMUNICATIONS 4846

and Brandy Association