Summer 2008

Issue Focus: Shape Up Your Motor-Driven Systems!

This page presents all the articles in the Summer 2008 issue of Energy Matters, the BestPractices quarterly of the U.S. Department of Energy's Industrial Technologies Program. This issue of Energy Matters focuses on energy efficiency and reliability in industrial motors and motor-driven systems. Learn about how to implement a motor maintenance program at your company. Read about a major cement manufacturer who is working with ITP to boost efficiency in motor and other systems. Our Ask an Energy Expert describes how to improve efficiency of industrial fan systems; another article clarifies questions about power factor correction. Find out about two new energy-saving motor technologies that are now commercially available. And, learn about financial resources from ITP to help you bring your technology to market.

In This Issue

• Motor System Reliability Impacts the Bottom Line
• CEMEX Mixes Sustainable Manufacturing with Profitability
• The 2007 Energy Act: Good News for Motor Users
• Ask an Energy Expert: Optimizing Your Industrial Fan Systems
• New Motor Technologies Boost System Efficiency
• Power Factor Correction: What It Can and Cannot Do
• Financial Opportunities Help Advance New Technologies

Motor System Reliability Impacts the Bottom Line

By Howard W. Penrose, Ph.D., CMRP

Facing rising energy costs, corporate fiscal concerns, and global competitiveness, more and more U.S. companies and utilities are focusing on the leading reliability and maintenance improvement opportunity in industrial facilities: electric motors. A sound reliability-centered motor maintenance program can help manufacturers achieve significant energy and cost savings. This article outlines steps to help you implement a program at your company.

Why Consider Motor System Management?

Since the 1990s, a variety of motor management program ideas have been presented to industry. Many of these programs are actually "energy-efficient electric motor retrofit-or-repair-versus-replace" ideas, and they represent only a small portion of all the opportunities for managing electric motor systems. Preventive and condition-based maintenance, and other motor system management techniques, are often left out of such programs, creating a narrow view of the overall system. A complete motor maintenance curriculum considers all aspects of the motor system, including energy, environment, life-cycle costs, and a robust reliability and maintenance (R&M) program.

A survey of motor decision-makers found that more than 70% emphasize reliability as the first consideration of their motor programs (see Figure 1). Even in the current environment, which stresses energy efficiency, the first priority for a plant in a reactive failure condition is getting equipment back online and in production. More than 60% of companies are operating their R&M practices in a reactive mode, so energy policies related to manufacturing and support equipment have become secondary. However, with a proactive R&M program in place, companies can improve energy efficiency and extend the life of the equipment, boosting the bottom line.

The impact of a full reliability-centered maintenance and management (RCMM) program for motor systems is multifold. In the United States alone, approximately $1.2 trillion is invested annually in maintenance programs; up to $750 billion of that amount is the direct result of poor R&M practices. An additional $2.5 trillion in potential business opportunities is lost per year as a direct result of poor R&M practices, or 20% of the annual U.S. gross domestic product. A majority of these are industrial motor systems.

Moreover, motor system maintenance and management provide significant opportunities for improving energy efficiency and productivity. DOE's United States Industrial Electric Motor System Market Opportunity Assessment (PDF 6.6 MB) states, "In 1994, electric motor-driven systems used in industrial processes consumed 679 billion kWh—23% of all electricity sold in the United States. Download Adobe Reader. Implementation of all well-established motor system energy efficiency measures and practices that meet reasonable investment criteria will yield annual energy savings of 75 to 122 billion kWh, with a value of $3.6 to $5.8 billion" and an equivalent reduction of 74 megatons of greenhouse gas emissions. Furthermore, the E-Source DrivePower Atlas at www.esource.com reports that, "The efficiencies of mechanical equipment, in general, can be increased typically 10% to 15% by proper maintenance."

A Reliability-Centered Motor Management Program

To begin developing a reliability-centered motor management (RCMM) program, first identify the equipment that will be included in the program. Figure 2 shows an overview of the program, which begins with a facility asset census. Set up a pilot area for developing the program, and expand the program incrementally to ensure its success.

Once a facility asset census is completed, establish a critical equipment list based on the following criteria:

Impact of Equipment	Include
Personal safety	Any equipment that affects personal safety if it fails
Regulatory	Equipment that involves regulatory issues such as the environment
Production	Equipment that affects production; the greater the impact, the higher the ranking
Cost	Equipment that surpasses a repair or replacement value cost threshold; average industrial value for consideration is $25,000
Other	Working environment, marketing/sales considerations, equipment deemed important by the organization.

Perform an equipment condition assessment in parallel with a preventive maintenance optimization and development of condition-based maintenance practices. In an equipment condition assessment, critical equipment is evaluated through tests and inspections such as those used in reliability-centered maintenance (RCM). Keep results on record, and repair or replace equipment that is in poor condition; significant energy improvements can be considered at this time.

The preventive maintenance optimization process can be as simple as reviewing existing processes to eliminate redundancies or as complex as advanced commercial preventive maintenance optimization processes. In almost every case, from one-third to two-thirds of existing planned maintenance procedures can be eliminated or combined. Compare the remaining preventive maintenance tasks to the results of a condition-based maintenance review, which determines when to perform corrective maintenance to maximize equipment and component life. This involves processes such as RCM or a maintenance effectiveness review.

A maintenance effectiveness review evaluates the testing that is currently being performed and compares that to the failure rate and modes of the equipment. If failure rate and modes exist and are as high as (or higher than) they were before the application of condition-based maintenance, consider improving the program. The process also provides an opportunity to decrease maintenance and identify new inspections, tests, or processes. Conduct a maintenance effectiveness review periodically; the equipment included in this review is usually selected by an experienced RCM analyst.

Select root-cause analysis procedures and train personnel in their application. Internal or external facilitation can aid teams in using more rigorous processes. In addition, consider applying other process-based best practices, such as the following:

• Motor Repair-versus-Replace Decision-Making
• Motor Repair Specifications
• Lubrication
• Storage
• System Energy Improvements: These include right-sizing and using variable-frequency drives (VFDs). In addition, use ITP software tools such as MotorMaster+, AirMaster+, Pumping System Assessment Tool (PSAT), and Fan System Assessment Tool (FSAT) to optimize motor-driven systems.

All of the findings and feedback support each of the other parts of the overall RCMM program map.

Key Performance Indicators

When applying an RCMM program, consider the appropriate best practices and a method of measuring the application of the program. Maintenance managers should develop a series of key performance indicators that relate to the program’s components. The details of each component within the key performance indicators depend on the company and its goals. Be sure to consider the following key performance indicators.

Electrical Maintenance: A solid electrical maintenance program must be in place for a program to succeed. At a minimum, consider the following components:

• Documentation and drawings of critical equipment
• General electrical maintenance practices
• Arc flash and personal protective equipment program
• A review of load and power quality of critical equipment
• An active electrical root-cause analysis program
• Electrical safe work practices and corporate safety program
• An emergency repair plan for critical equipment.

Motor and Driven Equipment Selection Program: Outline a process for the selection and specification of components for the motor system, including right-sizing, selection of controls and VFDs, and optimal selection of driven equipment for the complete motor system.

Commissioning: Inspect and test new and repaired equipment before application or storage. This ensures the reliability of the component and that changes have not been made that may reduce the component’s energy efficiency.

Operations and maintenance: This includes repair-versus-replace decision-making, maintenance training, failure analysis, testing technologies, lubrication, and inspections.

Electric motor system repair: Repair processes, procedures, and specifications, including the qualifications of the repair shop for specific equipment types and sizes. The primary purpose is to ensure reliability or energy efficiency.

Plant inventory and records: Motor system components in operation and maintained as spares; includes storage procedures and processes.

Utility management: This is the energy efficiency component of motor management programs. It should include selecting motor systems for evaluation for immediate energy improvement opportunities within the company’s financial constraints. For assistance, use the technical resources for fan, pump, motor, and compressed air systems on DOE's Industrial Technologies Program Web site.

Reliability-Centered Motor Management Team

Select a team to develop the RCMM program and to be involved in the RCM and maintenance effectiveness review processes. Include both in-house and external stakeholders in the motor management program, such as these:

• R&M managers
• R&M technicians
• Utility or energy managers
• Purchasing
• Operations managers
• Information technology specialists
• Associated vendors
• Others, as necessary.

It is important for this team to meet regularly, such as once a month, after the program begins. As the program matures, team meetings could be held quarterly.

Case Study: Automotive Transmission Manufacturer

A good example of this kind of program is taking place in Indiana. An Indianapolis-based transmission manufacturer has been implementing a motor management program since 2001, focusing on condition-based inspection, testing, vendor storage, motor repair practices, and root-cause analysis. The RCMM team consists of internal personnel and skilled tradespersons as well as a contracted electric motor repair facility. At the monthly team meetings, the repair facility reports volume and repair cost reductions and makes recommendations for improving the reliability of motors that have been repaired. The internal tradespersons conduct root-cause analyses and "repetitive failure analyses" that include investigations of instances in which equipment fails more than once in a given period.

When initial testing and inspection began, the program’s repair and replacement costs increased as equipment with poor levels of reliability were identified and corrected. Once the dust settled, staff determined that there were 720 average repair-or-replace decisions per year affecting electric motors. Focusing on just three of the seven key performance indicators, they reduced the number of repair-or-replace decisions to slightly more than 120 per year, the majority being minor repairs. The impact on overall equipment availability has been measurable, and the cost per unit manufactured has dropped significantly.

Warranty Recovery Opportunities

Most companies forget to investigate warranty recovery opportunities in failed equipment. The average motor repair vendor warranty is one year; however, many repair shops increase their competitiveness by offering warranties as high as five years! New, premium efficient, electric motors have warranties ranging from five to seven years.

One reason that both new and repair facilities are willing to offer these warranties for motors is that many companies do not track warranty opportunities. In a large number of facilities, the missed opportunities add up not to thousands of dollars but to hundreds of thousands or even millions of dollars in unclaimed warranties. It is a good idea to track warranty dates in computerized maintenance and management system programs or using third-party software to gain quick access to records; this ensures that your company is taking full advantage of warranty opportunities.

Final Considerations

A growing number of utilities and industrial companies are focusing on the number one R&M improvement opportunity: electric motors. These companies find that improving electric motor systems through partnerships, equipment storage, best motor management practices, repair standards, and robust maintenance programs have reduced overall energy use and increased competitiveness and profitability.

In this time of rising energy costs, corporate fiscal issues, and the need to improve competitiveness and capacity, establishing a motor system maintenance management program can be one of the most substantial improvements a company can make. The best time to start is now.

About the Author

Howard W. Penrose, Ph.D., is the President of SUCCESS by DESIGN, a reliability and maintenance services consultant and publisher. He has 25 years of experience in the R&M industry, from the shop floor to academia, manufacturing, and the military. Dr. Penrose was an Adjunct Professor of Industrial Engineering at the University of Illinois at Chicago and served as a Senior Research Engineer at the UIC Energy Resources Center. He has been active in IEEE as Vice-Chair and Chair in various chapters, and is presently on the IEEE DEIS Board of Directors. He is a DOE MotorMaster+ Certified Professional, a certified maintenance and reliability professional, both a NAVAIR and NAVSEA RCM specialist, and the founding director of the Institute of Electrical Motor Diagnostics. He is also the author of two books on motor management and reliability and a member of the National Writers Union and the International Federation of Journalists.

Please contact Dr. Penrose with questions about this article.

CEMEX Mixes Sustainable Manufacturing with Profitability

The manufacturing of cement is an energy-intensive process, consuming energy at every stage of production. The industry as a whole has been operating at less than 40% thermal efficiency, which indicates that there are significant opportunities to improve energy efficiency and reduce emissions.

Today, some companies are taking advantage of those opportunities to reduce the impact of their operations on the environment. CEMEX is one of those companies, and is committed to mixing sustainable business practices with profitability. To help achieve this goal, CEMEX is collaborating with DOE's Industrial Technologies Program (ITP) to improve energy efficiency at several of its U.S. cement plants.

The partnership between CEMEX, one of the world's largest cement producers, and ITP is already producing energy savings in several of the company's plants. These savings result from upgrading inefficient electric motors and improving the efficiency of motor-driven pumps, fans, and compressed air systems.

For instance, staff at CEMEX's Davenport, California, cement plant used DOE's MotorMaster+ software tool to evaluate motor inefficiency; they found that 13 of the plant’s electric motors required upgrading. These upgrades are saving the company $168,000 in annual energy costs while increasing reliability and production. What's more, CEMEX is actively participating in several Industrial Technologies Program (ITP) Save Energy Now energy assessments, bolstering its commitment to sustainable and environmentally responsible manufacturing while improving the bottom line.

Blending Productivity with Sustainable Manufacturing

CEMEX—which is headquartered in Monterrey, Mexico—is one of the world's leading providers of cement, ready-mix, and aggregate products. It operates in 50 countries and has 14 cement plants in the United States. CEMEX produces more than 96 million metric tons of cement, 80 million cubic meters of ready-mix concrete and 222 million metric tons of aggregates each year.

With such large operations, meeting energy efficiency and emissions reduction challenges while remaining globally competitive are top priorities. To address these challenges proactively, CEMEX helped found the Cement Sustainability Initiative (CSI), a consortium of cement industry leaders. CSI works to reduce CO₂ emissions, restore quarries, manage waste, ensure the safety of workers, and minimize operational impacts both to the local community and the global environment.

Cement manufacturing generates 5% of global CO₂ emissions, and reducing this impact is of paramount concern. Each of CEMEX's plants are monitored online by the CO₂ Emissions Inventory Electronic Platform, which provides data to help develop strategies to increase efficiency. Other efforts include substituting alternative raw materials, increasing the use of biomass and other alternative fuels in pyroprocessing, improving energy efficiency, and using renewable energy sources such as wind energy.

CEMEX also takes action to rehabilitate the land around its operations; by the end of 2007, 94% of its active cement sites had quarry restoration plans in place.  In addition, the company recently signed a 10-year agreement with BirdLife International, committing to the conservation of ecosystems on its operation sites around the world.

Shining a Spotlight on Energy Savings and the Environment

The CEMEX plant in Davenport, California, strives for sustainable operation, both in its energy efficiency efforts and in its care of the surrounding environment. These include developing an energy management program that tracks energy usage, working jointly with the local utility company to reduce consumption in times of high demand, and partnering with ITP to identify energy savings opportunities.

In 2004, plant personnel at the CEMEX Davenport facility used the MotorMaster+ software tool to evaluate the efficiency of motors on cement blowers and silo pumps. Before the evaluation, the plant experienced regular motor shutdowns that interrupted production and increased maintenance costs. Thirteen worn motors were replaced with high-efficiency ones, resulting in annual energy cost savings of $168,000, annual electricity savings of 2.1 million kWh, and maintenance cost reductions of $30,000 per year. Learn more about the project in the Performance Spotlight (PDF 220 KB). Download Adobe Reader.

In addition to improving energy efficiency, the Davenport plant actively practices environmental stewardship. This includes reclaiming more than 26,000 tons of cement dust per year from an existing cement kiln dust landfill; collecting and recycling wastewater from a nearby sanitary treatment system; and establishing a land stewardship program on its 9,000-acre forest land. For these achievements, the plant was recently awarded the Overall Environmental Excellence Award at the Portland Cement Association and Cement Americas magazine’s 2008 Environment and Energy Awards—the highest honor among cement manufacturing facilities in the United States and Canada. The Davenport plant also received the Land Stewardship Award for the second consecutive year.

Collaborating to Save Energy Now and Tomorrow

To identify near-, medium-, and long-term energy saving opportunities, CEMEX is partnering with ITP in the Save Energy Now initiative by conducting energy assessments at several of its U.S. plants. So far, six assessments have been conducted, identifying ways to increase efficiency in pump, fan, process heating and compressed air systems. Additional energy assessments are scheduled for the coming year.

"DOE's energy assessments allowed us to uncover substantial opportunities for additional energy savings on specific systems at various CEMEX facilities across the U.S.," said Bhaskar Dusi, CEMEX USA Corporate Technical Energy Manager. "Thanks to DOE, we are able to build on our past progress and move quickly to implement ideas for improved energy efficiency. The program validated the merits of some projects we had previously identified, and provided access to some valuable software-based tools that were useful in evaluating energy improvements."

Learn more about the CEMEX energy assessments on the Save Energy Now participating plants Web site.

CEMEX is committed to reducing energy use and minimize its environmental footprint through sustainable business practices. The partnership between CEMEX and ITP links a company with a strong corporate energy management program with sound resources to help it achieve greater energy savings and reduce environmental impacts.

The 2007 Energy Act: Good News for Motor Users

Reprinted with permission from the Copper Development Association

On December 19, 2007, President George W. Bush signed into law the Energy Independence and Security Act of 2007. Similar to its predecessors, the Energy Policy Act of 1992 (EPAct '92) and the Energy Policy Act of 2005 (EPAct '05), and related pieces of legislation dating back to the 1970s, the 2007 Act aims to restructure and reduce, or at least slow the rate of growth in America’s energy consumption. It also mandates higher automotive fuel economy, promotes use of biofuels and alternative energy sources, raises efficiency standards for public buildings, equipment and appliances, and provides public funding for a host of energy-related issues.

Perhaps more importantly for motor users, the 2007 version increases the mandated efficiency of electric motors in commercial and industrial applications, and expands the range of motors that are in question. Those provisions, contained in Title III, Section 313, represent a small section of the Act’s 822 pages, however, eventually they may bring about a very large reduction in wasteful energy use.

Why? Because electric motors account for nearly 50% of total U.S. energy use, and two-thirds of energy used in industrial settings. It follows then, that if the efficiency of those motors were raised by even a few percentage points, the savings, in kilowatt-hours and in dollars for both individual users and the nation-at-large, could be enormous.

EPActs '92 and '05, respectively, set minimum standards for motor efficiencies and mandated the use of premium-efficiency motors in Federal buildings. The new Act raises that bar and redefines—and thereby expands—the types of motors required to meet existing efficiency standards. Following are excerpts from the 2007 Energy Independence and Security Act as well as some of the benefits the new legislation will bring to motor users.

Definition of Covered Motors under New Act

As you can see, the term "general-purpose motors" has been expanded to include both the motors we generally think of in this regard (here called Subtype I), and another group of motor types (defined as Subtype II) to which neither the high-efficiency standards of EPAct '92 nor the NEMA Premium® standards called out in EPAct '05 previously applied.

Mandated Standards and Amendment

Table 12-12 of NEMA MG-1 (2006) defines NEMA Premium efficiency standards for motors up to 500 hp. Under the Energy Independence and Security Act of 2007, the minimum nominal full-load efficiency standards for "traditional" general-purpose motors, i.e., those running at 1200, 1800 and 3600 rpm with power ratings up to 200 hp, are raised to NEMA Premium values from the previously mandated EPAct '92 standards (for the so-called "EPAct motors"). In essence, NEMA Premium efficiency minimums replace EPAct '92 levels as the baseline for these motors.

Another noteworthy change pertains to general-purpose motors. Now, under the 2007 Act, they are governed by the Act's standards whether they are purchased "alone or as a component of another piece of equipment." In other words, applicable OEM-supplied motors are now included under NEMA Premium standards. Previously, equipment buyers often had to insist that the machines they purchased were powered by energy-efficient motors.

The one exception to this provision is that fire pump (sprinkler system) motor minimum efficiencies are raised only to the EPAct '92 standard. Fire pump motors, however, are seldom in operation, and, therefore, consume very little energy over their service lives.

Next:

Table 12-11 of NEMA MG-1 (2006) sets minimum efficiency standards for EPAct motors. As mentioned earlier, the "Subtype II" motors as defined in the 2007 Act had previously been excluded from energy legislation entirely, meaning that they could be sold lawfully as old-style, standard-efficiency models. That's no longer the case.

Finally:

This section of the 2007 Act extends EPAct '92 efficiency requirements to motors between 201 hp and 500 hp. According to the Consortium for Energy Efficiency (CEE), motors larger than 200 hp account for 45% of industrial motor energy use, despite the fact that they account for only 1% of units in the entire manufacturing inventory. Furthermore, CEE reports that approximately 80% of motors in the industrial inventory are pre-EPAct '92 models. In addition, the average duty cycle for these motors is 6,100 hours per year. CEE estimates that these motors represent a potential energy savings of 7.7 billion kWh annually.

The 2007 Act takes effect on December 19, 2010. Until then, it is lawful to purchase and install EPAct-level general purpose motors and standard-efficiency general purpose motors for those models to which EPAct '92 doesn't apply. On the other hand, if your motors operate at high duty cycles and/or they face high or rising utility rates, you will fare better by selecting NEMA Premium motors before they are mandated. It is wise to understand that better motors will return your investment by the time the new Act takes effect. Work smarter by upgrading sooner rather than later.

Ask an Energy Expert: Optimizing Your Industrial Fan Systems

Ron Wroblewski is a DOE Energy Expert who is proficient in optimizing industrial fan systems and who regularly conducts Save Energy Now energy assessments to help companies pinpoint ways to save energy and costs. In this issue of Energy Matters, Ron addresses some common questions about efficiency and operational costs of fan systems.

How can I tell if I have an inefficient fan?

It's not always obvious when a fan system is running inefficiently. Look at the system closely and understand the needs of the process to determine if inefficiency is an issue.

Indicators of fan system inefficiency usually fall into one of three categories: control, production/maintenance, or system effect. Use indicators to qualitatively select the systems that will benefit most from optimization projects.

Control indicators relate to the use of dampers to restrict flow and include:

• A motor that overloads unless a damper restricts flow
• Excess flow that is spilled or bypassed
• Use of a discharge damper, inlet damper, variable inlet vane or system damper
• A damper that is mostly closed.

Production and maintenance indicators signify wasted energy that causes equipment breakdowns and can include:

• Either too much or not enough flow or pressure for production
• A system that is unstable or hard to control
• Regular breakdowns
• Excessive noise, heat or vibration
• The need to weld ductwork cracks regularly.

System effect indicators point to problems with the design of the fan system that create excessive turbulence and instability. For example, abrupt turns can sometimes rob you of a significant portion of fan capacity. Some system effect indicators are:

• A 90° turn at or near the fan outlet or inlet
• A "dirt leg" at the bottom of the inlet duct, where the inlet duct is tapped into the side of a duct
• Lack of an outlet duct
• Restricted or sharp inlet.

If your facility has multiple fan systems with more than one of these indicators, use the Fan System Optimization Checklist (PDF 86 KB) to help you identify which systems are the best candidates for optimization. Download Adobe Reader.

How can I determine what it’s costing me to operate my fans?

Fan systems can consume a considerable amount of energy on an annual basis, making it important to estimate power usage and annual energy costs.

If you are planning a project to improve the efficiency of your fan system, estimate fan operating costs before you begin. This process, called baselining, lets you document the current system status, come up with accurate savings estimates and provide results to management after project completion.

1. The first step is to obtain accurate estimates of your system’s annual operating hours and the average cost of electricity from your utility company. To find your average electric rate, review the last 12 months of electric bills for your facility and choose one or two months that look typical. On the bill, look for two numbers:

• Total bill amount ($)
• Total energy used (kWh).

Divide the total bill by the total kWh to get the average electric rate for your facility:
Electric rate = Total bill/Energy used

This gives you the rate in $/kWh. In most instances, the average electric rate is adequate to make an accurate estimate of operating costs.

2. Have a qualified electrician take measurements of the system, using one of the methods described below:

• The power meter method is very accurate at measuring power, but requires the use of an expensive meter and takes only a snap-shot measurement.
• A recording power meter that can be left on the process for a week is the best way to monitor the power consumption so you can see any variation over time, and know exactly how long the equipment is run.
• The volt-ammeter method is widely used because the meters are less costly and readily available. Although based on actual measurements, it depends on an estimate of the motor power factor, thus introducing some uncertainty.

3. Calculate the operating costs using DOE's Industrial Technologies Program Fan System Assessment Tool (FSAT) software or the following method. The equations below are used for the volt-ammeter method.

1. Calculate electrical power drawn by the motor:

   

   Where:

   

   A word on power factor: If the motor is over 60% loaded, then it is probably fine to assume that the power factor is 0.8, however, if the motor is very lightly loaded then the power factor can be much lower.

2. Calculate annual energy use:

   

3. Calculate annual energy cost:

   

   For example, for a 125 hp combustion air fan that uses an average current of 107.3 amps operates at an average voltage of 461 volts and runs 8,760 hours/year, at a facility where the electric rate is 0.05 $/kWh, the calculations would be:

   For the electrical power drawn by the motor:

   

   For the annual energy use:

   

   And, for the annual energy cost:

   

These steps are used by FSAT to estimate baseline energy usage. Instead of the equations above, you could use FSAT to baseline operating costs; FSAT also includes a very good method to estimate power factor based on motor loading.

If the fan is operating with a damper that is mostly closed, you can also calculate the cost of the pressure drop across the damper. This is done by determining the ratio of the drop across the damper to the pressure rise across the fan, which shows you how much of the system’s energy is actually feeding the damper.

Baselining can also be performed on pumps, motors and compressors. Use this technique to identify the major energy users among your systems. This allows you to prioritize the systems for project work to increase efficiency. To learn more about baselining your fan systems or the effects of dampers, attend DOE's Industrial Technologies Program Fan Systems Assessment training session.

Additional Resources

For more information on how to improve your plant's fan system efficiency, please see the following ITP resources.

• Fan System Assessment Tool (FSAT)
• Technical tip sheets and briefs
• Improving Fan System Performance: A Sourcebook for Industry (PDF 1.2 MB) Download Adobe Reader.
• Fan System Assessment training.

Questions/comments about this column? Contact Ron Wroblewski at: Ron@ProductiveEnergy.com.

New Motor Technologies Boost System Efficiency

Electric motors in U.S. industrial applications account for more than 60% of electricity use; even small increases in efficiency improvements can make a big difference in energy savings. Two new motor technologies now available commercially offer breakthrough efficiency and reliability opportunities for U.S. industry.

Copper Rotor Motors are "Ultra-Efficient"

A new line of motors featuring the copper rotor motor technology has entered the U.S. industrial market, providing significant energy savings potential for manufacturers. Siemens Energy & Automation's induction AC motors include die-cast copper rotors which offer increased electrical energy efficiency, lower operating temperature, extended motor life, and reduced weight and size. In fact, these ultra-efficient motor designs have total losses that are 6.6% to 15.5% below those of comparable NEMA Premium® efficiency motors while exceeding the NEMA Premium full-load efficiency standards by up to 1.4%.

The die-cast copper rotor motor technology is the result of several years of R&D by both the Copper Development Association Inc. (CDA) and Siemens to achieve superior efficiency by substituting copper for aluminum in the squirrel cage induction motor. CDA led the way on manufacturing processes and high-temperature mold materials to enable cost-effective production of copper rotor motors. The Siemens project team developed design methods and conducted an extensive modeling program to optimize the motor for the high conductivity copper rotor. The result is a motor technology that offers high efficiency, performance, and reliability. According to the CDA, in the United States alone, a 1% increase in motor efficiency could save 20 billion kWh per year, or $1.4 billion in electricity (at 7 cents per kWh).

Siemens was instrumental in bringing the technology to the commercial market. The company incorporated the high-conductivity copper rotors into their motors, which include aluminum and cast-iron frame models. Other improvements include optimized rotor and stator design, low-friction bearings, redesigned cooling system, polyurea-based grease, dynamically balanced rotors, and precision-machined mating surfaces for reduced vibration. Specially designed insulation enables use with variable speed drives. The new line of motors is available up to 20 hp.

Unique Motor Controller Increases Efficiency and Improves Comfort

A new technology for variable speed control of single-phase AC induction motors in HVAC fan systems provides a low-cost, energy-efficient solution for indoor climate comfort and noise reduction. The Adaptive Climate Controller from Opto Generic Devices V-HVAC Inc. uses multiple, closed-loop signals, analog optical-based control, and sensor input to deliver climate and moisture control, healthy air quality, and proven electricity savings of 30%-50%.

With help from DOE's Industrial Technologies Program Inventions & Innovations program, Opto Generic Devices (OGD) Inc. created an optical programmable encoder and controller combination that offers:

• Continually adaptive/variable speed
• Optimized commutation
• Dynamic vector control
• Real-time feedback
• Application tuning
• Signal enhancement for operating AC motors.

Based on this technology, OGD's subsidiary, OGD V-HVAC Inc., developed the Adaptive Climate Controller (ACC) (PDF 399 KB) Download Adobe Reader. This unique technology is an alternative to digital controllers that can be complex, expensive, and can cause motors to run hot and generate noise. This intelligent and adaptive controller maintains temperature for the human comfort zone by gently mixing room air depending on needs of the space. By gradually ramping up fan speeds, energy is conserved by using only the electrical and thermal energy necessary to satisfy the demand. In addition, noise from electrical, motor, and air flow is reduced.

The ACC technology was commercialized in 2005 and has sold more than 2,500 units. Projected annual energy savings from the technology is 2.9 million Btu of electricity per 5,000 units.

To learn more, see page 107 of ITP's Impacts Report (PDF 3.9 MB) Download Adobe Reader

Power Factor Correction: What It Can and Cannot Do

Courtesy of the EERE Information Center

The U.S. Department of Energy's EERE Information Center receives a multitude of questions about the energy savings associated with installation of power factor correction capacitors for electric motors in industrial facilities. In fact, it seems that power factor is poorly understood by many people. This article highlights key questions from industrial customers, and seeks to set the record straight about what power factor correction can and cannot do.

Q. An equipment vendor claims that his devices can produce energy savings on the order of 10%. Is this true? Is it even possible?

A. Myths about power factor are sometimes exploited by marketers of power factor correction equipment. Misunderstandings often occur when marketers mislead prospective customers into thinking they are saving significant amounts of energy by doing "before and after" tests with just an ammeter. While power factor correction does reduce line currents supplied to low power factor loads, it does not result in a significant corresponding reduction in the load’s power requirements or annual energy consumption.

Q. How significant is power factor correction in industrial settings?

A. Power factor is low in industrial settings where most of the plant energy is used to power electric motors. It is lowest when the induction motors tend to be oversized and under-loaded. A lagging (less than 1.0) power factor causes some additional energy loss because more current is required—compared to an in-phase sinusoidal current—to deliver a certain amount of power. Correcting power factor can be an appropriate and cost-effective measure, but not because of energy savings.

Q. How much energy can be saved by installing correction capacitors?

A. Power factor correction does not save much energy—usually less than 1% of load requirements—but even that benefit depends upon how low the power factor is to begin with and how heavily loaded are in-plant distribution system conductors. Note that power supplied to your motor driven-equipment is proportional to Volts × Amps. Energy losses in your in-plant distribution system coincide with your voltage drop. If your transformer supplies power at 480 Volts and the voltage at your motor terminals is 470 Volts, you have a voltage drop of 10 Volts, or approximately 2% of 480 Volts. The total power loss in the in-plant distribution system upstream of connected load equipment seldom exceeds 2% of the load requirement.

The loss fraction saved through the installation of capacitors at the motor is:

{1 – (PF_initial/PF_final)²} × 100%

If your original power factor was 80%, and the system power factor is raised to 95% following the installation of capacitors, then the resistance or I²R losses in your in-plant distribution wiring will drop by 29.1%. Multiplying (29.1%/100) × 2% yields an expected energy savings of 0.58% of the load requirement. If you correct power factor at the switchyard or plant service entrance instead of very near the inductive loads (e.g. motors), you do not reduce in-plant distribution system losses at all because the correction only happens on the line side (the upstream, utility side) of where the capacitors are tapped in.

Q. Under what circumstances are capacitor corrections warranted?

A. Despite the slight energy savings, correcting power factor can bring significant savings in energy bills when the utility imposes a low power factor penalty in their rate structure, as most utilities do for industrial customers. The simplest penalty is imposed through basing demand charges on kVA instead of measured kW. Another penalty approach is to calculate a billable monthly demand charge that is equal to the measured demand times the ratio of the desired power factor (often 95%) divided by the measured power factor. How much you can save through installing capacitors depends upon your initial power factor, the level you correct to, motor horsepower rating and loading, and how the penalty charge is calculated by the utility.

Keep in mind that power factor correction reduces currents in conductors and transformers ahead of where the capacitors are installed. Simply correcting power factor does not change the current or operating condition of motors or other loads. Depending upon their location, installing capacitors can free up system capacity, and reduce voltage drop somewhat, but significant energy savings do not occur. The utility benefits because the current reductions decrease electrical energy losses in their transformers and transmission and distribution lines.

Q. How are power factor correction capacitors available?

A. Three-phase motor power factor correction capacitors are sold by kVAR at a particular voltage rating. Normally they are sold in a trio of three capacitors, which may or may not be packaged in a single enclosure. When power factor correction capacitors are to be switched with an induction motor, the maximum value of corrective kVAR should not exceed the value required to raise the motor’s no-load power factor to unity (1.0). Avoid overcorrecting into a leading power factor condition. NEMA Standard MG1 Part 14 offers the following warning:

Capacitor boxes often contain some surge suppression circuitry. Experts widely agree that surge suppression also saves virtually no energy. Yet, it may be highly beneficial in protecting valuable equipment if there are actually serious voltage spikes on the circuit.

Q. Should power factor be considered in the purchase of a motor?

A. Motors are generally loaded below their rating some or all of the time and an underloaded motor will operate with a power factor below its nameplate rating. However, with correction capacitors installed, the power factor of an underloaded motor actually improves as the load decreases because the capacitor continues to provide its full rating in leading kVAR. Some motor or motor-driven equipment purchasers attempt to minimize power factor penalty problems at the source by selecting motors that maximize both efficiency and power factor. This can be done when selecting common motor sizes if you have access to multiple manufacturers to ensure plenty of motor models from which to choose. DOE's MotorMaster+ is an excellent tool for choosing from many hundreds of motors; power factor at full and part-load is listed for each motor.

The old slogan, "Buy for efficiency and correct for power factor," tends to still be valid for several reasons. Even with the most severe power factor penalties, a point more of motor efficiency tends to save much more money on the energy bill than a point of power factor improvement. A good recommendation is to shop for the best efficiency. Consider power factor in the purchase if you are choosing between two motors of equal efficiency. After identifying the motor to be purchased, select correction capacitors if your rate structure penalty or in-plant distribution system limitations necessitate improving power factor.

Additional Reading

• Power Factor Correction: A Guide for the Plant Engineer (PDF 2.5 MB), July 2004. Download Adobe Reader. The information in this 26-page Eaton/Cutler-Hammer guide is very helpful. It covers topics like how much money you can save on your utility bill by eliminating power factor penalties, how to size capacitors, the pros and cons of potential capacitor locations (i.e. at the load or at a central bank), and power factor correction in the presence of non-linear loads like adjustable speed drives.
• "Exploring power factor myths," Energy Services Bulletin, August 2004. This article discusses power factor myths in layman terms.
• Industrial Power Factor Analysis Guidebook, Bonneville Power Administration, March 1995.

About the EERE Information Center

Through the U.S. Department of Energy's EERE Information Center, you can access the full portfolio of Industrial Technologies Program (ITP) resources to help make your industry more energy efficient, productive, and competitive. The Center can help you find resources such as publications and software, or information about working with ITP and cost-sharing opportunities. The Center is also a resource that specializes in providing technical advice about motor, steam, process heating and compressed air systems.

EERE Information Center engineers and technical staff expertly answer a wide range of industrial efficiency questions, Monday-Friday, 6:00 AM-4:00 PM Pacific Standard Time. The Center also has access to industry experts around the country. Call the EERE Information Center at (877) 337-3463, or go to www.eere.energy.gov/informationcenter/ for additional information.

Financial Opportunities Help Advance New Technologies

By Rolf Butters, Industrial Technologies Program Technology Manager

DOE's Industrial Technologies Program (ITP) leads national efforts to reduce U.S. industrial energy use and carbon emissions. A key component of this effort is to provide financial opportunities for research, development and deployment (RD&D) and promote commercialization of innovative, energy-saving technologies.

A company or research institution may have a great idea for a cutting edge, energy-saving technology, but lack the means to support it. This is where ITP and other federal agencies can help.

ITP Solicitations Offer Cost-Shared Funding for Technology RD&D

Each year, the Industrial Technologies Program (ITP) provides cost-shared funding to encourage RD&D of energy efficient technologies that enhance economic competitiveness of U.S. industry. This successful effort has produced more than 220 commercialized technologies, saving nearly 5 quadrillion Btus of energy, and reducing emissions by 86 million metric tons of carbon equivalent. For details on these technologies, read ITP's Energy Technology Solutions: Public-Private Partnerships Transforming Industry (PDF 3.7 MB) Download Adobe Reader.

ITP solicitations typically require collaborative partnerships, which may include manufacturers, universities, suppliers, national labs, and others. Industry partners are generally expected to provide matching funds. Visit the active solicitations page to see current funding opportunities. You can also register to be notified when new ITP solicitations are posted.

States Incentives Database Provides Information on Business Incentives and Resources

The ITP States Incentives and Resources Database is a repository of energy incentives, tools, and resources for commercial and industrial managers looking for assistance in making energy efficiency upgrades to their facilities. The database provides information on rebates, waived fees, tax credits, and loans offered by local and national government agencies as well as utilities, private companies, and non-profits.

For example, the incentives database listing for California includes the Thermal Energy Storage Incentive (PDF 115 KB) sponsored by Anaheim Public Utilities, whereby business customers can receive up to $21,000 for the purchase of a refrigerant-based thermal storage system. Download Adobe Reader. Learn about payback for this incentive.

This States Incentives and Resources Database also offers resources such as analysis tools, education and training programs, and energy audits.

The incentives database is an integral part of the Industrial Technologies Program State Activities Web site, which provides industry information, training events, energy assessments, and contacts for each state who can assist with resources to help reduce energy consumption.

Loan Guarantee Program Promotes Commercial Use of Innovative Technologies

Through the Loan Guarantee Program, which was established by the Energy Policy Act of 2005, DOE issues loan guarantees to eligible projects that avoid or reduce greenhouse gases and employ new or significantly improved technologies. The program is geared toward commercial use of innovative technologies, and is therefore not targeted at RD&D projects. A commercialized technology is defined by DOE as one that has been installed in three or more commercial facilities in the United States and has been in service for at least 5 years.

In June 2008, DOE announced three solicitations for a total of up to $30.5 billion in federal loan guarantees for projects that employ advanced energy technologies and that avoid, reduce, or sequester anthropogenic emissions of air pollutants or greenhouse gases. The three solicitations are in the areas of: energy efficiency; renewable energy and advanced transmission and distribution technologies; advanced nuclear power facilities; and advanced nuclear facilities for the 'front-end' of the nuclear fuel cycle. This marks the second round of solicitations for DOE's Loan Guarantee Program. The third solicitation will be issued later in the summer for advanced fossil energy projects (up to $8 billion). Learn more and apply for DOE's Loan Guarantee Program solicitations.

Grants.gov: Easy Access to Information on Federal Grants

Grants.gov is a user-friendly resource for locating and applying for more than 1,000 annual federal grant programs available from 26 federal agencies. The site provides access to approximately $400 billion in awards each year. Users can search for opportunities by keyword, Funding Opportunity number, agency, or category. Grants.gov also offers helpful tools such as a user guide, tutorials, Webcasts, and newsletter to assist in locating and applying for grants, as well as an application tracking feature. Before submitting an application, you must first register on the Grants.gov Web site. You may also sign up to receive automatic email notifications of new grant postings and updates on the Grant Email Alerts Web page.

Additional Funding Opportunities

Through the Small Business Innovation Research (SBIR) and Small Business Technology Transfer (STTR) program, 11 federal agencies provide annual funding to U.S. small businesses to research, develop, and commercialize their technologies. The goal of these solicitations is to encourage private sector commercialization of technologies through R&D, and improve the return on investment from federally funded research for economic and social benefits to the nation.

To receive alerts on funding opportunities, subscribe to the SBIR/STTR Alerting Service. This free service provides bi-weekly notification of SBIR and STTR solicitation announcements, news, information, and Internet resources relevant to the programs.

The National Association of Energy Service Companies (NAESCO) is the primary industry organization for the energy services industry, working with trade groups, energy service companies (ESCOs), distributed generation companies, engineers, and finance companies to deliver cost-effective energy services to customers. Visit the NAESCO Web site to get tips on prioritizing and refining your strategies, read case studies and find out how to cost-effectively implement your energy projects. Also included are press releases on member companies’ programs, many of which include innovative technologies and financing opportunities.

Financial Opportunity Resources At-a-Glance

Financial Opportunity	Agency/Organization/Program	Web site
Industrial technology RD&D	ITP	www.eere.energy.gov/industry/ financial/solicitations.html
Energy efficiency incentives (rebates, waived fees, tax credits, loans)	ITP (together with ITP partners including states and utilities)	www.eere.energy.gov/industry/about/ state_activities/incentive_search.asp
Loan Guarantee Program for commercialized technologies	DOE	www.lgprogram.energy.gov
Funding from 11 federal agencies for U.S. small business technology R&D and commercialization	Small Business Innovation Research and Small Business Technology Transfer Program	www.sba.gov/aboutsba/sbaprograms/sbir
Federal grant programs available from 26 federal agencies	Grants.gov	www.grants.gov
Business development resources from National Association of Energy Service Companies (NAESCO)	NAESCO	www.naesco.org

NOTICE: This online publication was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof.