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[null,"ENERGY EFFICIENCY TOOLS FOR MOTORS ENERGY EFFICIENCY"]
[null,"VER_02/150918"]
[null,"INTRODUCTION: ..."]
[null,"INTRODUCTION: This workbook consists of tools that conduct Assessment of Motors, and calculate Energy Saving Potentials in Motors."]
[]
[]
[null,"HOW TO USE:"]
[null,"1. Insert data from your company in cells that are highlighted in white.\n2. Results of calculations will be displayed in Orange Cells.\n3. Examples of Data and Calculation are shown in each tool."]
[null,"SOURCES:"]
[null,"1. Compressed Air Best Practice Tool; Sustainable Energy Authority of Ireland (seai)\n2. Recuperable heat from compressors, Energy Agency NRW\n3. Compressed Air Systems in the European Union, EU 2001\n4. International Energy Agency (IEA)\n5. Energy Markets International Limited\n6. ISO 11011 Compressed air – Energy Efficiency – Assessment\n7. Energy Efficiency Guide for Industry in Asia – www.energyefficiencyasia.org\n8. US Department of Energy  – www.eere.energy.gov/industry\n9. www.motorsmatters.org\n10. www.rapidtables.com\n11. Consortium for energy efficiency\n12. www.energy.gov\n13. Bureau of Energy Efficiency India\n14.  APO Japan"]
[null,"WHO WE ARE:"]
[null,"ESPIRE is a partnership project between the Training and Development Centers of the Bavarian Employers‘ Association (bfz) gGmbH and business associations in Lahore and Karachi in Pakistan. \n\nThe objective of ESPIRE project is to support industries in Pakistan to work economically more efficiently and ecologically more sustainable and start making energy conservation and cleaner production part of their work routine. \n\nMain project partners are; Pakistan Association of Automotive Parts and Accessories Manufacturers (PAAPAM), Pakistan Hosiery Manufacturers Association (PHMA), Pakistan Readymade Garments Manufacturers and Exporters Association (PRGMEA), Small and Medium Enterprises Development Authority (SMEDA), Towel Manufacturers Association of Pakistan (TMA).\n\nThe Project is funded by the German Federal Ministry for Economic Cooperation and Development (BMZ) via Sequa gGmbH."]
[null,"DISCLAIMER:"]
[null,"The information, calculations and conclusions in this tool are based on the projects executed by the experts and consultant under Project ESPIRE by bfz gGmbH – International Division. Some sources (as mentioned above) were also consulted to validate the contents. The efficiency improvement measures proposed in this tool are tested and tried in many companies in Pakistan. However, implementation of these measures in any particular case should be based on real time data analysis by qualified engineers after judging financial viability. Bfz gGmbH – International Division and it's Project Partners in Pakistan accepts no liability whatsoever to any person, company or entity for any injury, loss or damage that may arise in connection with any misuse or reliance on the information.\n\nThe tool is provided as a freeware. Users may make copies and distribute the tool without making any changes."]
[null,"CONTACT:"]
[null,"Users may contact following for any clarification, suggestion and/or improvement in this tool;"]
[null,"Muhammad Salman Butt\nProject Manager\nProject ESPIRE\nbfz gGmbH International Division\n0092 300 4322343",null,"Sajid Mahmood Lakhan\nManaging Director\nGreen Energy Associates, Karachi\n0092 321 2117115\nsajid@gea.com.pk"]

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[]
[null,"CHECKLIST FOR ENERGY SAVING OPTIONS IN THE MOTORS"]
[null,null,"ENERGY SAVING OPTIONS"]
[null,"LEVEL","DESIGN / PURCHASE","RATING"]
[null,"-","Develop purchasing specification of all motors including criterion to judge energy performance.","»"]
[null,"-","Compare life-cycle cost of available alternate motors while purchasing and do not make your decision based on purchase price only [A motor consumes energy equal to its purchase price in less than 2 months].","»"]
[null,"-","When purchasing a large number of small motors or a large motor, ask for a detailed test certificate.","»"]
[null,"-","For optimum efficiency, select motor size appropriate to the load.","»"]
[null,"- -","Investigate use of multi speed motor for variable load conditions.","»"]
[null,"- - -","Check technical and financial feasibility of using energy-efficient motors","»"]
[null,"- - -","Where possible, investigate installing a Direct Current (DC) motor instead of Alternating Current (AC) motor.","»"]
[null,null,"USE","RATING"]
[null,"-","Prepare and regularly update Inventory of installed motors in the facilities, including their design parameters, locations of installation and maintenance record.","»"]
[null,"-","Ensure a balanced power supply to motors with balanced voltage across phases [An imbalanced voltage can de-rate motor by 3 – 5%].","»"]
[null,"-","Ensure power supply to motors is within recommended voltage limits [5% or more voltage drop observed at motor input, while motor shifts to high load, indicates undersized cables].","»"]
[null,"-","Check load conditions of motors and identify overloaded and underloaded motors [A change in motor load indicates a possible change in the driven load].","»"]
[null,"- -","Convert lightly loaded motors [below 30% of rated power] from Delta to Star connection [Star connection reduces the voltage across the motor windings to 58% of the Delta connection].","»"]
[null,"- -","Install Variable Speed Drive (VSD) for variable load or lightly loaded motors. ","»"]
[null,"- -","Use synchronous motors to improve power factor.","»"]
[null,"- -","Investigate machine-side inefficiencies, such as idle operations, throttling of pumps, damper operations in fans, leakages, etc.","»"]
[null,null,"SAFETY and MAINTENANCE","RATING"]
[null,"-","Ensure good housekeeping conditions and proper ventilation for motors [For every 10°C increase in motor operating temperature over recommended peak, the motor life is estimated to be reduced by 50%].","»"]
[null,"-","Ensure appropriate lubrication as per manufacturers' recommendations.","»"]
[null,"-","Ensure that supply wiring and terminal boxes are properly sized and installed.","»"]
[null,"-","Inspect regularly the connections at the motor and starter to be sure that they are clean and tight.","»"]
[null,"-","Identify motors with low voltage, low power factor and voltage imbalance and immediately take improvement measures.","»"]
[null,"-","Develop a motor assessment programme and identify motors with rising temperature, high noise, high vibration and increased power consumption.","»"]
[null,"-","Develop and implement a predictive and preventive maintenance programme.","»"]
[null,"-","Inspect motors regularly for wear in bearings and housings and for dirt/dust in motor ventilating ducts to ensure proper heat dissipation.","»"]
[null,"-","Develop guidelines for proactive repair/replace decisions, based on operating and maintenance cost and energy performance.","»"]
[null,"- -","Periodically check alignment of the motor and the driven equipment [Improper alignment can cause shafts and bearings to wear quickly, resulting in damage to both the motor and the driven equipment].","»"]
[null,"- -","Periodically check motor load at Zero-load condition [Motors consuming 5% or more power at Zero-load conditions indicate increased losses and should be replaced].","»"]
[null,"- -","Check and maintain motor efficiency after repair or maintenance [e.g. If rewinding is not done properly, the efficiency can be reduced by 5 – 8%].","»"]
[null,"- -","Avoid frequent rewinding of motors. The greater the number of rewinds, the lesser the efficiency.","»"]
[null,"- -","Identify and investigate cases of repeated motor failure and take immediate improvement measures.","»"]
[null,"- -","Provide interlock for electric motors to avoid idle running.","»"]
[null,"- - -","Replace eddy current controls with variable frequency drives for varying speed driven equipment.","»"]
[]
[null,"LEVEL OF DIFFICULTY:"]
[null,"-","No/Low Cost or Short Term Investment [Pay-back period < 6 months]"]
[null,"- -","Medium Term Investment  [Pay-back period < 18 months]"]
[null,"- - -","Long Term Investment or Needs Feasibility Study  [Pay-back period > 18 months]"]
[]
[null,"RATING OF IMPLEMENTATION STATUS:"]
[null,null,"Energy Saving Option has not been considered yet.",1]
[null,null,"Energy Saving Option is in the planning stage but not yet realized.",2]
[null,null,"Energy Saving Option is partially (not in all areas/ machines or not all the time) implemented/ realized. ",3]
[null,null,"Energy Saving Option has been mostly implemented/ realized.",4]
[null,null,"Energy Saving Option is fully realized. ",5]
[null,null,null,"»"]

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[]
[null,"ENERGY SAVING BY INSTALLING HIGH EFFICIENCY MOTOR"]
[null,"ISSUE: Installing energy efficient motor is very feasible because of lower operating and maintenance costs, coupled with relatively short payback periods. Energy efficient motors accomplish more work per unit of electricity than their less efficient counterparts. \n\nWHAT WE DO HERE: Calculate the energy savings achievable by using a high efficienc motor instead of a standard motor. "]
[null,null,"Example",null,"Motor Power"]
[null,null,75,null,null,"[kW]",">","Compressor motor rating"]
[null,null,null,null,"Motor Efficiency"]
[null,null,0.92,null,null,"[%]",">","Standard compressor motor efficiency (default =92%)"]
[null,null,null,null,"% Full Load"]
[null,null,0.7,null,null,"[%]",">","Estimate of average percentage motor load factor (default =65%)"]
[null,null,null,null,"Annual Operation Hours"]
[null,null,6240,null,null,"[h/y]",">","24h/7d =8.760 hours; 24h/5d =6.240 hours; h/5d = 2.080 hours"]
[null,null,null,null,"New Motor Efficiency"]
[null,null,0.93500000000000005,null,null,"[%]",">","= Efficiency new motor [%]-Efficiency old standard compressor motor [%] \n(default = 1,5% higher than old motor)"]
[null,null,null,null,"Energy Savings"]
[null,null,{"$f":"C5*C9*C11*((1/C7)-(1/C13))","v":5712.6249709370268},null,{"$f":"E5*E9*E11*((1/E7)-(1/E13))","v":{"$error":"#DIV/0!"}},"[kWh/y]",">","= (Motor Power [kW] x (Full Load [%]) x Operation Hours [h/y]) x (1/Compressor Motor Efficiency [%] - 1/New Motor Efficiency [%])"]
[null,null,null,null,"Average Electricity Price"]
[null,null,18,null,null,"[PKR/kWh]",">","Insert from Energy Bills"]
[null,null,null,null,"Annual Cost Savings"]
[null,null,{"$f":"C15*C17","v":102827.24947686648},null,{"$f":"E15*E17","v":{"$error":"#DIV/0!"}},"[PKR/y]",">","= (Annual Energy Savings [kWh/y] x (Average Electricity Price [PKR/kWh])"]
[null,null,null,null,"Investment for new motor"]
[null,null,150000,null,null,"[PKR]",">","Price of new motor quoted by vendors"]
[null,null,null,null,"Payback Period"]
[null,null,{"$f":"C21*12/C19","v":17.505087505087399},null,{"$f":"E21*12/E19","v":{"$error":"#DIV/0!"}},"[Months]"]
[]
[]
[null,"HOW TO USE:"]
[null,"1. Insert data from your company in cells that are highlighted in white \n2. Data for Motor Power, Motor Efficiency, % Full Load and Annual Operation Hours can be compiled in table \"Equipment Data\" once and inserted from this source. \n3. If your rated motor mentioned in HP, convert it KW by multiplying 0.746 "]
[null,"ADDITIONAL INFORMATION & TIPS"]
[null,"1. Rule of Thumb: a high efficiency motor will typically be 1,5% more efficient than a standard compressor motor. Please, insert exact value if available from supplier.  \n2. Payback: Base load machines that operate more hours annually show quicker returns on investment than trim machines that only operate few hours to cover peak demand.\n3. Compressors usually do not come with high efficiency motors as standard, however, motors with higher efficiency are often offered as option. For compressors for base load a high efficiency motor may be more economical.  \n\n"]

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[]
[null,"ENERGY SAVING BY INSTALLING VARIABLE SPEED DRIVE"]
[null,"ISSUE: Traditionally, motors are subject to variable load conditions. Various motor controls are used to reduce affect of load variation on motors. VSD motors are interesting for conditions with high variance in demand profile. \n\nWHAT WE DO HERE: Calculate the energy savings achievable by using a Variable Speed Drive (VSD). "]
[null,null,"Example",null,"Motor Power"]
[null,null,12,null,null,"[kW]",">","Enter Motor rating in kW"]
[null,null,null,null,"Motor Efficiency"]
[null,null,0.92,null,null,"[%]",">","Standard motor efficiency (default = 92%)"]
[null,null,null,null,"VSD Efficiency"]
[null,null,0.96,null,null,"[%]",">","Variable Speed Drive efficiency (default = 96%)"]
[null,null,null,null,"Average Part Load Condition"]
[null,null,0.7,null,null,"[%]",">","Average motor loading expressed as a percentage of the rated capacity"]
[null,null,null,null,"Annual Operation Hours"]
[null,null,6240,null,null,"[h/y]",">","24h/7d =8,760 hours; 24h/5d =6,240 hours; h/5d = 2,080 hours"]
[null,null,null,null,"Average Power Saving"]
[null,null,{"$f":"C5/C7*70%*(100%-C11)*C9","v":2.6295652173913044},null,{"$f":"E5/E7*70%*(100%-E11)*E9","v":{"$error":"#DIV/0!"}},"[kW/h]",">","= Motor Power [kW] / Motor Efficiency [%] x 70% x (100%-Average Part Load Condition [%] x VSD Efficiency [%]"]
[null,null,null,null,"Annual Energy Savings"]
[null,null,{"$f":"C13*C15","v":16408.486956521741},null,{"$f":"E13*E15","v":{"$error":"#DIV/0!"}},"[kWh/y]",">","= Average Power Saving [kW] x Annual Operation Hours [h/y]"]
[null,null,null,null,"Average Electricity Price"]
[null,null,18,null,null,"[PKR/kWh]",">","Insert from Energy Bills"]
[null,null,null,null,"Annual Cost Savings"]
[null,null,{"$f":"C17*C19","v":295352.76521739137},null,{"$f":"E17*E19","v":{"$error":"#DIV/0!"}},"[PKR/y]",">","= (Annual Energy Savings [kWh/y] x (Average Electricity Price [$/kWh])"]
[null,null,null,null,"Investment for VSD"]
[null,null,110000,null,null,"[PKR]",">","Price of VSD/VFD quoted by vendors"]
[null,null,null,null,"Payback Period"]
[null,null,{"$f":"C23*12/C21","v":4.4692318997874541},null,{"$f":"E23*12/E21","v":{"$error":"#DIV/0!"}},"[Months]"]
[]
[]
[null,"HOW TO USE:"]
[null,"1. Insert data from your company in cells that are highlighted in white "]
[null,"ADDITIONAL INFORMATION & TIPS"]
[null,"1. If your rated motor mentioned in HP, convert it KW by multiplying 0.746\n"]