Presentation by : Milind Raje General Manager – Projects International Copper Promotion Council (India)

High Efficiency Motor Application Presentation by : Milind Raje General Manager – Projects International Copper Promotion Council (India)

ICPCI-International Copper Promotion Council (India)Indian centre of ICA to promote Copper applications in India. • ICA-INTERNATIONAL COPPERASSOCIATION • 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.

Presentation Structure • Why HEM s • HEM implementation • Policies & Regulation • Supply chain involvement • End Users involvement • Conclusion

Sector wise energy consumption Industry consumes the most Energy

Sector wise Energy Saving potential Sector Conservation potential (%) Industrial Sector Up to 25 Agriculture Sector Up to 30 20-25% Domestic Sector Up to 20 Commercial Sector Up to 30 Energy Handled by Motors (%) 70-75% 2-3% 4-5%

Presentation Structure • Introduction & Why HEM s • HEM implementation • Policies & Regulation • Supply chain involvement • End Users involvement • Conclusion

Barriers to penetration of HEM s • Lack of knowledge/ awareness with users • Non availability of EE motors • Confusion – EE motor definition • Need to have focused market transformation • Higher initial cost • Low demand; high price • Lesser working hours • Lack of technology • Poor power quality in rural sector • Application limitations

HEM Implementation Towards increasing penetration of HEM s Policies Regulation Standards Marketing Promotion Supply Chain

Standards • Standard • Prescribes Energy performance of manufactured products (Minimum Energy Performance Standards, MPES).

Legislation Three-phase induction motors 0.75 to 150kW 60Hz 2, 4, and 6 pole Specifies minimum efficiencies Testing to IEEE-112b Voluntary Three-phase induction motors 1.1 to 90kW 50 Hz 2 and 4 pole Efficiency labelling Testing to IEC60034-2 Standards scenario - International EPACT CEMEP Agreement

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

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

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

Motor Efficiency Levels (qualitative comparison) Super Premium NEMA Premium High Efficiency Standard Eff. % Efficiency (at full load) EFF 1 ~ EPAct=JIS 4212 EFF 2 Induction Motor Kilowatt rating - 3 phase - 4 pole, general purpose

Efficiency is a differentiator for Major Motor manufacturers Voluntarily adopted Eff1 Eff2 Min benchmark Forced to follow Eff3 Major manu. Small/medium scale manu. Future aim

Reduce Iron Loss Reduce Copper Loss Reduce Stator Cu Loss Reduce Rotor Cu Loss Increase Copper Section Stator slot area Reduce Flux Density Increase Rotor bar section Low Loss Magnetic matl. Increase Reduce Stator Yoke Rotor Diam Increased Starting current Reduced S t a r t i n g T o r q u e Loss reduction Source: Bharat Bijlee Core length has to be increased to maintain starting torque

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 • High Grade (low loss) laminations • More Copper Rs Source: Bharat Bijlee

Education of all the elements Motor Manufacturer - Supply Push Consultants influence I N F L U E N C E Dealer O.E.M Contractor Pull End User - Demand

End User involvement Awareness creation Conviction Adoption

Awareness Yes No Willing to Change - Conviction Reasons? Barriers /issues Lack of info. (tech. /general) Corporate culture, Individual mindsets no interest in Energy Cons. Know –all attitude Yes No How – Adoption Identify key implementers Why? Barriers /issues Price premium, availability, Claims Vs savings actual, Tech. Support, rewinding issues No finance,Not decision maker Solutions Provide information Help them Solutions Remove doubts Structured program on Energy Management through motors

Opportunities to adopt HEM 1. First purchases Existing motors New Project Expansion 2. Replacement 3. Retrofit Projects / Consultants Plant Personnel Top Management/Financers

Lowest Cost purchases can be deceptive • Purchase decisions are normally dependent on - • Reliability • Price • Brand • Service Rarely attention given to the Life Cycle Cost in capital purchases

Economic Analysis Payback Reduced with Longer Hours, Greater Load

The operating costs are what count ! ! ! 12 yrs 15 yrs 20 yrs Source: Siemens

Retrofitting of existing motors • Statistical Approach • Analytical Approach

Motor data & initial load survey

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

Analytical Approach • Classify on the basis of • operating hours • Repair/rewind history • Load factor • Age • Identify critical motors for field study/payback calculations • Make investment proposals for motor replacements

To conclude ……. Oil from being burned coal from being burned Carbon emissions from being released into the atmosphere and... Upgrading one, 1 HP motor to a high Efficient motor ... Every single year will eliminate:---- or... Source: Baldor

We all have our personal doomsday scenarios with respect to an extremely “energy hungry” world Year 1900 History repeats itself scenario Year 2000CFL Year 1800 Year 2050 Year 2020, LED Source-Gtz

Thank you !! E Mail – info_copper@icpci.orgWebsite – www.copperindia.orgPhone- +91 22 66937989Fax- +91 22 66939282

Presentation by : Milind Raje General Manager – Projects International Copper Promotion Council (India)