Energy Saving Fact Sheet |

Motors

Power your way to greater energy savings

Motors are everywhere in industry and business. Since they power almost everything, from pumps and fans to compressors, theyre serious energy users. But of course, they offer major scope for energy saving which is where this practical fact sheet can help. It will enable you to identify areas where you can save money, and make your business more efficient, too.
Energy wasting hot spots
Want to know where you can save energy? Theres no better place to start than motors and drives, as these account for over two-thirds of power used in industry. For many more helpful hints, simply call the Carbon Trust on 0800 085 2005. Breakdown of electricity use across industry Other

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Motors and drives

Energy Saving Fact Sheet |

Motors

Motors are cheap to repair, so having them rewound and reconditioned is often the automatic choice whenever they break. But consider: The true cost (in most cases). A rewound motor is usually less energy-efficient than a new one. Although the cost of a rewind will be lower than buying a new motor, the increased running costs will quickly wipe out your initial saving.

Repair, rewind or replace

Fitting the right drives now can save up to 50% in energy. Its that simple. Think efficient. Always specify high-efficiency motors (HEMs). They rarely cost more but use 3-5% less energy and qualify for 100% tax relief under the Enhanced Capital Allowance scheme.

Buying and installing

Dont skimp. A rewound motor could cost you more long term in breakdowns and lower reliability. Factor this into your purchase decision. Get advice. Ask your motor supplier to calculate the energy you would save by buying a new motor compared to repairing an old one.

Plan ahead. Create a motor management plan for buying and repairing motors. A structured approach will reduce downtime and cause less disruption to your operation when motors do fail. Not too big. Many motors are hugely over-sized for the machines they power. Check the equipment and buy a motor that matches the load requirements, plus a small margin of error.

What you should know about motor efficiency

Most motors operate using AC (alternating current) induction they use electricity to generate magnetic fields that turn the motor. Some energy is lost within the motor through friction and magnetic losses, so no motor is 100% efficient. On the other hand, new higher-efficiency motors can be more than 90% efficient.
Hidden costs
The cost of an electric motor can be very deceptive; in particular, the annual energy cost to run the motor can be up to ten times its purchase cost. Running costs of a fully-loaded motor can range from 1,000 a year for a 2.2 kW motor to 18,000 a year for a 37 kW one. When you consider running costs and efficiencies together, its clear that buying the most efficient motors and ensuring that they are properly maintained can save a large amount of money. For example, a 10 kW motor operating at 87% efficiency could cost 75 more per year to run than one that is just 5% more efficient. Over the motors lifetime, the less efficient motor would cost 1,500 more than the higher-efficiency model.

Small differences, big savings

Common sense and forward thinking can help you save thousands of pounds in energy a year.

Day-to-day operation

Drivetrains

Maintain well. Motors work hard and become less efficient over time through wear and tear. Check your drive systems and alignment regularly to extend their useful life. Automate it. Think about automated process control systems to manage motor speeds. This can save up to 15% of a process running-cost.

Many motors are connected to machinery with gears, pulleys or belts but this can be wasteful. Here are some solutions: Go direct. Energy can be wasted when it is transmitted through a drivetrain. If possible, choose directlyconnected motors running at the right speed this is much more efficient. Maximise efficiency. Ensure that drivetrains operate as effectively as possible by checking and maintaining regularly belt tension and gear lubrication.

Switch off. Always the cheapest way to save energy turn motors off when theyre not in use, provided this is in line with the machine manufacturers guidelines.

Line them up. Check the alignment of gears and other linkages. Youll avoid the loss of hundreds of pounds over the lifetime of the motor. Even a small misalignment will reduce system efficiency by several percent costing you money.

Look at every motor

Like many businesses, you probably have motors that are part of the furniture; they are tucked away in all kinds of places and their operation is no longer noticed. However, you can make significant energy and cost savings by examining each motor system and how it is used; the diagram below will help you identify the various options.

Five questions

Ask whether the system is doing a useful job

For each motor on your premises, ask the following: 1. Can the motor be switched off? 3. Is the motor correctly sized? 2. How can motor efficiency be improved? 4. Can the speed of the motor be reduced?

Reduce system losses Select the motor for best efficiency

5. How can good maintenance improve efficiency? The results will enable you to make all kinds of operational improvements.

Select the driven machinery for best efficiency

Slow it down Switch it off

Reduce transmission losses This diagram shows a system in which a motor drives a pump to recycle liquid from process to a feed reservoir

The Carbon Trust 0800 085 2005

www.thecarbontrust.co.uk/energy

One of the best ways to save energy with motors is to fit variable-speed drives (VSDs) to units that need to operate at a range of speeds.

Variable speed drives

Quick, slow, save. It can be wasteful to drive every motor at the maximum speed all the time. VSDs enable the motor to be driven at different speeds in order to match the load required by the equipment or application. This is important because lowering the speed of a motor by just 20% can save up to 50% in energy. More cost-effective. Many types of motor-driven equipment are now available with built-in VSDs. These include air conditioning units, pumps and fans. Buying equipment that incorporates a VSD is usually cheaper than acquiring the equipment and the VSD separately.

Distributed power. Installing VSDs can prove even more attractive when you realise that a single drive is often able to control several motors at once.

Improved control. As well as slashing energy bills, VSDs offer a wide range of speed, torque and power, and give improved process control. That means added flexibility and quality across your plant.

Take action!

Start saving energy today

Allocate responsibility to a member of staff or small team who can drive forward energy saving measures, such as:

1. Power down. The cheapest way to save energy from motors is to make sure that they are turned off when not in use! 2. Go slow. Fit variable speed drives (VSDs) wherever possible to match motor speed to the load. 3. Use forward thinking. Write a basic motor management plan to ensure a structured approach to the purchase and repair of your companys motors. 4. Look at the real costs. Make purchase decisions based on operating costs, not on initial cost. The annual cost of running motor can be ten times its purchase cost. 5. Get your hands dirty. Motors work hard and lose efficiency through wear and tear. Good maintenance saves money.

Call the Carbon Trust for a copy of How to select a variable speed drive our step-by-step guide to energy saving. We can also give you further energy saving advice for your business.

The Carbon Trust 0800 085 2005 www.thecarbontrust.co.uk/energy

More ways to save

ECA and Energy-Efficiency Loans

If youre considering installing a new motor or components, buy from the approved Energy Technology List (at www.eca.gov.uk). This details products that meet certain energy efficiency criteria. You may also qualify for a valuable Enhanced Capital Allowance and an interest-free loan from the Carbon Trust. Call 0800 085 2005 for more information.

The Carbon Trust helps businesses and public sector organisations cut their energy costs to combat climate change through the provision of free, professional advice and assistance.
You can obtain these energy saving guides at www.thecarbontrust.co.uk/energy or by calling the Carbon Trust on 0800 085 2005. GIL152 How to select a variable speed drive

Want to find out more?

GIL056 Energy savings from motor management policies

Weve got many more tips on motors and drives that will help you save energy and money. So give the Carbon Trust a call today.

The Carbon Trust 0800 085 2005 www.thecarbontrust.co.uk/energy

The Carbon Trust is funded by the Department for Environment, Food and Rural Affairs, the Scottish Executive, the Welsh Assembly Government and Invest Northern Ireland. Whilst we have taken reasonable steps to ensure that the information contained within this leaflet is correct, we give no warranty and make no representation as to its accuracy and we accept no liability for any errors or omissions and neither does the Government.

The Carbon Trust is a company limited by guarantee. Registered in England and Wales Number 4190230. Registered at: 8th Floor, 3 Clements Inn, London WC2A 2AZ. Queens Printer and Controller of HMSO, March 2006

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