1 Schweizerische Agentur für Energieeffizienz Swiss Agency for Efficient Energy Use MOTOR SUMMIT th International Motor Summit for Energy Efficiency powered by S.A.F.E. Rapid market penetration for energy efficient electric motor systems Electric motors and motor systems in industrial and infrastructure applications together with pumps, fans and compressors in buildings, are responsible for 45 % of the world s total electricity consumption. New and existing technologies offer the potential to reduce the energy demand of motor systems across the global economy by 20 % to 30 % with short payback periods, if market barriers can be overcome. The Swiss Agency for Efficient Energy Use (S.A.F.E.), in collaboration with the Electric Motor Systems Annex (EMSA) of the International Energy Agency s Implementing Agreement Energy Efficient Electrical End-Use Equipment (IEA 4E) and the national Swiss- Energy program are pleased to announce the Motor Summit 2014, 5 th edition. The Motor Summit 2014 will bring together selected experts from research, federal and local governments, utilities, manufacturers of motors, pumps and fans, OEMs, motor systems users and other interested parties. Participants will debate global strategies and actions to overcome barriers hindering the widespread use of highly efficient motor systems with speakers from Europe, Australia, Brazil, Canada, China, Japan, and USA. Workshops Policy & Technology, Tuesday 7 October 14 Time Policy Workshop, Chair: Rita Werle Speaker 9:00 Policy Guidelines for Efficient Electric Motor Systems 12:00 Lunch Dutch Long Term Agreements and the new Green Deal Energy efficiency potentials for different motor system levels New US MEPS for motors and applications Konstantin Kulterer, Austrian Energy Agency, Austria Maarten van Werkhoven, EMSA, Netherlands Svetlana Paramonova, Linköping University, Sweden Rob Boteler, Nidec/NEMA, USA Technology workshop, Chair: Conrad U. Brunner 13:30 Measurements of efficiency for converters and motors in industry reality The way forward for IEC standards of converters and motors Recent results of efficiency measurements of converters and motors 17:00 SEAD motor award ceremony & reception Sinan Altındağ, Gamak, Turkey Tim Schumann, SEW-Eurodrive, USA Pierre Angers, Hydro Quebec, Canada SEMA UCME Schweizerischer Verband der Elektromaschinenbaufirmen Union Suisse des entreprises de construction de machines électriques
2 Date From 7 to 9 October 2014 Organization Swiss Agency for Efficient Energy Use (S.A.F.E.) Tel +41 (0) Fax +41 (0) Host S.A.F.E. (organization) Topmotors 4E Electric Motor Systems Annex EMSA SwissEnergy Partners act EKZ EnAW Faktor Verlag AG NEMA Öbu ProKlima SEMA swisscleantech Swissmem swisst.net Sponsors SFOE Swiss Federal Office of Energy AWEL, Canton Zurich Building department Canton Zug EKZ Elektrizitätswerke des Kantons Zürich NEMA National Electrical Manufacturers Association S.A.F.E. Exhibitors ABB Schweiz AG Control Techniques AG ebm-papst AG Conference registration Documentation A documentation of executive summaries of all speakers will be handed to the participants at the conference. The presentations and other relevant materials will be available after the conference to all participants and the public under: Conference venue Conference Center Glockenhof, Sihlstr. 33, CH-8001 Zurich +41 (0) Program overview Tuesday 7 Oct EMSA Workshops* Wednesday 8 Oct MS 14 International Strategy Thursday 9 Oct MS 14 Swiss Implementation English English German Policy a.m. session a.m. session Lunch Technology p.m. session p.m. session SEAD award *Places are limited MS 14 Dinner Hotel accommodation Make your reservation directly at one of our five recommended hotels before 1 September Please mention «Motor Summit» to profit from the discount of the group arrangement. Hotel Glockenhof, ****, Sihlstrasse 31, CH-8001 Zürich +41 (0) , Hotel Seidenhof, ***, Sihlstrasse 9, CH-8001 Zürich +41 (0) , Leoneck Hotel, ***, Leonhardstrasse 1, CH-8001 Zürich +41 (0) , Hotel Limmathof, ***, Limmatquai 142, CH-8001 Zürich +41 (0) , Hotel City, ***, Löwenstrasse 34, CH-8001 Zürich +41 (0) , Conference fee (including conference documentation) Packages (details: CHF EUR Complete registration: October International package: 7 8 October Motor Summit 2014 package: 8 9 October Single Events EMSA Workshop «Policy»: 7 October EMSA Workshop «Technology»: 7 October International Strategy day: 8 October Swiss Implementation day: 9 October MS 14 Dinner: 8 October Discount Participants who pay the registration fee before 30 June 2014 receive a 20 % early bird discount. Members of 4E, ACT, EMSA, EnAW, NEMA, Öbu, ProKlima, S.A.F.E., SEMA, swisscleantech, Swissmem or swisst.net receive a 20 % discount. Payment: You will receive payment instructions after your online registration. Swiss Agency for Efficient Energy Use
3 Welcome to the Motor Summit 2014! It has become a rule to have the EEMODS conference (Energy Efficiency in Motor Driven Systems) and the Motor Summit in a smaller format in Switzerland in alternating years. The scope of the Motor Summit has remained since the first such event in 2007, but technological development and new policies for implementation have changed a great deal. We are sure that the 180 participants from 25 countries will enjoy intensive and useful three days. We would like to thank all partners, exhibitors and sponsors. We thank the SwissEnergy program for supporting the Swiss motor implementation program Topmotors and for contributing to the Motor Summit. We enjoy the global partnership with 4E EMSA which gives us an excellent occasion to host specific workshops open to an interested public. This year workshops on "Policy" and "Technology" and the SEAD Award ceremony are on the agenda. The IECEE Global Motor Labeling Program will also hold its meeting in Zurich. You are all invited to join the Global Motor Systems Network by subscribing to our newsletter at (English, German, Russian, Japanese and Chinese). We wish you interesting days in Zurich and hopefully also a view of the city, the lake and the snow-covered mountains that surround this beautiful place. See you at the next EEMODS in Helsinki, Finland, on September 2015! Willkommen zum Motor Summit 2014! Es ist schon fast zur Regel geworden, dass in einem Jahr die EEMODS Konferenz (Energy Efficiency in Motor Driven Systems) und im folgenden Jahr der Motor Summit in Zürich in einem kleineren Format stattfindet. Seit der ersten Austragung in 2007 hat sich die Aufgabe zur Einsparung von elektrischer Energie bei Antriebssystemen nicht geändert, aber die technologische Entwicklung und die Chancen und Möglichkeiten der Umsetzungspolitik haben sich stark verändert. Wir sind sicher, dass die 180 Teilnehmer aus 25 Ländern drei interessante Tage in Zürich verbringen werden. Wir danken allen Partnern, Ausstellern und Sponsoren. Wir danken EnergieSchweiz für die Unterstützung des Schweizer Umsetzungsprogramms Topmotors und den Motor Summit. Wir freuen uns über die globale Partnerschaft mit 4E EMSA, das uns eine gute Gelegenheit gibt, interessante Workshops für ein Fachpublikum anzubieten. Dieses Jahr stehen "Policy", und "Technology" und die Preisverleihung des SEAD Awards auf der Agenda. Sie sind alle eingeladen, sich am Global Motor Systems Network zu beteiligen, indem Sie sich auf (deutsch/französisch) oder (englisch, russisch, chinesisch und japanisch) für den Newsletter abonnieren. Wir wünschen Ihnen schöne Tage in Zürich und hoffentlich auch einen Blick in die Stadt, auf den See oder die schneebedeckten Berge rundherum. Auf Wiedersehen an der nächsten EEMODS in Helsinki, Finnland, vom 15. bis zum 17. September 2015! Das Motor Summit Team Conrad U. Brunner Rita Werle Rolf Tieben Bea Meyer Silvia Berger
4 MOTOR SUMMIT 2014 Workshops Policy & Technology, Tuesday 7 October 14 Time Policy Workshop, Chair: Rita Werle Speaker 9:00 Policy Guidelines for Efficient Electric Motor Systems 12:00 Lunch Dutch Long Term Agreements and the new Green Deal Energy efficiency potentials for different motor system levels New US MEPS for motors and applications Konstantin Kulterer, Austrian Energy Agency, Austria Maarten van Werkhoven, EMSA, Netherlands Svetlana Paramonova, Linköping University, Sweden Rob Boteler, Nidec/NEMA, USA Technology workshop, Chair: Conrad U. Brunner 13:30 Measurements of efficiency for converters and motors in industry reality The way forward for IEC standards of converters and motors Recent results of efficiency measurements of converters and motors 17:00 SEAD motor award ceremony & reception Sinan Altındağ, Gamak, Turkey Tim Schumann, SEW-Eurodrive, USA Pierre Angers, Hydro Quebec, Canada
5 MOTOR SUMMIT 2014 International Strategy, Wednesday 8 October 2014 Time Topic Speaker Introduction, Chair: Conrad U. Brunner 09:00 Welcome & introduction Conrad U. Brunner, 4E EMSA, Switzerland 09:30 Energy Strategy 2050 Walter Steinmann, Swiss Federal Office of Energy, Switzerland 09:50 Motor market update Alex Chausovsky, IHS, USA 10:10 IECEE Global Motor Labeling Program Dan Delaney, Regal Beloit, USA 10:30 Coffee Policies across the globe, Chair: Maarten van Werkhoven 10:50 European experience in motor and motor systems MEPS 11:10 Japan starts with mandatory motor requirements 11:30 Brazil moves ahead with MEPS for motors Marcos Gonzáles Àlvarez, European Commission, Belgium Takeshi Obata, JEMA/Hitachi, Japan George Alves Soares, Eletrobras, Brazil 11:50 Swiss audit program Easy Rita Werle, Topmotors, Switzerland 12:10 Improving Motor System Efficiency in Zheng Tan, Topmotors China, China China 12:30 Lunch Testing, Chair: Bill Hoyt 13:50 Ecopliant first results of check testing of motors 14:10 NVLAP motor energy effciency testing experience with accreditation and performance 14:30 New developments in IEC standards for motors driven by converters 14:50 State of the art in efficiency measurements of converters and motors 15:10 Coffee New Technology, Chair: Bill Hoyt 15:30 Total drive train optimization of industrial fans and pumps considering VFD driven motor, transmission and load 15:50 European Ecodesign Lot 30: new ideas for advanced MEPS 16:10 Next horizon for efficiency in electric motors 16:30 SEAD Global Efficiency Medal Competition for Electric Motors Sandie B. Nielsen, Danish Institute of Technology, Denmark Timothy Rasinski, National Voluntary Laboratory Accreditation Program, USA Martin Doppelbauer, Karlsruhe Institute of Technology, Germany Andrew Baghurst, CalTest, Australia Steve Dereyne, University of Ghent, Belgium Anibal de Almeida, University of Coimbra, Portugal John Petro, JPEAM, USA Chad Gallinat, Department of Energy, USA 16:50 Introduction to EEMODS 2015 in Finland Jukka Tolvanen, ABB, Finland Panel, Moderator: Conrad U. Brunner 17:00 Panel discussion 18:00 End 19:00 MS'14 Gala Dinner (for registered guests): University of Zurich, tower
6 MOTOR SUMMIT 2014 Umsetzung Schweiz, Donnerstag, 9. Oktober 2014 Zeit Thema Vortragende Einführung, Moderator: Conrad U. Brunner 09:00 Begrüssung/Einführung Conrad U. Brunner, Topmotors, Zürich 09:30 EnergieSchweiz Daniela Bomatter, Bundesamt für Energie, Bern 09:50 ACT: ein neuer Player zur Umsetzung Marloes Caduff, Agentur Cleantech, Zürich der Energieeffizienz in der Industrie 10:10 Stand der Energieverordnung für Richard Phillips, Bundesamt für Energie, Bern elektrische Antriebssysteme 10:30 Kaffeepause Anwendungen und Systeme, Moderator: Roland Brüniger 10:50 Pumpensysteme: Effizienz optimierung Jürg Nipkow, Topmotors, Zürich 11:10 Ventilatoren werden immer besser Werner Schneeberger, ebmpapst, Oberhasli 11:30 Frequenzumrichter: Chancen und Adrian Omlin, Hochschule Luzern Risiken beim Energie Sparen 11:50 Hydraulische Systeme mit weniger Johann Lodewyks, Hochschule Luzern Energie 12:10 Effiziente Transmissionssysteme Heinrich Huber, Fachhochschule Nordwestschweiz, Muttenz 12:30 Lunch Praxiserfahrungen, Moderator: Roland Brüniger 13:50 Messungen auswerten mit dem Rolf Tieben, Topmotors, Zürich Standard Test Report (STR) 14:10 Expériences de Easy dans la Suisse Nicolas Macabrey, Planair, La Sagne Romande 14:30 Praxiserfahrungen mit effizienten Jan Krückel, ABB, Baden Antriebssystemen 14:50 Frequenzumrichter in der Praxis Michael Burghardt, Danfoss, Offenbach, Deutschland 15:10 Antriebssysteme mit Permanentmagneterregung 15:30 Kaffeepause Hansjörg Biland, Emerson Industrial Automation, Birmenstorf Weiterbildung, Programme, Moderator: Marton Varga 15:50 Formation continue pour des experts en technologie et management de l'énergie 16:10 Easy: vom Finanzprogramm zum Weiterbildungsprogramm 16:30 Weiterbildung für effiziente Energienutzung 16:50 Effizienzziele für Energie-Grossverbraucher im Kanton Zürich Podium, Moderator: Conrad U. Brunner 17:10 Podiumsdiskussion 18:00 Apéro im Zentrum Glockenhaus 19:00 Ende Catherine Cooremans, Université de Genève, Genf Rita Werle, Topmotors, Zürich Christian Wirz-Töndury, Institut für Wissen, Energie und Rohstoffe Zug, Zug Alexander Herzog, AWEL, Kanton Zürich
7 Motor Summit 2014 List of Participants Name First Name Organization Country Aarniovuori Lassi Lappeenranta University Finland Advani Ajit Hirasing Copper Alliance India Altindag Sinan Gamak Turkey Alves Soares George Eletrobras Brazil Anderson Kirk UL USA Angers Pierre Hydro Quebec Canada Atre Vinayak Regal Beloit India Baghurst Andrew CalTest Australia Bagianathan Madhan Raj ELGI India Bailly Estelle EDF France Baker Kim C. Novatorque USA Barnbacher Johannes Sempact Germany Bartos Frank Control Engineering USA Baskan Burçak Gamak Turkey Baumgartner Ron Ziehl-Abegg Switzerland Beghain Frederic EASA Luxembourg Berge Gerhard KSB Germany Berger Silvia S.A.F.E. Switzerland Betschmann Oskar Ziehl-Abegg Switzerland Bieri Hans Bieri Motoren Switzerland Biland Hansjörg Emerson Switzerland Bilgiç Ece Gamak Turkey Bomatter Daniela BFE Switzerland Bonn Peter Sulzer Germany Boteler Rob Nidec USA Brühwiler Josef Bühler + Scherler Switzerland Brüniger Roland R. Brüniger Switzerland Brunner Conrad U. S.A.F.E. Switzerland Buchter Florian Groupe E Switzerland Burghardt Michael Danfoss Germany Burkhalter Daniel CSD Switzerland Burla Thomas Fotograf Switzerland Caduff Marloes Cleantech Switzerland Chang Su Hahn KATECH South Korea Chausovsky Alex IHS USA Chen Celine China P.R. Chevailler Samuel HES-SO Valais Switzerland Christensen Morten Grundfos Denmark Chun Yon-Do KERI South Korea Colotti Alberto ZHAW Switzerland Cooremans Catherine Université de Genève Switzerland de Almeida Anibal T. University of Coimbra Portugal De Ridder Leo Journalist The Netherlands Delay Antoine Amstein + Walthert Switzerland Dereyne Steve University Gent Belgium
8 Motor Summit 2014 List of Participants Name First Name Organization Country Devidas Mathieu Emerson Switzerland Doppelbauer Martin KIT Germany Duboc Wagner CEPEL Brazil Dudli Philipp Kanton St. Gallen Switzerland Eckervogt Lionel SEW Germany Eggmann Hanspeter ZZ Wancor AG Switzerland Eiger Edmond IWB Switzerland Erb Fredy Emerson Switzerland Erismann Manfred IB Aarau Switzerland Esengin İsmet Gamak Turkey Everaert Willem Atlas Copco Belgium Falkner Hugh Atkins Global UK Finley William R. Siemens USA Forbes Pirie Mia The Policy Partners UK Franck Per-Åke CIT Sweden Frei Christian Electrosuisse Switzerland Gadermann Michael Infineon Germany Gallinat Chad S. DOE USA Gonzalez Alvarez Marcos European Commission Spain Graber Kasimir ATB Motors Switzerland Gründler Stefanie Bildungsmanagement Switzerland Gut Peter Binkert-Medien Switzerland Hagemann Björn SEW Germany Hallberg Anders Swedish Energy Agency Sweden Haller Michael ABB Switzerland Hartmann Stefan Presseladen Switzerland Herzog Alexander AWEL Switzerland Hesselbach Wolmer B. Bühler Switzerland Hofer Peter UFA Switzerland Holzer Roger Lonza Switzerland Hongler Roland Belimo Switzerland Hoyt Bill NEMA USA Huber Heinrich FHNW Switzerland Hüsser Daniel Zitt Elektromotoren Switzerland Jan Spaniol SEW Germany Jenni Felix FHNW Switzerland Kammermann Stefan HTW Chur Switzerland Kang Byung-Guk KTL South Korea Kern Rolf EBM Switzerland Kim Dong-Jun KERI South Korea Klein Roland Bürge-Fischer Switzerland Klompen Erik Weir Minerals The Netherlands Kolb Bernhard Antriebe Rüti Switzerland Könen Michael KSB Germany König Ivan BFE Switzerland
9 Motor Summit 2014 List of Participants Name First Name Organization Country Krückel Jan ABB Switzerland Kulterer Konstantin Austrian Energy Agency Austria Kummer Michael Küffer Elektro-Technik Switzerland Laborde Yannick Alstom Switzerland Langenegger Fritz Bühler Switzerland Lassal Said Rockwell Automation Switzerland Lee Sujin Hyosung South Korea Leumann Christof Leumann & Uhlmann Switzerland Liang Daniel Copper Alliance China P.R. Lodewyks Johann HSLU Switzerland Loeliger Peter InterDrive Switzerland Macabrey Nicolas Planair Switzerland Madeira Bein Klaudia Alstom Switzerland Maik Albert DM Energieberatung Switzerland Marks Tim AEMT UK Meyer Andreas Rockwell Automation Switzerland Meyer Bea S.A.F.E. Switzerland Minetti Oliver Sulzer Germany Monney Lorenzo Groupe E Switzerland Moser Michael BFE Switzerland Mühlebach Martin Lemon Consult Switzerland Muller Frédéric Danfoss Switzerland Nessler Christoph Emerson Switzerland Niederberger Patrick IB Aarau Switzerland Nielsen Sandie B. DTI Denmark Nipkow Jürg S.A.F.E. Switzerland Nordmann Thomas TNC Consulting Switzerland Nunez Miguel EMZ- Unitec Switzerland Obata Takeshi Hitachi Japan Ogawa Susumu Jema Japan Oldenhof Ernst Alstom Switzerland Omlin Adrian HSLU Switzerland Pagani Enrico Electrosuisse Switzerland Paramonova Svetlana Linköping University Sweden Petro John Consultant USA Phillips Richard BFE Switzerland Pirovino Guido ABB Switzerland Protas Erich WATT Austria Pushpagiri Salim R. ELGI India Rasinski Timothy NVLAP USA Rosatzin Christa Sprachwerk Switzerland Sadouk Abder Lafert UK Schmidlin Benno BSM Switzerland Schneeberger Werner ebm-papst Switzerland Schuch Dieter Franklin Electric Germany
10 Motor Summit 2014 List of Participants Name First Name Organization Country Schuh Charles HS Antriebssysteme Switzerland Schultheiss Martin Elektron Switzerland Schumann Tim SEW USA Schweer Carsten Helios AG Switzerland Schweizer Sarah Polyscope Switzerland Scozzafava Antonio Motovario Italy Siegenthaler Urs Fotograf Switzerland Sigloch Uwe ebm-papst Germany Sommer Peter SBB Switzerland Špaček Antonin Rieter Czech Republic Spielmann Grégoire Küffer Elektro-Technik Switzerland Spurgeon Daniel ebm-papst Switzerland Süselbeck Reiner TECO Germany Staudacher Christian Staudacher Switzerland Steinmann Walter BFE Switzerland Stieger Leila SECO Switzerland Stockman Kurt University Gent Belgium Surányi Andreas ABB Switzerland Tammi Ari ABB Finland Teepe Markus Wilo Germany Thöni Markus EMWB Switzerland Tieben Rolf S.A.F.E. Switzerland Tolvanen Jukka ABB Finland Utsuno Mamoru Oriental Motor Japan Van Acker Frederic Atlas Copco Belgium van Broekhoven Rudi Weir Minerals The Netherlands van Werkhoven Maarten TPA Adviseurs The Netherlands Varga Márton Energie Zukunft Schweiz Switzerland Waeber Toni Steinegger Switzerland Walker Thomas UL USA Wehrli Ferdinand Hidrostal Switzerland Weibel Andreas ZZ Wancor AG Switzerland Wenger Ronald ABB Switzerland Werle Rita S.A.F.E. Switzerland Wetter Roland EPFL-LEI Switzerland Weyl Debbie Karpay CLASP USA Wirz-Töndury Christian WERZ Switzerland Wunderlich Mark Electrosuisse Switzerland Yang Chun Hsiang ITRI Taiwan Zheng Tan Top10 China China P.R. Ziegler Manuel EnAW Switzerland
11 7 October 2014 EMSA Workshops
12 Policy Guidelines for Efficient Electric Motor Systems Konstantin Kulterer Austrian Energy Agency Mariahilfer Str EMSAs Motor Policy Task EMSA has been engaged in motor policy since its outset in A first analysis was published in 2009 as "Motor MEPS Guide" profiting mainly from the US experience in setting mandatory standards. In 2011 a second volume followed: "Motor Policy Guide, Part 1: Assessment of Existing Policies" analyzing motor policy instruments in nine countries/regions. This "Policy Guidelines for Electric Motor Systems" builds on these previous publications and showcases best-practice policy examples that have been implemented in various countries around the globe, now presented as Motor Systems Toolkit consisting of MEPS, labeling, voluntary agreements with industry, energy management and energy audit programs, company motor policy, financial incentives, awareness raising, and information provision. It is crucial to consider all these elements in order to increase the efficiency of new motor systems and systems already in use. To achieve their objectives, policies not only need to be well designed, but they also need to be implemented effectively. Consideration of supporting activities and mechanisms required to implement policies therefore should be integrated within the policy development process and be included in cost estimates. For most policy measures, ensuring that products perform as they claim, is vital to achieving expected energy savings. As such, product certification, registration schemes and effective verification regimes provide the necessary conditions to underpin successful policy implementation. The basis for these activities are international standards. Furthermore, national policy makers can benefit greatly from the experience and expertise from other countries and international experts through engagement in the many policy and technical exchanges available. For the Policy Guidelines for Electric Motor Systems EMSA has been able to draw from the experience of a number of experts engaged with motor policy implementation within and out-side of EMSA who have contributed to the publication. With this publication EMSA wishes to help countries, governments, industry as well as standard makers to find a path towards a comprehensive energy efficiency development for electric motor systems. Conclusions The most effective government policies are those that stimulate action amongst key stakeholders within the motor systems market to achieve long term market transformation. A comprehensive range of policies are therefore required to influence international/national standard makers, industry associations, industrial users and power utilities. Figure 1 illustrates the potential for policy interaction among these groups.
13 Figure 1, Influence of National Policy Makers, A+B International, 2014 At least five different stakeholders have to be involved to take the road to high efficient motor systems: Governments can set mandatory energy performance standards (MEPS). MEPS based on international standards are already applied in several countries, reducing barriers to trade. For setting MEPS, all relevant motor systems components and their combinations need to be considered, as well as a system for tracking which products enter the market (e.g. registration) and for enforcing compliance. Governments can choose to complement MEPS with other policy instruments: defining an energy label, setting energy efficiency targets, entering into voluntary agreements with industry, implementing energy management and energy audit programs, encouraging individual businesses to set up a company motor policy, launching awarenessraising campaigns and giving financial incentives. International standard makers should focus on developing international standards in all relevant areas from motor system components to certification and labeling programs, energy management and energy audits, measurement, verification and benchmarking. Manufacturers and industrial associations can develop and/or support energy label programs, establish accredited testing laboratories, initiate and support training programs and define procurement guidelines. Industrial users are encouraged to set energy saving targets, define responsibilities and train personnel for designing new motor systems and retrofitting old systems. Electric power utilities can design and run procurement programs and subsidy programs for end-users and use innovative financing instruments to benefit from energy savings. Co-Authors of the Policy Guidelines for Efficient Electric Motor Systems are Rita Werle, Petra Lackner, Conrad U. Brunner and Mark Ellis. EMSA would like to thank all the experts and reviewers who have contributed with their valuable comments to the publication.
14 Dutch Long Term Agreements and the new Green Deal Maarten van Werkhoven EMSA - Electric Motor Systems Annex c/o TPA consultants Generaal Winkelmanlaan WV Aerdenhout The Netherlands Introduction In industry the electricity use for electric motor systems amounts to 70% of the total electricity use. The associated economically feasible savings total from 20% up to 30% by applying system optimization and best available drive technology. Motor systems cover pumps, fans, compressors and industrial production systems, including motor, drive, transmission and driven application. However, implementation appears not to be a done case. Many different aspects play a role in this, in the supply chain itself and in the way industrial organizations work in respect to analyzing and implementing energy efficiency measures. In the EU the European Directive (2005/32/EC) forms the basis for defining legally binding requirements on the minimum efficiency of energy using products. For electric motor systems, the Commission Regulation (EC) No 640/2009 implements MEPS on EU-level in 3 stages, starting in 2011, where motors must meet the IE2 efficiency level. In stage 2 (from 1 January 2015) motors with a rated output of kw must meet the IE3 efficiency level, or the IE2 level if fitted with a variable speed drive. And in stage 3 (from 1 January 2017) motors with a rated output of kw must meet the IE3 efficiency level or the IE2 level if fitted with a variable speed drive. Dutch policy on energy efficiency in industry: Long Term Agreements (LTA) The Dutch Ministry of Economic Affairs has established Voluntary Agreements on Energy Efficiency improvement targets with industry partners and institutions. The objective was to reduce the quantity of energy used per unit of product or service delivered through a 2 per cent per annum improvement in energy efficiency. The programme is being operated via the Netherlands Enterprise Agency. The participating companies have to implement a three-fold set of activities: (1) making an Energy Efficiency Plan every four years, (2) yearly monitoring of production levels and energy use and (3) having an up and running energy management system. The Energy Efficiency Plan describes the energy saving measures that are to be implemented over a period of 3 years, an assessment of the expected energy saving and the corresponding time line. With these measures, the company also creates the basis for the development of the energy paragraph in the environmental license. The instrument of Voluntary Agreements engages the companies with energy efficiency related activities like thematic workshops, pilot projects, energy audits and technology roadmaps. Participating companies operate a required energy management system. These systems can be based on ISO 50001, elements of ISO 14001, or new methods such as the CO 2 performance indicator. Certification of the energy management system is not required. Market barriers concerning motor systems The analysis of the market of electric motors supply and maintenance in the Netherlands, and the practices of the Original Equipment Manufacturer (OEM) and industrial end-users show that for a successful acceptance of efficient motor systems all market parties have to get involved. Each supply
15 chain party involved encounters different barriers, starting with the suppliers and via the OEM and installers coming at the end-users. Some main barriers are 1) the focus on lowest investment cost; the OEM and the end user s main interest is to buy the motor at the lowest price possible; 2) the split in allocation of investment and operational cost with the end user. At the end user the employee that is responsible for buying the motor is usually not the one that holds the energy budget; 3) focus on motors only, instead of system benefits; 4) low knowledge of opportunities for system efficiencies. The energy costs associated with the motor s lifetime operation are estimated to be around 95% of the total cost, while initial purchase price and maintenance account for the remaining 5%. Green Deal Efficient Motor Systems The Green Deal Efficient Motor Systems is initiated by the Federation of suppliers of Electric Motors (FEDA), the trade association of installation and electromechanical maintenance companies (Uneto- VNI) and the Dutch Ministry of Economic Affairs. The aim is to encourage a wider application of efficient electric motor systems by reducing some of the above mentioned issues. Furthermore, to assist the users of the motor systems in achieving direct energy savings as well as strengthening their competitiveness by developing innovative products and services. Key aspects of the Green Deal program are three-fold. 1) Defining a standard method for the analysis of opportunities for efficiency improvements in motor systems. 2) Developing sound business cases on efficient motor systems, delivering concrete energy savings. 3) Knowledge transfer and communication to end users and the supply chain to create leverage in terms of working methods, capacities and energy savings. The Green Deal program aims at reducing some of the issues raised in the market, improving the conditions and cooperation in the supply chain, and the realization of a number of (example) projects by end users. The program runs from 2012 up to At the moment 20 projects have been initiated and are in different phases of execution. Towards efficient motor systems The EU minimum requirements serve as a good starting point for the involved supplying parties: first of all the supply chain itself has to act on it, i.e. bring its production up to date, engineering and sales organization, including its dealers. Secondly, help the end user in making the right choices in implementing the new regulation in its daily practice. The end users are all bound by the LTA s, and its program, in implementing measures on energy efficient production and use. They are all, in principle, open for services helping them to identify, analyze and implement energy efficient measure in motor systems. That is to say: in competition with all other possible energy efficiency measures, investments, possibly feasible at the user s facilities. The results in energy savings differ per project (Green Deal program) depending on the project targets, the partners and end users expertise and available capacity. At the lower end of the savings spectrum we find projects where the focus was on applying premium motors. Here savings start at 4-5% up to 10% where older motors are replaced. On the other end of the spectrum some projects show savings of up to 40% as a result of improving a total motor system, including benefits like increased level of productivity. The main challenges for the Green Deal partners, the government and the end users are to focus on efficient motor systems. All parties involved have to make specific efforts in order to make this happen. That is, because of the complexity of motor systems on all levels, the heterogeneous market, the durability of the technologies involved and the continuous competition for the right capacities, i.e. in terms of mandate, knowledge, time and financing. The framework of the Dutch LTA s gives a sound basis for the Dutch government to work with the industrial end users on concrete energy efficiency measures. By engaging the motor systems industry in the Green Deal program, a complementary initiative, they can bring more focus and attention towards the implementation of efficient electric motor systems in industry and deliver an effective way to deal with the complex supply chain (of motor systems). Representatives participate in these activities to enable effective and efficient means of operation and to utilize the opportunities for synergy.
16 Energy efficiency potentials for different motor system levels an empirical study of PFE implemented energy efficiency measures Svetlana Paramonova Linköping University SE Linköping Patrik Thollander Linköping University SE Linköping Introduction Improved industrial energy efficiency (IEE) is a cornerstone in reducing greenhouse gas emissions. The implementation of Energy Efficiency Measures (EEMs) is the primary means of improving IEE. However, EEMs are not always, as many measures in the building sector, stand-alone measures. Rather, EEMs are intertwined in the production system and various other sub-systems calling for a systems approach to be applied. In industry, nearly 70 percent of the power use emanates from motor systems (Waide & Brunner, 2011). Electric motor systems can be categorized into three system levels; motor, core motor system, and whole system, where Waide and Brunner (2011) state the large energy efficiency potential to be found in the upper system levels. Backlund et al. (2012) state that a large unexploited potential also lies in measures related to management and operation of the energy system. However, previous research has been scarce in showing on which system levels that the highest potential for improved IEE is found. Based on a large dataset of electric motor system measures from the Swedish energy policy program PFE (Program for improving energy efficiency in energy-intensive companies) consisting of about 1250 EEMs saving 900 GWh/year, the aim of this study was to analyze, using an extended version of the system level categorization, on which system levels the implemented measures were found. Methodology The basis for the categorization of the measures was motor system levels defined by Waide and Brunner (2011). They define three levels of motor system to make energy efficiency improvements: Level 1 (Electric motor), Level 2 (Core motor system) and Level 3 (Total motor system). In the current study, an additional category, Level 4 (Extended motor system), was introduced in order to include measures related to energy management and operative actions, which lie outside the total motor system. The most obvious here would be when a measure clearly involves a person to do something, demand-based adjustment, switching off, regulation or optimization we define as level 4. Only measures that are related to motor systems and with estimated energy saving potential were selected from the PFE data and assigned a respective motor system level. Example of measures found in PFE and divided by motor systems levels are presented in Table 1. Table 1. Examples of measures from PFE classified into the motor systems levels. Motor system level Level 1: Electric motor Level 2: Core motor system Level 3: Total motor systems Level 4: Extended motor system Example from PFE Replace pump motor, Change to more efficient electric motors, Removal of motor, Change of fan motor in washing machine Replacement of backwater pump, Replacement of fan, VFD on green liquor pump, VFD on backwater pump Replacement of mixer, Replacement of chips conveyer, Reduce consumption of compressed air, New cooling tower Adjust ventilation, Automatic stop, Change of operative time on paper machine, More efficient production of compressed air, Decrease specific electricity consumption
17 Results In total around 850 measures were categorized from the total 1250 measures as motor related with the total energy saving potential of approximately 600 GWh/year (compared to all EEMs in the PFE amounting to savings of 900 GWh/year). Results show that implemented EEMs found in the upper system levels (Level 3,Total motor system, and Level 4, Extended motor system) present almost half of the total number of measures (Figure 1). Figure 1: Number of measures and % of total energy savings for different system levels The number of measures belonging to Level 2 (Core motor system) is approximately the same as sum for Level 3 (Total motor systems) and 4 (Extended motor system). However, despite the number of measures on Level 4 is approximately half of the Level 2, the energy saving potential for Level 4 is close to the potential for Level 2. Thus, the specific energy saving potential (kwh per measure) increases with higher system levels. From the preliminary results of categorization, it is clear that the large potential for energy saving is achievable by not only replacing of existing motors with the most efficient ones (Level 1, Electric motor). The companies participating in the PFE program has found both a greater number of measures and a greater potential in all the other three levels. It is important to emphasize that these measures have been detected by the companies which have implemented energy management systems and thus were actively working on improving energy efficiency in their organizations. One conclusion that can be drawn from this is that energy efficiency requirements in the whole motor system thus become more powerful than the mere requirements on energy-efficient motors. The work on energy efficiency is and will be a critical success factor to increase awareness and knowledge of system effectiveness and propose the actions that take into account the entire system, rather than individual components. That so far remains scarcely studied, calling for new and more innovative approaches to energy end-use policies than for example administrative. References Backlund, S., Thollander, P., Ottosson, M., Palm, J., (2012). Extending the Energy efficiency gap. Energy Policy, (51), Waide P., Brunner C., (2011). Energy-Efficiency Policy Opportunities for Electric Motor-Driven Systems. IEA (International Energy Agency). Energy Efficiency, Paris.
18 American Motor Regulations and Extended Product Labeling Two stages of motor driven systems energy savings Rob Boteler Nidec Motor Corporation [Chairman NEMA Energy Management Committee] 8050 West Florissant Ave, St Louis MO Stage one- US regulations amended for low voltage AC motors The United States has been the global leader in motor efficiency regulations since the original enactment of standards in Since 1997 the US has continued down a path of routinely increasing motor efficiency levels. NEMA has been a constant partner with DOE in evaluating, drafting and promoting these motor regulations. The most previous motor regulation was part of a much larger bill referred to as the Energy Independence and Security Act EISA which addressed many aspects and products important to the efforts in the US to improve efficiency of industrial and commercial applications. Since its release the motor manufactures have been aware that EISA required the US Department of Energy to review and make a recommendation for amending the EISA regulations within two years. The motor manufacturers reached out to ACEEE [American Council for and Energy Efficient Economy] in an effort to collaborate with ACEEE and a group of energy advocates closely aligned with ACEEE. The results of this initiative were the formation of a motor coalition made up of a cross section of the energy community with a common goal. The coalition is made up of a wide range of individuals including engineers, lawyers, utility program staff and manufacturers. The coalition came to agreement early in our discussions that any revision to the EISA regulations should deliver three essential things; first it must deliver the greatest potential energy savings, while having little to zero impact on product utility and last it should be implemented in two years or less. The group met several times to draft and evaluate how best to achieve our goal. The results of our efforts were then written into a petition that was submitted to the DOE [US Department of Energy]. Following statutory requirements the DOE held public hearings which gave others the opportunity to review and discuss possible regulatory changes. On May 29 th of 2014 the DOE issued a final rule amending the previous regulation. The rule as issued contains the vast majority of the elements in the motor coalition s petition and delivers the most energy savings of any regulation ever issued by the DOE to date. The scope of motors covered under the amended regulation has been expanded to include virtually all categories of polyphase continuous duty motors from 1 to 500 HP [ KW]. The level of efficiency was a key element in the motor coalition s petition. Within the energy community some people continue to believe that raising the level of a motor s efficiency beyond what can be provided within current physical size and performance limits will not have an adverse impact on end-users, OEM and ultimately energy savings. The US motor coalition reached the conclusion that raising the efficiency level one or two NEMA bands 0.4 to 0.8%, when tested at full load under laboratory conditions, would only perpetuate the continued use and repair of the existing lower efficient motors. The coalition believes that motors, as the most efficient component of the motor driven system is best left at the NEMA [IE3] levels and our efforts should move to the extended product and away from efficiency to managing kw. To the coalition, it seems obvious that we should use our resources
19 to figure out how we can move the market to incorporate more extended products that have potential energy savings of 20% or more than chasing 0.4% - 0.8% motor gains. Stage two EMPLI [extended motor product labeling initiative] the move to managed kw Members of the motor coalition met in December of 2013 to establish a team that expanded from motors only to include fans, pumps, and compressors trade associations. All of these three driven loads" are going through DOE energy regulations rule making. The initiative has been named EMPLI Extended motor product labeling initiative. The motivation and role model for EMPLI is based on the success of the NEMA premium label for motors meeting or exceeding NEMA table nominal efficiency. Since NEMA premium was trademarked and launched to the world market it has been adopted by thousands of end-users and OEMs as the gold standard of motor performance. Power utilities were quick to create incentives for their customers to purchase and install NEMA Premium motors which greatly accelerated the adoption of NEMA Premium and saved energy. Today there is an estimated $7-9 billion in efficiency incentive funding available within power utilities in the US. EMPLI will address several issues necessary to position these three products to achieve similar successes as NEMA Premium. Power utilities and utility program managers face a daunting task. They are charged with producing, implementing and managing incentive programs that deliver a specific amount of savings [kwh] per dollar spent for administration and incentives. Program managers have developed three different incentive categories that describe energy savings program methods based on required resources. 1. Prescriptive a. Utilizes product description and performance to prequalify items to be incentivized b. Used to reach the most products and applications with the least resource administration required 2. Quasi prescriptive a. Utilizes a deemed savings measure to evaluate a category of product used in an more specific applications b. Requires a higher level of administration resource to evaluate and qualify product based on performance label 3. Custom a. Requires before and post installation measurement to verify savings b. Applicants may invest resources prior to confirmation of energy savings to meet program requirements The coalition learned that while there can be substantial savings in any of the categories, the custom programs fit the extended product, sometimes referred to as motor driven systems the best. We also learned that custom programs typically require before and after measurement and verification with no guarantee of an incentive being paid. This led us to explore ways to utilize the DOE s rulemaking in such a manner that we fit the three products into a quasi-prescriptive program. The goal of EMPLI is to work within the DOE process to establish test methods, metrics and baseline performance for each of the three extended product categories. It will then be our task to establish performance level[s] above the DOE baseline that meet the utility requirements and can be delivered by the manufacturers. Once this is done, each of the trade associations representing the product will establish a labeling scheme that identifies their high performance products. Utilities will then have an option they do not currently have for a relatively low administrative cost incentive program that will cover three products which incorporate nearly 60% of industrial/commercial polyphase motors sold.
20 Measurements of efficiency for converters and motors in industry reality Sinan ALTINDAĞ GAMAK MAKİNA SANAYI A.Ş. R&D Manager Dudullu Organize Sanayi Bölgesi Baraj Yolu Caddesi No: Ümraniye / İSTANBUL - GAMAK test laboratory in Istanbul What makes a laboratory high accuracy? o Hardware side o Software side - Comparison tests of IE2 and IE3 motors o Comparison when driven directly from mains under laboratory conditions o What happens on the customer s side? Low accuracy measurements - reality in industry Comparison of efficiency achieved under laboratory conditions against low accuracy measurements in industry reality Natural load comparison of IE2 IE3 motors, variable torque applications - Test results Inverter driven motors o Additional losses measured under laboratory conditions High accuracy o Additional losses measured on customer real application Low accuracy - Analyzes of discrepancies between Low and High accuracy measurements Gamak Motor Test Laboratory: Data Acquisition