2009 Motors Session2 Garg

7/29/2019 2009 Motors Session2 Garg

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SandeepSandeep GargGarg

BureauofEnergyEfficiencyBureauofEnergyEfficiency

Standards & labeling Program for motorsStandards & labeling Program for motors

inin

IndiaIndia

MEPSA 2009 , 4MEPSA 2009 , 4--5th February 2009, Sydney5th February 2009, Sydney

BureauofEnergyEfficiencyy Establishedin2002,undertheEnergyConservationAct,2001.y Improveenergyefficiencythroughvariousregulatoryand

promotionalinstrumentsy Plan,manageandimplementprovisionstheECAct

y Appliancestandardsandlabelingy Industrialenergybenchmarksy

EnergyConservation

Building

Codes

y Monitorenergyuseinhighenergyconsumptionunitsy Certifyandaccreditenergyauditorsandenergymanagers

y Provideapolicyframeworkanddirectiontonationalenergyconservationactivities

y Disseminateinformationandknowledge,andfacilitatepilotanddemonstrationprojects

y Establish EE delivery systems through PublicPrivatePartnerships(PPP).

2


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3

Action Plans of BEE

(S&L)-12 Projects

(ECBC) NBC

Energy consumptionnorms for

Designated Consumers (15)Schedule-Section 2(s)-ECA

EA/EMNational Certification Exam

BEE created as a nodal statutory body to improve energy efficiencythrough:

Bachat Lamp Yojna

EE delivery systems through Public-Private Partnerships (PPP)

State Designated Agencies(30-SDAs)

Fund

Req.983.3 InRs.Mn

Collectively Save 308 MW ofEnergy

Rs.1843 Cr. Per yr.By implementation of

Energy Efficiency measures.

SDC (9)Required Auditing

& by BEE certified Auditor ESCOs

Installed Capacity India (as on 31st August, 2008)

TOTAL IC-1,45,627 MW

HYDRO, 36198, 24.8

%

THERMAL9311564%

NUCLEAR41202.8%

R.E.S., 121958.4%


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Per Capita Consumption of Electricity in India

Source:CEA

176

348

559632 672

704

1000

613

1980-

81

1990-

91

2000-

01

2004-

05

2005-

06

2006-

07

2007-

08

2011-

12

kWh/year

(Projected)

AsperUNMethodology(GrossElectricalEnergyAvailability/Population)

Growth Pattern

6

Up to 30

Up to 20

Up to 30

Up to 25

Conservationpotential (%)

20-25%

Commercial Sector

Domestic Sector

Agriculture Sector

Industrial Sector

Sector

Sector wise Energy Saving potential

Energy Handledby Motors (%)

70-75%

2-3%

4-5%

Source : AFF report


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Products covered under Indian S&L

ProgramCurrent List1. Frost-free Refrigerators

2. Tubular Fluorescent Lamps (TFL)

3. Air-conditioners

4. Direct cool /Frost Free Refrigerators

5. Distribution Transformers

6. Motors

7. Pump sets8. Ceiling fans9. LPG Stoves10.Colour TVs11.Storage Water Geysers

Launched on 18thMay

2006 , for 4 products byBEE

Future Products under Indian S&L Program

Compact Fluorescent Lamps ( CFLs)Transport Sector

Passenger Cars2 & 4 WheelersHeavy Commercial Vehicles.

Office Equipments ( Monitors, Fax, Copiers etc)Washing Machines

Consumer ElectronicsSet-Top Boxes, Microwaves etc

InvertorsUninterrupted Power Supply (UPS)External Power Supplies (EPS)Battery Chargers (BCs)CompressorsIndustrial Fans & Blowers


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100%

70%

40%

3%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Theorotical

Potential

Technically

feasible

Economically

viable

Market

penetration

9

BarrierstopenetrationofHEMs1. Lack of knowledge/ awareness with users2. Non availability of EE motors3. Confusion EE motor definition

4. Need to have focused market transformation

Higher initial cost Low demand; high price

Lesser work ing hours Lack of technology

1. Poor power quality in rural sector

2. Application limitations

10

Regulation:

Policies & its frameworkStandards & Labels to be made mandatory atappropriate time

Supply Push

Design & technology developmentsAlign with international trendsHandholding of some segments ofmanufacturers

Demand Pull

Awareness & disseminationDemand for the EEproducts

Energy Efficiency


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Institutionalframeworkforregulationy BIS NationalStandardsBody

Formulation&ImplementationofNationalStandards

Productioncertification,Qualitysystemcertification,EMS

certificationetc.

y BureauofEnergyEfficiency(BEE)

BEEisestablishedtoimplement&monitortheEnergy

ConservationAct,2001

OneofthekeythrustareasofECAct,2001isStandards&

LabelingProgramme

FormulationofEnergyEfficiencyStandards.

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ImpactofS&LProgramS.No. Part iculars Motors (< 15kW)

1. No. of products currently in use (Million) (31 December 2005) 1.68

2. Total energy use by the products (Mil lion kWh/Year) (2005-06) 24988

3. Contribution to demand (MW) (2005-06) 5112

4. Current Annual Sales (Million/Year) 0.36

Energy Savings Potential

5. 2009 (MUs/Yr) 314

6. 2011 (MUs/Yr) 974

7. 2015 (MUs/Yr) 3051

8. 2020 (MUs/Yr) 6455

Demand Saving Potential (MW)

9. 2009 64

10. 2011 199

11. 2015 624

12. 2020 1320


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Market Transformation Potential : Induction Motors

EFF3

EFF2

EFF 1

IEEMA

members

Small

MM

Focus area

Minimum BenchmarkCrompton

Greaves 40%

Bharat Bijlee

& Others 7%

ABB 16%

Siemens 37%

Source: Primary Survey, AFF Estimates

Market Share - EFF1 Motors (Nos.)

EE Motors: Current Market Status

Market growth CAGR of 2 % , with 50 %unorganized sector

Policy interventions

Designated consumers, which are basically energy intensive

industry, commercial buildings and establishments.

Energy consumption standards and labeling program for

equipment and appliances.

Energy conservation building codes for efficient use of energy and

its conservation in the buildings and building complex.

Promotion of R&D, energy efficiency in buildings and

establishments, awareness creation among educational institutions

etc.


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Methodologyusedforformulatingtheschemey MarketSurvey

y SelectSampleratings&makeofmotors

y PurchaseofStandardmotors

y TestforperformanceinNABLaccreditedlaboratories.

y Assessconstructionalfeatures,quantity&qualityofactivematerials

y Technocommercialanalysis

y

Finalize

recommendations

with

all

the

stakeholders

y Launchofschemeafterdueapprovals

15

MotorMarketSegmentsFractional HP motor s

9.32 Mill ion Units

DC Motor s

6,500 Units

0.75-7.5 kW

1.18 Mill ion Units

11-37.5 kW

0.13Mill ion Units

+ 37.5 kW

10,000 Units

Low Tension

Squirrel Cage1.31 Mill ion Units

Low Tension

Slip Ring4,000 Units

AC

Low Tension Motors

1.31 Mill ion Units

AC

High Tension Motors

1,000 Units

Motors

10.64 Mill ion Units

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Domestic AppliancesLight Loading

60% Agricultural Pumps30% I ndustr ial10% Domestic

90% I ndustr ial10% Agricultural

Industr ial

Source: AFF Estimates, IEEMA Statistics, Primary Survey


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0.75-7.5kW

89%

11-37kW

10%

>37kW

1%

National

players

54%

regional

/Local

players

46%

17

Source: AFF Estimates, IEEMA Statistics, Primary Survey

89%

Market Size & break up

Rating wise break up for3 ph sq cage Induction motors(2003-04)

Manufacturing sector break upInduction motors (2003-04)

SamplePlanfortechnocommercialstudyy 3phase4polesquirrelcageinductionmotor:2.2kW

(26motors),3.7kW(27motors)

y 8nationalmanufacturers

y 18regional/localmanufacturers

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DistributionbyEfficiencyClass2.2kW 3.7kW2.2kW 3.7kW

19

38.5 38.5

23.1

0

5

1015

20

25

30

35

40

45

50

Eff2 Eff2(-) non-Eff2

S

h

are

%

48.1

22.2

29.6

0

5

1015

20

25

30

35

40

45

50

Eff2 Eff2(-) non-Eff2

Source: AFF Estimates, Primary Survey

EfficiencyImprovementAnalysisy Efficiencyimprovementwillinvolve

y motordesignchanges/redesign

y manufacturingpracticeschanges

y manufacturingequipmentchanges.

y Materialoptimization

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3 HP ( 2.2 kW ) Induction Motors - Efficiency, Material Used & Price

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

100.00

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Samples

Efficiency(%)/WattLoss:W15/50(W/kg)

2,000

3,000

4,000

5,000

6,000

7,000

100 % loadW 15/50 ( W/kg @ 1.5 tesla )Weight of steelCu WeightPrice ( INR )

EFF1 : 86.40 ~ 84.36 %

EFF2 : 81.00 ~ 78.15 %

Electr ica l Steel : < 8 W/ kg / 5.3 W/Kg

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Analysis background

Source: AFF Report

Classification ofMotorsMotorswereclassifiedintoefficiencyclassesdependingonfull load

efficiency:

Followingoptionswereconsidered

y Eff1andEff2formotorshavingefficiencyasperefficiency

classin

IS

12615

but

without

the

allowed

lower

tolerance

y Eff1()andEff2()formotorshavingefficiencyuptotheallowedlowertolerance

y NonEff2formotorshavingefficiencylowerthantheEff2valuewithallowedtolerance.

ItwasagreedthatEff2iswellestablishedefficiencylevelsbyvirtueofbeingspecifiedinIS12615.

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BenefitsofEff2BenefitsofEff2

23

Eff 2(-) Eff 2

Savings, GWh/yr 30.6 102.2

Savings, Rs crores 15.29 51.11

Affected Production, % 18.9 53.7

Source: AFF Report

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Scope of motors covered

General purpose, S1 duty, 3 phase squirrel cage

induction motors

Motors up to 15kW, 4 & 2 pole considered

Governing standard-

IS 12615: 2004

IS 325: 1996


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MOTOREFFICIENCYLEVELS(qualitativecomparison)

Vision & Choice

Prepared for ICA by Peter

Liu, E&E, May 2008

75

80

85

90

95

100

1 5 10 20 40 75 150

Induction Motor Kilowatt rating - 3 phase - 4 pole, general purpose

%E

fficiency

(atfullload)

NEMA Premium

Standard Eff.

High Efficiency

Super Premium

EFF1~

EPA

ct=JIS4

212

EFF 2

26

Final labeling plan

MEPS to be at Eff2 level and qualify for energy efficient

endorsement label.

Eff1 would be a High energy efficient endorsement label

Consider efficiency at 100% loading

Include 2 pole motors also on addition to 4 pole motors

Label contents

Parameters spelt out in clause 20.1a of IS 325 : 1996

BEE logo, license number & Efficiency class marking

Mandatory process to be initiated after positive market

transformation.


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Future plans

Undertake DSM initiatives with the end users.

Develop CDM framework to instigate new buisness

models.

Review the plan after periodically to up grade & align

with international standards & norms.

Align National Programs such as APDRP and RGGVY

schemes to trigger market pull and transformation.

Manufacturing of energy efficient motors

9EPACT (NEMA MG1-2006)motors

already being exported to north & south

America.

9EPACT motors are tested as per IEEE 112

(method B) standard for efficiency

determination.


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Project Objective

Overall objective:

y Transfer high pressure die casting technology & Energy Efficient Motor

(EEM) design capabilities to motor industry in order to achieve energy

savings

Project Components:

1. Establish Centre of Excellence (C o E) with skills & technology

2. Enhance Energy efficiency Motor design competence to support SMEs

3. Transfer technology to at least two manufacturers

4. Technology commercialization

Component 1: Manufacturing capability

Specific objective:

y Establish physical & operational facility

Sub components

y Launch project, constitute team

y Select the site

y Finalize equipment specifications

y Procure & install the equipments

y Make the manufacturing facility operational

y Die casting trials

UNDP- BEE and ICA Joint Project on thetechnology development of Die Casting Copper

Rotors


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Component 2: Design Competence

Specific objective:

y Enhance EEM design competency to support SMEs

Sub components

y Procure design software

y Engage consultants to train design engineers of C o E

y Select motor types / Applications for design optimizations

y Vetting of designs & guidance from industry experts

y Prototype EEM manufacture & testing

Component 3 : Technology Transfer

Specific objective:

y To transfer the technology to at least two Indian motormanufacturers

Sub components

y Identify potential partners

y Enter in to agreement

y Conduct design optimizations & die casting trials for them


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Component 4: Tech. Commercialization

Specific objective:

y To disseminate technology to industry

Sub components

y Dissemination workshops

y Technology demonstration to motor industry

y Training to motor manufacturers & die casters

Thank you for your attention,

Contact information:

Sandeep Garg ([email protected])Bureau of Energy Efficiency

(Ministry of Power, Govt. of India)4th Floor, Sewa Bhawan

R.K.PuramNew Delhi - 110066

www.bee-india.nic.in

Documents

2009 Motors Session2 Garg