www.ecn.nl

Energy efficient electric motors

and their driven systems

Jeffrey Sipma, Himsar Ambarita

Jakarta

05/05/15

Content

1. General overview electric motors and their driven systems

2. Quantifying the Indonesian project

3. Barriers: literature and interviews

4. Policy instruments to reduce barriers

2

10.30 – 11.00 : Presentation of ECN; saving potentials, barrier analyses, results of

the interviews, policy options, examples from other countries

11.00 – 11.30 : Discussion of ‘electric motor driven systems’ – beyond MEPS,

what systems are we talking about, what potential is there in Indonesia?

5. Which industrial sector should

we look at in the next phase, as

a pilot project?

3

11.45 – 12.45: Discussion on next steps

Pilot: which industrial sector (10min)

Pilot: what has been done in that sector so far (running programmes) (10min)

Pilot: which of the presented policy options do we want to link with that sector (10min)

Feedback each group: 3 * 5 min

1. General overview electric

motors and their driven

systems

4

Global and Indonesian electricity

demand 2006

Where this electricity goes to?

5

19 % is used to light our world

6

46% flows to electric motor-

driven systems (EMDS)!

• 2,5 times electricity

consumption of light

• To keep things turning

• To keep things moving

7

Small motors,

up to 0,75 kW

• Residential sector, electrical appliances

• Often integrated in a ‘packaged machine’

• Refrigerators, mixers, DVD-players, PC hard disks

• Account for 90% of all electric motors

• Only 9% of total electricity used by motors8

Medium size motors,

between 0.75 kW and 375 kW

• Commercial and industrial sector

• Ordered from catalogues: stand alone or ‘specific device’

• Pumps, compressors, fans, conveyers, industrial handling and

processing applications

• Account for 10% of all electric motors

• But 68% of total electricity used by motors! 9

Large size motors,

above 375 kW, until 100.000 kW

• Industrial sector and infrastructure

• Custom designed for a special application, assembled on site,

often integrated with other functions (cooling, heating, etc)

• Examples: waste water treatment plant, oil industry

• Account for 0,03% of all electric motors

• But 23% of total electricity used by motors! 10

Priority for size of electric motor

Prioritas pada ukuran motor listrik

11

Priority for type of electric motor

• 80% of global

stock!

• Fixed speed

• Clear

international

testing

standard

12

Priority for sector and application

Pumps + Fans + Compressors: 62% Pumps + Fans + Compressors: 82%

Motors industrial sector: 70% Motors commercial sector: 35%

13

Energy efficient electric motors:

IE-classes

14

• 5 international

classes

• IE0 ‘unbranded and

cheap Chinese

motors’

• 1 kW motors:

10% efficiency

improvement IE1-IE3

• 400 kW:

3% efficiency

improvement IE1-IE3

MEPS programs around the

world

15

Contribution to life-cycle cost

literature

• 97 % of total cost is

electricity usage

• Higher efficient motor

could be twice the price of

standard motor (but less

repair and maintenance

cost)

• Only a few % efficiency

improvement is enough to

earn addition investment

back over lifetime

Life-cycle cost with 4000 operating hours per year

16

Contribution to life-cycle cost

Indonesia

Purchase prices:

• Cheap Chinese 1 kW electric motor: 800,000 IDR

• IE2 East European 1kW electric motor: 1,600,000 IDR

Electricity tariffs:

• Industrial sector: 796 IDR/kWh

• Commercial sector: 1,073 IDR/kWh

• Average for Indonesia: 818 IDR/kWh

• Government subsidy: 540 IDR/kWh

17

IE2 purchase costs during life

cycle

18

0%

1%

2%

3%

4%

5%

6%

7%

8%

9%

10%

0 1000 2000 3000 4000 5000 6000 7000 8000 9000

% p

urc

ha

se c

ost

s o

ve

r li

fe t

ime

Running hours a year

Industry IE2 (757 Rp/kWh)

Commercial sector IE2 (1073 Pr/kWh)

Avarage without subsidy IE2 (1358 Rp/kWh)

Conclusion:

At 4000 h:

2% - 3.3%

Payback period: replacement of

broken down IE0, by IE2 instead IE0

19

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

0 1000 2000 3000 4000 5000 6000 7000 8000 9000

ye

ars

Running hours a year

Industry (757 Rp/kWh)

Commercial sector (1073 Pr/kWh)

Avarage without subsidy (1358 Rp/kWh)

Conclusion:

Industry: 3 years at

minimum 1500 h

Comm: 3 years at

minimum 1200 h

No sub: 3 years at

minimum 900 h

Earlier IE2

placement:

[h replacement x 2]

It is about Energy Efficient Electric

Motor-Driven Systems (EE-EMDS)

20

It is about Electric Motor-Driven

Systems (EMDS)

MEPS = Minimum Energy Performance Standard

Maka bukan sebaiknya tidak hanya fokus pada motor, tetapi sistem secara

keseluruhan

21

Conclusion priorities

22

Many success stories

23

2. Quantifying the Indonesian

project

24

• Electricity consumption

• Electricity savings

• Financial savings sector and government

• Other benefits

Consumption electric motor systems

2014: Bottom-up versus Top-down

25

Consumption electric motor systems:

BAU projection towards 2035

26

BAU: Present market share IE-

classes Indonesia

27

Savings: by IE-class and for optimizing

electric-motor driven systems (EMDS)

28

Electricity savings: effect MEPS

29

0

20

40

60

80

100

120

140

160

2014 2016 2018 2020 2022 2024 2026 2028 2030 2032 2034

Mil

lio

n B

OE

BAU total consumption

IE1 total consumption

IE2 total consumption

IE3 total consumption

IE4 total consumption

EE-EMDS total

consumption

30

Other benefits

31

• Jobs

• Education

• International cooperation (motor conferences)

• Indonesia as a motor producing country again?

3. Barriers: literature and

interviews

But is doesn't go by itself….

32

Barriers at the level of

international trade

• Differences in grid voltage and frequency

• Different measuring systems (horsepower versus kW, motor frame size)

• Non-harmonised standards for Minimum Energy Performance Standards

(MEPS)

• Non-harmonised standards for efficiency tests

33

Barriers at the level of

manufactures and wholesale

• Customers demand for low investment cost, not life-cycle cost

• Manufacturers tendency to discourage energy-efficient EDMS

• Inability to effectively explain the economy of energy-efficient EDMS and

customer loyalty

• Inadequate assessment of actual use for EDMS

• Fear of EDMS failure that will disrupt production

• Lack of incentive to innovate

34

Barriers at the level of planning

and engineering

• Limited types of motors and components to minimise capital costs

• Outdated engineering skills

35

Barriers at the level of investors

and energy managers

• Complexity of EDSM

• Sales generally not the end-user

• Large stock of old inefficient replacement motors

• Purchasing decisions typically based on lowest investment cost

• Limited knowledge of energy-efficient options

• Inadequate understanding of how to avoid energy losses

36

Interviewed markets and users

Market

2015-01-27 Glodok Plaza (lower market)

2014-11-25 Teco wholesale and manufacturer (normal market)

2014-11-26 ABB wholesale (normal market)

2014-11-25 Grainger sales (upper market)

2014-11-26 Nidec sales (upper market)

2015-01-26 Persero PT EMI (market survey)

2015-01-29 PT Citra Solvindo (market survey)

Users Industry

2014-11-26 Indorama industrial

37

Interviewed organisations

Governmental stakeholders:

2015-01-28 Ministry of Trade

2015-02-03 Badan Standarisasi Nasional (BSN)

38

Some additional barriers found

in Indonesia

• Cheap (unbranded) import of bad quality Chinese electric motors, can this

really be stopped? And should it actually be stopped for all situations (e.g.

only little running hours a year)?

• Changing name plates to make the performance of a motor look better

• Brochures and catalogue with electric motor specifications can not always

be trusted

• Low electricity costs due to subsidizing program � although we have seen

that even then a payback period of three years can often be achieved

• Own electricity production with own generators

• Rewinding industry, including low quality rewinding (but fast)

• Large stock old ‘bad’ motors, often rewinded and oversized

• The employees working with motors and pumps, are not trained to

operate the system in an efficient way (e.g. keeping it running at night). 39

4. Policy instruments to reduce

barriers

Luckily there are is a lot of information available to face these challenges!

40

Interviewed organisations with

running programmes

2014-11-27 ADB (Audits)

2015-01-28 UNIDO (ISO 50001 Energy management, voluntary agreements)

2015-01-30 GIZ (Energy awareness trainings, incl workshops on electric

motors textile industry)

2015-01-29 UNDP BRESL (MEPS, testing facility)

2015-02-02 International Copper Association (MEPS, including other

countries)

41

Policy instruments to reduce

barriers

42

Stakeholders involved

43

Technical lifetime versus actual

motor age

44

Stakeholders versus policy

instrument

45

How does all of this works in

practice (see hand out)?

46

Support:

Target: Manufacturer

Importer

Sales

EE motor,

pumps,

fans...

Purchaser Industrial sectors

Individual businesses

Tool: MEPS high 3-5 years high

low quick varies

high 1-2 years low

medium quick varies

Energy Audit medium quick varies

Energy Management medium 1-2 years varies

Motor Policy medium quick low

Voluntary Agreements medium quick low

Speed CostsGovernment, PLN, Power Utilities and Associations

Financial Incentives

Labels

Awareness and Information

Direct

impact

5. Which industrial sector should

we look at in the next phase, as

a pilot project?

47

11.45 – 12.45: Discussion on next steps

Pilot: which industrial sector (10min)

Pilot: what has been done in that sector so far (running programmes) (10min)

Pilot: which of the presented policy options do we want to link with that sector (10min)

Feedback each group: 3 * 5 min

48

Electric savings potentials

sectors Indonesia

Thank you

Jeffrey Sipma; sipma@ecn.nl

Himsar Ambarita

ECN

Westerduinweg 3 P.O. Box 1

1755 LE Petten 1755 ZG Petten

The Netherlands The Netherlands

T +31 88 515 49 49 info@ecn.nl

F +31 88 515 44 80 www.ecn.nl49

Other available information

(examples)

• Policy guidelines, best practices,

• Several conferences, e.g. ,

• Technical support, e.g. energy saving / optimization calculators, as the

IEA4E :

50

How strong is 0,75 kW?

• Lift a person of 75 kg 1 meter

high, within 1 second

• The energy that you consume is

about 1 horse power, is about

0,75 kW

• A motor of 0,75 kW could do

the same

51