EISA anniversary time to take stock of motor efficiency

Almost always, no matter the industry or application, there is an electric motor at work. The challenge for engineers, and one of the keys to American energy independence is simple: Do more with less.

12/26/2012


December 19, 2012 marks the five-year anniversary of the Energy Independence and Security Act of 2007 (EISA), the expansion of the Environmental Policy Act of 1992. Deep within EISA is Section 313, five sentences about Electric Motor Efficiency Standards that encourage industry advances in motor efficiencies from companies like ABB and subsidiaries like Baldor Electric, the leading U.S. manufacturer of industrial electric motors. European laws similar to EISA are not scheduled to take effect until 2015-2017.

Electric motor driven systems, ranging from fractional horsepower units (in a small cooling fan, for example) to 100,000 horsepower turbines, convert electricity into the mechanical energy needed to run just about everything that moves in industrial and commercial facilities, from conveyers to elevators, pumps, compressors, fans and other mechanized operations. In U.S. factory settings, motor-driven systems account for over nearly two thirds of the total energy consumed, and roughly 25% of total U.S. energy use overall.

Year over year, that’s a staggering amount of power and a massive demand on the energy grid for a single product category. A well-designed motor can convert over 90% of its input energy into useful power for decades. When the efficiency of a motor is raised by even a few percentage points, the savings in kilowatt hours (and therefore in cost) are enormous.

In addition, few people realize that motors gain even more efficiency, operationally, through motor drives. Drives enable motors to operate in precise concert with motor loads, rather than the motor running at constant speed and being braked to control speeds. Motors and drives together create immediate and dramatic energy and cost savings in virtually all applications that utilize motors.

The National Electrical Manufacturers Association (NEMA), working closely with other interested stakeholders, helped to draft the new efficiency standards incorporated EISA. Based on U.S. Department of Energy data, it is estimated that the NEMA premium-efficiency motor program would save 5.8 terawatt (5,800 gig) hours of electricity and prevent the release of nearly 80 million metric tons of carbon dioxide into the atmosphere over the next ten years. This is equivalent to keeping 16 million cars off the road.

ABB and its subsidiaries, including Baldor, were already working to engineer efficiency improvements into their product lines that exceeded EISA standards. The new motors use more copper and high-grade steel than their less-efficient counterparts, with more precise tooling and tighter tolerances, all of which reduce energy losses.

In some cases, the newly engineered Baldor motors have gone from 90% operational efficiency to as high as 98%. Even at an average efficiency gain of 2%, for a company that puts five million new motors into the American marketplace every year, it adds up to a lot of power.

Since its January 2011 acquisition of 92-year-old Baldor, ABB now claims one of the most extensive lines of motors and drives in the world. Over the last year alone, efficiencies engineered into ABB's drives installed worldwide saved an estimated 310 million megawatt-hours (MWh) of electricity, equivalent to 260 million metric tons of CO2. Variable speed drives, by reducing a motor’s speed by half, can lower the energy it consumes to one-eighth of its consumption at full speed. 

John Malinowski is the Senior Product Manager for AC Motors at Baldor Electric Company in Fort Smith, Ark. He is a Senior Member of IEEE and is a member of the IEEE Industry Application Society. He is Chairman of NEMA MG1 Motor & Generator Section, and Baldor’s representative for Energy Star Partners and other energy advocate organizations. 



, Non-US/Not Applicable, India, 01/03/13 03:47 AM:

Effeicency increase with Reliability increase is needed.
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
2016 Engineering Leaders Under 40; Future vision: Where is manufacturing headed?; Electrical distribution, redefined
Strategic outsourcing delivers efficiency; Sleeve bearing clearance; Causes of water hammer; Improve air quality; Maintenance safety; GAMS preview
World-class maintenance: The three keys to success - Deploy people, process and technology; 2016 Lubrication Guide; Why hydraulic systems get hot
Flexible offshore fire protection; Big Data's impact on operations; Bridging the skills gap; Identifying security risks
The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Applying network redundancy; Overcoming loop tuning challenges; PID control and networks
Driving motor efficiency; Preventing arc flash in mission critical facilities; Integrating alternative power and existing electrical systems
Package boilers; Natural gas infrared heating; Thermal treasure; Standby generation; Natural gas supports green efforts

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
This article collection contains several articles on strategic maintenance and understanding all the parts of your plant.
click me