Energy efficient electric motors and their driven systems

Energy efficient electric motors and their driven systems Jeffrey Sipma, Himsar Ambarita Jakarta 05/05/15 www.ecn.nl

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 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? 2

5. Which industrial sector should we look at in the next phase, as a pilot project? 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 3

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 motordriven 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 motors 8

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 Motors industrial sector: 70% Motors commercial sector: 35% Pumps + Fans + Compressors: 62% Pumps + Fans + Compressors: 82% 13

Energy efficient electric motors: IE-classes 5international classes IE0 unbranded and cheap Chinese motors 1 kw motors: 10% efficiency improvement IE1-IE3 400 kw: 3% efficiency improvement IE1-IE3 14

MEPS programs around the world 15

Contribution to life-cycle cost literature Life-cycle cost with 4000 operating hours per year 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 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 % purchase costs over life time 10% 9% 8% 7% 6% 5% 4% 3% 2% 1% 0% Industry IE2 (757 Rp/kWh) Commercial sector IE2 (1073 Pr/kWh) Avarage without subsidy IE2 (1358 Rp/kWh) 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 Running hours a year Conclusion: At 4000 h: 2% -3.3% 18

Payback period: replacement of broken down IE0, by IE2 instead IE0 years 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 Industry (757 Rp/kWh) Commercial sector (1073 Pr/kWh) Avarage without subsidy (1358 Rp/kWh) 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 Running hours a year 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] 19

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 Electricity consumption Electricity savings Financial savings sector and government Other benefits 24

Consumption electric motor systems 2014: Bottom-up versus Top-down 25

Consumption electric motor systems: BAU projection towards 2035 26

BAU: Present market share IEclasses Indonesia 27

Savings: by IE-class and for optimizing electric-motor driven systems (EMDS) 28

Electricity savings: effect MEPS 160 140 BAU total consumption 120 IE1 total consumption Million BOE 100 80 60 IE2 total consumption IE3 total consumption 40 IE4 total consumption 20 0 2014 2016 2018 2020 2022 2024 2026 2028 2030 2032 2034 EE-EMDS total consumption 29

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Other benefits Jobs Education International cooperation (motor conferences) Indonesia as a motor producing country again? 31

But is doesn't go by itself. 3. Barriers: literature and interviews 32

Barriers at the level of international trade Differences in grid voltage and frequency Different measuring systems (horsepower versus kw, motor frame size) Non-harmonisedstandards 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

Luckily there are is a lot of information available to face these challenges! 4. Policy instruments to reduce barriers 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, inclworkshops 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)? Support: Government, PLN, Power Utilities and Associations Direct impact Speed Costs Target: Manufacturer Importer Sales EE motor, pumps, fans... Purchaser Industrial sectors Individual businesses Tool: MEPS high 3-5 years high Awareness and Information Labels Financial Incentives 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 46

5. Which industrial sector should we look at in the next phase, as a pilot project? 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 47

Electric savings potentials sectors Indonesia 48

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 885154949 F +31 885154480 info@ecn.nl www.ecn.nl 49

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