Emerging Trends inIntegrated Motor Systems

Demand Side Energy Consultant Inc.Alex Fleming, P.Eng.– Principal

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Markus Zeller, P.Eng.– BC Hydro

Presentation Outline• Integrated Motor Systems and Energy Use• Trends and Opportunities

– Component Efficiency– Premium Control– Energy Engineering– Application Engineering

• System Energy Performance• Closing the Gap

Early Adopters Early/Late

Majority LaggardsInnovators

Electric Motor Energy Usage

50% of total electricity consumed in BC isconverted to shaft power in motor driven systems:

Large(>500 hp),

23%

Medium(1-500 hp),

68%

Small(< 1 hp),

9%

Medium(1-500 hp),

11%

Small(< 1 hp),

89%

0%

20%

40%

60%

80%

100%

%-Energy %-Units

Efficient conveyorcomponents can boostsystem efficiency, but not improve thebasis of design.

Component Efficiency has an Impact

ηConveyor system = ηMotor X ηBelt X ηReducer X ηChain X ηdragchain

Component 30% = 0.904 x 0.95 x 0.55 x 0.90 x 0.70

EE Component 54% = 0.942 x 0.97 x 0.94 x 0.90 x 0.70

Limits and Diminishing Returnsin Motor Component Efficiency

70

75

80

85

90

95

100

- 50 100 150 200 250 300 350 400 450 500Rating (hp)

Full

Load

Effi

cien

cy (%

)

Super Premium

2010

19971994

Premium Control

The ‘load’ is a process and the motor system boundary is now crossed

Allows equipment to follow the load and maintain the Best Efficiency Point (BEP)over an operating range

Premium Control

Chart courtesy of CEATI

Complicates component efficiency predictions

Premium Control

69 70 71 72 73 74

74

75

75

76

76

77

77

77

7878

78

79

7979

79

79

80

8080

80

81

8181

81

81

82

8282

82

82

83

83

8383

83

83

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84

84

8484

85

85

85

8585

86

86

8686

87

87

8787

8888

88

88

8989

89

90

90

90

91

91

Speed (% Nominal)

Torq

ue (%

Nom

inal

)

25 50 75 1000

25

50

75

100

Conveyors

Pumps & Fans

Requires motor, VFD & equipment efficiencies

Premium ControlPlus any minimum pressure requirementneeds modified ‘Laws of Affinity’

3

1

min

1

2

1

min

1

2 1

H

HQQ

HH

PowerPower

2

1

min

1

2

1

min

1

2 1

H

HQQ

HH

HeadHead

1

min

1

2

1

min

1

2 1H

HQQ

HH

SpeedSpeed

Five Motor System Opportunities

ACTIVITY APPROACH MOTOR SYSTEM OBJECTIVE

Catalogue Engineering

Remove and replace (R&R) Low Distraction/TransactionLow Cost/Low Risk

Go to E.E. Catalogue

Install energy efficient components

Improve Component Efficiency

PremiumControl

Load match the supply side with process demands

Achieve Best Efficiency Points

EnergyEngineering

Optimize supply side efficiency with demand-side consideration

Optimize PerformanceReduce components

Application Engineering

Integrated Motor Systems –OEM Industrial Appliances

Re-visit the Basis of DesignIntegrated Energy Mgt System

Premium Control and EE Components comprise majority of present activity

Power Smart Pump Video

Five Motor System Opportunities

ACTIVITY APPROACH MOTOR SYSTEM OBJECTIVE

Catalogue Engineering

Remove and replace (R&R) Low Distraction/TransactionLow Cost/Low Risk

Go to E.E. Catalogue

Install energy efficient components

Improve Component Efficiency

PremiumControl

Load match the supply side with process demands

Achieve Best Efficiency Points

EnergyEngineering

Optimize supply side efficiency with demand-side consideration

Optimize PerformanceReduce components

Application Engineering

Integrated Motor Systems –OEM Industrial Appliances

Re-visit the Basis of DesignIntegrated Energy Mgt System

Energy/Application Engineering • Basis of Design – Packaged unit with lowest

risks and lowest total cost of ownership– High speed motor with magnetic bearings– Oil-free variable speed compressor– Off-load power lowest in industry– Half weight and size– Low maintenance– Low noise– But what’s in the box?

What is an Integrated Motor System?An electric motor driven system that serves theprocess application efficiently and effectivelyas well as addresses the design intent

Integrated Fan Motor All-electric LNG PlantSystem (30 Watts) (4 motors, 260 MW)

The Trend is Toward the‘On-Demand’ Appliances• OEM go back to basis of design. • Variable capacity and intelligent control. • Packaged ‘system knowledge’• ‘Other Benefits’ noise, footprint, reliability.

+ =

Application Engineering Commercial HVAC ApplianceVariable Refrigeration Volume (VRV) is more than variable frequency drives on chillers & fans.

• Variable System output - tracks load profile and demand

• Volume regulated by electronic expansion valve

• Simultaneous heating/cooling• Ductless heating and cooling• Intelligent and Proprietary Controls

Application EngineeringIndustrial Wastewater Appliance

• High-speed blower designed for wastewater

• High speed & variable speed motor

• Balanced design – low noise, small footprint

• Intelligent & Proprietary Controls

• Energy performance metric is kWh per kg of BOD removed

High Speed Turbo Blower …..Just add electricity and piping

Multi‐StageTurbo

Induction Motor Geared 

Single Stage Turbo

Performance

Induction MotorMagnetic Bearing 

Direct  DriveSingle Stage 

Turbo

PM MotorFoil BearingDirect  Drive

Stainless Steel ImpellerSingle Stage Turbo

Bellows P.D.

Price

Photos courtesy of KTurbo Inc.

High Speed Turbo Blowers

Industrial Appliance DesignStarts with the process requirement and the basis of design, then considers the mostappropriate integrated motor system options.

How to ID Application Engineering• A renewed ‘basis-of-design’, fully integrated,

definite purpose, plug & play.• Re-engineered as an appliance package with

embedded specific algorithms and controls.• Energy performance is based upon its

process function - not just efficiency. – kWh per unit of process outcome

Examples: Integrated Motor Systems

• Energy Efficient Components• Premium Control• Energy Engineering• Application Engineering

Early Adopters

Early/Late Majority

LaggardsInnovators

Gearless Mill Drives

VSDHigh

Speed

VSDLow

SpeedVSDGMD

Transformer 99.1% 99.1% 99.1%Converter 98.6% 98.6% 99.2%Motor 97.2% 97.2% 96.8%Gear Reducer 98.5% n/a n/aRing-gear 98.0% 98.0% n/aOverallEfficiency 91.7% 93.1% 95.2%

Basis of Design:• very large (16MW), low-speed, variable speed

Motorized Pulleys• Basis of Design:

– Integrated design– Sealed unit– Low maintenance

Motor Shaft Load Shaft

Constant Speed Direct Drive Coupling• Basis of Design:

– Small speed reductions can result in large energy savings– Fixed speed tuning for centrifugal loads (similar to sheaves)– Reversed by removing shims (impeller trim is not reversible)– Isolate pump from motor (alignment & vibration)

Photos courtesy of MagnaDrive Inc.

Integrated Fan Motor Systems• Basis of Design:

– Greenhouse ventilation & control– Energy savings (60-80%)– Variable speed

Direct Drive Cooling Tower Fan ?

Dust Extraction Technology• Basis of Design:

– Eliminates baghouse filter system by encapsulating the dust particles into atomized water

– Removes abrasive dust particles out of air stream– No reduction in performance under high dust loads– High dust collection efficiencies– Compact high volume design– Low maintenance– Self cleaning

Photos courtesy of Engart Global .

Electro-Mechanical Actuators• Basis of Design:

– Eliminate pneumatic or hydraulic completely– Improved control & reliability

Same Fish Growth with 60% less waterWell pump energy reduced by 50%

Site energy consumption reduced by 25%

Fish Hatchery Raceway Recirc.

Performance

Application Engineering for Dry Kilns

ConventionalKiln

HighEfficiency Kiln

PremiumEfficiency Kiln

ProgressiveKiln

Electricity 0.16 kWh/kg 20-25% savings 30-50% savings >50% savings

Thermal 5.0 MJ/kg 10-15% savings 20-30% savings >30% savings

Next Steps: Closing the Gap -System versus Components

– Standardized system boundaries of unit process function

– Baseline and benchmarking protocols

Next Steps: Closing the Gap -System versus Components• Development of process specific energy

performance metrics are critical:• Ability of field measurement for energy

performance verification and diagnostic:

Impacts on Codes & StandardsShift from the energy efficient components to system energy performance requires:

– Definitions: Efficiency versus Effectiveness– Scope: System Boundaries and Load Profiles– M&V: Process Specific Energy Performance – EnMS: Energy Management System

Thank You!

Demand Side Energy Consultants1-800 668-6771alex.fleming@demandsideenergy.com

Alex Fleming, P.Eng. – Principal

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