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Industry heading towards increased motor efficiency

BELT-DRIVE MOTOR
The most effective means of reducing operational costs is through enhanced energy use

BELT-DRIVE MOTOR The most effective means of reducing operational costs is through enhanced energy use

23rd January 2015

  

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The biggest cost factor involved in owning a compressor is its motor’s energy use, with cost cutting in this area resulting in substantial savings for the operator, says air process company Airgas Compressors.

According to Airgas marketing coordinator Andreas Stubel, the energy costs involved in running a standard compressor over its lifetime far outweigh the initial investment and maintenance costs. “The most effective means of reducing operational costs is, therefore, through enhanced energy use.”

He adds that electric motors worldwide consume between 30% and 40% of all electricity produced. “This is a major concern and, to enhance electric motors, international regulatory organisations have introduced various standards,” says Stubel.

The most familiar of these standards is the IEC 60034-30:2008 standard.

The International Electrotechnical Commission (IEC) has focused on single- speed, three-phase, 50 Hz and 60 Hz alternating current cage-induction motors in the range of 0.75 kW to 375 kW, which is the most widely used range of motors.

According to this standard, motors are produced and categorised as IE1 – standard efficiency, IE2 – high efficiency, and IE3 – premium efficiency. IE4 is currently in development.

The IE1 motor is less efficient, compared with an IE3 motor, with the core difference being in the materials used during manufacturing. The most obvious difference is the physical size of the different motors. IE3 motors are larger and heavier than IE2 or IE1 motors.

Stubel explains that IE3 motors are efficient owing to a combination of factors, such as a higher mass of copper coil, with thinner laminations, improved cooling fans and the use of special bearings.

Increasing the mass and cross section of copper in a coil increases the electrical energy efficiency of the motor. “IE1 and IE2 motors are common in South Africa, while IE3 motors are seldom used,” he says, adding that IE3 motors will become mandatory by 2015 in countries such as Germany.

Although IE3 motor efficiency is commonly used in the European and North American marketplace, Stubel admits that it is still in its infancy in South Africa. “Although the idea of energy efficiency is becoming more common in business practice, the process of implementation is a long and complex one, especially in South Africa, which has such a rich mix of industries.

“Mindsets are slowly changing, and energy efficiency will become increasingly important in the near future, especially with energy costs rising at such a rapid rate,” he says.

Stubel notes that the initial purchase cost of IE3 motor technology is high; however, he stresses that the long-term environmental and capital savings of the new technology far outweigh the initial cost difference.

Another approach to improve the efficiency of motor systems is through the use of variable-speed drives that regulate the speed of the motor and reduce energy use.

Regular maintenance is another method of reducing energy consumption while increasing productivity. “Effective maintenance not only entails individual components, but rather examining the entire system and its performance as a whole.

“It is important to first establish the current condition and inefficiencies of the system by gathering operating data before assessing the energy consumption of the system, and looking at future production needs,” he concludes.

Edited by Megan van Wyngaardt
Creamer Media Contributing Editor Online

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