Motor Systems
Motor-driven industrial systems consume huge amounts of energy: about 2194 billion kWh annually on a global basis. In the US, Motors are 64% of industrial electrical consumption or 553 billion kWh. For pumping systems worldwide, motor systems contribute to 20% of the total electrical energy demand. These systems (motor/drive, fan, pumping & compressed air) are present across all industrial sectors and represent a major energy savings opportunity, typically 20% or more.
Background
Chinese factories, particularly in the coastal cities and enterprise zones, have been growing very rapidly (up to 100% annually) to meet both domestic and export demand. By 2004, many of these factories were experiencing both caps on and interruptions to electrical supply which constrained growth and resulted in involuntary work stoppages. By optimizing industrial motor systems, Chinese factories could more effectively apply the available electrical supply to support production.
System optimization techniques include:
- Evaluating work requirements and matching system supply to these requirements
- Eliminating or reconfiguring inefficient uses and practices (throttling, open blowing, etc)
- Changing out or supplementing existing equipment (motors, fans, pumps, compressors) to better match work requirements and increase operating efficiency
- Applying sophisticated control strategies and variable speed drives that allow greater flexibility to match supply with demand
- Identifying and correcting maintenance problems; Upgrading ongoing maintenance practices
Program Goals
A 4-year pilot program was developed in two provinces, Shanghai and Jiangsu, in order to:
- Demonstrate the benefits of using a systems approach to improve industrial energy efficiency
- Create the foundation for a national program
- Develop national standards for system energy efficiency
- Prepare motor system optimization experts to conduct plant assessments, develop system optimization projects, publish case studies and train factory personnel in the basics of system optimization.
Another purpose was to determine if system optimization techniques can be transferred across language and cultural barriers by providing intensive training blocks of 1 to 1-1/2 weeks at a time over the course of 18 months. Training included both classroom and hands-on training in factories. LBNL's role was to develop the program design, form and lead a team of international system optimization experts, provide ongoing technical assistance and project development support to the Chinese experts, and draft the system efficiency standards.
- Each Energy Center developed their own approach based on their strengths and local needs.
- Jiangsu trained >700 factory personnel and conducted 18 plant assessments with most of the projects developed by the factories.
- Shanghai trained 250 factory personnel and conducted 23 plant assessments, with most projects developed (and financed) by the Energy Center.
Results
The first 38 plant assessments conducted by Chinese experts identified nearly 40 million kWh in annual energy savings, with an average per system energy savings of 23%.
- 22 Chinese system optimization experts now form the core for a national program.
- Under the forthcoming EUEEP, these experts will co-train with international experts to bring system optimization techniques to more engineers in 2-3 additional provinces, with two experts receiving additional training in US.
Links to studies on Motors in China
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Study of Pumps and Fans Market in China Prepared by CERF/IIEC for LBNL and ACEEE. December 2002. |
Download 977KB PDF, 36 pp |
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China Motor Systems Energy Conservation Program Case Study: Performance Optimization of Pump System of a Pharmaceuticals Company Wang Wenkang, Zhang Tiechang, Qinhongbo. Shanghai Energy Conservation Service Center. Click here for more information about the China Motor Systems Energy Conservation Program. |
Download 329KB PDF, 5 pp |