1
Harmonized Standards for Motors and Systems
Global progress report and outlook
International Energy Agency IEA
Implementing Agreement Efficient Electrical End-Use Equipment 4E
Electric Motor Systems Annex EMSA
Conrad U. Brunner, Zurich Switzerland
Operating Agent: Electric Motor Systems Annex EMSA
Paul Waide, Navigant
Martin Jakob, TEP Energy
EEMODS’11 Washington DC, USA, September 2011
2
Gearmotor for sewage pump system
Old, oversized, fixed speed and inefficient
EEMODS September 2011
3
1. Global Electric Motor Energy Use
2. Efficiency Standards
3. IEA 4E EMSA
We have come a long way………………
Terminology IE1 > IE2 > IE3 >
Efficiency Test One preferred method
Motor MEPS countries 70% of electricity
EEMODS September 2011
Sources 4
1. Motor and Systems: Global Market
Study
(Zurich June 2009, unpublished)
Conrad U. Brunner,
A+B International
Martin Jakob, Martin Meyer,
TEP Energy
2. Scenario for electricity demand
2006-2030
(Paris 2010, unpublished)
Paul Waide et. al. Navigant
3. Energy-Efficiency: Policy
Opportunities for Electric Motor-
Driven System
(Paris, May 2011)
Paul Waide & Conrad U. Brunner;
IEA Energy Efficiency Series,
Working Paper
EEMODS 2011 Washington DC
Electricity for electric motors 5
Losses 2 PWh General purpose
medium size
industrial motors 4.8
transmission/transformation
All kinds of Pumps 0.9 PWh Heating & Cooling
0.6 Losses 3 PWh in motors,
Electric motors 1.6 PWh Infrastructure
PWh VFDs and applications
7 PWh Fans 0.9 PWh Ventilation & Blowers
Mechanical Movement 1.5 PWh Conveyors & Escalators Losses 1 PWh in OwU, etc.
Industrial Processing &
Useful
Handling
Net mechanical energy used
Compressors 1.5 PWh Compressed Air mechanical
Cooling & Refrigeration energy
Final electricity Small Medium Large Core Motor Systems Application Necessary work
375
EEMODS September 2011
Global Motor Use by Sector 6
Sector Electricity Fraction of motor Fraction of sector
consumption systems electricity electricity
TWh/a % %
Industrial 4 488 64% 69%
Commercial 1 412 20% 38%
Residential 948 13% 22%
Transport and agriculture 260 3% 39%
Total 7 108 100% 45%
EEMODS September 2011
Electricity Consumption Motor Systems
7
16'000
14'000
Motor system electricity consumption (TWh)
20%
12'000 30%
10'000
8'000
6'000 Policy scenario
Reference scenario
4'000
LLCC scenario
2'000
0
2005 2010 2015 2020 2025 2030
Paul Waide & Conrad U. Brunner, IEA Energy Efficiency Series, Working Paper, 2011
EEMODS September 2011
Consistent Market Data?
8
Motor Motor Electricity
Sales Stock Demand
$
EEMODS 2011 Washington DC
Quantification methodology
9
Top down
Global/national electricity consumption: total and per sector (IEA
statistics 2006)
Percentage of light/heat/electronics/electrolysis, standby/motors
(literature: P. Waide, M. Ellis, et al.)
Percentage of motors per sector (literature: de Almeida, et al.)
Bottom up
National census/survey sales data
National census/survey stock data
Sales-to-stock diffusion model (age)
Standard operation model (size, operation h/a, Load Factor)
National electricity sector demand: motor demand estimates
Match Top down and Bottom up?
EEMODS 2011 Washington DC
Product definition
10
What is an "Electric Motor"
General vs. special vs. definite purpose
AC induction vs. synchronous, DC, PM, et al.
TEFC vs. OPD
Flange type: foot, top, side
horizontal vs. vertical
Low vs. Medium vs. High Voltage
Continuous (S1) vs. intermittent vs. any other
Vehicles: cars, trains, airplanes
Motors within machines (elevator)
Motors packaged (small pump)
Motors in appliances and electronics
small – medium - large
EEMODS 2011 Washington DC
Sales – Stock - Consumption 11
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Motor systems sales
Motor systems stock
Electricity consumption for motor systems 45% Light 19% Heat 19% Electronics
Global electricity consumption 16.8 PWh/a (2008)
EEMODS September 2011
Domestic Production vs. Trade
12
Import motor Domestic Export motor
motor
production
domestic usage = domestic production – export + import
EEMODS 2011 Washington DC
Trade & Manufacturing
13
Import motor Domestic Export motor
motor &
machine
Import machines production Export machines
domestic usage ?= domestic production ?– export ?+ import?
EEMODS 2011 Washington DC
Standard Operating Condition
14
Back-up Motors?
Output Size Operating hours
Life span Load factor
EEMODS 2011 Washington DC
Diffusion of Efficiency Level 15
100% IE3
IE2
Share of IE classes
80% IE1
on sales data (%)
IE0
60%
40%
20%
0%
-28-26-24-22-20-18-16-14-12-10 -8 -6 -4 -2 0 2 4 6 8 10
Time (a)
Country or country group Lag compared to the reference t=0
Canada and US +2 to 0 years
Mexico -2 years
Australia, NZ -3 to -4 years
China, South Korea -5 to -6 years
Taiwan, Brazil -7 to -8 years
EU
EEMODS 2011 Washington DC -8 to -10 years
Other countries with no MEPS or VA -12 to -15 years
Three Key Regions: MEPS update 16
Motor MEPS 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
USA IE2 IE3
Europe EU-27 IE2 IE3* IE3**
China P.R. IE0 IE1 IE2 IE3
*) > 7.5 kW or IE2+ VFD
**) all sizes or IE2+ VFD
Three key regions:
56% of global electricity consumption for motors
EEMODS September 2011
Sales and stock: World 17
Sales
100%
90%
80%
70%
Market share (%)
IE3
60%
IE2
50%
IE1
40%
IE0
30%
20%
TEP Energy
10%
0%
1995 2000 2005 2010 2015
Stock
100%
80%
Market share (%)
IE3
60%
IE2
IE1
40%
IE0
20%
TEP Energy
0%
1995 2000 2005 2010 2015
EEMODS 2011 Washington DC
Global Motor Standards 18
70% of motor system electricity is used in „MEPS Countries“
Efficiency Levels Efficiency Classes Testing Standard ≥ 7.5 kW
Performance Standard
3-phase induction motors IEC 60034-30 IEC 60034-2-1 Mandatory MEPS ****
Global classes IE-Code incl. stray load losses National Policy Goal
2008; rev. 2012 * 2007; rev. 2012 **
Super Premium Efficiency IE4 Preferred Method
Premium Efficiency IE3 Canada
Mexico
USA
Summation of losses with Europe*** 2015 / 2017
High Efficiency IE2 load test: Australia
Brazil
PLL determined from
China
residual loss
Europe
South Korea
New Zealand
Switzerland
Standard Efficiency IE1 Costa Rica
Israel
Taiwan
bold means in effect
13 September 2011 CUB *) Sizes 0.12 kW - 800 kW, **) for 3-phase machines, ***) Europe* 2015 IE3 (below 7.5 kW),
A+B International 50 and 60 Hz rated output power < 1 MW 2017 IE3 (all) or IE2 + Variable Speed Drive
****) Minimum Energy Performance Standard
IEC: Harmonized Motor Standards 19
IEC 60034-1 (2010) RATING & PERFORMANCE
IEC 60034-30 (2008) EFFICIENCY CLASSES
Revision 2012 (draft for review):
0.12 kW – 800 kW, all kinds of electric motors, Super Premium Efficiency IE4
IEC 60034-31 (2010) GUIDE
Guide for the selection of energy-efficient motors
IEC 60034-2-1 (2007) TESTING
Revision 2012: Only one preferred method for motors up to 1000 kW
Preferred method: segregated losses with stray load from residual loss
Improvements for sequence of tests, seals, standard reporting format
Round Robin Report, published 2011:
17 laboratories in 11 countries, 75 motors with total of 194 tests
Motor Efficiency Classes: Update 20
• Wider scope : all kinds
• Broader size: 0.12 – 800 kW
• IE4: Super Premium
EMSA Washington 8/9 Sept 2011 Draft IEC 60034-30 (2011)
New Rating Plate 21
IE-Code
Efficiency Class
Confirms conformity to European Ecodesign
requirements
Confirms conformity
to European
Ecodesign
requirements
Efficiency class
and nominal
efficiency
RFID
1234
Radio-Frequency
Identification
EEMODS September 2011
22
EEMODS September 2011
4E Implementing Agreement 23
EEMODS'11, 14/9/2011
EMSA 2008 - 2011 24
Publications Motor Systems Tool
Events
Standards
EMSA Washington 8/9 Sept 2011
25
www.motorsummit.ch
EEMODS September 2011
26
EEMODS September 2011
Global Motor Systems Network 27
NEMA, JEMA,
EuP APEC WBCSD ICA CEMEP
EU Ecodesign Asia-Pacific Economic World Business Council for International Copper International Industry
Directive Cooperation Sustainable Development Association Associations
IEA IAs 4E IPEEC
Efficient Electrical End-use equipment International Partnership
M & B, Motors, SSL, Standby for Energy Efficiency
IEA EEU Cooperation
ISO EMSA New Synergy
SEAD
Super-efficient Equipment
Electric Motor
IEC
and Appliance Deployment
New Task Systems Annex
UNIDO CLASP
Country Programs and Policy Collaborative labeling and
Experts Network appliance standards program
EMSA Members
UNDP UNEP
Australia Austria Denmark Netherlands Switzerland
Rest of the World
USA China Brazil Japan EU
UNFCCC GEF
Motor Programs 28
Coverage Name of program or leading Internet URL
agency
Global 4E EMSA www.motorsystems.org
Australia Energyrating E3 www.energyrating.gov.au
Austria Klimaaktiv www.klimaktiv.at
Brazil Procel www.eletrobras.com
Canada NRCan OEE www.oee.nrcan.gc.ca
China China Motor Challenge www.motorsystem.org.cn
Europe Motor Challenge Programme www.motor-challenge.eu
India Bureau of Energy Efficiency BEE www.bee-india.nic.in
New Zealand EECA electric motors programme www.eeca.govt.nz
South Africa Eskom IDM www.eskomidm.co.za/industrial
South Korea KEMCO www.kemco.or.kr
Switzerland S.A.F.E. Topmotors www.topmotors.ch
USA Motor Decisions Matter www.motorsmatter.org
EEMODS September 2011
Where do we go from here? 29
1. More countries get motor MEPS: Japan, India, Russia
2. Move MEPS level up to IE3
3. Fewer exceptions: brakes, explosion, gears, 40°C, 1000 m
4. Enforcement – compliance – monitoring – testing
5. Cheap & rapid on-site evaluation
6. Product registration: RFID
7. Help OEMs understand LCC
8. Variable load efficiency: MEPS
9. Systems efficiency: MEPS for pumps, fans, compressors
10. Get old motors out after 20 year – no rewind!
EEMODS September 2011
30
Zurich Switzerland
EEMODS September 2011
Contact Information 31
www.motorsystems.org
Conrad U. Brunner
Operating Agent for IEA 4E
Electric Motor Systems Annex
A+B International, Gessnerallee 38a
CH 8001 Zurich Switzerland
Tel +41 44 240 36 15
cub@cub.ch
Rita Werle
rita.werle@abinternational.ch
EEMODS September 2011