WSU Energy Program Logo
Bonneville Power Administration Logo
  • Home
  • About
  • Database
      • Browse
      • Energy Systems
        • Building Envelope
        • Electronics
        • HVAC
        • Irrigation
        • Lighting
        • Motors & Drives
        • Multiple Energy Systems
        • Power Systems
        • Process Loads & Appliances
        • Refrigeration
        • Transportation
        • Water Heating
      • Sector
        • Agricultural
        • Commercial
        • Industrial
        • Residential
        • Utility
  • TAG Portal
      • 2017 Residential Lighting TAG (#14)
      • 2016 Multifamily Building TAG (#13)
      • 2015-1 Commercial HVAC TAG (#11)
      • 2014 Residential Building TAG (#10)
      • 2014 Commercial Building TAG (#9)
      • 2013 Information Technology TAG (#8)
      • 2013 ALCS TAG (#7)
      • 2012 Smart Thermostat TAG (#6)
      • 2012 LED Lighting TAG (#5)
      • 2011 Energy Management TAG (#4)
      • 2010 HVAC TAG (#3)
      • 2009 HVAC TAG (#2)
      • 2009 Lighting TAG (#1)
  • Webinars
    • Webinar Archives
  • Glossary
>

Summary

Encourage Replacement of In-Service Standard Efficiency Motors with Premium Efficiency Models

Induction Motors: Premium Efficiency vs. Standard and Energy Efficient

Encourage replacement of in-service industrial motors with NEMA Premium®- or Enhanced-efficiency motors that are 2% to 9% more efficient than standard motors.

Synopsis:

The National Electrical Manufacturers Association (NEMA) adopted a voluntary NEMA Premium® efficiency motor standard in 2001, which applies to most 1- to 500-hp motors operating at 600 Volts or less. Under the Energy Independence and Security Act of 2007 (EISA), the mandatory minimum nominal efficiency for general purpose motors with a power output from 1 to 200 hp was raised to the NEMA Premium level. (DOE issued a NOPR to extend this to motors up to 500 hp in December, 2013).  This mandatory minimum efficiency requirement applies to motors purchased alone, as part of an equipment package, or imported into the country. However, unfortunately, EISA does not apply to motors that are in service, and therefore plant operators are not mandated to replace operating standard-efficiency motors.

Facilities built after 1997 tend to have energy-efficient motors due to mandatory minimum full-load efficiency requirements. Older industrial plants tend to operate older, standard efficiency motors. Assessments conducted between 2005 and 2011 at 123 industrial plants indicate that over 70% of operating motors are of standard efficiency design. Failed standard efficiency motors from 25 hp to 50 hp are typically rewound and returned to service due to excessive simple payback.

NEMA Premium efficiency motors are available in all low-voltage hp ratings. Replacing a 200-hp standard efficiency motor with a NEMA Premium motor can save 34,520 kWh/year (at 75% load and in operation for 8,000 hours/year). Only a handful of utilities offer incentives ($3,300 for a 100-hp motor) large enough to make it cost effective to replace operating standard efficiency motors with Premium-efficiency or Enhanced-efficiency (one percentage point greater than Premium) motors, but most do not.

Energy Savings: 4%
Energy Savings Rating: Approved Measure  What's this?
LevelStatusDescription
1Concept not validatedClaims of energy savings may not be credible due to lack of documentation or validation by unbiased experts.
2Concept validated:An unbiased expert has validated efficiency concepts through technical review and calculations based on engineering principles.
3Limited assessmentAn unbiased expert has measured technology characteristics and factors of energy use through one or more tests in typical applications with a clear baseline.
4Extensive assessmentAdditional testing in relevant applications and environments has increased knowledge of performance across a broad range of products, applications, and system conditions.
5Comprehensive analysisResults of lab and field tests have been used to develop methods for reliable prediction of performance across the range of intended applications.
6Approved measureProtocols for technology application are established and approved.
Simple Payback, New Construction (years): 4.7   What's this?

Simple Payback is one tool used to estimate the cost-effectiveness of a proposed investment, such as the investment in an energy efficient technology. Simple payback indicates how many years it will take for the initial investment to "pay itself back." The basic formula for calculating a simple payback is:

Simple Payback = Incremental First Cost / Annual Savings

The Incremental Cost is determined by subtracting the Baseline First Cost from the Measure First Cost.

For New Construction, the Baseline First Cost is the cost to purchase the standard practice technology. The Measure First Cost is the cost of the alternative, more energy efficienct technology. Installation costs are not included, as it is assumed that installation costs are approximately the same for the Baseline and the Emerging Technology.

For Retrofit scenarios, the Baseline First Cost is $0, since the baseline scenario is to leave the existing equipment in place. The Emerging Technology First Cost is the Measure First Cost plus Installation Cost (the cost of the replacement technology, plus the labor cost to install it). Retrofit scenarios generally have a higher First Cost and longer Simple Paybacks than New Construction scenarios.

Simple Paybacks are called "simple" because they do not include details such as the time value of money or inflation, and often do not include operations and maintenance (O&M) costs or end-of-life disposal costs. However, they can still provide a powerful tool for a quick assessment of a proposed measure. These paybacks are rough estimates based upon best available data, and should be treated with caution. For major financial decisions, it is suggested that a full Lifecycle Cost Analysis be performed which includes the unique details of your situation.

The energy savings estimates are based upon an electric rate of $.09/kWh, and are calculated by comparing the range of estimated energy savings to the baseline energy use. For most technologies, this results in "Typical," "Fast" and "Slow" payback estimates, corresponding with the "Typical," "High" and "Low" estimates of energy savings, respectively.

Status:

Details

Encourage Replacement of In-Service Standard Efficiency Motors with Premium Efficiency Models

Induction Motors: Premium Efficiency vs. Standard and Energy Efficient

Encourage replacement of in-service industrial motors with NEMA Premium®- or Enhanced-efficiency motors that are 2% to 9% more efficient than standard motors.
Item ID: 230
Sector: Industrial
Energy System: Motors & Drives--Motors
Technical Advisory Group: 2013 Information Technology TAG (#8)
Average TAG Rating: 2.17 out of 5
TAG Ranking Date: 10/25/2013
TAG Rating Commentary:
  1. Applicability and cost of implementation would likely lead to a more limited number of facilities where this technology could be deployed.
  2. Difficult to implement/ costly
  3. Some systems are ET's but most are not.

Synopsis:

The National Electrical Manufacturers Association (NEMA) adopted a voluntary NEMA Premium® efficiency motor standard in 2001, which applies to most 1- to 500-hp motors operating at 600 Volts or less. Under the Energy Independence and Security Act of 2007 (EISA), the mandatory minimum nominal efficiency for general purpose motors with a power output from 1 to 200 hp was raised to the NEMA Premium level. (DOE issued a NOPR to extend this to motors up to 500 hp in December, 2013).  This mandatory minimum efficiency requirement applies to motors purchased alone, as part of an equipment package, or imported into the country. However, unfortunately, EISA does not apply to motors that are in service, and therefore plant operators are not mandated to replace operating standard-efficiency motors.

Facilities built after 1997 tend to have energy-efficient motors due to mandatory minimum full-load efficiency requirements. Older industrial plants tend to operate older, standard efficiency motors. Assessments conducted between 2005 and 2011 at 123 industrial plants indicate that over 70% of operating motors are of standard efficiency design. Failed standard efficiency motors from 25 hp to 50 hp are typically rewound and returned to service due to excessive simple payback.

NEMA Premium efficiency motors are available in all low-voltage hp ratings. Replacing a 200-hp standard efficiency motor with a NEMA Premium motor can save 34,520 kWh/year (at 75% load and in operation for 8,000 hours/year). Only a handful of utilities offer incentives ($3,300 for a 100-hp motor) large enough to make it cost effective to replace operating standard efficiency motors with Premium-efficiency or Enhanced-efficiency (one percentage point greater than Premium) motors, but most do not.

Baseline Example:

Baseline Description: Standard Efficiency Motors
Baseline Energy Use: 242700 kWh per year per unit

Comments:

This estimate reflects the energy use of a 100 hp, 1800 rpm, Standard Efficiency TEFC motor operating 4,000 hours per year at 3/4 load with an efficiency of 92.2%. Estimate of baseline energy use of 242,679 kWh/year was calculated using MotorMaster+ software.

Manufacturer's Energy Savings Claims: Currently no data available.
Best Estimate of Energy Savings:

"Typical" Savings: 4%
Low and High Energy Savings: 3% to 5%
Energy Savings Reliability: 6 - Approved Measure

Comments:

This estimate reflects the energy use of a 100 hp, 1800 rpm, Premium Efficiency motor with an efficiency of 95.3%, operating 4,000 hours per year at 3/4 load compared with the baseline motor of a Standard Efficiency TEFC motor with an efficiency of 92.2%. Estimate of baseline energy use of 242,679 kWh/year with an energy savings of 7,841 kWh/year was calculated using MotorMaster+ software.

The actual savings in a particular application will depend on the hours of operation, motor loading, whether or not a of variable frequency drive (VFD) is used, and baseline efficiency.


Energy Use of Emerging Technology:
232,992 kWh per unit per year What's this?

Energy Use of an Emerging Technology is based upon the following algorithm.

Baseline Energy Use - (Baseline Energy Use * Best Estimate of Energy Savings (either Typical savings OR the high range of savings.))

Technical Potential:
Units: unit
Potential number of units replaced by this technology: 73,000
Comments:

In this analysis, we only include industrial motors, and only those between 1 and 500 hp, since those are the sizes covered by the NEMA Premium standard. Trying to estimate or find the number of horsepower in service in the Northwest is challenging. What we can estimate, though, is the total energy usage of industrial motors, and divide that by the energy usage per horsepower calculated in the Baseline Energy Use field to get a number of hp that would give us that estimated total regional energy usage. According to the Northwest Power and Conservation Council's Sixth Power Plan estimates, industrial energy usage in the Northwest in 2014 is estimated to be approximately 4000 aMW, or 35,040 billion kWh/yr. (NWPCC, 2010 Pg 3-6) DOE estimates that 70% of industrial energy usage is motors, or 24,500 billion kWh/yr. Of this, approximately 73% of the energy usage is between 1 and 500 hp, based on typical horsepower distribution estimated by DOE (Xenergy, 2002 App B). That gives us approximately 7.3 million hp of industrial motors in the Northwest between 1 and 500 hp.  (Divide by 100 to come up with equivalent 100 hp motors for a total of 73,000).

Regional Technical Potential:
0.71 TWh per year
81 aMW
What's this?

Regional Technical Potential of an Emerging Technology is calculated as follows:

Baseline Energy Use * Estimate of Energy Savings (either Typical savings OR the high range of savings) * Technical Potential (potential number of units replaced by the Emerging Technology)

First Cost:

Installed first cost per: unit
Emerging Technology Unit Cost (Equipment Only): $6750.00
Baseline Technology Unit Cost (Equipment Only): $2680.00

Comments:

NEMA Premium motors typically cost 10% to 15% more than standard efficiency motors.  MotorMaster+ defaults indicate the cost of a motor repair (rewind plus new bearings) at $2677 for a 100 hp, 1800 RPM, totally enclosed fan-cooled (TEFC) motor.   The cost of a new Premium Efficiency motor by an industry is about $6750 when a 45% list price discount is taken into account.  It is most cost-effective to replace old standard efficiency motors at their time of failure.    

Cost Effectiveness:

Simple payback, new construction (years): 4.7

Simple payback, retrofit (years): N/A

What's this?

Cost Effectiveness is calculated using baseline energy use, best estimate of typical energy savings, and first cost. It does not account for factors such as impacts on O&M costs (which could be significant if product life is greatly extended) or savings of non-electric fuels such as natural gas. Actual overall cost effectiveness could be significantly different based on these other factors.

Reference and Citations:

NEMA, 2013. NEMA Premium Motors
National Electrical Manufacturers Association

NEMA, 2013. NEMA Premium Product Scope and Nominal Efficiency Levels
National Electrical Manufacturers Association

Xcel Energy, 08/01/2013. Motor and Drive Efficiency 2013 Motor Rebate Application
Xcel Energy

Paul Scheihing, 02/01/2012. United States Industrial Motor-Driven Systems Market Assessment: Charting a Roadmap to Energy Savings for Industry
Energy Efficiency & Renewable Energy

Avista, 10/01/2012. Premium Efficiency Motor Rebates
Avista Utilities

Richard deFay, 07/20/2012. New CDA Program Teaches Motor Efficiency to Industrial Facilities
Copper Development Association Inc.

NWPCC, 02/01/2010. Sixth Northwest Conservation and Electric Power Plan
Northwest Power and Conservation Council

Xenergy, 12/01/2002. United States Industrial Electric Motor Systems Market Opportunities Assessment
US DOE

Rank & Scores

Encourage Replacement of In-Service Standard Efficiency Motors with Premium Efficiency Models

2013 Information Technology TAG (#8)


Technical Advisory Group: 2013 Information Technology TAG (#8)
TAG Ranking: 45 out of 57
Average TAG Rating: 2.17 out of 5
TAG Ranking Date: 10/25/2013
TAG Rating Commentary:

  1. Applicability and cost of implementation would likely lead to a more limited number of facilities where this technology could be deployed.
  2. Difficult to implement/ costly
  3. Some systems are ET's but most are not.


Contact
Copyright 2023 Washington State University
disclaimer and privacy policies

Bonneville Power Administration Logo