EnergY EfficienCY MEAsure ECO EMS N. 0.04 MOTOR REPAIR POLICY

ENERGY SAVING AREA:           electric motors COMPONENT CATEGORY:             Efficiency Improvement ACTION TYPE(S):                                Replace   /  Install

TECHNICAL DESCRIPTION

• DESCRIPTION of the Measure (Suggested Action): If you wait a motor fails, your primary concern will be speedy installation/replacement. Evaluate, before fails occur, all motors in your facility. Develop a replacement plan for all critical motors. Decide what motors have to be replaced with a HE motors or smaller size, contact your motor dealers for replacements. Consider purchasing critical replacement motors as backups.
• TYPICAL APPLICATIONS:  Anywhere motors are used.
• CAUTIONS SUMMARY and CONSIDERATIONS:The implementation of a repair policy must involve not only the factory or department manager, but also the Operation and Maintenance responsible persons and to inform all the staff concerned with motors.
• PROBLEMS due to LACK of THIS ECO (Background): Maintenance staff, without any engineering analysis, usually takes the replace/rewind decision. Often the same brand and model is chosen. Each time a motor fails and wrong decision is taken, an improvement opportunity and lack of profitability is lost. If the decision is to rewind the motor instead of replacing it with a High Efficiency Motor, the new working condition will be with reduced efficiency from poorly repaired motors. This is the more true if the repair is given to a repair service without guarantee of efficiency of the repaired motor.
• SIDE BENEFITS: Proper replacement planning and policy allow a more careful investment plane.
• DISADVANTAGES: Some time and effort required to set up policy/system 

• IMPLEMENTATION COST: Some small costs are needed in setting up the repair policy, which will be repaid in short period of time
• COST EFFECTIVENESS: Payback on effective policy is in the order of 1-2 years.
• O & M REQUIREMENTS AND RELATED COST VARIATION: Little cost variation on O&M but repair policy will affect the O&M requirements.
• REMARKS on COST FACTORS. Small costs are needed to adopt HEM's to replace standard motors - foot print of motor, etc

DECISIONAL and EVALUATION PROCEDURE

• iMPLEMENTATION STRATEGY: Policy can be adopted at any time. Decisions made about size threshold of motor to be replaced by High Efficiency Motors should be made and incorporated into policy.
• IMPLIED ECOS:  ECO-EEM 1.1.1 Replace existing motors with High Efficiency ones.

• GENERAL COMMENTS and RECOMMENDATIONS: Where motors widely used in industrial plant, motor repair policy is a good thing to implement.

• BASELINE TECHNOLOGY to be upgraded:  No repair/replacement policy

• AUDIT & IMPLEMENTATION DECISION PROCEDURE: The decision to implement an energy efficiency policy should be based on the size of a careful estimate of the cost-effective savings obtainable from the implementation of such a policy in the company. First of all, the assessment should be made by checking, how and how frequent replacements of old motors occur. Secondly, what is the common practice when a motor fails and what is the importance and costs associated to production downtimes. The repair policy should also determine on the basis of the estimated motor lifetime, motor size and operating hours, repair and replacement HEM costs, the threshold under which the motor stock is replaced and above which motors are rewinded.
• ENERGY SAVING POTENTIAL: High standard of repair provides 0.5% savings with respect to non accurate repair procedures
• ENERGY SAVING EVALUATION PROCEDURE: The energy saving can be estimated by summing up the energy savings obtainable from the replacement the most important motors working more than 1000 hours/year.
• EX-POST ACCEPTANCE & PERFORMANCE COMPLIANCE CHECK PROCEDURE: The ex-post evaluation can be made by measuring the energy consumed (power x operating hours) and comparing with the adjusted baseline. Adjustments needs to be made to take into account variations in operating hours and in installed power occurred for production changes.

USER INFORMATION and COMMERCIAL ISSUES

• PURCASE AND O&M PROBLEMS
• ECO ENVIRONMENTAL IMPACT & CONSTRAINTS: The implications of scrapping motors rather than repair can be justified as a result of the CO2 savings from more efficient units
•  USER'S/CLIENT's ACCEPTANCE: Simple - Policy not likely to cause major concern
•  EASE OF USE: No problems at all
•  PRACTICAL IMPLEMENTATION PROBLEMS: Change in Operating & Maintenance practices may need to be adopted and source of repairs may need to be changed.
• OTHER NON-TECHNICAL BARRIERS: Larger companies are keener to implement a repair policy. A barrier can be the common rule to replace small motors and rewind large motors. A policy could redefine the threshold between small and large motors. Maintenance staff could perceive a motor repair policy deined by other people as an implicit criticism to their professional expertise and, therefore, to create obstacles to the policy implementation.     Another barrier can be due to the invisibility or low importance given to energy expenditures. In this case the company management and the operating staff have lack of incentives to implement any kind of energy saving on motor systems.
• COMMERCIAL INFO. ON MANUFACTURERS: Approach repair companies on best repair service needs to be actively sought.
• REFERENCES, LITERATURE & LINKS:

1) Good Practice Case Study n. 162 – EEO

2) Nadel, Shepard,Greenberg, Katz and De Almeida, "Energy Efficient Motor Systems", ACE3, 1992

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