January 2010 - Saving Electrical Costs
Why is Energy Efficiency Important?
Electric motor-driven systems used in industrial processes consume some 679 billion kWh or 63 percent of all electricity used in U.S. industry, according to a Department of Energy report published in 1998. The report goes on to reveal that industrial motor electricity consumption could be reduced by up to 18 percent if companies were to apply ''proven efficiency technologies and practices" Specifically, the DOE recommends motor efficiency upgrades and application improvements.
The purpose of this brochure is to show you the energy saving opportunities from using premium efficient motors and drives. The opportunities are real.
In 1992, the Energy Policy Act (EPAct) established minimum efficiency standards for industrial electric motors built after October 1997. Yet only about 1 0 percent of all motors in use today comply with the minimum efficiency levels the Act mandates.
When you factor in the savings potential of using adjustable speed drives in many applications it's easy to see that the environment along with your profitability, stand to benefit significantly.
How is Motor Efficiency Measured?
The Efficiency of any machine, including an electric motor, is determined by the amount of useful power it produces compared to the amount of electricity required to operate it. The graphic above illustrates how a Baldor Super-E® effectively turns $1000 in electrical power into 
$930 worth of mechanical power. Since motor efficiencies are commonly expressed as a percentage, you can see that this Super-E efficiency rating equals 93%. Measuring specific efficiency ratings involves precise lab testing. To do this, Baldor uses IEEE Standard 112, Test Method B and CSA 390A. These are the most complete and accurate methods to test motor efficiency, encompassing all energy losses that might occur.
Premium Efficiency Pays For Itself
To understand what a motor really costs, compare initial purchase price with the cost of the electricity it uses over its working lifetime. Often, too much attention is paid to purchase price. For most motors, this initial cost represents less than two percent of its lifetime cost. Electricity accounts for about 97 percent. Baldor Electric Company's motors and drives save customers money every minute they operate. Whether it's lower energy costs or greater reliability, these savings go straight to the bottom line. Baldor is the industry leader in overall efficiency ratings. Better than 96 percent of the energy used by some of Baldor's Super-E motors is converted to mechanical work. The Baldor-Reliance Super-E runs cooler and longer with greater reliability than any other industrial motor. When you consider that a typical 50 horsepower motor costs over $36,000 to operate continuously in a year, it's easy to see how just a few percentage points of higher efficiency can quickly reduce electricity costs. Even seemingly modest percentage point differences in efficiency ratings can yield substantial electricity cost savings when the motor is operating continuously every day.
In many instances, the greatest potential for energy savings lies in the overall design of the application. The US Department of Energy has indicated that application and process improvement yield the lightest energy savings.
In some applications, savings can be as much as 60 percent. For example heat and air systems can be made more efficient by pairing a Baldor premium efficient motor with an adjustable speed drive (ASD). The savings result from the ASD automatically adjusting the motor speed to maintain an appropriate temperature and airflow.
What is the energy savings potential from using Baldor ASD’s in other applications? According to the Wisconsin Center for Demand-Side and Research, many applications for pumps and compressors could deliver savings up to 25 percent; fans, blowers and centrifugal refrigeration system add up to 35 percent and boiler fans and feed water pumps as high as 50 percent in energy savings.
Baldor's broad line of drive products for fan and pump applications, soft starts and line regenerative AC drives provide our customers with a variety of energy saving solutions.
The Fastest Way to Calculate Payback from Electricity Savings
How long before the electricity savings from a premium efficiency motor equal or exceed your cash outlay to purchase it? The answer depends on how the motor is rated, how it is used, and the cost of electricity per kWh. Although a premium efficiency motor costs more than a standard motor, users soon recover that cost and more. Baldor Energy Savings Tool (B.E.$.T.), an energy savings program makes the calculation easy. Cost savings and payback time frames from the addition of an adjustable speed drive can be calculated as well. In a single motor mode, the motor analysis section of BE$T 3.0 compares the annual operating costs of your motors with a Baldor Super-E premium efficient motor and a Baldor Standard-E' based on its ratings and operating cycles giving you a financial summary of the annual savings and payback in months for each. The ASD analysis compares the use of an Adjustable Speed Drive to various mechanical means of flow control in pump or fan systems, calculating annual cost of operation, savings potential, and payback. In multi- motor mode, BE$T is powerful enough to perform a complete plant analysis and provide a complete project summary. The BE$T program can also factor in rebates and make the payback calculation using motor rewind cost as an offset.
Simple facility surveys can lead to identification of the age and efficiency of the motor population and can lead to a motor management strategy designed to increase plant uptime and productivity (often worth 5-8 times possible energy savings). Based on their usage and efficiency, motors can be tagged to be replaced immediately with Baldor Super-E premium motors, replace on failure with Super-E or simply rewind the motor.
Ask for Baldor Electric's Method to Reduce Energy Costs to learn how we have been able to save over $ 1 million dollars annually in energy costs in our own manufacturing facilities. Ask about our full line of premium efficiency products or simply click here to have a representative contact you about how you can dramatically reduce your energy costs using tools like BE$T software from Baldor.
Save More Than You Think—Realize Your Energy Savings with Gates Synchronous Systems Getting a Grip on Energy Costs
In
an effort to reduce maintenance costs, a large hospital chose to target
their air handling system. By converting from a V-belt drive to a Gates
synchronous drive system; they got exactly what they wanted: a system
that didn’t require constant retensioning or quarterly replacement.
But they saved more than maintenance costs. They realized an energy cost reduction of 7.9%. This was real money – a return they would see for decades to come.
Do More With Less
The US Department of Energy has calculated that American businesses would realize $1.5 billion in energy savings by simply converting their V-belt drives to synchronous belt drives. That’s serious change — in return for one relatively small change. The hospital achieved continuous energy savings of 7.9% by converting from a V-belt to a Gates synchronous belt drive.
Efficient Drives = Energy Savings
Gates PowerGrip® GT®2 and Poly Chain® GT® Carbon™ belt drive systems operate with positive tooth/groove engagement which means they don’t slip. No slip equates to no speed loss which saves energy. Other energy wasters include torque loss, bending belts around pulleys and friction, all of which are at an absolute minimum with Gates synchronous belt drive systems. Due to reduced belt elongation and stretch, Gates synchronous belts require no retensioning when properly installed which saves you time and money.
Conserving energy is good for everyone. And Gates is making it easy to do. By going a little green…you save some of that other green.
It’s Time to Realize Your Savings
Find helpful software tools for customizing a new system at www.gates.com/drivedesign. Informative White Papers are also available at www.gates.com/ptsavings. You’ll see how quickly you can recover your investment. For you, the math is simple. The more drives you convert, the more you save. Every hour, every day. The belts you now use are costing more than you think.
To find out just how much you could be saving – visit www.gates.com/ptsavings and use our easy online calculator.
It All Adds Up
A manufacturing facility in North Carolina asked Gates to help convert 21 drives. A few simple procedures gave them $60,000 additional savings. Per year. Here’s how their savings stacks up:
This is How You’ll Save More Than You Think:
Boost productivity by slashing downtime. Lower replacement costs with belts that last much longer than all other options. Reduce day-to-day maintenance costs. Meet your objectives for sustainability and lower your carbon footprint. The efficiency and durability Gates synchronous systems provide will change the way you operate… and deliver savings you can measure. As part of the Gates partnership with the U.S. Environmental Protection Agency’s ENERGY STAR, we help customers improve the energy efficiency and performance of their facilities. Just contact your local distributor for details. As your trusted partner, we’d rather see you achieve optimal efficiency than sell you a steady stream of replacement parts. Our distributors have the knowledge and experience to help you find lasting solutions that perfectly fit your needs. If you’re ready to save money, time and energy, then let’s get started. Making the change to Gates synchronous belt drives is easier than you think.
The Right Partner With the Right Tools Will Make it Easy
As part of Powered® Savings, ISC Companies works closely with Gates to:
- Analyze operational efficiencies, including maintenance time and downtime.
- Target a drive system with the greatest potential for energy savings.
- Show you how we can redesign that drive for your specific use.
- Document your savings in a way that’s easy to understand. This will include a breakdown of replacement costs and ROI. In your success we measure our own. That’s why we’ll help you find the savings you’ve been missing.
In 2008, Gates customers confirmed $12.3 million in cost savings. Click here if you would like to be contacted about energy saving ideas for your belt drives.