ACE ENABLERS LLP

A mini EPC
Motor integration network initiative- mini is an initiative to integrate the complete motor
system in order to achieve enhanced energy efficiency as well as reliable performance of
the motor system and achieve lower life-cycle cost.

As mini EPC, ACE ENABLERS LLP, undertake end-to-end implementation of Premium efficiency motors
(IE3) with careful consideration of the entire network of the motor system. End use energy efficiency in
the electrical induction motor system is of paramount importance since motors account for >75% of
industrial energy. While premium efficiency IE3 motors lower self (internal) losses, integrated system
approach lowers the overall losses in constituent elements. A mini project to upgrade the existing motor
network can identify other opportunities to overcome intrinsic and operational deficiencies which will
improve reliability and asset efficacy.

Our scope includes (a) baseline study of final target motors, (b) sizing and Finalisation of the motor list,
(c) procurement and supply of IE3 motors, (d) assisting in installation and commissioning and (e)
measure and verification of benefits from IE3 motors.r

#74, Tiny industrial Estate, Ekkattuthangal, Chennai- 600032- email- ace@aceenablers.com

How to approach the task?
 Inventory preparation- Prepare a comprehensive list of all the plant motors and group them in to
small, medium and large category. The list must contain the make, year of manufacture and the
plant location too.
 Initial load survey- Electrical data must be measured to fix the load factor, hours of operation and
compliance with Type 2 coordination.
 Key motor identification- Based on the age, load factor and the history of rewind/repair, key
motors can be identified and prioritized for replacement program.
 Load mapping- measuring power and energy of the key motors will help identify the energy saving
potential (baseline data) and the re-engineering opportunity in the motor system.
Motors management can be approached under three categories. Motors, Motor systems and the end use
applications.

Matching the speeds of the old and new motors is critical to match the flow, pressure and power of the
driven load such as the Fan, Pumps & compressors.

Comprehensive system savings

• Based on the grouping and the age of the existing motors, small motors can be replaced
using “Desk-top Audit” from payback estimates. Medium size motors can be replaced using
a combination of ‘Desk-top audit” and “in-situ estimation” of motor efficiencies at site.
• Proper sizing of motors to optimally load them would also offer additional efficiency
operating points
• Energy loss is seen in the transmission elements such as the belt-pulleys, worm gear and
fixed speed operations. While replacing the old motors with IE3, retrofitting with flat belts or
helical gears enhances the savings.
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 Nearly 2/3 of the loads are variable torque loads which offer energy saving when speeds are
regulated with VSD. While planning for IE3 motors, including VFD duty motors and achieving
process optimisation would add further savings.

 #74, Tiny industrial Estate, Ekkattuthangal, Chennai- 600032- email- ace@aceenablers.com