Dr. Eng.

/ Tarek ElShennawy
Manager of Electrical Engineering Sector & Energy Manager
Alexandria National Refining & Petrochemicals Co. (ANRPC)

CATEGORY: PGTO
SESSION: 20
ABSTRACT NUMBER: 1657
Challenges to improve energy efficiency in oil refineries when
modernizing electric motor systems
Agenda
 Introduction to Motor System improvement (MSO)
 Benefits of MSO
 Opportunity (1): High Efficient Motors
 Barriers to Implementing Opportunity (1)
 Opportunity (2): Variable Speed Drives (VSD)
 Barriers to Implementing Opportunity (2)
 Recommendations for Removing Barriers
 Conclusions & Discussion.
Petroleum Sector Modernization Program
Energy Efficiency & Motor Systems
• Program 4: downstream performance & energy efficiency
(Group 4B)
• Energy means electricity & fuel (natural gas).
• Concerning electrical energy, studies show that almost
80% of the total electricity consumption in refineries are
due to Electric Motors.
• Improving energy efficiency of motors means doing the
same job (or better) with less consumed energy.
Benefits of Motor System improvement
• Energy savings = Money saving.
• Ability to increase production without requiring additional
(and possibly constrained) energy supply.
• Improved operation control.
• Increased competitiveness.
• Reduces risk/exposure to rising energy prices.
• CO2 emission reduction (0.5 kg of CO2 is saved per 1 kWh of
electrical energy saved).
Aim of the Presentation
• Present some Energy Conservation Opportunities (ECO’s)
related to motor systems, and the barriers that face energy
teams when implementing these ECO’s.
• Barriers are defined as forces or mechanisms that inhibit
behaviors or investments that would increase the efficiency
of energy use.
• Removing barriers is a lot smarter and cheaper than trying
to get thousands of individuals over these barriers.
Opportunity (1): High Efficient Motors
- Comparing among 3 similar motors (75 kW or 100 HP)
but with different efficiencies.
- Loading factor = 75%
- Annual running hours = 4000 hrs.
- Price of 1 kWh = 0.10 $
- Motor Lifetime = 20 years
- The motor will be repaired 2 times during its lifetime,
each time will cost 50% of its initial cost. (assuming that
the motor efficiency will not be reduced after repair).
 Motor Standard IE1 High Efficient IE2 Premium IE3
Output Power 75 kW 75 kW 75 kW
Efficiency 90% 93% 95%
Input Power 83.3 kW 80.6 kW 78.9 kW
Annual kWh consumed 250,000 kWh 242,000 kWh 237,000 kWh
Annual Cost of Energy 25,000 $ 24,200 $ 23,700 $
20-year Energy Cost 500,000 $ 484,000 $ 474,000 $
Cost of Motor 7,000 $ 8,000 $ 9,000 $
Cost of Repair 7,000 $ 8,000 $ 9,000 $
Life Cycle Cost of Motor 514,000 $ 500,000 $ 492,000 $
Evaluation of Opportunity (1)
- The initial cost of the motor = 2% of the motor LCC.
- The energy cost of the motor = 96% of the motor LCC.
- We assumed that the energy costs are fixed for the next 20
years. What about an escalation of 10% annually?
- Simple Pay Back Time (PBT) shows that IE2 motors will
pay back the incremental investment (1,000 $) in 15
months, whereas IE3 motors will pay back the
incremental investment (2,000 $) in 18 months.
Barriers to Opportunity (1)
- Responsible personnel do not recognize the opportunity.
- The Culture of replacing equipment is same same.
- There is no national Minimum Energy Performance
Standards (MEPS) that mandate that new or replaced
motors shall be of premium efficiency (IE3).
- In most cases, the Capital Cost (initial or purchase cost) is
the determinant factor. No LCC is carried out.
- No Motor Management Plan; when to repair, when to
replace, plans for modernizing, . . .
Opportunity (2): Variable Speed Drives (VSD)
• VSDs are electronic devices that match the speed of the
motor to the driven machinery. Typical applications include
centrifugal fans and pumps.
• According to the Affinity Laws of the hydraulics:
Flow is directly proportional to the speed,
Pressure is directly proportional to the square of the speed,
Power is directly proportional to the cube of the speed.
• Therefore, if the motor runs with 70% of its speed (using
VSD), then the power will be (0.70)3 or 34% its rated power.
Opportunity (2): VSD
- We have an air cooler system consisting of 8 fans.
- Each motor is 37 kW with 90% efficiency.
- The average loading factor is 70%
- Annual Operating hours = 8000 running hours.
- Price of 1 kWh = 0.10 $
- We will install 4 VSDs (complete with the cabinets).
- We will also replace the motors with others of high
efficiency (93%) and that can work with the VSDs.
 Motor D.O.L. VSD
Output Power 37 kW 37 kW
Efficiency 90% 93%
Input Power 41.1 kW 13.6 kW (average)
Annual kWh consumed 230,000 kWh 109,000 kWh
Annual Cost of Energy 23,000 $ 10,900 $
20-year Energy Cost 460,000 $ 218,000 $
Cost of Motor 5,000 $ 6,000 $
Cost of VSD - 10,000 $
Cost of Repair 5,000 $ 16,000 $
Total Cost of System 470,000 $ 250,000 $
Evaluation of Opportunity (2)
- The annual money saving / motor
= 23,000 - 10,900 = 12,100 $
- PBT = 16 months.
- Excellent opportunity even for existing systems.
- Allows smooth and precise control of air flow, compared
to actuators for adjusting the blade angle of the fans, or
using dampers.
Barriers to Opportunity (2)
- Responsible personnel do not recognize the opportunity.
- VSDs need modern engineering skills. Several parameters
have to be set as well as knowledge with power electronics.
- Poor realization among senior management of the scale of
the opportunity.
- Lack of monitoring/measurement data hinders savings
calculations from VSDs.
- Defensiveness –“I’m already doing a good job!”
- Financial barriers.
Recommendations for Removing Barriers
- Capacity Building through:
- Training programs for energy teams
- Awareness sessions for decision makers
- Encourage the implementation of an Energy Management
System (EnMS) within organizations, including Motor
Management Plan & Motor System Optimization (MSO)
Program
- Conducting Feasibility Studies for the individual
opportunities, using Life Cycle Cost (LCC).
Recommendations for Removing Barriers
(cont’d)
- Minimum Energy Performance Standards (MEPS) required to
be set, at least within the petroleum sector:
- All newly purchased motors should be high efficient
motors (at least IE2).
- 50% of all newly purchased or replaced air cooler systems
should be supplied with Variable Speed Drives (VSD’s).
- Install measuring instruments for the system under study.
- Establish an Energy Services Company (ESCO) within the
Petroleum Sector for funding.
Conclusions
• Electric motors represent more than 80% of electrical loads
within refineries.
• Motor capital cost represent only 2% of the total cost of
ownership of the motor within its lifetime.
• Increasing energy prices should push decision-makers to
pay attention to energy efficient solutions. These include:
1. Replacing old motors with new high efficient ones
2. Installing VSD’s for motors with varying loads (specially
for air coolers).
 THANK YOU
Dr. Eng. / Tarek ElShennawy
Manager of Electrical Engineering Sector & Energy Manager
Alexandria National Refining & Petrochemicals Co. (ANRPC)