Energy Efficiency Program for Motor
Systems in Turkey
M. Hürol METE
Motor Summit 11 October 2016,
Zurich Switzerland
Outline
Energy Intensity is High!
0.35
Energy Intensity (toe/1000 USD)
0.3
Czechia
Slovakia
0.25
Poland
Korea
Mexico
0.2
Canada
TURKEY
USA
0.15
OECD Total
OECD
Europe
Portugal
Sweden
France
Spain
Netherlands
Almanya
İtaly
Japonya
UK
Denmark
0.1
0.05
0
0
1
Source: IEA, OECD, 2013
2
3
4
5
6
Per Capita Consumption of Energy (toe/person)
7
8
Energy Efficiency is a MUST!
• Energy efficiency is critical to help Turkey continue its trajectory of economic
growth in a sustainable manner
• With limited domestic reserves of fossil fuels, Turkey is highly dependent on
energy imports with more than 70% (which accounted for about 60 billion USD
or 7% of GDP)
• Electricity growth forecast: Electricity consumption increase of 72% from 2013
to 2023.
• In Turkey, 47% of net electricity consumption is from the industrial sector, with
an estimated approx. 75% of this electricity consumption from electric motordriven systems
• 88% of electric motors used in industry are inefficient (regarding the inventory
analysis – 2015)
Legal Basis
10th Development Plan (2014 – 2018)
Improvement of Energy Efficiency
Transformation Programme
Industrial Energy Efficiency Component
Action Plan for Transformation of Low Efficient Electric
Motors used in Industry Sector
The action entitled “to prepare an inventory of AC electric
motors being used in Turkish industry with a power rate 7,5 kW
and higher
Sources of Data
Sampling
• Electricity consumption data of 110.000 manufacturing firms
• 10.250 firms which have electricity consumption > 50 toe/year (population)
• Sector, scale and location data have been analyzed and sample distribution
has formed
Field Studies
• Company visits (2 or 3 times)
• 887 companies in manufacturing industry from 62 provinces which have
annual electricity consumption > 50 toe
• Power > 7,5 kW electric motors taken into consideration
• Detailed data of 93.139 AC Motors + 1.758 DC Motors have collected
 Other Data Used
• Electric motors domestic production data for last 10 years (from 8
manufacturers)
• Electric motors import data for last 10 years
• Data about number of employees, electricity consumption and real assets
of companies (for generalization)
Methodology
Motor Inventory Analysis
Design of Information Form
Forming the Sample Group
Training Programme for 85 staff (from
MoSIT Provincial Directorates)
Field Studies (June-October 2015)
Data Analysis (data clearing  revisions
 analysis)
Inventory Analysis Report (March 2016)
Methodology
•
•
•
•
•
•
•
•
•
Brand / Model
Efficiency Level (IE or EFF)
Power (kW)
Motor Age (year)
No. of Rewirings
Use of EE equipment (VSD, etc.)
Annual Working Hours
Average Loading Rate
Distribution of motors by application
AC Motor Label
Efficiency
EFF3
Inefficient
IE1
Inefficient
IE3
Efficient
IE4
Efficient
IE2 without VSD
IE2 equipped with VSD;
• Motor age > 15
• Motor age < 15
Inefficient
Inefficient
Efficient
Data Analysis
AC Motors Analysis
DC Motors Analysis
Sectoral Analysis
Current Stock
Estimate
Total Electricity
Consumption
Analysis
Total Cost of
Transformation
Potential Electricity
Savings
Inventory Analysis
Current Stock
•
Estimation for number of AC electric motors is:
4.306.622 motors (Power > 7,5 kW)
•
Sectoral Distribution:
18%
35%
Food
Other Sectors
6%
Non-metallic minerals
Wearing
11%
Machinery &
Equipment
Textile
6%
Other
Manufacturing
12%
Fabricated Metal
Products
Basic
Metals
3%
6%
3%
Inventory Analysis
Domestic Production vs. Imported
Domestic
Domestic & Imported (%)
100
80
60
40
20
Imported
0
.
Power Ranges (kW)
Imported
Domestic
Inventory Analysis
Power
40
36
Number of Motors (%)
35
30
24
25
20
16
15
10
9
5
4
0
7,5~11
11~22
– Average: 42,5 kW
– Median: 18,5 kW
22~37
37~55
55~75
3
75~90
3
90~132
Power Ranges (kW)
2
132~200
2
200~400
1
+400
Inventory Analysis
Age
– Average Age = 12 years
13.5
Motor Age (year)
13
12.5
12
11.5
11
10.5
10
7,5~11
11~22
22~37
37~55
55~75
75~90
90~132 132~200 200~400
Power Ranges (kW)
+400
Inventory Analysis
Rewiring
– Average Number of Rewirings = 2,5 times
4
Number of Rewirings
3.5
3
2.5
2
1.5
1
0.5
0
7,5~11
11~22
22~37
37~55
55~75
75~90
90~132
Power Ranges (kW)
132~200
200~400
+400
Inventory Analysis
IE 3
100
90
IE 2
IE 1
0
20
40
60
80
Number of AC Motors (%)
88 % of electric motors in
current stock are INEFFICIENT!
100
Number of AC Motors (%)
Efficiency Level
Efficiency
80
70
60
50
IE 1
40
IE 2
30
20
IE 3
10
0
Power Ranges (kW)
Inventory Analysis
.
Number of Motors equipped with VSD (%)
Use of VSD
Average use of VSD = 24%
40
35
30
25
20
15
10
5
0
7,5~11
11~22
22~37
37~55
55~75
75~90
90~132
Power Ranges (kW)
132~200
200~400
+400
Inventory Analysis
Annual Working Hours
– Average Working Hours = 5.456 hours/year
+400
200~400
Power Ranges (kW)
132~200
90~132
75~90
55~75
37~55
22~37
11~22
7,5~11
5000
5200
5400
5600
Annual Working Hours
5800
6000
6200
Inventory Analysis
Loading Rate
– Average Loading Rate = 77 %
81
Loading Rate (%)
80
79
78
77
76
75
74
7,5~11
11~22
22~37
37~55
55~75
75~90
Power Ranges (kW)
90~132
132~200
200~400
+400
Inventory Analysis
Distribution of motors by application
Conveyor systems
Machining / metal cutting
Pumps
Plastic forming
Crusher systems
Compressors
Generator
Heat systems
Hydraulic and pneumatic
Power transmission
10.65
0.73
26.05
5.47
4.91
4.23
0.01
0.54
0.34
6.10
Fans
Casting equipment
Others
24.65
0.01
16.32
Number of Motors (%)
Results
• More than half the motors are imported;
• Average motor output power is 42.5 kW and that 76% of the motors in the survey were
between 7.5 - 37 kW;
• The average age of AC electric motors is 12 years. The service life of old motors in the
has been extended through rewiring (on average 2,7 times per motor), a practice that
is very popular in Turkey based on the large number of workshops located in industrial
zones dedicated to motor rewinding.
• More than 63% of the motors are IE1 (inefficient) class and 28% of these motors being
in the IE2 class.
• 27% of the motors are equipped with variable speed drive;
• The annual average working hours of the electric motors is 5,456 hours;
• The loading rate of the motors average 78%;
• Industrial electric motors are generally used in fans, pumps and compressors as well as
power transmission equipment and conveyor systems.
The most comprehensive motors inventory study of the world
Turkey MoSIT (2016), (887 firms and 95.000 motors ) vs. USA DoE (2000), (265 firms, 30.000 motors)
Results
Total Cost of Transformation = 4,06 billion €
(3,78 million inefficient AC motors)
Average Cost for motor transformation in a firm = 128.918 €
(annual electricity consumption of firm > 50 toe)
Potential Electricity Savings = 2,3 billion €
Average Time for Return of Investment = 21 months
Transformation Period (target) = 2017 - 2025
Activities of MoSIT on EE Electric Motors
New regulations parallel with EU eco-design directives
Market surveillance
Inventory analysis (expanding the database)
Awareness raising / capacity building
Collaboration with Turkish EE Motors Manufacturers Industry
Association
• Establishment of testing facilities (in Turkish Standards Institute)
• Kayseri Pilot Project
• New GEF Project (with UNDP)
•
•
•
•
•
Kayseri OIZ Pilot Project (2016)
- Energy audits in 130
firms
OIZ
Directorate
-50 % grant for EE motors
Banks
Kayseri OIZ
(1.000 firms)
ORANKA
(Regional
Development
Agency)
Credit line (max.100.000
-USD per firm)
1 year non-refundable
36 months term
MoSIT
KOSGEB
Loan support (appx.
25.000 USD per firm
interest costs covered by
KOSGEB
Promotion of Energy Efficient Electrical Motors in
Manufacturing Industry – GEF Project (2017-2021)
Component 1: Strengthening policy and
institutional frameworks for energy efficient
electric motors
Component 2: Capacity building for relevant
stakeholders to promote the benefits of EE
motors
Component 3: Upgraded Turkish Standards
Institute Test Laboratory and strengthened
monitoring, verification, and enforcement
Component 4: Support the development of a
one-stop-shop financial support mechanism to
support EE motors replacement and
procurement of new EE motors in Turkey
Component 5: Knowledge management and
M&E
Partners: Turkish Standards
Institute, KOSGEB, Ankara
Chamber of Industry, İstanbul
Chamber of Industry, Turkish
Motor Manufacturers (Arçelik,
Gamak, Volt, Aemot)
GEF Fund: 4 million USD
Duration: 2017-2021 (60
months)
Primary Barriers for Transformation of Electric Motors in
Turkey
• The low level of awareness amongst companies on the benefits of energy
efficiency. Decisions on motor investments almost always involves lowest
cost options (not life cycle costs).
• The general lack of liquidity of SMEs to pay up front costs for EE motor
investments.
• Most incentive schemes target larger industrial consumers; but funds have
not always been fully utilized
• Limited capacity of ESCO market (13 ESCOs for industry sector, located in big
cities) + limited number of energy audits
• Inefficient coordination in the implementation of the EE Law that slows the
pace of legislative changes.
• Need to develop systems to collect information on implementation
experiences—case studies, financing modalities, sample contracting
schemes, etc.
Thank you…
M. Hürol METE
Tel: +90 312 467 55 90
e-mail: [email protected]