Quantum Controls Motor Presentation

1. Quantum Controls Motor Presentation

2. Profile – Quantum Controls Ltd Quantum Controls Ltd are the largest supplier of ABB Drives and Motors in UK since 1994 Established 1989 £6.5 million turnover 36 employees Specialist in supply, installation, commissioning, repair and maintenance of Electric Motors, Variable Speed Drives, motors starters. 10,000sq ft Control Panel Manufacturing Facility

3. Why Focus on Energy Saving with Electric Motors? 75% “95% of all motors are oversized”

4. Low voltage electric motors today UK motor repair industry twice size of new motor market While mechanical repairs – such as bearings and shafts – will always be needed, why are there so many rewinds? No one should be making inferior motors Today’s technology gives motors 20+ year life expectancy Yet many repairers are rewinding motors less than 5 years old

5. 1.25 Zetec Engine Unleaded petrol Max speed 112 mph ABS and power steering and CAT 35-50 mpg 4 Air Bags. Central locking Engine management system Longer service intervals (12-18,000 miles) 3 Year Warranty 1.3 OHV engine 4 Star leaded petrol Max Speed 98 mph No ABS,power steering or CAT 32 mpg No air bag. No central locking No engine management system Need regular maintenance (Every 6000 miles) For the enthusiast only! Remember this? When was the last time your car broke down? Is your car rusty? Do you own a Haynes manual for your car? Would you spend 50% of the value of a new fiesta repairing the engine of your old fiesta?

6. Low voltage electric motors today Significantly different from 20 years ago Advances in materials and manufacturing processes = better reliability and efficiency 75% of industrial electricity consumed by electric motor 110kW IE3 motor running 8760 hours per annum will create 19 tonnes less CO2 emissions than a less efficient model It is estimated that there are over 10 million motors running in the UK today. Why are motor owners acting like fiesta enthusiasts?

7. You worry about mpg, so why not p/kWh • When buying a car you always look at the mpg • Fact – fuel cost for average saloon car over 10 years would amount to 20% of original purchase cost • Initial purchase is important but mpg is always taken into consideration

8. You worry about mpg, so why not p/kWh • When buying an electric motor do you request the efficiency rating? • Fact – Energy cost over 10 years 25 times original purchase cost • Initial purchase cost almost irrelevant but efficiency rarely considered

9. You worry about mpg, so why not p/kWh The energy cost of a running motor dwarfs its original purchase cost. But many people worry more about getting a slightly more fuel-efficient car, even though the savings are tiny compared to its original cost.

10. Confused? Since 2005 Quantum Controls has conducted over 600 drives energy appraisals in UK. How many motor energy audits?? Information suggests industry does not effectively manage its motor assets which leads to unplanned downtime, increased repair costs and higher than necessary energy bills and CO2 emissions With UK PLC fighting for survival why is nothing being done about this?

11. Is this really a big problem? • Metals process line • Downtime is £400/hr. • Rip out / repair / re-install time is 48hr • Unplanned outage cost is £19,200 • This is the hard cost… • What about the soft cost? • Loss of reputation • Loss of customer • Loss of margin

12. Help is at hand Quantum believes UK industry is ineffectively managing its installed motors Base which leads to unplanned downtime, higher energy bills and higher CO2 emissions than necessary. Based on information collected over 7 years and from over 600 plants we believe that there is an unarticulated need. We launched MotorAdvantage as a way of articulating and addressing that need.

13. MotorAdvantage from QuantumWhat is it? Motor management plan encouraging process industry to uncover true cost of running electric motors Identify up to five motor-driven applications offering best potential for analysis Site visit by motor engineer to assess identified motors Shows financial impact of production loss through motor failure and recommends ways to minimise or mitigate Shows energy savings and CO2 reductions by fitting premium efficiency motors and calculates payback period.

14. 3 steps to improving profitability 1. Consultation Examine plant installed motor asset register Identify up to five critical applications running continuously or more than 4,000 hrs per annum

15. 3 steps to improving profitability 2. The Appraisal Inspect selected motors; get an understanding of plant; inventory of spare motors; energy and maintenance plans. Old motors can be 1-5% lower in efficiency compared to new premium efficiency. If that motor is running continuously then typical payback of 2-3 years is achievable if motor scrapped prior to failure. If the motor is replaced at point of failure then, taking rewind cost into payback calculation, a new motor cost can be recovered in <12 months

16. 3 steps to improving profitability 3. Proving savings – report and recommendations Findings analysed and potential savings identified using dedicated software Among data available includes: estimation of present energy usage whether application benefits from variable speed control payback time if investment is made in new Motors CO2 emission reductions Cost of unplanned outage

17. Sample report – Engineers Report

18. Sample report – Executive Summary

19. Benefits to motor user • Clearly determines: • Current policy in event of motor • failure. • Financial impact on company • Areas for improvements in maintenance and stockholding • Energy use of current installation • Repays investment in plan within weeks • Quantum predicts when motor needs • maintaining and overhauling. • Downtime minimised – Profits maximised

20. Quantum Controls Low Voltage Motors Efficiency Classification & Legislation

21. Old Efficiency Markings X

22. Why? • Efficiency levels and the way in which we measure efficiency has changed (the IEC standard has changed) • Efficiency classification is changing – the old EFF1 / EFF2 classifications is being replaced by new IE X designations • The EuP has issued a directive outlining minimum efficiency levels that will become mandatory in the coming years • As such ABB has undertaken a significant programme of re-design for various products so we are ready for the changes as they are introduced.

23. International standards Efficiency Class Standards • IEC 60034-30 is now published • It defines IE1, IE2, IE3 & IE4

24. EuP Directive IE class defined in the IEC 60034-30 standard

25. EuP DirectiveDirective 2005/32/EC • Directive 2005/32/EC: Ecodesign of Energy-using Products: “EuP Directive” : • Target : Economical & Ecological balance required CO2 reduction in Europe • Final Draft Regulation : Leading to mandatory Minimum Energy Performance Standard (MEPS) for industrial electric motors being phased in between 2011 and 2017 in Europe

26. EuP DirectiveMotors covered by the Regulation • Regulation apply to motors: • Rated voltage up to 1000V • Single-speed, three-phase, 50Hz (50/60Hz) • 2, 4 and 6-pole • Rated output from 0.75 to 375 kW • Regulation does not apply to motors designed to operate: • In potentially explosive atmospheres as defined in ATEX directive 94/9/EC • Brake motors • Ambient air temperature outside the range (-15°C…+40°C) • Altitudes exceeding 1000m asl • Maximum operating air temperature above 400°C

27. EuP DirectiveTimetable according to the draft Regulation

28. EuP Directive Information requirements on motor documentation from 16th June, 2011 • Information required: • Efficiency η (100%), η (75%), η (50%) of rated load and voltage UN • Rated power or range power output kW • Rated voltage or voltage range • Rated speed • Efficiency level: IE2 or IE3 • Year of manufacture • Information relevant for disassembly, recycling or disposal at end-of-life • Manufacturer’s name or trade mark, commercial registration number and place of manufacturer • Product’s model number

29. EuP DirectiveRating plate marking Rating plate marking required • The lowest efficiency value and the associated IE-code • Efficiency at the full rated load and voltage (%) ABB takes the new rating plate design into use during 2010 for all the motors valid according to IEC/EN 60034-30 • As standard ABB will stamp 400V, 415V and 690V and the efficiency value is given for 400V

30. Summary – The bits you really need to know! • Motor rewind industry twice the size on new motors market in UK, Gambica introducing new legislation, each motor rewind loses 2 – 5% efficiency from original manufacturers specification • In an effort to harmonize efficiency measurement methods a new standard has been introduced and ratified by the IEC • Based on the new test methods the standard IEC 60034-30 now defines new efficiency classes, namely IE1, IE2 IE3 etc. • This new classification means the EFF1 / EFF 2 markings will disappear being replaced by the new IE1, IE2 , IE3 markings. Remember what we know as EFF1 now compares to IE2 • Remember the new IE markings are applicable to a much wider range of products that the current EFF1 / EFF2 standard • A timetable is in place regarding minimum motor efficiency levels for the future. As of 2011 minimum efficiency levels of IE2 (equivalent to EFF1) will be mandatory • Customers will be forced to move to high efficiency

31. How can Quantum Controls Help You? • First in UK to completely re-stock with IE3 products • Help identify inefficient motors on plant • Site surveys and energy saving reports