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Feature | November 2015

Some companies are adopting global standards

KN Hemanth Kumar, Chief Manager-EE Motors & Distribution Transformer, International Copper Association India

To what extent manufacturers are adopting the latest global standards?
Only about 10% of motor production in the country is adapted to IE2 & above level. The country is losing a great opportunity of energy conservation. With just shifting to IE2 level as mandatory, at current levels of motor production, in the first year itself India can save about Rs.500 crore. With the cascading effect, by the fifth year, the savings would be about Rs.5000 crore per year.

Briefly outline the global energy efficiency standards for motors ...
In 2008, in IEC 60034-30, the International Electro-technical Commission introduced the precisely defined and open ended international efficiency classification scheme using IE1, IE2, IE3 as the classification system and the testing procedure for motors IEC 60034-2-1.

Globally many developing countries the motor standards are harmonized to the international standards.
This removes export barrier.
Recently International Electro-technical Commission has published the first edition of IEC 60034-30-1, which replaces IEC 60034-30 (2008). IEC 60034-30-1 widens the product range covered in the first edition of IEC 60034-30 significantly. The power range has been expanded (starting at 0.12 kW and ending at 1000 kW). The IE4 class is newly included in this standard.

What are the latest global standards adopted and applied in India at present?
The Bureau of Indian Standard (BIS), which formulates the standards in India, has launched the revised energy efficient motor standards IS12615:2011 in line with the international motor standards IEC 60034-30.

IS12615:2011 is the second revision done in 2008. Going further, in 2011, India also adopted i.e. harmonized with the global IEC standard and also came up with its Indian standard IS12615:2011. Its scope was revised/extended from 0.37kw to 375kw, over IS12615: 2004. Going further, BIS has created a road map stating the way forward for the scope to be IE3.

Are the available testing facilities sufficient to measure efficiency levels of motors?
In India motor manufacturers have developed capability & capacities to meet 100 % Industry demand with IE2 & IE3 motors and invested in test facilities to measure actual stray load losses as per International standard IEC 60034-30-1. Also institutions such as ERDA has developed Test facilities for measurement of motor efficiency levels as per new standards and offering services to Industry as third party testing also. This will also help country to reduce import considerably from present level of about Rs.2000 crore/ annum and increase export as global usage is increasing of IE2 & IE3 motors.

Indian consumer is said to be too cost-conscious. How that tendency affects their purchase decisions?
End users from large, medium Industries units & SMEs have to change their mindset towards the life cycle cost of the motor. There is always a tendency in the Indian market to go for the lowest initial cost, instead of analysing the life cycle cost. Many end users are not aware that the initial cost of a motor is much lower that its annual consumption cost. For example, the initial cost of an 11 kW motor is only 3.9% of the running cost in the first year of operation. Improved efficiency means lower running costs and an early recovery of the extra price paid for the energy efficient motor. With power tariff rates reaching over Rs. 9/kWh, the payback is working out between 8 months to 14 months for most of the industrial motors.

What are the hindrances for adopting high efficiency motors across the board?
In India, the following are barriers affecting penetration of high efficiency motors:

  • Lack of awareness among motor purchasers regarding the potential for energy and cost savings by using more efficient motors within energy-efficient motor driven systems (EMDS).
  • Inclination towards lowest purchase price while buying and lack of awareness of lifecycle cost for motors:
  • Company organizational structures that manage their equipment procurement budget separately from operations and maintenance budgets.
  • The fact that motors are often integrated into equipment produced by OEMs before sale to the final end-user

What measures are to be taken to expedite adoption of latest standards?
Lead has to be taken by Industrial end users in the country by insisting for higher efficiency level motors (IE2 , IE3 & IE4 ) from equipment (OEM´s) suppliers & consultants. Hence with latest development in standards in India, and by adopting Lifecycle cost principle, every purchase and technical specifications for these motor Driven systems needs to revised and updated with new standard, i.e. by including IE2 & IE3 motors in the specifications.

In Industry motors running for over 20 years to be scrapped as these are low efficiency level than IE2 and/or oversized, leading to savings in power consumption as well as early payback to user. Replacing them with energy efficient ones has to be done. Such practices not only lower energy costs but also improve equipment reliability.

Ministry of Commerce should follow the lead taken by other countries and make IE2 level energy efficient motors as mandatory minimum energy performance standards (MEPS) at the earliest. This would lead to reduction in energy shortages and improvement in the quality of life for all.

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