DEXA-MCP Project Dissemination, Extension and Application of … · Software tool: French, Italian,...

1102�

DEXA-MCP Project

Dissemination, Extension and Application of the Motor Challenge Programme

Results of the project

2102�

Grant agreement no. No EIE/04/164/S07.38650

Intelligent Energy – Europe (IEE) SAVE

ADEME

AERE

Edgard Blaustein

AEA - Austrian Energy Agency

Fraunhofer ISI

dena

MOTIVA

CRES

ENEA

LEI

SenterNovem

ISR – University of Coimbra

ADENE

JSI JSI JSI JSI ---- JJJJozef Stefan Institute - Energy

Efficiency Centre

STEM - Swedish Energy Agency

15 partners15 partners

from from

11countries11countries

DEXADEXA--MPC consortiumMPC consortium

Start date of the project: January, 1st 2005 Duration: 30 Months End date of the action: June, 30th 2007 Project coordinated by ADEME Report produced by Jacques-Olivier BUDIN/ADEME Project websites: www.motor-challenge.eu www.ademe.fr/dexa-mcp

DEXA-MCP


3102�

Participants of DEXA-MCP project

Participants of the project

Family name, first name

Address of Participant

ADEME BUDIN, Jacques-Olivier 20 avenue du Grésillé BP 90406, 49004 ANGERS CEDEX 01, France

Sofronis Ilias CRES Karamani Fotini

19th km Marathonos Ave, 19009, Pikermi Attiki, Greece

ENEA Vignati Sigfrido Via Anguillarese 301 00123 Santa Maria di Galeria (Roma), Italia

AEA Kulterer, Konstantin Mariahilfer Straße 136 1150 Wien, Österreich

DENA Agricola, Annegret-Cl. Chausseestr. 128 A D-10115 Berlin, Germany

Fhg - ISI Radgen, Peter

Breslauerstr. 48, 76139 Karlsruhe, Germany

SenterNOVEM Hartkamp Frank Catharijnesingel 59 Pstbus 8242 UTRECHT 3503 RE, the Netherlands

ADENE Oliveira, Fernando Rua Dr. António Loureiro Borges, 5 – 6º Arquiparque – Miraflores – 1495-131 Algés, Portugal

UC-ISR Almeida, Aníbal Department of Electrical and Computer Engineering, University of Coimbra Pólo II 3030 – 290 Coimbra, Portugal

JSI Evald Kranjcevic Jamova 39 SI-1000 Ljubljana, Slovenia

LEI Skema Romualdas Breslaujos str.3 LT-44403 Kaunas, Lithuania

STEM Widerström, Glenn P.O.Box 310 Eskilstuna SE-631 04, Sweden

MOTIVA Hille HYYTIA Urho Kekkosen Katu 4-6 A P.O.Bax 489 HELSINKI, FIN-00101

AERE Dr. RIALHE Anne 3 Impasse de la Retourde F-73100 Aix-les-Bains

Edgar Blaustein

Edgar Blaustein 67 rue de la Fraternité 93100 Montreuil, France

DEXA-MCP


4102�

Table of content

EXECUTIVE SUMARY OF THE PROJECT _______________________________________5

Achieved results _______________________________________________________________5

Lessons learnt_________________________________________________________________6

I The DEXA-MCP Project objectives____________________________________________8

II The summary of the achieved during the project ________________________________10

II.1 Major project achievements ___________________________________________________ 10

II.2 Activities and impact after end of the action _______________________________________ 11

III The Actions in details done by DEXA-MCP: _________________________________12

III.1 DEXA-MCP European activities _________________________________________________ 12 III.1.1 Development of new tools – Extension of the Motor Challenge Programme to Refrigeration and

Electric Distribution systems_______________________________________________________________ 12

Upgrades ________________________________________________________________________ 23

Design and installation______________________________________________________________ 24 III.1.2 Development of new tools – Self evaluation tools _______________________________________ 24 III.1.3 Dissemination of the Motor Challenge in Europe – The European conferences and workshops __ 27

III.2 National activities ___________________________________________________________ 29 III.2.1 Summary activities at the national level: ____________________________________________ 29 III.2.2 The new Partners and Endorsers of the Motor Challenge programme ______________________ 29 III.2.3 Small summaries of the national success stories with the dissemination of the Motor Challenge

during DEXA-MCP______________________________________________________________________ 31

IV Conclusions ___________________________________________________________43

DEXA-MCP


Page 5 of 43

DEXA-MCP as Dissemination Extension and Application of the Motor Challenge Programme, was built with specific internal objectives and one goal:

Creating widely in Europe a real and continue progress in the industry energy efficiency in electricity and motor systems.

The electricity consumption inside the industrial sector in Europe is due for 69% of the total electricity consumption the electrical motor systems such as compressed air, pumping, fans, refrigerating and general other driving systems. Several specific studies and many experiences on these systems have shown a very important source of energy savings. The DEXA-MCP project focuses on stimulating, through a real Challenge, the industry sector to with the dissemination of the Motor Challenge Programme and the Motor Challenge Label to the enterprises which are engaged in an effective Energy Efficiency plan. The activities are based on communication, training, auditing, technical support, developing decision help tool and integrating of the tool set into national energy programmes.

1 �� Dissemination activities: many channels explored by the DEXA-MCP consortium:

� 247 Audits and MCP presentations which have leaded to 61 new Partners and 33 new Endorsers

integrating the programme during the duration of the project. 10 case studies have been developed to be disseminated as “Best practices”.

� Contacts and promotion of the Motor Challenge programme through the organization of : � 18 Workshops and 62 Interventions in seminars/conferences � More than 960 Meetings, interviews and MCP presentations and 2690 Emailing

and mailing information about MCP � Organization of 39 Trainings sessions � Participation at EEMODS 05 at Heidelberg, Germany: 200 attendees (3 papers

from DEXA consortium). � Construction of dissemination support tools: 12 Posters, 5 Brochures, 10 leaflets, 13 information

Internet websites or part of websites dedicated to the Motor Challenge Programme, 2 “24 hours Hotline” about MCP, 18 PowerPoint presentation and 4 small movies.

� Redaction or contribution of 76 articles on the Motor Challenge programme.

2 �� Extension of the Motor Challenge Programme:

� 5 new contact points in Eastern Europe countries through the collaboration built by DEXA-MCP with the 4EM-MCP project.

� 4 new contact points ready to integrate the MCP European network: DEXA-MCP has established new contacts with Macedonia, Croatia, Cyprus, Malta, and Turkey and has tried to intensify the

EXECUTIVE SUMARY OF THE PROJECT

Achieved results

DEXA-MCP


Page 6 of 43

cooperation with Ireland and Great Britain. Good results have been received from Croatia, Macedonia, Turkey and UK for their integration into the MCP European network.

� Integration of 2 new systems in the Motor Challenge and development of 2 new technical modules for these systems: industrial refrigeration systems and industrial electricity distribution systems used within industrial plants.

� Creation of 2 new MCP tools: 1 paper guide and 1 software tool. These tools are more awareness than expert tools and the goal to achieve was to create a simple and easy to adapt base that could be used in all countries.

3 �� Integration of the MCP at the National Level for an efficient programme:

� The technical modules have translated in all the languages of the project consortium. � Translation from the English of the 2 new modules in all the 10 different languages of the project :

German, Slovenian, Lithuanian, Portuguese, Swedish, Greek, Italian, Dutch, French and Finnish. � Translation from the English of the 2 new tools (paper guide and software) in the different

languages: � Paper technical guide: French, Italian, Portuguese, Slovenian, Finnish, German. � Software tool: French, Italian, German, Finnish, Greek, Lithuanian, Portuguese,

Swedish, Slovenian

The 3 main conclusions of the DEXA-MCP project are the following ones: 1 – Knowledge about cost effective energy efficiency measures in motor driven systems is still not very common in enterprises and their remains a strong need to further disseminate information with new tools and continuous efforts. The Motor Challenge programme has proved to be a good tool for a EU wide approach for efficiently helping to support the European Industries by developing common tools and supporting industrial efforts. The public support of the programme should therefore be constant in the time and avoid breaks due to periods without any public funding. 2 – Helping the enterprise to act and improve their energy efficiency is essential. The support of walk through audits and auditing programmes are one key to identify energy efficiency measures. Enterprises highly welcome the support of an expert to realize the audit and to follow the implementation of measures. Training of energy auditors in the field of motor driven systems is essential. Convincing the enterprises to use this expertise is facilitated by the public support and engagement of the EC and the national governments. The second key to help the enterprises to act is to train their internal staff and especially in the SMEs. 3 - To further develop the outreach of the Motor Challenge Programme in the EC two levels of actions are required: a real and permanent European Coordination and support by public funding is essential for the long term success of the program and its required impact on energy savings and emission reductions and a strong coordination at the national level is essential in order to integrate the programme within the national context, organizations and policies. The national contact points of the program are the key players for the further outreach and development of the Motor Challenge Programme.

Lessons learnt

DEXA-MCP


Page 7 of 43

DEXA-MCP Project


Results of the project

DEXA-MCP


Page 8 of 43

Electric motor driven systems account for 69% of industrial electricity consumption in Europe1. Numerous studies and projects have shown the considerable potential for improvement of energy efficiency of these systems2. Nevertheless, there are multiple reasons that explain why profitable (sometimes very profitable) energy savings measures are not put into practice in the private sector. The Motor Challenge Programme and the associated MCP Tool Set offer means to overcome these barriers through a systemic approach. All the previous studies have shown that the energy saving potentials are important in the motor driven systems, not only with the motor itself. Looking at the entire system is very important to optimize the benefits. This is why the Motor Challenge Programme, and especially during DEXA-MCP project, a hard job has been done to develop specific technical modules on all the main important motor driven systems showing all the possible energy gains.

1 "Actions to Promote Energy-Efficient Electric Motors", DG XVII, October 1996.

2 For instance:

• the Compressed Air Systems study estimates technico-economic energy savings potential at 36%

• the "Improving the Penetration of Energy Efficient Motors and Drives" study identified potential savings of 24% and

18%, for pumps and fans, with EEMs and VSDs.

I The DEXA-MCP Project objectives

Compressed Air system Pumping system

Ventilation system Refrigeration system

Motor Driven system Industrial electric system

DEXA-MCP


Page 9 of 43

All the objectives of the DEXA-MCP project were to provide a strong effort to contribute to the success of the Motor Challenge Programme, developing a strong panel of activities, pushing the programme to a new level. The key actions of the project were:

Dissemination and extension of the Motor Challenge programme, for a complete and well known tool. Integration and application into the national programmes for an efficient synergy in improving the energy

savings in Motor Driven systems in the enterprises. 1 - Dissemination of the Motor Challenge Programme to a new and higher level: The DEXA-MCP project aimed at a step change, carrying out at least 150 enterprise interventions at a national level, with an effort to integrate them into national policies giving an even greater multiplying effect on the SAVE resources used for these interventions. Based on audits on the different Motor Challenge systems, the objective was to test the MCP tool set and to convince a large amount of enterprise that energy savings potential exist on the motor driven systems. Through these audits, the enterprises were able to build energy savings action plan and to ask for the MCP Partner label. The dissemination was also to be done with and through the new Endorsers, committing to participate to the dissemination of the MCP, integrating the network after the acceptance of their promotion plan. � The project crew had the target to try to convince 120 new Partners and Endorsers to join the MCP, which was a high step change for the MCP. � The dissemination was also through a lot of communication channels, such as the organization of specific workshops and seminars, article publications, websites development, creation of materials such as leaflets, brochures or posters, etc. 2 - Extension of the Motor Challenge Programme: � The DEXA-MCP project had the objective to extend the MCP with:

� new MCP "Modules" for two important cross cutting energy technologies: � industrial refrigeration systems � industrial electricity distribution systems used within industrial plants

� Integration of new national participants’ part of the project consortium: Finland, Lithuania, and Slovenia. � Information and training for new national participants out of the project consortium: such as, for example new

EU countries and Turkey. � Developing specific, easy to use tools, to meet the specific needs of SMEs.

3 - Integration of the MCP at the National Level for an efficient programme: In the European Union, the key organizations which can implement this type of programme are involved at a national level. These organizations are often well-known at the national level and are involved in a variety of national programmes. The DEXA-MCP consortium was built with this type of national actors. � One of the main objectives of the DEXA-MCP project was to integrate use of the MCP Tool Set into the national programmes of Energy agencies and organisations. Integrating the "tool set" into the programmes and activities of the national energy agencies was absolutely essential: while the EC, through the SAVE programme, plays an essential role in catalysing European level efforts to build synergy between national agencies, it must be kept in mind that the "force de frappe" lies in national programmes. Therefore, DEXA was built to support specific actions in each participating country, creating a global European movement. The global objective of the DEXA-MCP project was to support the development of the Energy Efficiency in Motor Driven systems. In that way, this project had to contribute to give to the Motor Challenge Programme a new dimension and to become a common well-known European banner for energy efficiency in motor driven systems in the entreprises.

DEXA-MCP


Page 10 of 43

II.1 Major project achievements

�� Dissemination activities: many channels explored by the DEXA-MCP consortium: � 247 Audits and MCP presentations which have leaded to 61 new Partners and 33 new Endorsers integrating

the programme during the duration of the project � Direct contacts through the organization of:

� 18 Workshops � 964 Meetings, interviews and MCP presentations � 66 Interventions in seminars/conferences � Organization of 39 Trainings sessions (internal, external, partially or totally on the Motor

Challenge Programme). � Participation at EEMODS 05 at Heidelberg, Germany: 200 attendees, 9 participants of the

DEXA-MCP consortium with 3 papers accepted. � Mailing and email contacts:

� 3960 Emailing and mailing information about MCP

� Construction of dissemination support tools: � design, redaction and publication of 12 Posters, 5 Brochures, 10 leaflets � 13 information Internet websites or part of websites dedicated to the Motor Challenge

Programme � 2 “24 hours Hotline” about MCP � 22 PowerPoint presentation � 4 small movies

� Redaction or contribution of 76 articles on the Motor Challenge programme (redaction of 19 press Releases) � Development of 10 case study started to be disseminated as “Best practices”

�� Extension of the Motor Challenge Programme: � 5 new contact points in Eastern Europe countries through the collaboration built by DEXA-MCP with the

4EM-MCP project. � 4 new contact points ready to integrate the MCP European network:

DEXA-MCP has established new contacts with Macedonia, Croatia, Cyprus, Malta, and Turkey and has tried to intensify the cooperation with Ireland and Great Britain. Good results have been received from Croatia, Macedonia, Turkey and UK for their integration into the MCP European network.

� Integration of 2 new systems in the Motor Challenge and development of 2 new technical modules for these systems:

� industrial refrigeration systems � industrial electricity distribution systems used within industrial plants

� Creation of 2 new MCP tools: 1 paper guide and 1 software tool. These tools are more awareness than expert tools and the goal to achieve was to create a simple and easy to adapt base that could be used in all countries.

�� Integration of the MCP at the National Level for an efficient programme: � The translation of the technical modules (for the 6 systems) in national languages has been completed for

the new countries being part of the DEXA-MCP consortium: Slovenia, Lithuania and Finland (for Finland: compressed air and refrigeration there is already more detailed Finnish modules were used instead of the small MCP technical guides).

� Translation from the English of the 2 new modules in the different languages:

II The summary of the achieved during the project

DEXA-MCP


Page 11 of 43

� Refrigeration module: German, Slovenian, Lithuanian, Portuguese, Swedish, Greek, Italian, Dutch, French (and Finnish see above).

� Electrical Distribution: German, Slovenian, Lithuanian, Portuguese, Swedish, Greek, Italian, Dutch, French, and Finnish.

� Translation from the English of the 2 new tools (paper guide and software) in the different languages: � Paper technical guide: French (7000 copies printed), Italian, Portuguese, Slovenian,

Finnish, German. � Software tool: French, Italian, German, Finnish, Greek, Lithuanian, Portuguese, Swedish,

Slovenian

II.2 Activities and impact after end of the action During DEXA-MCP project, the Motor Challenge programme has reached a new level. The motor Challenge programme had, before the launch of DEXA-MCP, about 40 partners and endorsers. During the project, 94 new companies have joined the programme giving a real kick off. With more than 28 national contact points, the programme is really a Pan-European programme even if some important countries were not taking part until now (like Spain, UK and Ireland). This leads to the 2 following conclusions:

� many countries find the Motor Challenge concept interesting; � the Motor Challenge can be implemented in many different situations.

� After the end of DEXA-MCP project, the European network of NCPs developed during DEXA-MCP project will continue to exist. � The MCP has been integrated into the national programmes so its dissemination will continue with the dissemination of the national activities. � All the Partners and the Endorsers involved in the MCP will continue to implement their Action and Promotion plans, which mean a continue action on energy saving actions and on the dissemination of the best practices such as on the communication on the Motor Challenge itself. After the end of the project:

� the European MCP webpage at www.motor-challenge.eu will still exists and be maintained; � the 13 national Internet websites will still exist and be maintained; � the tools such as the 6 system technical modules, the MCP technical brochure, the MCP software will

continue to be disseminated by the National Contact Points; � the project Internet website, www.ademe.fr/dexa-mcp/ will be maintained; � new MCP Partner and Endorsers will be integrated in the Motor Challenge programme due to the new level

of visibility of the programme. In a medium term period, it seems important to continue to reinforce the European network with:

� the creation of an independent entity which must be dedicated to the Motor Challenge programme, in order to have a real European coordination and to develop a quality procedure;

� the continuation of the development of common tools and common events; � a coordination with the other European Programmes such as Green Light.

DEXA-MCP


Page 12 of 43

III.1 DEXA-MCP European activities

III.1.1 Development of new tools – Extension of the Motor Challenge Programme to Refrigeration and Electric Distribution systems

I.1.1.a Industrial refrigeration MCP module

The situation of the industrial refrigeration systems was not so well known in Europe. Several national activities had previously shown a high potential of energy savings. Most of the refrigeration systems have a compressor with a motor inside which leaded to the logical conclusion to extend the MCP with these systems.

III The Actions in details done by DEXA-MCP:

Refrigeration system

DEXA-MCP


Page 13 of 43

Industrial refrigeration: European Energy consumption estimation

1st of all, the work done during the project had the goal to give an estimation of the electricity consumption for industrial refrigeration in the EU. This estimation was done, based on some assumptions and the statistical data from:

20 case studies, covering Germany, France, Austria, Greece, Portugal and Sweden. Germany, where very detailed data on the electricity consumption and the consumption for refrigeration is available France with a study for the French energy consumption in the industrial sector in 1999. It has to be mentioned that uncertainties are coming from the fact, that refrigeration has not a clear definition in relation to energy consumption: there is a distinction between refrigeration (temperatures below 0°C) and active cooling systems (temperatures between 0°C and ambient temperature). Whereas for the first part electricity consumption peaks in the food and the chemical industry, active cooling systems are widespread in Industry for process cooling and air conditioning. In industry often process cooling and air conditioning is provided from the same chiller plant, split of consumption is typically not available. In the food industry an additional problem occurs stemming from the fact, that the industrial sector can not always clearly defined, as a significant number of refrigeration installations relates to food transport and storage. However this electricity consumption can be either found in the industrial food sector, the service sector or private households, depending on the ownership of the equipment. In order to derive at least some estimates of the electricity consumption for refrigeration and active cooling, a mixed top down and bottom up approach was used. The total electricity consumption in Industry for the EU-25 countries for 2002 has been taken from EUROSTAT3. In the electricity statistics, the electricity consumption is split further into 8 subsectors:

♦ Iron and steel industry ♦ Non-ferrous metals ♦ Chemical industry ♦ Non-metallic mineral production. ♦ Food, drink, tobacco ♦ Pulp, paper and print ♦ Engineering & metal ♦ Other industries

♦ The data for the electricity consumption in industry in the European Union are summarized in Table 2. Based on the data collection in the different member states, only for Germany and France a full set of shares for refrigeration has been available. However the main German source of information states electricity consumption in the food industry which is higher than the total electricity consumption of this sector4. Therefore these values have been adapted and linked with case study data and recent confidential studies of Fraunhofer ISI regarding the split of the electricity consumption. The French data are based on a study of CEREN for ADEME, analysing the energy consumption of cross cutting technologies in industry5.

3 Energy Statistics 2002. Eurostat, Themenkreis 8 Umwelt und Energie, Luxembourg, 2004.

4 Steimle, et.al.: Energiebedarf für die technische Erzeugung von Kälte. Statusbericht des Deutschen Kälte- und

Klimatechnischen Vereins, Nr. 22, Juni 2002. 5 CEREN: Le gisement de maitrise de l'energie dans l'industrie en 1999 – Opérations transversales. Mars 2002

DEXA-MCP


Page 14 of 43

Table 1 shows the data available for the different countries in the EU-25. The base year for the data given in the table is different but the changes in shares of electricity for refrigeration change only slowly over time based on changes in processes and user behaviours, such as the increased consumption of refrigerated food products. Table 1: Share of electricity for refrigeration and active cooling

Finland France Germany Sweden United Kingdom Average share

Iron&steel industry 0.021% 1.000% 0.510% Non-ferrous metals 0.074% 0.100% 0.087% Chemical industry 4.552% 14.000% 17.300% 4.200% 10.013%

Non-met. mineral prod. 0.192% 0.500% 0.346% Food, drink, tobacco 25.000% 17.334% 29.000% 22.960% 7.100% 20.279% Pulp, paper and print 0.216% 2.500% 1.358% Engineering & metal 2.000% 0.704% 2.800% 1.835%

Other industries 18.000% 4.260% 10.000% 1.700% 8.490% To calculate the share of electricity for refrigeration in the different countries of the EU, the average shares are than multiplied by the total electricity consumption in each sector of each country. Table 2: Electricity consumption in the European industry [2002]

Final electricity consumption by sector of industry(2002) (GWh)

Austria Belgium Cyprus Czech Republic

Denmark Estonia Finland France Germany Greece

Iron&steel industry

2882 6833 0 3751 733 4 2615 16162 24070 1416

Non-ferrous metals

626 1997 0 104 62 3 2072 10211 18827 3929

Chemical industry

3164 13177 19 3211 1293 282 5369 24738 49185 1154

Non-met. mineral prod.

1457 2515 186 2162 842 172 924 8550 15087 2049

Food, drink, tobacco

1257 3907 147 1534 2226 292 1540 18931 14957 1285

Pulp, paper and print

4516 2497 16 1877 735 130 24958 13617 22151 473

Engineering & metal

2929 2984 25 3783 1718 196 2537 22851 29738 808

Other industries

2492 2751 56 2660 1874 550 2809 13373 53102 1775

Total 19323 36661 449 19082 9483 1629 42824 128433 227117 12889

DEXA-MCP


Page 15 of 43

Hungary Ireland Italy Latvia Lithuania Luxembourg Malta Poland Portugal Slovak

Republic Iron&steel

industry 685 22 19966 137 40 1960 0 5446 863 1541

Non-ferrous metals

1085 323 5619 3 0 0 0 3523 117 0

Chemical industry

3048 1137 20236 75 507 299 0 8057 2331 1415


977 646 14312 100 232 0 0 3047 2350 855


1403 2015 12360 308 454 84 0 3980 1603 1080


450 168 10480 36 99 0 0 2773 1995 801

Engineering & metal

1432 1130 26064 199 391 640 0 4705 1547 650

Other industries

885 1939 21970 447 472 348 802 4190 2892 686

Total 9965 7380 131007 1305 2195 3331 802 35721 13698 7028

Slovenia Spain Sweden The Nederlands United

Kingdom EU-15 EU-25

Iron&steel industry

860 16228 4933 2573 6353 107609 120073 GWh

Non-ferrous metals

1494 10484 2915 5769 6309 69260 75472 GWh

Chemical industry

479 12111 5513 11893 22284 173884 190977 GWh


412 11026 1433 1544 6997 69732 77875 GWh


254 9183 2834 6680 12186 91048 100500 GWh


669 6898 23085 3752 11744 127069 133920 GWh

Engineering & metal

764 10489 4464 4792 19741 132432 144577 GWh

Other industries

603 10114 8683 2970 22692 149784 161135 GWh

Total 5535 86533 53860 39973 108306 920818 1004529 GWh

Energy consumption for refrigeration and cooling is however depended on average ambient temperatures. The specific consumption in the Nordic countries (lower temperatures) is therefore lower than in central Europe (e.g. France, Germany). In similarity, specific electricity consumption for refrigeration and cooling is higher in southern countries (eg. Portugal, Greece) in which temperatures are much higher and in which process cooling as well as air conditioning will consume much more energy. Table 3 shows the correction factors used to take into account the temperature variations across Europe. The average shares for electricity consumption for refrigeration are multiplied by the correction factor to obtain the values for each country and sector.

DEXA-MCP


Page 16 of 43

Table 3: Temperature correction of electricity consumption for refrigeration Central European Southern

European Northern European

Countries Austria, Belgium, Czech Republic, Estonia, France, Germany, Hungary, Ireland, Latvia, Lithuania, Luxembourg, Poland, Slovak Republic, Slovenia, The Netherlands, UK

Cyprus, Greece, Italy, Malta, Portugal, Spain,

Denmark, Finland, Sweden

Correction Factor 1.0 1.2 0.95

Based on the assumptions explained before and the statistical data for the overall electricity consumption in different sectors of industry, an overall consumption for refrigeration and cooling of 60 TWh (2002, EU-27) is achieved. If only the traditional countries of the EU are taken into account, the consumption for refrigeration and active cooling is about 55 TWh (2002, EU-15), which is 92% of the consumption in the EU-27. As it is well know, the electricity consumption in the EU is dominated by the old member states and as a rough estimate the new ascension countries make up about 10 % of the energy consumption in the enlarged Union. An earlier study trying to identify energy saving potentials in motor driven systems6 quantified the electricity consumption for refrigeration to be 87 TWh (1999; EU-15). Compared to the total electricity consumption in Industry in 1999 this is equivalent to a share of 9.6% of electricity for cooling, which is a much higher than the values obtained in this analysis, where the share has been calculated to be only 6 % (2002, EU-27). Figure 1 shows the breakdown of electricity for refrigeration by sector of industry. The largest consumption for cooling and refrigeration occurs in the chemical industry and in the food industry, which make up about one third of the total consumption each.

Electricity Consumption for Refrigeration [EU-27; 2002]

Iron&steel industry; 689

GWh; 1,1%

Non-ferrous metals; 70

GWh; 0,1%

Chemical industry; 19436

GWh; 32,3%

Pulp, paper and print;

1937 GWh; 3,2%

Engineering & metal;

2823 GWh; 4,7%

Other industries; 14225

GWh; 23,7%

Non-met. mineral prod.;

300 GWh; 0,5%Food, drink, tobacco;

20644 GWh; 34,3%

Figure 1: Electricity consumption for refrigeration and active cooling in the EU-27 [2002]

6 Almeida et. al.: Improving the penetration of energy efficient motors and drives. European Commission,

Directorate-General for Transport and Energy, SAVE II Programme 2000, Contract Nº.: 4.1031/Z/96-044.

DEXA-MCP


Page 17 of 43

Figure 2 shows a further breakdown by country. Those countries with larger total electricity consumption have also higher consumption for refrigeration. The consumption in Germany, Italy, France, UK and Spain largely dominates the consumption.

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

11000

12000

13000

14000

15000

16000

17000

18000

19000

20000

Au

str

ia

Be

lgiu

m

Cy

pru

s

Cze

ch

Re

pu

bli

c

De

nm

ark

Es

ton

ia

Fin

lan

d

Fra

nc

e

Ge

rma

ny

Gre

ec

e

Hu

ng

ary

Ire

lan

d

Ita

ly

La

tvia

Lit

hu

an

ia

Lu

xe

mb

ou

rg

Ma

lta

Po

lan

d

Po

rtu

ga

l

Slo

va

k R

ep

ub

lic

Slo

ve

nia

Sp

ain

Sw

ed

en

Th

e N

ed

erl

an

ds

Un

ite

d K

ing

do

m

country

GW

h

Iron&steel industry Non-ferrous metals Chemical industry

Non-met. mineral prod. Food, drink, tobacco Pulp, paper and print

Engineering & metal Other industries

Figure 2: Electricity consumption for refrigeration by country and sector of industry in the EU-27 in 2002. With 30.4% for Germany, 14.3% for Italy, 8.6% for France and 8.7% for Spain and 7.2% for the UK, these five countries are responsible for more that 69 % of the electricity consumption for refrigeration in the EU-27, cf. Figure 3.

Germany

30.4%

Portugal

1.7%

Slovak Republic

0.8%

Spain

8.7%

Sweden

3.6%

The Nederlands

4.8%

United Kingdom

7.2%

France

8.6%

Czech Republic

1.6%

Estonia

0.2%

Finland

3.0%

Denmark

1.2%

Cyprus

0.1%

Belgium

4.1%Austria

1.5%

Italy

14.3%

Poland

3.6%

Luxembourg

0.2%

Slovenia

0.3%

Latvia

0.2%

Lithuania

0.3%

Malta

0.1%

Ireland

1.2%Greece

1.1%Hungary

1.2%

Figure 3: Distribution of electricity consumption for refrigeration in the EU-27 (2002) However it is strongly recommended not to over evaluate the results presented for the electricity consumption for refrigeration and cooling in the European industry. The data presented depends on a small number of information and especially the average shares of electricity consumption for refrigeration are based on a limited number of case studies. However the values obtained seem to be reasonable and are mainly in line with data from other sources.

DEXA-MCP


Page 18 of 43

However it is strongly recommended to complement the data acquisition by measurements and questionnaires in companies of all sectors. Especially air conditioning systems are installed in an increasing number throughout industry, increasing the share of consumption for refrigeration continuously.

Industrial refrigeration: MCP module guide The development of the refrigeration module had been done like for the already existing MCP technical modules:

- an introduction on the system, - Technical definitions and presentation of the system - Table of the best practices and technical measures - Guide to write an Energy Efficiency action plan and to report for the Motor Challenge

Programme.

DEXA-MCP


Page 19 of 43

The energy savings opportunities have been listed for these refrigeration systems and quantification, based on the case studies have been made to asses a range possibility of energy savings which can be shown in the table below: Measure Saving potential Reduction of cooling demand System optimization 8 – 10 % Operating and maintenance measures 4 – 8 % Thicker Insulation 5 – 10 % Heat recovery 80 % (heat) Efficient equipment/lighting in the cold storage 2% Use of efficient equipment Adjustable speed drives for compressor, fan, pumps 4 – 6 % High-efficiency evaporator fan motors 2 - 5 % High-efficiency compressor systems 2 - 5 % High-efficiency condenser fan motors 2 - 5 % Evaporative condensers Proper operation avoiding unnecessary low temperatures Cleaning of heat exchangers 3% Floating head pressure controls 10 - 15% Defrost controls 5 % I.1.1.b Industrial electric distribution module An inventory of the transformers and other electric distribution equipments was realized to make a first assess of the power quality interaction between electric distribution systems and motor systems, to asses energy saving potential for the company, and to choose the most pertinent energy saving measures.

Industrial electric system

DEXA-MCP


Page 20 of 43

For the energy savings potential is quite impossible to give a range, because the measures are very sensitive (to the load factor, the harmonics level, the end user in the grid, etc.), the calculus could be a little bit complicated and the gains are mostly indirect ones. Nevertheless, the economical savings with a better quality of the internal industrial grid have been assessed with some literature research and could be presented as a summary in the following tables: (source: Electrotek Concepts)

Examples of economical loss by voltage dip, in three different companies Economical loss by voltage dip Semiconductor manufacturing 3 800 000 € Iron industry 350 000 € Glass companies 250 000 €

Cost of momentary interruption (1 minute), in $/kW demand

Cost of momentary interruption ($/kW demand)

Minimum Maximum Automobile manufacturing 5.0 7.5 Rubber and plastics 3.0 4.5 Textile 2.0 4.0 Paper 1.5 2.5 Printing (newspapers) 1.0 2.0 Petrochemical 3.0 5.0 Metal fabrication 2.0 4.0 Glass 4.0 6.0 Mining 2.0 4.0 Food processing 3.0 5.0 Pharmaceutical 5.0 50.0 Electronics 8.0 12.0 Semiconductor manufacturing 20.0 60.0

The Motor Challenge module is targeted the “inside the fence” electricity distribution systems used in industry, that is to say transformers, capacitors, cabling, invertors.

DEXA-MCP


Page 21 of 43

The different actions have been split into 3 steps depending on the life situation of the installation:

- Maintenance - Upgrades - Design and Installation

DEXA-MCP


Page 22 of 43

Maintenance A regular preventive maintenance allows to avoid operating faults. For example, the failure of a transformer may lead to important or dramatic consequences, by shutting down an installation power supply, with a possible global manufacturing shutdown.

Description

Savings Frequency Feasibility Skill required

Clean bushings and connections (to prevent from corrosion risks) – the contact surface has to be large and clean Tighten bus bar Check protection equipments

Once a year +++ Internal

Test protection cells and circuit breaker

Once a year ++ Internal

Leakage detection of the insulation oil, check liquid level and closing elements


Painting damage detection (overheating indicator)


Check the possible existence of condensation or water infiltration in the terminals box


Infra-red detection of overheating cables

Once a year ++

Assess the load profile for a typical operation duration by measuring currents and voltages

Check the air circulation around transformers


Test the powers, currents and voltages supplied to detect possible overloads

Once a year ++

Oil analysis for immersed transformers (chromatography, insulation properties, water percentage, gas analysis Buchholz relay...), every two years for breathing transformers and every six years for non breathing transformers

Every two or six years

+ External

Measurements of winding and connections resistance

Once a year

Insulation tests

Once a year

DEXA-MCP


Page 23 of 43

Upgrades

In case of defective equipment or material, there are three different possible lines of action: � repair the defective material, � replace the defective material with an equivalent one available onsite, � replace the defective material with a new one with higher energy efficiency. In any case, a technical and economical analysis should be performed, taking into account the global cost, the standards or specific characteristics and the delivery or reparation duration. In general, the replacement of an old or defective standard equipment with a new one, more efficient, is cost effective and quick (standards equipments are easily available). On the other hand, for specific equipment or if in the past standards have changed, the repair option is usually the quickest and the most cost effective solution.

Description


Rewinding is generally a cost effective solution for non standards transformers or rotating machines

+ External

Replace tank joints

External

Replace the insulation liquid after tank cleaning

External

Replace old transformers with high efficiency transformers

15 to 20% of no-load losses

External

Replace old (<1980) general low voltage table with new (>2000) ones (conductors length reduced by 40%)

Joule losses reduced by 30%

External

Select high efficient elements for general low voltage table, with low energy consumption (e.g. standards circuit breaker (20 W) and efficient (7 W). Such power reduction can also prevent the need for air conditioning

External

Replace old power inverters with new efficient inverters: the efficiency is higher and the power factor is enhanced by 10 to 15%

External

Add harmonics filters in case of poor power quality networks

external

DEXA-MCP


Page 24 of 43

Design and installation

Description


Select high efficiency transformers rather than standards transformers

15 to 20% of no-load losses

++ Internal

Make sure the transformer is correctly cooled if located in a small enclosed area

-- ++ Internal

Choose natural convection cooled transformer (ONAN) rather than forced convection transformer (ONAF )

++ Internal

Gather non linear loads close to the transformer low voltage feeders

-- + Internal

Contain non linear loads

-- + Internal

Reduce the transformer short circuit voltage (or the impedance) / derate transformer

-- ++

For specific processes such as metallurgy, harmonics filters won’t be sufficient enough; a global approach is therefore needed regarding the network design.

The assessment should, for each of the measures in previous tables, evaluate applicability and profitability. This might take a form similar to the following table.

III.1.2 Development of new tools – Self evaluation tools

The objective of the self evaluation tools was to enlarge the scope of the MCP tool set, by adapting it to smaller enterprises in order to greatly extend the range and the effectiveness of the MCP to these SMEs. 2 tools have been designed with the help of communication and software expert companies for the shape and the functionalities: - 1 small technical guide very easy to use as a paper tool (also available in a pdf form for an easier dissemination). - 1 small software, downloadable from the MCP internet websites, and dissiminated on a CDrom support.

DEXA-MCP


Page 25 of 43

1 - a paper tool, in the form of a small and attractive brochure, which leads the reader through the first

steps in identifying potential energy savings:

The paper tool set was developed so as to be very easily used by technical users, providing in a graphical form, all the potential energy efficiency actions that could be implemented for each system. The highly colour schemes help to disseminate efficiently the advice. The paper guide covers the 6 technical module documents of the MCP. This guide was graphically designed and consists of a larger number of tips and information about the typical flaws, their energy impact and on ways how to improve the systems. The paper guide had been completed first in English before the translations.

The paper technical guide is translated in French, Italian, Portuguese, Slovenian, Finnish and German (Austria and Germany).

DEXA-MCP


Page 26 of 43

2 - a simple computer based web tool:

The software is shared between the different motor systems and provides for each one of them a list between 10 to around 20 questions to which the user has to answer. When all the questions have been filled in, a summary report is shown at the screen, with some advice for each one of the question. The paper guide had been completed first in English before the translations. A standalone version has been chosen distributed in a CD-Rom.

The Software tool is translated in French, Italian, German, Finnish, Greek, Lithuanian, Portuguese, Swedish and Slovenian.

DEXA-MCP


Page 27 of 43

III.1.3 Dissemination of the Motor Challenge in Europe – The European conferences and workshops

I.1.1.a EEMODS 2005 conference

EU-wide exhibitions were organized like the EEMODS (Energy Efficiency in Motor Driven Systems) conference, in Heigelberg (Ger.) by Fraunhofer ISI with more than 200 participants. I.1.1.b Motor Challenge European workshops A European MCP launch event have been organized (2nd MCP workshop in Paris), with participations of 23 countries and with a production of 5 posters in English of best practices (the 5 MCP awarded companies) and a film which present the Motor Challenge Programme. The summary of the project have been provided to the EC for the “Innovative Approaches in Industry: 7 Innovative Projects supported by the IEE Programme” published in December 2006. The 1st Workshop was organized in Vienna (organized by AEA on March 22nd 2006) was to exchange experience between the experienced MCP member countries and the new member countries (Finland, Slovenia and Lithuania) and counsel the new participants in adapting the MCP to local conditions. The main result of this workshop was the understanding that the frameworks of energy efficiency activities are very different between the countries. But MCP is flexible enough to be integrated in national context with appropriate effort. So for each country different strategies were developed. The 2nd Workshop was organized in Paris (organized by ADEME, AERE and Edgar Blaustein on February 27 2007) a much broader perspective was taken: it included short interviews of different countries and their strategies to integrate MCP, presentations on the whole programme and the MCP award ceremony. The afternoon was dedicated to get new ideas for solving special MCP issues. As almost all new MCP National Contacts participated in the workshop, for them it was a good opportunity to learn about the implementation of the MCP and best case examples. A specific invitation has been printed and distributed by the MCP network. This workshop was the first one open not only to the national contact points: 70 persons from 23 European countries participated. The 5 awarded companies:

DEXA-MCP


Page 28 of 43

DEXA-MCP


Page 29 of 43

III.2 National activities

III.2.1 Summary activities at the national level:

The main goal of the project was to increase the MCP awareness within main actors of national Rational Use of Energy programmes, consultant engineers in the field and of course industrial companies. The key to massive dissemination was the integration of the MCP and its tools inside the national programmes. The results of the national activities are:

� 18 Workshops and 66 Interventions in seminars/conferences.

� 76 articles and 19 press Releases which has leaded to 974 Meetings, interviews and MCP

presentations

� 13 Posters

� 5 Brochures

� 10 leaflets

� 13 Websites information

� 39 Trainings (external and internal trainings

� 3960 Emailing and mailing information about MCP

� “24 hours Hotline” about MCP

� 22 PowerPoint presentations

� 10 case studies published

� 61 partners + 33 endorsers

� 249 onsite interventions

The dissemination of the MCP tool set at national level implies to disseminate the tools translated into the national languages (excepted for some countries in which the business is mainly done using the English). The entire tool set was translated in all the national languages.

III.2.2 The new Partners and Endorsers of the Motor Challenge programme

During the DEXA-MCP project, the application of the tools at national levels consisted in 2 major actions:

- In order to disseminate the tools, 39 training sessions have been organized to auditors, internal staff, enterprises, etc.

- 249 audits have been organized in the different countries in order to test the MCP tool set, and to train the auditors to use it.

DEXA-MCP


Page 30 of 43

The results of the project are shown in the above table per country, leading to 247 audits and 34 external training sessions:

External trainings audits

FRANCE 2 71 GREECE 3 10

ITALY 5 2 AUSTRIA 4 10

GERMANY 8 79 THE NETHERLANDS 0 10

PORTUGAL 3 15 SLOVENIA 2 13 LITHUANIA 0 7 SWEDEN 3 18

FINLAND 4 14

TOTAL 34 249

� The motor Challenge programme had, before the launch of DEXA-MCP, about 40 partners and endorsers. During the project, 94 new companies have joined the programme giving a real kick off with: 61 new Partners

33 new Endorsers

Endorsers

6

5

5

2101

3

6

1

3

France

GREECE

ITALY

AUSTRIA

GERMANY

THE

NETHERLANDS Portugal

SLOVENIA

LITHUANIA

SWEDEN

FINLAND

Partners

3

9

9

8

7

1

6

8

2

4

4

DEXA-MCP


Page 31 of 43

III.2.3 Small summaries of the national success stories with the dissemination of the Motor Challenge during DEXA-MCP

Many activities have been realized at the national level in order to disseminate the Motor Challenge in the different countries of the DEXA-MCP partners. In the following pages, some of the success stories are presented in order to show all the kind of activities, projects and tools developed in the national activities by the project partners. The integration of the MCP, at different level, into some national programmes was one of the main objectives. AUSTRIA: "In Austria the integration of the Motor Challenge Programme in the national energy efficiency programme (klima:aktiv energieeffiziente betriebe) was successful. Due to the integration of the European MCP into the national Energy Efficient Company Programme, interested Austrian companies receive financial support for energy audits in the field of motor driven systems. The following activities were set:

• Energy savings in motor driven systems were chosen as the first focus of the national programme, a result of the successful MCP pilot studies.

• The technical modules for pumps, fans, compressed air and drives of the Motor Challenge Programme were fully integrated in the support tools for consultants.

• For all technologies (compressed air, pumps, drives, fans, chillers) special information for consultants were written (9-40 pages) and published on the webpage.

• More than 50 consultants has been provided with detailed information on MCP in 4 Training workshops. For finding potential partners several methods were used: Direct contacts to energy managers, presentations at workshops and mails via branch organisations. The main “carrots” were the co-financed MCP energy audits. The most difficult step was to convince the companies to sign the action plan to become MCP partner. To give additional benefit, MCP partner certificates were handed over, either individually (Knauf and Danfoss) or during the Energy EXPO 2007 in Wels. In addition AEA wrote press releases as an additional value for the companies. Especially those releases were well received by a lot of magazines and newspapers, as they presented concrete best case examples. The results of the audits were published in two papers for IEWT and for eceee 2007 conference and in the press release “Reduktion des Gesamtstromverbrauchs um 10% möglich, zehn österreichische Betriebe nehmen an freiwilligem Effizienzprogramm teil”. Possible savings of at least 7% of total electricity consumption in the companies were found." GERMANY: Motor Challenge websites: http://www.motor-challenge.de/de/ The German Inititative EnergieEffizienz is a nationwide promotion initiative for efficient use of electricity in all consumption sectors, which is organised and administered by dena in cooperation with the energy suppliers, and is supported by the Federal Ministry of Economics and Technology. In the framework of this Inititative EnergieEffizienz, a information and motivation campaign for electricity users in industry and trade, was initiated by the German Energy Agency GmbH (dena), together with sections of the VDMA (Verband Deutscher Maschinen- und Anlagenbau - German Engineering Federation, an association representing approx. 3000 mainly small/medium sized member companies in the engineering industry). This national campaign, titled “Energieeffiziente Systeme in Industrie und Gewerbe – ESIG” (Energy efficient systems in industry and trade). The ESIG campaign aims to develop the market for energy efficient techniques by providing

DEXA-MCP


Page 32 of 43

information and support as well as publicity activities. It addresses to enterprises in all industrial sectors, with special emphasis on small and medium-sized enterprises (SMEs). The campaign provides relevant information, assistance tools, consultancy services, and general support to the target group, and develops supporting press and public relations activities. Furthermore, it aims to motivate decision makers in industry and trade to implement measures increasing energy efficiency. Several customised offers are developed and disseminated for individual target subgroups, such as technical staff, procurement and commercial departments, top management, as well as consultants and planning engineers. Managers are informed about economic energy saving potentials including financing services (e.g. performance contracting). Plant engineers can receive assistance for the realization of measures to increase the energy efficiency.

DEXA-MCP


Page 33 of 43

ITALY: Motor Challenge website: http://motorchallenge.casaccia.enea.it/. The essential base of the MCP is its integration into the national programmes on energy efficiency. In Italy, in the period of the realization of the Motor Challenge, the programmes relative to energy efficiency are:

• Energy Managers • The white certificates • Fiscal deduction.

Energy Managers The basic law on energy efficiency is Law No. 10/1991, entitled “Regulations for the implementation of the National Energy Plan with regard to the rational use of energy, energy savings and the development of renewable energy sources”. It is a framework law to introduce regulations aimed at the efficient use of energy sources in all end-use sectors including the specific reduction of energy consumption in production processes, especially in buildings and heating plants. Article 19 of Law 10/91 deals with the compulsory appointment of a responsible (i.e. energy manager) for energy efficiency and conservation issues. To comply with this article, each industrial company consuming more than 10.000 toe/a (in terms of primary energy) or every commercial, public and transport sectors organisation or end-user of the building sector consuming more than 1.000 toe per year, must appoint an energy manager. Around 750 companies operating in industrial branches have appointed an energy manager. Companies which fail to comply with this regulation are ineligible for grants for energy efficiency investments and are liable to be fined. An implementing agreement between the Ministry of Production Activity (former Ministry of Industry), ENEA and FIRE (Italian Federation for the Rational Use of Energy), has been established to provide support in view of strengthening the role, visibility and functions of the energy managers operating in the different sectors. ENEA and FIRE are providing information on energy efficiency matter and are organising training courses. Learning courses are also organised locally by several organisations. DEXA-MCP has organized several training courses and journal articles to Energy Managers. The white Certificate Scheme The White Certificates Scheme (WCS) was first introduced in Italy, on July 2004, in the framework of legislative decree n.79/99, issued to comply with the European directive 79/99 concerning the liberalization of energy market. This scheme represents a very innovative mechanism which combines a “command and control” approach with a “market-based” instrument for the improvement of energy efficiency. Electricity and gas Distribution System Operators (DSO) are obliged to achieve quantitative annual targets of energy saving in end-uses. Suggested measures are listed within an attachment of the decree. The up-take of high efficiency electrical motors and VSD in all sectors is among the suggested measures. ENEA has proposed MCP as a good tool to individuate interventions suitable for white certificates.

Fiscal deduction On February 2007, the Italian Government put in place a new legislative framework to address strategic key-issues, such as: security and competitiveness of energy supply, improvement of energy efficiency and widening the use of renewable energy sources, strengthening the economic growth. Namely, a so called “energy package” of measures for the promotion of energy saving and of the use of renewable sources has been published by the Ministry of Economic Development with the aim of stimulating the demand of energy efficient products and of supporting the development of a stronger domestic energy industry. The measures included in the package concern both the energy demand and supply side. On the demand side, 6 actions have been launched. Herewith it is important remind the action strictly collected with the MCP. The action is relative to promote the diffusion of high efficiency electric motors and variable speed drive in industry. The measures guarantees fiscal incentives (20% fiscal deduction) to investments for: a) new

DEXA-MCP


Page 34 of 43

installation or replacement of existing electric motors with high energy-efficiency motors; b) the installation of variable speed drivers. Brochure In order to disseminate the Italian Decree about white certificates concerning high efficiency motors and VSD, ENEA has written and published a brochure. The title of the brochure is: “Risparmiare energia elettrica per essere più competitivi”. The Brochure is composed of three different parts concerning:

1. Decree on Energy Efficiency 2. Technologies 3. Motor Challenge Programme

The first and second part of the document inform on the Decree and on technologies about HE motors, VSD and capacitors. These technologies are suggested either from the Decree or from the MCP. The third part informs about MCP and the vantages to joint it and the possible links between MCP and the Decree. Besides the brochure suggests to the enterprises to apply the MCP in order to individuate the cost effective interventions on energy saving, then to propose these interventions to a Distributor or an ESCO in order to utilise them to ask the white certificates. The brochure is composed of 24 pages, instead of 4 reported on the contract, and it was published on July 2006 in 2.000 copies. The brochure has been distributed during seminars, meetings and courses. FINLAND: In the beginning of the project the basic question was to find out, if it is possible to introduce or integrate the 5 step approach of MCP to the Finnish National Voluntary Energy Conservation Programme, National Energy Management Programme for SME and National Energy Audit Programme. The study showed that in the case of Finland there is a need for change the existing MCP approach, because at present the companies get better benefits from the national programmes than they could get from MCP. Due to this some modifications, accepted also by EC, were made for applying for partnership of MCP and reporting to EC, action plans of the endorsers and their reporting to EC. By the end of the project four partners and three endorsers joined to the MCP. Individual contacts and discussions with the potential endorsers and partners proved to be essential to make them to join the program. Leaflet of Compressed Air System was made in Finnish and in English. The leaflet was mailed to more than 1000 Motiva Energy Auditors and it has been delivered in every relevant occasions. THE NETHERLANDS: Motor Challenge website : http://www.senternovem.nl/english/products_services/towards_sustainable_energy/disseminating_results_of_the_motor_challenge_programme.asp SenterNovem has integrated MCP into the LTA programme. Main outcomes are:

� LTA team knows about MCP and include energy efficiency of motor systems within their daily practice. � All MCP modules (including the new ones on refridgeration and transformers) and MCP brochure are

translated into Dutch and will be published autumn 2007. The content of the modules will be integrated in the new measure list which will be available for the new 2009 – 2012 Energy Conservation Plan, which all LTA companies (appr. 1000) will make in 2008.

DEXA-MCP


Page 35 of 43

� A user group on MCP started end of 2006. Two workshops have been organises (third one will be in October 2007), in all companies (10) audits have been done. All user group participants will make an MCP action plan, not all will sign up as partner. In spring 2007 a second user group started in the sector of oils, fat and margarine and will continue up to 2008.

� Making a MCP action plan is on the EIA list, (Energy Investment Allowance), since January 2007. Eff 1 motors already was in this list.;

� Several contacts with sector organisations and companies at the endorser site have been made, where MCP has been the subject of discussion and/or presentation.

� Motor System efficiency is higher in the energy efficiency agenda in the Netherlands. As part of the new policy plan Schoon en Zuinig (clean and efficient), with 2% efficiency improvement yearly up to 2020, motor systems will get extra attention.

� Due to the success of DEXA MCP SenterNovem will take the lead in formulating a follow up project for DEXA MCP.

� A national event is being prepared to give attention to the results of the first usergroups. A communication research was conducted showing that for the companies involved media attention for this subject is to early. Decided is to first publish an article on the results, paying attention to DEXA MCP and the new efficiency classes on motors coming from the lot 11 study from the Directive on Ecodesing of Energy using Products. The event will be held later, as soon as the (management of the) companies involved are ready to use their results. SWEDEN: Motor Challenge website : http://www.energimyndigheten.se/WEB/STEMEx01Swe.nsf/F_PreGen01?ReadForm&MenuSelect=0F5337AEE9FB6325C1256E350035651D&WT.Ti=Effektiv%20energianvändning.Effektivisering%20i%20industrin.Motordrivna%20system.Motor%20Challenge%20Programme Integration with the voluntary agreement programme,PFE: The Swedish government has introduced a programme – PFE, which allows companies in the manufacturing industry to participate in a five-year programme to improve energy efficiency. The aim is for the companies to introduce energy management systems, and to take direct action to minimise their electricity consumption. More than 100 energy intensive companies participate and have carried out in-depth audits. Based on the audits, a list of measures to improve electricity efficiency which can realistically be implemented over the following three years of the programme period was submitted to the Energy Agency in September 2006. The projected electricity savings amounts to 1 TWh/year. During the first two years, the participating companies will also introduce a standardised energy management system, which is to be certified by an accredited certification body. Companies must also create purchasing and planning routines aimed at providing more energy-efficient equipment, systems that are more effective, and improved operation of the plant. The Energy Agency has produced several guides directed towards the PFE-companies concerning e.g. audits, purchasing routines and energy management. These documents can be downloaded from the Agency’s website where also links to MCP and MCP-tools are found. Partners from PFE-companies Since the companies participating in the PFE-programme have carried out all the necessary steps that are required from an MCP-partner, the Energy Agency have invited all PFE companies to also join MCP. The invitation has been sent out to all the companies together with the MCP-brochure. They have also been invited at workshops with the PFE-companies. A special application form, approved by the Commission, has been prepared. Integration with the regional programme EnergiFokus The project EnergiFokus aims at creating a strong regional network for energy related activities with the industry of

DEXA-MCP


Page 36 of 43

western Sweden. All the 18 companies in EnergiFokus have personally been invited to join the Motor Challenge Programme. 18 onsite interventions, with walk-through audits, have been carried out in connection with the regional programme EnergiFokus. The target group was companies with a total energy use between 3 and 300 GWh/year. The purpose was to reach companies with a substantial energy use, but still limited resources for internal energy management activities. Furthermore, the larger and more energy-intensive companies are reached through the PFE programme, see below. Geographically it was limited to the region “Västra Götaland” in western Sweden. Contacted companies represented the pulp and paper industry, food industry, textile industry, chemical industry and other manufacturing industry. The division between industrial sectors for the 18 participating companies was similar.

In addition, more than 100 companies within the national programme PFE have carried out in-depth audits. The PFE-companies reported to the Energy Administration in September 2006 and the projected electricity savings amounts to 1 TWh/year. Some key figures are shown in the charts below.

64%

4%

1%

7%

17%

5% 2%

Pulp and paper

Food and beverage

Wood and w ood products

Chemicals and plastics

Mining and quarrying

Iron, steel and metals

Others

Projected savings per industry sector

Production

processes

Fan systems

6%

Lighting

1%Others

7%

Pumps

17%

Indirect

efficiency

measures

2%

Compressed

air

10%

Refrigeration

2%

Heating and

ventilation

3%

Motors

4%

Projected savings per type of measure

DEXA-MCP


Page 37 of 43

FRANCE: Motor Challenge website : www.motorchallenge.fr 1 – Integration of the Motor Challenge into the national programme: The white certificates programme was launched in France the 1st of July 2006. In this programme, specific actions relative to the high efficiency motors (EFF 1) and to the use of the Variation Speed Drives for ventilation, compression and pumping have been integrated within the programme. ADEME has worked on the BREF document related to the Energy efficiency and proposed several input after the draft version. Information on the label programme like the Motor Challenge had been given. ADEME which has developed an energy efficiency auditing system, providing to the enterprises funding (500 diagnoses a year) and also technical orientations, has introduced into this mechanism the Motor Challenge Programme and develop a specific brochure explaining how to proceed, using the ADEME auditing system help and joining the MCP. 32 diagnoses have been analysed totally in details (in 71 audits signed with the enterprises on the Motor Driven systems) with the following summary results:

� 46 energy efficiency actions were identified for the compressed air systems for 6610 MWh of energy savings identified.

� 30 for the refrigeration systems for 2 483 MWh of energy savings identified. � 2 for the pumping systems for 480 MWh of energy savings identified. � 7 for the industrial electric distribution networks � 6 for the ventilation systems for 924 MWh of energy savings identified.

2 - A communication plan was developed in France .with the following results: � Development of a high quality “marketing brochures” (printed in 4000 copies). � Development of a Motor Challenge French website: www.motor-challenge.fr and www.motorchallenge.fr � Development of a specific graphic environment that would be used for all the MCP tools in France but also

that can be extended at the European level. � Printing and dissemination of the high quality technical guide in French (printed in 7000 exemplars). � Development of a multimedia presentation support (voice and pictures) in French but also in English. � Organization of a TV show during the Pollutec trade fair to launch the Motor Challenge in France. � Realization of filmed interviews to be published during the public events (seminars/workshop) organized by

ADEME and the MCP partners/Endorsers. � Development of some specific tools to accompany the companies which have obtained the label Motor

Challenge to communicated on their good practices with : - the realization of “Motor Challenge best practices leaflets”, - the design of specific electronic signature for their electronic messages of the MCP partners and the

endorsers, - a specific link offered with the press and the journalists, - the development of specific CDrom dedicated to the French partners and Endorsers with all the MCP

tools inside, - preparation of a French MCP newsletter, - Design of an MCP French award support.

� 7 general posters were produced, and integrated into the set of posters used in professional exhibitions.

DEXA-MCP


Page 38 of 43

“Motor Challenge best practices leaflets”

Specific electronic signatures for their electronic messages of the MCP partners and the endorsers

Design of an MCP French award

support.

DEXA-MCP


Page 39 of 43

GREECE: Motor Challenge website : www.cres.gr/motorchallenge The DEXA-MCP project has been presented and elaborated on during various meetings with the Ministry of Development as well as with potential partners. The Ministry of Development is regulating industry and energy matters and is also running the “Programme For Competitiveness” – an essential tool for the promotion of RUE in Greece. The Ministry was informed about the existence and aims of the Motor Challenge Programme and DEXA-MCP, through its participations in Committees for the adaptation of CHP and the Energy Performance Building Directive in Greece as well as through discussions with consultants to the Ministers. Effort has been made to include the aims of MCP into the Programme for Competitiveness and promote projects with MCP related actions. On May 31st 2006, a national workshop for the Greenbuilding Program took place in Athens. The 330 attendants of the workshop, were also informed about MCP and the availability of information on the ways of improving the energy efficiency of their motor-systems at the national website of the Motor Challenge Programme. Energy audits have been performed in ten industries in central and Northern areas of Greece. A training package has been formed in cooperation with the Education department of CRES. The package analyses an one-day program for the promotion of MCP objectives to industry personnel. The training package is downloadable from the Greek Website www.cres.gr/motorchallenge and all partners could use it as a basis for country training courses. All the Motor Challenge tools (guidelines and modules) have been translated and adapted to Greek and has been placed in the appropriate sections. Such material (in Greek) is

Registration modules 1. Guidelines for partners 2. Guidelines for endorsers

Technical modules 1. Electric motors 2. Fan systems 3. Compressed air systems 4. Pumps 5. Management policies 6. Industrial Refrigeration 7. Electric distribution systems

This material can be accessed and downloaded by interested persons. Several interested people have contacted CRES and have been given information and advice on MCP related issues.

PORTUGAL:

A road-show was organized in October 2005 (Oporto session at 25th Oct.; Guarda session at 26th Oct.; and, Coimbra session at 27th Oct.), was a big success. It involved a total of 90 participants, and as its most important result permitted to get the minimum foreseen number of industrial companies (15) interested to “test” MCP and, in principle, to become MCP Partners. The companies “obtained” by this “process” complemented the few ones (5) already gathered by other means, like direct contacts and other sensitizing actions. Besides this, it permitted to accomplish other goals, namely: to disseminate the MCP among the Industry sector, and to sensitize companies about the huge potential of energy saving opportunities related to electric motor driven systems.

The 15 onsite interventions, focusing a maximum of 2 MCP Modules, were chosen by the companies and considered as the most appropriate for these ones. These energy diagnoses produced the correspondent audit reports in

DEXA-MCP


Page 40 of 43

Portuguese, reporting the main conclusions of the measurements carried out, observations in loco done and other information collected and treated, including an evaluation of the cost-effectiveness of the identified potential savings. These reports for the companies were the basis for the decision-makers. 6 companies, i.e. 40% of the sample of 15 companies, decided to submit an Action Plan and to apply to the Partnership commitment. The total energy saving potential identified for the 15l companies was about 3 GWh/year or 176,000 EUR/year of electricity costs reduction, equivalent to 1,510 tonnes of CO2 emissions reduction, and all this possible with a total investment needed for the implementation of the energy savings measures that has a payback period lower than 2 years. SLOVENIA: Motor Challenge website : http://www.rcp.ijs.si/ceu/sl/node/26 Slovenia was a new country inside the Motor Challenge European network. In 2005 Jozef Stefan Institute (JSI) focused its actions mainly on preparation of relevant tools and promotional material (e.g. articles, leaflet and brochure), while in the 2006 and 2007 it organized 2 MCP workshops/info seminars and several individual discussions (at company level). Integration of MCP into existing field of rational use of energy (RUE) could be considered as successful, as MCP as a program was accepted as very positive (DEXA project was co-financed by Slovenian Ministry of Environment). All the Motor Challenge tools (guidelines, modules as well as the new tools) have been translated to Slovenian :

Registration modules

1. Guidelines for partners 2. Guidelines for endorsers

Technical modules

1. Electric motors 2. Fan systems 3. Compressed air systems 4. Pumps 5. Management policies 6. Industrial Refrigeration 7. Electric distribution systems

13 on-site interventions were performed in two different ways: � Energy audit for motor-driven systems: 6 energy audits (which normally takes 5-7 working

days). � Short on-site interventions: 7 short on-site interventions which consist of 1 day survey and

active discussion with site operator/owner.

DEXA-MCP


Page 41 of 43

A leaflet was made for national use in 2-page format. It gives brief (basic) information on the objective of MCP, participation procedures (so called 5 step approach) and partner benefits. 500 copies printed. Leaflet was disseminated at both national MCP seminars, also per post (to individual companies).

LITHUANIA: Lithuania a new country inside the Motor Challenge European network. Kaunas city water supply company for energy audits was selected. Kaunas city water supply company has 13 second lift stations, 30 third lift water pumping stations, 31 waste water pumping stations. The total power of installed electrical equipment (mostly water pumps) is 48 MW. Company is one from the biggest electricity consumers in the Kaunas city (23 952 million kWh per year). After selection Kaunas city water supply company 7 audits were done (second lift stations and waste water pumping stations) Energy saving potential (changing existing not efficient electrical motors to new with new electronic regulation) evaluated. Results of audits shoes, that energy saving potential for the company can be about 40% from the total electricity consumption (it is about 9600 million kWh per year). All the Motor Challenge tools (guidelines, modules as well as the new tools) have been translated in Lithuanian:

Registration modules 1. Guidelines for partners 2. Guidelines for endorsers

Technical modules 1. Electric motors 2. Fan systems 3. Compressed air systems 4. Pumps 5. Management policies 6. Industrial Refrigeration 7. Electric distribution systems

DEXA-MCP


Page 42 of 43

A case study with the enterprise Kauno vandenys have been written in English as well as a synthesis of all the audits. 1 Lithuanian leaflet was prepared, 500 units were printed and distributed between interested organisations:

DEXA-MCP


Page 43 of 43

The 3 main conclusions of the DEXA-MCP project are the following ones: 1 – Knowledge about cost effective energy efficiency measures in motor driven systems is still not very common in enterprises and their remains a strong need to further disseminate information with new tools and continuous efforts. The Motor Challenge programme has proved to be a good tool for a EU wide approach for efficiently helping to support the European Industries by developing common tools and supporting industrial efforts. The public support of the programme should therefore be constant in the time and avoid breaks due to periods without any public funding. 2 – Helping the enterprise to act and improve their energy efficiency is essential. The support of walk through audits and auditing programmes are one key to identify energy efficiency measures. Enterprises highly welcome the support of an expert to realize the audit and to follow the implementation of measures. Training of energy auditors in the field of motor driven systems is essential. Convincing the enterprises to use this expertise is facilitated by the public support and engagement of the EC and the national governments. The second key to help the enterprises to act is to train their internal staff and especially in the SMEs. 3 - To further develop the outreach of the Motor Challenge Programme in the EC two levels of actions are required - a real and permanent European Coordination and support by public funding is essential for the long term success of the program and its required impact on energy savings and emission reductions - a strong coordination at the national level is essential in order to integrate the programme within the national context, organizations and policies. The national contact points of the program are the key players for the further outreach and development of the Motor Challenge Programme.

IV Conclusions

Date post:	01-Aug-2020
Category:	Documents
Upload:	others
View:	0 times
Download:	0 times

DEXA-MCP Project Dissemination, Extension and Application of … · Software tool: French, Italian,...

Documents