Step one: Estimate operating costs
Click to register for free and use our Online Motor Cost Calculator.
Step two: Review optimization checklists
Identify potential opportunities for efficiency improvement using the optimization checklists below.
- Motors that are not energy-efficient
- Motors that have been rebuilt incorrectly
- Motors that limit production quality or quantity
- Critical production motors that are not standard NEMA
- Lightly loaded motors that have a poor power factor
- Motors that are fed with voltage imbalance
- Motor systems that are mismatched to the load
- Motor systems that run when they don't need to
- Motors that are unreliable, or "need" soft starts
- Motors that overload unless the machine is throttled
- When the motor fails consider replacing it with an energy-efficient model
- A mis-matched bearing or the wrong wire can degrade motor efficiency and hasten repeat failure. In general, do not rewind Open Drip Proof (ODP) motors
- Motor Systems can and should be problem free. Find and fix the root problem
- Specify NEMA design motors when purchasing equipment if possible
- If the motor is loaded less than 25%, the power factor and efficiency will be very poor
- Voltage imbalance places extra stress on the motor and windings and hastens failure
- Match the machine to the load and save 20-50%
- Turn it off when it's not needed. Save 5- 30%
- Downtime costs you money and credibility. Fix the problem instead of accepting it
- Modify the machine to match the flow and pressure that the process needs and save 20-50%
Use the Motor System operating cost calculator to estimate the energy cost of any Industrial or commercial three-phase motor. Assuming that the motor is 75% loaded is usually fine for a quick estimate of motor energy usage. If a more accurate estimate is desired, have a trained technician connect a portable meter that reads out true kW, and put that in instead of estimating part load. Measuring amps alone is not a good estimating procedure for lightly loaded motors.
If you do not have a true power meter or a meter that will give you power factor, ask your electric utility if they can help. Have their trained technician connect it using the proper safety equipment and procedures.
Step three: Begin Online Training or Schedule Training/Consultation
Click to access your Online Training Course Catalog,
or Contact Productive Energy Solutions to schedule an in-person training session or consultation.
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