The Motor Decisions Matter Web site (www.motorsmatter.org) includes 24 case studies from a variety of industries, two of which are summarized below.
Ash Grove Cement, Overland Park, Kan.
Ash Grove Cement, which operates eight cement manufacturing plants, used a motor management plan to increase the reliability and reduce downtime for its fleet of 600 large motors. The company worked with the Electric Motor Management program to develop a motor repair purchasing specification, which included using service centers that used a core loss tester.
Improved ability to determine which motors had core loss damage helped the company avoid $6,000 per hour in downtime costs. And, because a damaged core reduces a motors efficiency, Ash Grove saves on electricity costs by not repairing motors with damaged cores. Ash Grove estimates that replacing one 700-hp motor will result in $5,000 in energy savings over the life of the motor.
Note: The Electric Motor Management program is part of the Industrial Efficiency Alliance initiative of Northwest Energy Efficiency Alliance, an MDM sponsor. For more information about NEEA: 503-827-8416 or www.nwalliance.org.
Eastman Kodak, Rochester, N.Y.
Kodak Park, home base for Eastman Kodak, has about 80,000 motors. In an effort to achieve greater efficiency, plant managers are using Motor Master+ software to make repair/replace decisions. In one small manufacturing area, 44 standard-efficiency motors were replaced with NEMA Premium motors, resulting in savings of 250,000 kWh and $17,250 annually. The New York State Energy Research and Development Authority (NYSERDA), an MDM sponsor, encouraged Kodaks use of NEMA Premium motors by providing rebates. Contact NYSERDA services at 1-866-NYSERDA or www.nyserda.org.
The full text of these case studies and additional reports can be accessed at www.motorsmatter.org/kit/case_studies.html.