Process Monitoring and High Efficiency Solutions as the Future of Energy Saving in Industrial Applications

This article addresses the monitoring of motors operating in industrial applications worldwide. The motors are monitored with wireless Ability™ Smart Sensors, and the data obtained over several months is used to analyze the real average efficiency and active power of the motors. A population of induction motors with different efficiency classes is chosen. The utilization degree, i.e., the ratio of the average actual power output of the motors when they are used to their nominal power, is presented. Upgrading of the motors is considered, where the population of motors is used as reference. Replacement of the motors, while maintaining the same power and shaft height, with a higher efficiency class is proposed and the possibility for yearly energy savings is estimated. A new technology — the Synchronous Reluctance (SynRM) motor — is proposed as an alternative solution, providing higher efficiency for future energy savings.