Energy Efficient Belt Drives Workgroup Meeting January 2014 Energy Efficient Belt Drives Abdul Qayyum “Q” Mohammed Engineer

Why is this important ? Industries have more number of larger motors that are belt driven compared to the commercial and residential sectors. Why Belt drives ? Ease to locate motors, ease of maintenance, universal Change speeds at the end use equipment without a Variable Frequency Drive (VFD) The most common belts are V-belts

V-Belt Losses Simplified Bending Losses (Hysteresis). Largest loss in v-belts. Other Losses: Friction (in and out of pulley) , Slip (speed), Stretching (Creep) Belt Temp increases with losses => Reduced belt life End Use (Power Out) Bending Required Bending Required Motor Power In

How to reduce Largest Loss ? SIMPLE ! Use a Notched (Cogged) V- belt

Okay, What Does that Mean? Average Efficiency of Belts* Standard-V = 93% Notched-V = 95% 2-3% Efficiency Boost 100 hp motor Operating 8760 hours/year $0.10 /kWh Demand Savings ~ 2.13 kW Cost Savings of ~$1,200 /year Notched-V’s last longer Twice** the life of a smooth V ** Based on discussions with maintenance personnel *S. Nadel, R.N. Elliot, M. Shepard, S. Greenberg, G. Katz, A.T. de Almeida, Energy-efficient Motor Systems: A Handbook on Technology, Program, and Policy Opportunities. 2nd ed. American Council for an Energy-Efficient Economy, 2002. Off the Grid !

I want to be even more efficient ! Use Synchronous Belts Low bending loss Low friction NO Slip NO Creep Used in all timing and precision applications Average Efficiency – 98% Demand Savings = 4 kW Cost Savings = $3,600 /year New system Incremental cost ~ 30% - 50% Higher Retrofit Cost, but more savings Not Suitable for High Shock load applications.

Who Needs Efficient Belts ? Everyone ! Top 6 recommendation for industrial facilities Over 4,000* recommendations Implementation Rate: 55%* *Data for 1981 to 2013

Conclusions Notched V’s Synchronous Belts Longer life offsets ~ 40% cost premium Energy Savings ! (2-3% efficient than smooth v-belts) Synchronous Belts 98% efficient throughout operating range with No slip Higher energy savings combined with rebates may result in paybacks less than 2 years. Example for 100 hp, running 8,760 hours/year on smooth-V belt @ $ 0.1/kWh

Abdul Qayyum “Q” Mohammed Questions ? Thanks for Listening! Abdul Qayyum “Q” Mohammed www.gosustainableenergy.com 614-268-4263 x308 aqmohammed@gosustainableenergy.com

Smooth V Notched V Synchronous Efficiency 92% 95% 98% Demand Savings - ~2 kW ~4 kW Implementation +40% of belt cost +40% System Cost Life X 2x Cost Savings/ year $1,200 $2,400