The 2020 US Department of Energy (USDOE) Motor System Market Assessment Motor (MSMA) was a follow-up to the 2002 MSMA. The assessments studied motor-driven systems for industrial and commercial motors greater than or equal to 1 hp.
Key findings and takeaway excerpts from the 2020 MSMA are in the condensed list below, taken from the report’s Executive Summary. A longer longer version of the key findings and takeaways is also available for download. These documents provide excerpts of the many “nuggets” of information that EASA members can use to identify current market conditions and trends in various motor system sectors and assist in future planning. The complete 252-page 2020 MSMA Report is also available for download.
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Key Findings + Takeaways
Decision-makers
The title of the person making motor system-related decisions has changed drastically. In 2002, the president/general manager made these decisions at 40 percent of facilities, and the plant manager did so at 13 percent of facilities. This has nearly reversed in the 2020 MSMA report. Motor system-related decisions are made by the plant/facility manager at 48 percent of facilities and by the general manager/president at nine percent of facilities.
Motor System Electricity Consumption
- Industrial and commercial three-phase motor systems greater than or equal to 1 hp consume ~1,079 terawatt-hours (TWh)/year, about 29 percent of the total electric grid load.
- Industrial: 546,963 gigawatt-hours (GWh), about 6 9 percent of all electricity consumption and 13 percent of overall energy consumption in the sector.
- Commercial: 532,016 GWh, about 43 percent of all electricity consumption and 26 percent of overall energy consumption in the sector.
- Twenty-nine percent of all industrial sector motor system electricity consumption is for materials processing, followed by 21 percent for pumps and fans/blowers each.
- Seventy-five percent of industrial motor system electricity consumption is attributed to 1-500 hp motor systems.
- Forty-eight percent of all commercial sector motor system electricity consumption is for refrigeration compressors (e.g., chillers, air conditioners). Refrigeration compressors, fans/blowers and pumps account for 94 percent of the sector’s motor system electricity consumption.
- Eighty percent of commercial sector motor system electricity consumption is attributed to the 1-50 hp size range.
Motor System Counts + Size
- There are 52.5 million motor systems greater than or equal to 1 hp in the industrial and commercial sectors, with 10.8 million in industrial and 41.7 million in commercial facilities.
- The average connected motor system horsepower at a facility is 1,595 hp for the industrial sector and 89 hp for the commercial sector.
- Average motor size is 27 hp for industrial and 8 hp for commercial.
- Ninety-nine percent of the motor system units in the industrial sector are in the 1-500 hp range, with 49 percent in the 1-5 hp range.
- Ninety-nine percent of the motor system units in the commercial sector are in the 1-50 hp size range.
Motor System Load Control
- On average, 16 percent of motor system capacity at an industrial facility uses variable frequency drives (VFDs), and 74 percent has no load control technology/equipment.
- The rate of installation of VFDs and other load control technologies in the industrial and commercial sectors increases with motor system size.
- On average, four percent of motor system capacity at a commercial facility uses VFDs, and 91 percent has no load control technology/equipment.
Motor System Energy Management
- Forty-nine percent of industrial facilities consider energy efficiency in the procurement of motor system components, and 58 percent consider energy efficiency in the design of new motor systems.
- Large industrial facilities are more likely to consider energy efficiency in the procurement and design of motor systems and related components compared to small facilities.
- Fifty-nine percent of commercial facilities consider energy efficiency in the procurement of motor system components, and 67 percent consider energy efficiency in the design of new motor systems.
- Large commercial facilities are less likely to consider energy efficiency in the procurement and/or design of motor systems and related components than small facilities.
Motor System Maintenance (Downtime, Repair/Replace, Rewinding)
- It is estimated that commercial and industrial facilities experience more than eight million and six million hours annually of unplanned motor system downtime, respectively, due to failure.
- On average, a commercial facility experiences three hours of unplanned motor system downtime due to failure per year, and an industrial facility experiences 47 hours per year.
- In the industrial sector, 54 percent of all facilities have a repair/replace policy, with the leading criteria guiding the policy being lowest first cost, which is used by 36 percent of facilities.
- In the commercial sector, 16 percent of all facilities have a repair/replace policy. Most facilities were unaware of the criteria underpinning the policy. The most commonly cited criteria guiding the policy are lowest first cost (11 percent) and quickest option (10 percent).
Related Reference and Training Materials
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