Billions wasted when replacing failed motors

By Electricity Forum


Substation Relay Protection Training

Our customized live online or in‑person group training can be delivered to your staff at your location.

  • Live Online
  • 12 hours Instructor-led
  • Group Training Available
Regular Price:
$699
Coupon Price:
$599
Reserve Your Seat Today
According to the Department of Commerce, U.S. industry will have to replace nearly 3 million failed electric motors rated between 1 and 200 HP in their plants this year. Unfortunately, in more than 4-out-of-5 cases, plant operation or purchasing managers will choose the wrong replacement unit.

This is because organizations across the board continue to specify motors based on lowest capital cost, rather than looking at total cost of ownership.

“If you look at the total cost of operating an electric motor over its typical 20 year service lifetime, you will find that the initial purchase price of the motor represents about 2% of the total lifetime cost,” said Valone Gomes, national OEM sales and product manager at WEG Electric Motors Corp., “whereas 97% of the total expenditures are for the electricity to power the motor. Clearly this means that motor efficiency and reliability should be the principle selection criterion, not the cheapest initial purchase price.”

Gomes explained that since the passage of the Energy Policy Act of 1992 (EPAct), U.S. industry had to meet certain minimum electrical efficiency standards when replacing electric motors. These were embodied by a class of EPAct high efficiency motors which represented a snapshot of the best available motor technology available around 1990 to gain 1 to 4% in efficiency.

But, technology has improved considerably, and a new class of motors — called NEMA Premium Efficiency (NPE) motors — is now available from suppliers throughout the industry. NPE motors deliver efficiencies of 1 to 4% above EPAct designs, but are more expensive to manufacture and so have initial cost premiums of 10 to 30% over EPAct units.

“So the vast majority of people replacing a motor will buy the EPAct variety based on its lower initial purchase cost,” Gomes said. “But by selecting an NPE motor for the same application, they could have saved the purchase premium in as little as two or three months in reduced electricity bills, and pay for the entire motor in less than 3 years based on the lower energy costs during that period. And this does not take into account the programs sponsored by local governments and utilities that subsidize the purchase of higher efficiency motors with rebates, tax credits, and other incentives.”

Gomes noted that, “NEMA Premium Efficiency motors will be required for motor replacement after 2010, when the Energy Independence and Security Act comes into force. But in the meantime, U.S. industry could be saving million of dollars a years if they selected motors based on lifetime cost rather than purchase price.

“In fact, the Department of Energy has estimated that switching exclusively to NEMA premium motors would save U.S. industry more than $10 billion annually, and reduce carbon emissions by nearly 80 million metric tons – the carbon equivalent of taking 16 million autos off the road. That’s good business and good environmental citizenship.

Related News

Energy Vault Secures $28M for California Green Hydrogen Microgrid

Calistoga Resiliency Centre Microgrid delivers grid resilience via green hydrogen and BESS, providing island-mode backup during PSPS events, wildfire risk, and outages, with black-start and grid-forming capabilities for reliable community power.

 

Key Points

A hybrid green hydrogen and BESS facility ensuring resilient, islanded power for Calistoga during PSPS and outages.

✅ 293 MWh capacity with 8.5 MW peak for critical backup

✅ Hybrid lithium-ion BESS plus green hydrogen fuel cells

✅ Island mode with black-start and grid-forming support

 

Energy Vault, a prominent energy storage and technology company known for its gravity storage, recently secured US$28 million in project financing for its innovative Calistoga Resiliency Centre (CRC) in California. This funding will enable the development of a microgrid powered by a unique combination of green hydrogen and battery energy storage systems (BESS), marking a significant step forward in enhancing grid resilience in the face of natural disasters such as wildfires.

Located in California's fire-prone regions, the CRC is designed to provide critical backup power during Public Safety Power Shutoff (PSPS) events—periods when utility companies proactively cut power to prevent wildfires. These events can leave communities without electricity for extended periods, making the need for reliable, independent power sources more urgent as many utilities see benefits in energy storage today. The CRC, with a capacity of 293 MWh and a peak output of 8.5 MW, will ensure that the Calistoga community maintains power even when the grid is disconnected.

The CRC features an integrated hybrid system that combines lithium-ion batteries and green hydrogen fuel cells, even as some grid-scale projects adopt vanadium flow batteries for long-duration needs. During a PSPS event or other grid outages, the system will operate in "island mode," using hydrogen to generate electricity. This setup not only guarantees power supply but also contributes to grid stability by supporting black-start and grid-forming functions. Energy Vault's proprietary B-VAULT DC battery technology complements the hydrogen fuel cells, enhancing the overall performance and resilience of the microgrid.

One of the key aspects of the CRC project is the utilization of green hydrogen. Unlike traditional hydrogen, which is often produced using fossil fuels, green hydrogen is generated through renewable energy sources like solar or wind power, with large-scale initiatives such as British Columbia hydrogen project accelerating supply, making it a cleaner and more sustainable alternative. This aligns with California’s ambitious clean energy goals and is expected to reduce the carbon footprint of the region’s energy infrastructure.

The CRC project also sets a precedent for future hybrid microgrid deployments across California and other wildfire-prone areas, with utilities like SDG&E Emerald Storage highlighting growing adoption. Energy Vault has positioned the CRC as a model for scalable, utility-scale microgrids that can be adapted to various locations facing similar challenges. Following the success of this project, Energy Vault is expanding its portfolio with additional projects in Texas, where it anticipates securing up to US$25 million in financing.

The funding for the CRC also includes the sale of an investment tax credit (ITC), a key component of the financing structure that helps make such ambitious projects financially viable. This structure is crucial as it allows companies to leverage government incentives to offset development costs, including CEC long-duration storage funding, thus encouraging further investment in green energy infrastructure.

Despite some skepticism regarding the transportation of hydrogen rather than producing it onsite, the project has garnered strong support. California’s Public Utilities Commission (CPUC) acknowledged the potential risks of transporting green hydrogen but emphasized that it is still preferable to using more harmful fuel sources. This recognition is important as it validates Energy Vault’s approach to using hydrogen as part of a broader strategy to transition to clean, reliable energy solutions.

Energy Vault's shift from its traditional gravity-based energy storage systems to battery energy storage systems, such as BESS in New York, reflects the company's adaptation to the growing demand for versatile, efficient energy solutions. The hybrid approach of combining BESS with green hydrogen represents an innovative way to address the challenges of energy storage, especially in regions vulnerable to natural disasters and power outages.

As the CRC nears mechanical completion and aims for full commercial operations by Q2 2025, it is poised to become a critical part of California’s grid resilience strategy. The microgrid's ability to function autonomously during emergencies will provide invaluable benefits not only to Calistoga but also to other communities that may face similar grid disruptions in the future.

Energy Vault’s US$28 million financing for the Calistoga Resiliency Centre marks a significant milestone in the development of hybrid microgrids that combine the power of green hydrogen and battery energy storage. This project exemplifies the future of energy resilience, showcasing a forward-thinking approach to mitigating the impact of natural disasters and ensuring a reliable, sustainable energy future for communities at risk. With its innovative use of renewable energy sources and cutting-edge technology, the CRC sets a strong example for future energy storage projects worldwide.

 

Related News

View more

Electric Ferries Power Up B.C. with CIB Help

BC Ferries Electrification accelerates zero-emission vessels, Canada Infrastructure Bank financing, and fast charging infrastructure to cut greenhouse gas emissions, lower operating costs, and reduce noise across British Columbia's Island-class routes.

 

Key Points

BC Ferries Electrification is the plan to deploy zero-emission ferries and charging, funded by CIB, to reduce emissions.

✅ $75M CIB loan funds four electric ferries and chargers

✅ Cuts 9,000 tonnes CO2e annually on short Island-class routes

✅ Quieter service, lower operating costs, and redeployed hybrids

 

British Columbia is taking a significant step towards a cleaner transportation future with the electrification of its ferry fleet. BC Ferries, the province's ferry operator, has secured a $75 million loan from the Canada Infrastructure Bank (CIB) to fund the purchase of four zero-emission ferries and the necessary charging infrastructure to support them.

This marks a turning point for BC Ferries, which currently operates a fleet reliant on diesel fuel. The new Island-class electric ferries will be deployed on shorter routes, replacing existing hybrid ships on those routes. These hybrid ferries will then be redeployed on routes that haven't yet been converted to electric, maximizing their lifespan and efficiency.

Environmental Benefits

The transition to electric ferries is expected to deliver significant environmental benefits. The new vessels are projected to eliminate an estimated 9,000 tonnes of greenhouse gas emissions annually, and electric ships on the B.C. coast already demonstrate similar gains, contributing to British Columbia's ambitious climate goals. Additionally, the quieter operation of electric ferries will create a more pleasant experience for passengers and reduce noise pollution for nearby communities.

Economic Considerations

The CIB loan plays a crucial role in making this project financially viable. The low-interest rate offered by the CIB will help to keep ferry fares more affordable for passengers. Additionally, the long-term operational costs of electric ferries are expected to be lower than those of diesel-powered vessels, providing economic benefits in the long run.

Challenges and Opportunities

While the electrification of BC Ferries is a positive development, there are some challenges to consider. The upfront costs of electric ferries and charging infrastructure are typically higher than those of traditional options, though projects such as the Kootenay Lake ferry show growing readiness. However, advancements in battery technology are constantly lowering costs, making electric ferries a more cost-effective choice over time.

Moreover, the transition presents opportunities for job creation in the clean energy sector, with complementary initiatives like the hydrogen project broadening demand. The development, construction, and maintenance of electric ferries and charging infrastructure will require skilled workers, potentially creating a new avenue for economic growth in British Columbia.

A Pioneering Example

BC Ferries' electrification initiative sets a strong precedent for other ferry operators worldwide, including Washington State Ferries pursuing hybrid-electric upgrades. This project demonstrates the feasibility and economic viability of transitioning to cleaner marine transportation solutions. As battery technology and charging infrastructure continue to develop, we can expect to see more widespread adoption of electric ferries across the globe.

The collaboration between BC Ferries and the CIB paves the way for a greener future for BC's transportation sector, where efforts like Harbour Air's electric aircraft complement marine electrification. With cleaner air, quieter operation, and a positive impact on climate change, this project is a win for the environment, the economy, and British Columbia as a whole.

 

Related News

View more

Ontario will refurbish Pickering B NGS

Pickering nuclear refurbishment will modernize Ontario's Candu reactors at Pickering B, sustaining 2,000 MW of clean electricity, aiding net-zero goals, and aligning with Ontario Power Generation plans and Canadian Nuclear Safety Commission reviews.

 

Key Points

An 11-year overhaul of Pickering B Candu reactors to extend life, keep 2,000 MW online, and back Ontario net-zero grid.

✅ 11-year project; 11,000 annual jobs; $19.4B GDP impact.

✅ Refurbishes four Pickering B Candu units; maintains 2,000 MW.

✅ Requires Canadian Nuclear Safety Commission license approvals.

 

The Ontario government has announced its intention to pursue a Pickering refurbishment at the venerable nuclear power station, which has been operational for over fifty years. This move could extend the facility's life by another 30 years.

This decision is timely, as Ontario anticipates a significant surge in electricity demand and a growing electricity supply gap in the forthcoming years. Additionally, all provinces are grappling with new federal mandates for clean electricity, necessitating future power plants to achieve net-zero carbon emissions.

Todd Smith, the Energy Minister, is expected to endorse Ontario Power Generation's proposal for the plant's overhaul, as per a preliminary version of a government press release.

The renovation will focus on four Candu reactors, known collectively as Pickering B, which were originally commissioned in the early 1980s. This upgrade is projected to continue delivering 2,000 megawatts of power, equivalent to the current output of these units.

According to the press release, the project will span 11 years, create approximately 11,000 annual jobs, and contribute $19.4 billion to Ontario's GDP. However, the total budget for the project remains unspecified.

The project follows the ongoing refurbishment of four units at the nearby Darlington nuclear station, which is more than halfway completed with a budget of $12.8 billion.

The proposal awaits the Canadian Nuclear Safety Commission's approval, and officials face extension request timing considerations before key deadlines.

The Commission is also reviewing a prior request from OPG to extend the operational license of the existing Pickering B units until 2026. This extension would allow the plant to safely continue operating until the commencement of its renovation, pending approval.

 

Ontario's Ambitious Nuclear Strategy

The announcement regarding Pickering is part of Ontario's broader clean energy plan for an unprecedented expansion of nuclear power in Canada.

Last summer, the province announced its intention to nearly double the output at Bruce Power, currently the world's largest nuclear generating station.

Additionally, Ontario revealed SMR plans to construct three more alongside the existing project at Darlington. These reactors are expected to supply enough electricity to power around 1.2 million homes.

Discussions about revitalizing the Pickering facility began in 2022, after the station had been slated to close as planned amid debate, with Ontario Power Generation submitting a feasibility report to the government last summer.

The Ford government emphasized the necessity of this nuclear expansion to meet the increasing electricity demands anticipated from the auto sector's shift to electric vehicles, the steel industry's move away from coal-fired furnaces, and the growing population in Ontario.

Ontario's capability to attract major international car manufacturers like Volkswagen and Stellantis to produce electric vehicles and batteries is partly attributed to the fact that 90% of the province's electricity comes from non-fossil fuel sources.

 

Related News

View more

27 giant parts from China to be transported to wind farm in Saskatchewan

Port of Vancouver Wind Turbine Blades arrive from China for a Saskatchewan wind farm, showcasing record oversized cargo logistics, tandem crane handling, renewable energy capacity, and North America's longest blades from Goldwind.

 

Key Points

Record-length blades for a Canadian wind farm, boosting renewable energy and requiring heavy-lift logistics at the port.

✅ 27 blades unloaded via tandem cranes with cage supports

✅ 50 turbines headed to Assiniboia over 21 weeks

✅ Largest 250 ft blades to arrive; reduced CO2 vs coal

 

A set of 220-foot-long wind turbine blades arrived at the Port of Vancouver from China over the weekend as part a shipment bound for a wind farm in Canada, alongside BC generating stations coming online in the region.

They’re the largest blades ever handled by the port, and this summer, even larger blades will arrive as companies expand production such as GE’s blade factory in France to meet demand — the largest North America has ever seen.

Alex Strogen described the scene as crews used two tandem cranes to unload 27 giant white blades from the MV Star Kilimanjaro, which picked up the wind turbine assemblies in China. They were manufactured by Goldwind Co.

“When you see these things come off and put onto these trailers, it’s exceptional in the sheer length of them,” Strogen said. “It looks as long as an airplane.”

In fact, each blade is about as long as the wingspan of a Boeing 747.

Groups of longshoremen attached the cranes to each blade and hoisted it into the air and onto a waiting truck. Metal cage-like devices on both ends kept the blades from touching the ground. Once loaded onto the trucks, the blades and shaft parts head to a terminal to be unloaded by another group of workers.

Another fleet of trucks will drive the wind turbines, towers and blades to Assiniboia, Saskatchewan, Canada, over the course of 21 weeks. Potentia Renewables of Toronto is erecting the turbines on 34,000 acres of leased agriculture land, amid wind farm expansion in PEI elsewhere in the country, according to a news release from the Port of Vancouver.

Potentia’s project, called the Golden South Wind Project, will generate approximately 900,000 megawatt-hours of electricity. It also has greatly reduced CO2 emissions compared with a coal-fired plant, and complements tidal power in Nova Scotia in Canada’s clean energy mix, according to the news release.

The project is expected to be operating in 2021, similar to major UK offshore wind additions coming online.

The Port of Vancouver will receive 50 full turbines of two models for the project, as Manitoba invests in new turbines across Canada. In August, the larger of the models, with blades measuring 250 feet, will arrive. They’ll be the longest blades ever imported into any port in North America.

“It’s an exciting year for the port,” said Ryan Hart, chief external affairs officer.

The Port of Vancouver is following all the recommended safety precautions during the COVID-19 pandemic, including social distancing and face masks, Strogen said, with support from initiatives like Bruce Power’s PPE donation across Canada.
As for crews onboard the ships, the U.S. Coast Guard is the agency in charge, and it is monitoring the last port-of-call for all vessels seeking to enter the Columbia River, Hart wrote in an email.

Vessel masters on each ship are responsible for monitoring the health of the crew and are required to report sick or ill crew members to the USCG prior to arrival or face fines and potential arrest.

 

Related News

View more

Electricity blackouts spark protests in Iranian cities

Iran Power Outage Protests surge as electricity blackouts, drought, and a looming heat wave spark unrest in Tehran, Shiraz, and more, with chants against leadership, strikes, and sanctions-driven economic pressures mounting.

 

Key Points

Protests across Iran over blackouts, drought, and economic strain challenge authorities and demand accountability.

✅ Rolling blackouts blamed on drought, heat wave, and surging demand.

✅ Chants target leadership amid strikes and wage, water shortages.

✅ Legitimacy questioned after low-turnout election and sanctions.

 

There have been protests in a number of cities in Iran amid rising public anger over widespread electricity blackouts.

Videos on social media appeared to show crowds in Shar-e Rey near Tehran, Shiraz, Amol and elsewhere overnight.

Some people can be heard shouting "Death to the dictator" and "Death to Khamenei" - a reference to Supreme Leader Ayatollah Ali Khamenei.

The government has apologised for the blackouts, which it has blamed on a severe drought and high demand.

Elsewhere, similar outages have had political repercussions, as a widespread power outage in Taiwan prompted a minister's resignation earlier this year.

President Hassan Rouhani explained in televised remarks on Tuesday morning that the drought meant most of the country's hydroelectric power plants were not operating, placing more pressure on thermal power plants, and that electricity consumption had surged as people used air conditioning to cope with the intense summer heat.

"I apologise to our dear people who have faced problems and suffering in the past few days and I urge them to co-operate [by cutting their electricity use]. People complain about power outages and they are right," Mr Rouhani said.

A video that has gone viral in recent days shows a woman complaining about the blackouts and corruption at a government office in the northern city of Gorgan and demanding that her comments be conveyed to "higher-ups like Mr Rouhani". "The only thing you have done is forcing hijab on us," she shouts.

The president has promised that the government will seek to resolve the problems within the next two or three weeks.

However, a power sector spokesman warned on Monday that consumption was exceeding the production capacity of Iran's power plants by 11GW, and said a "looming heat wave" could make the situation worse, as seen in Iraq's summer electricity crunch this year.

Iranians have also been complaining about water shortages and the non-payment of wages by some local authorities, while thousands of people working in Iran's oil industry have been on strike over pay and conditions, as officials discuss further energy cooperation with Iraq to ease supply pressures.

There was already widespread discontent at government corruption and the economic hardship caused by sanctions that were reinstated when the US abandoned a nuclear deal with Iran three years ago, even as Iran supplies about 40% of Iraq's electricity through cross-border sales.

Analysts say that after the historically low turnout in last month's presidential election, when more than half of the eligible voters stayed at home, the government is facing a serious challenge to its legitimacy.

Mr Rouhani will be succeeded next month by Ebrahim Raisi, a hard-line cleric close to Ayatollah Khamenei who won 62% of the vote after several prominent contenders were disqualified, while Iran finalizes power grid deals with Iraq to bolster regional ties.

The 60-year-old former judiciary chief has presented himself as the best person to combat corruption and solve Iran's economic problems, including ambitions to transmit electricity to Europe as a regional power hub.

But many Iranians and human rights activists have pointed to his human rights record, accusing him of playing a role in the executions of thousands of political prisoners in the 1980s and in the deadly crackdowns on mass anti-government protests in 2009 and 2019.

 

Related News

View more

Ontario Power Generation's Commitment to Small Modular Reactors

OPG Small Modular Reactors advance clean energy with advanced nuclear, baseload power, renewables integration, and grid reliability; factory built, scalable, and cost effective to support Ontario energy security and net zero goals.

 

Key Points

Factory built nuclear units delivering reliable, low carbon power to support Ontario's grid, renewables, climate goals.

✅ Factory built modules cut costs and shorten schedules

✅ Provides baseload power to balance wind and solar

✅ Enhances grid reliability with advanced safety and waste reduction

 

Ontario Power Generation (OPG) is at the forefront of Canada’s energy transformation, demonstrating a robust commitment to sustainable energy solutions. One of the most promising avenues under exploration is the development of Small Modular Reactors (SMRs), as OPG broke ground on the first SMR at Darlington to launch this next phase. These innovative technologies represent a significant leap forward in the quest for reliable, clean, and cost-effective energy generation, aligning with Ontario’s ambitious climate goals and energy security needs.

Understanding Small Modular Reactors

Small Modular Reactors are advanced nuclear power plants that are designed to be smaller in size and capacity compared to traditional nuclear reactors. Typically generating up to 300 megawatts of electricity, SMRs can be constructed in factories and transported to their installation sites, offering flexibility and scalability that larger reactors do not provide. This modular approach reduces construction time and costs, making them an appealing option for meeting energy demands.

One of the key advantages of SMRs is their ability to provide baseload power—energy that is consistently available—while simultaneously supporting intermittent renewable sources like wind and solar. As Ontario continues to increase its reliance on renewables, SMRs could play a crucial role in ensuring that the energy supply remains stable and secure.

OPG’s Initiative

In its commitment to advancing clean energy technologies, OPG has been a strong advocate for the adoption of SMRs. The province of Ontario has announced plans to develop three additional small modular reactors, part of its plans for four Darlington SMRs that would further enhance the region’s energy portfolio. This initiative aligns with both provincial and federal climate objectives, and reflects a collaborative provincial push on nuclear innovation to accelerate clean energy.

The deployment of SMRs in Ontario is particularly strategic, given the province’s existing nuclear infrastructure, including the continued operation of Pickering NGS that supports grid reliability. OPG operates a significant portion of Ontario’s nuclear fleet, and leveraging this existing expertise can facilitate the integration of SMRs into the energy mix. By building on established operational frameworks, OPG can ensure that new reactors are deployed safely and efficiently.

Economic and Environmental Benefits

The introduction of SMRs is expected to bring substantial economic benefits to Ontario. The construction and operation of these reactors will create jobs, including work associated with the Pickering B refurbishment across the province, stimulate local economies, and foster innovation in nuclear technology. Additionally, SMRs have the potential to attract investment from both domestic and international stakeholders, positioning Ontario as a leader in advanced nuclear technology.

From an environmental perspective, SMRs are designed with enhanced safety features and lower waste production compared to traditional reactors, complementing life-extension measures at Pickering that bolster system reliability. They can significantly contribute to Ontario’s goal of achieving net-zero emissions by 2050. By providing a reliable source of clean energy, SMRs will help mitigate the impacts of climate change while supporting the province's transition to a sustainable energy future.

Community Engagement and Collaboration

Recognizing the importance of community acceptance and stakeholder engagement, OPG is committed to an open dialogue with local communities and Indigenous groups. This collaboration is essential to addressing concerns and ensuring that the deployment of SMRs is aligned with the values and priorities of the residents of Ontario. By fostering a transparent process, OPG aims to build trust and support for this innovative energy solution.

Moreover, the development of SMRs will involve partnerships with various stakeholders, including government agencies, research institutions, and private industry, such as the OPG-TVA partnership to advance new nuclear technology. These collaborations will not only enhance the technical aspects of SMR deployment but also ensure that Ontario can capitalize on shared expertise and resources.

Looking Ahead

As Ontario Power Generation moves forward with plans for three additional Small Modular Reactors, the province stands at a critical juncture in its energy evolution. The integration of SMRs into Ontario’s energy landscape promises a sustainable, reliable, and economically viable solution to meet growing energy demands while addressing climate change challenges.

With the support of government initiatives, community collaboration, and continued innovation in nuclear technology, Ontario is poised to become a leader in the advancement of Small Modular Reactors. The successful implementation of these projects could serve as a model for other jurisdictions seeking to transition to cleaner energy sources, highlighting the role of nuclear power in a balanced and sustainable energy future.

In conclusion, OPG's commitment to developing Small Modular Reactors not only reinforces Ontario’s energy security but also demonstrates a proactive approach to addressing the pressing challenges of climate change and environmental sustainability. The future of energy in Ontario looks promising, driven by innovation and a commitment to clean energy solutions.

 

Related News

View more

Sign Up for Electricity Forum’s Newsletter

Stay informed with our FREE Newsletter — get the latest news, breakthrough technologies, and expert insights, delivered straight to your inbox.

Electricity Today T&D Magazine Subscribe for FREE

Stay informed with the latest T&D policies and technologies.
  • Timely insights from industry experts
  • Practical solutions T&D engineers
  • Free access to every issue

Download the 2025 Electrical Training Catalog

Explore 50+ live, expert-led electrical training courses –

  • Interactive
  • Flexible
  • CEU-cerified