APPENDIX 12A. SMALL ELECTRIC MOTORS MANUFACTURER’S INTERVIEW GUIDE

TABLE OF CONTENTS

12A.1 INTRODUCTION .............................................................................................................. 12A­2

12A.2 ENGINEERING ANALYSIS............................................................................................. 12A­3

12A.3 SMALL ELECTRIC MOTORS MARKET DATA ......................................................... 12A­10

12A.4 PRELIMINARY MANUFACTURER IMPACT ANALYSIS ........................................ 12A­12

LIST OF TABLES

Table 12A­1. Covered Motor Characteristics............................................................................... 12A­4

Table 12A­2. Example of Filled Out Engineering Table .............................................................. 12A­5

Table 12A­3. Small Motor A.1 Polyphase: 1 HP, 56 Frame, 4 Poles......................................... 12A­6

Table 12A­4. Small Motor A.2 Capacitor­start, induction­run: 1⁄2 HP, 56 Frame, 4 Poles.......... 12A­7

Table 12A­5. Small Motor A.3 Capacitor­start, induction­run: 1⁄2 HP, 48 Frame, 4 Poles.......... 12A­8

Table 12A­6. Small Motor A.4 Capacitor­start, capacitor­run: 3⁄4 HP, 56 Frame, 4 Poles......... 12A­9

Table 12A­7. Apportioning End­use Consumers of Motors by Sales Channel .......................... 12A­11

Table 12A­8. Operating Hours and Frame Size Apportionment ................................................ 12A­11

12A­1

EERE-2007-BT-STD-0007 COMMENT 07.2
APPENDIX 12A. SMALL ELECTRIC MOTORS MANUFACTURER’S INTERVIEW GUIDE

12A.1 INTRODUCTION

Navigant Consulting, Inc. (NCI) has prepared the following manufacturer’s interview guide with the

understanding that certain information asked for is sensitive to the manufacturer. Therefore, NCI wishes

to enter into a non­disclosure agreement with your company in order to ensure any data you provide in

response to this guide is held in the strictest confidence. NCI will combine your response with

responses from several other companies to develop a representative industry ‘average’ relationship

between a manufacturer’s cost and efficiency for small electric motors. If you have any questions about

the questionnaire, please feel free to contact either:

Contacts at Navigant Consulting, Inc.

Matthew Nardotti Michael Scholand

Tel: (202) 481­7546 Tel: (202) 973­2482

matthew.nardotti@navigantconsulting.com mscholand@navigantconsulting.com

Purpose: NCI is seeking your input to an engineering analysis that estimates the average relationship

between a manufacturer’s cost and the efficiency for small electric motors. NCI is also seeking your

input on market­related information and any anticipated manufacturer impacts. This guide is broken

into three sections: A) the Engineering Analysis, B) the Market Questionnaire, and C) the Manufacturer

Impact Questionnaire. The interview guide is part of a larger standards rulemaking process in which the

U.S. Department of Energy is considering energy conservation standards for small electric motors.1

Request: Please review the attached interview guide and then contact NCI to discuss whether you are

interested in participating in this process. If so, then NCI will work with you to establish an nondisclosure agreement, and we will schedule a conference call to discuss your inputs at your earliest

convenience.

Schedule: Due to DOE’s schedule to publish the Advance Notice of Proposed Rulemaking in

September 2008, NCI will be looking to start holding calls with manufacturers to obtain your responses

to the questions in this Guide starting the week of November 19, 2007.

DOE published a positive determination for Small Electric Motors on July 10, 2006. DOE maintains a website for Small

Electric Motors where it publishes documentation associated with this rulemaking, including the July 2006 determination

notice: http://www.eere.energy.gov/buildings/appliance_standards/commercial/small_electric_motors.html

12A­2

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EERE-2007-BT-STD-0007 COMMENT 07.2
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3

4

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12A.2 ENGINEERING ANALYSIS

PART A. ENGINEERING ANALYSIS

The engineering analysis will represent general purpose, alternating­current, induction motors, built in a

two­digit frame number series. Of these, there are three major types being analyzed:

• Polyphase motors

• Capacitor­start, induction­run motors (CSIR)

• Capacitor­start, capacitor­run (or two­value capacitor) motors (CSCR)

For each of the small motors proposed for analysis, NCI is seeking an understanding of the discrete

design steps you would undertake to achieve the efficiency level shown in the table. In each case, start

with a baseline motor (i.e., the typical efficiency level you would sell), and identify the specific design

improvements you would incorporate in order to increase the efficiency of the motor.

The following are the four motors are the ones NCI is seeking input on:

Small Motor A.1 Polyphase: 1 HP, 56 Frame, 4 Poles

Small Motor A.2 Capacitor­start, induction­run: 1⁄2 HP, 56 Frame, 4 Poles

Small Motor A.3 Capacitor­start, induction­run: 1⁄2 HP, 48 Frame, 4 Poles

Small Motor A.4 Capacitor­start, capacitor­run: 3⁄4 HP, 56 Frame, 4 Poles

We need to construct a curve that denotes the relationship between cost and efficiency, and therefore we

are asking you to provide detailed information on incremental step increases in efficiency from the

baseline to a level called the “maximum efficiency” level. The maximum efficiency level may be a

motor that you don’t make today, but is one that represents the highest efficiency level you could

achieve if price were no object, and you incorporated every measure you could think of to increase

efficiency. That said, when considering the design of the maximum efficiency level, please do not

consider exotic core steel, such as boron­based material, please use the best grade of conventional steel.

In order to describe the cost­efficiency curve with some degree of accuracy, NCI is asking you to

provide the baseline and maximum efficiency, as well as four interim efficiency values. To summarize,

the requested designs would be at the following efficiency points:

0. Baseline motor efficiency – your typical efficiency for the specified motor.

. Incremental level

. Incremental level

. Maximum efficiency level seen in market today (i.e., commercially available)

. Gap fill between maximum market and maximum feasible

. The maximum efficiency level feasible regardless of price yet using conventional, non­exotic

materials.

For each design change, please also provide an estimate of your incremental production cost over the

baseline, as well as the total unit selling price to an OEM or distributor. In case it is not possible to list

the increase in cost per design change, please specify the total bill­of­materials cost increase for all the

improvements.

12A­3

EERE-2007-BT-STD-0007 COMMENT 07.2
We recognize that detailed designs may be difficult to prepare; therefore, in the interests of generating

reasonable results in a short period of time, we invite you to use your best judgment and experience

when completing the following tables.

Please use the following design specifications for all small electric motors (or please indicate to us if one

or more of these are problematic):

Table 12A­1. Covered Motor Characteristics

Application: General Purpose

Motor Type: Induction motor

Frame Size: NEMA Two­Digit

Input: Alternating­Current, 60 Hz

Speed: Single Speed

Duty: Continuous Duty

Construction: Open

The following example illustrates the kind of information that would be helpful for NCI in compiling an

aggregate engineering analysis. In this particular example, we show a set of improvements for

increasing the efficiency of a polyphase, 4 pole, 1 HP, 56 frame size motor (note: this example is purely

illustrative as it’s “Defining Design Characteristics” are not completely accurate of a motor of this type,

nor is its incremental value of efficiency). This table is intended only to provide an indication of the

degree of detail being requested in this Interview Guide.

12A­4

EERE-2007-BT-STD-0007 COMMENT 07.2
Table 12A­2. Example of Filled Out Engineering Table

Example: Polyphase: 1 HP, 56 Frame, 4 Poles

# Level Rated Full Load

Efficiency

Defining Design

Characteristics

Mfr. Production

Cost

Total Mfr.

Unit Selling Price

0

Baseline:

lowest cost

motor

78.5%2

Stack Length = 10 inches ­

$2753

Slot Fill = 55% ­

Steel Type = Cold rolled,

Grade A, (4.51 W/lb @ 15kg,

60 Hz)

­

AWG = 25 ­

# Level Rated Full Load

Efficiency

Design Changes of Baseline

to Meet Efficiency Level

Incremental Cost

(over Baseline)

per

Improvement4

Total Mfr.

Unit Selling Price

1 Incremental

value 80%

Increase Stack length to 10.25

inches +$20

$350

Upgrade steel to Cold rolled,

Grade B, (4.15 W/lb @ 15 kg,

60 Hz)

+$15

Additional steel processing

operation

+$5

Miscellaneous additional

components (e.g. XXXX)

+$10

2 Baseline efficiencies are estimates based on information gathered from various product catalogs. 3 Price is an estimate based on information gathered from various product catalogs. 4 The values in this column are based on estimates shown in the Technical Support Document for small electric motors;

again, they are purely illustrative.

12A­5

EERE-2007-BT-STD-0007 COMMENT 07.2
Table 12A­3. Small Motor A.1 Polyphase: 1 HP, 56 Frame, 4 Poles

# Level Rated Full Load

Efficiency

Defining Design

Characteristics

Mfr. Production

Cost

Total Mfr.

Unit Selling

Price

0 Baseline: lowest cost

motor 78.5%5

# Level Rated Full Load

Efficiency

Design Changes of

Baseline to Meet

Efficiency Level

Incremental Cost

(over Baseline) per

Improvement

Total Mfr.

Unit Selling

Price

1 Incremental

value

2 Incremental

value

3 Maximum value in

market today

85.5%

4

Gap fill between

maximum in market

and maximum

feasible

Maximum

5 technology

feasible

Efficiency value was taken from composite catalog data. Please modify if this number is incorrect.

12A­6

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EERE-2007-BT-STD-0007 COMMENT 07.2
Table 12A­4. Small Motor A.2 Capacitor­start, induction­run: 1⁄2 HP, 56 Frame, 4 Poles

# Level Rated Full Load

Efficiency

Defining Design

Characteristics

Mfr. Production

Cost

Total Mfr.

Unit Selling

Price

0 Baseline: lowest cost 61.4%6

motor

# Level Rated Full Load

Efficiency

Design Changes of

Baseline to Meet

Efficiency Level

Incremental Cost

(over Baseline) per

Improvement

Total Mfr.

Unit Selling

Price

1 Incremental

value

2 Incremental

value

3 Maximum value in

market today

68.7%

4

Gap fill between

maximum in market

and maximum

feasible

Maximum

5 technology

feasible

Efficiency value was taken from composite catalog data. Please modify if this number is incorrect.

12A­7

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EERE-2007-BT-STD-0007 COMMENT 07.2
Table 12A­5. Small Motor A.3 Capacitor­start, induction­run: 1⁄2 HP, 48 Frame, 4 Poles

# Level Rated Full Load

Efficiency

Defining Design

Characteristics

Mfr. Production

Cost

Total Mfr.

Unit Selling

Price

0 Baseline: lowest cost 64%7

motor

# Level Rated Full Load

Efficiency

Design Changes of

Baseline to Meet

Efficiency Level

Incremental Cost

(over Baseline) per

Improvement

Total Mfr.

Unit Selling

Price

1 Incremental

value

2 Incremental

value

3 Maximum value in

market today

68.7%

4

Gap fill between

maximum in market

and maximum

feasible

Maximum

5 technology

feasible

Efficiency value was taken from composite catalog data. Please modify if this number is incorrect.

12A­8

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EERE-2007-BT-STD-0007 COMMENT 07.2
Table 12A­6. Small Motor A.4 Capacitor­start, capacitor­run: 3⁄4 HP, 56 Frame, 4 Poles

# Level Rated Full Load

Efficiency

Defining Design

Characteristics

Mfr. Production

Cost

Total Mfr.

Unit Selling

Price

0 Baseline: lowest cost 67.8%8

motor

# Level Rated Full Load

Efficiency

Design Changes of

Baseline to Meet

Efficiency Level

Incremental Cost

(over Baseline) per

Improvement

Total Mfr.

Unit Selling

Price

1 Incremental

value

2 Incremental

value

3 Maximum value in

market today

85.2%

4

Gap fill between

maximum in market

and maximum

feasible

Maximum

5 technology

feasible

Efficiency value was taken from composite catalog data. Please modify if this number is incorrect.

12A­9

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EERE-2007-BT-STD-0007 COMMENT 07.2
12A.3 SMALL ELECTRIC MOTORS MARKET DATA

PART B. ADDITIONAL ISSUES FOR DISCUSSION

DOE’s rulemaking is focusing on general purpose, alternating­current, induction motors, built in a twodigit frame number series, including: capacitor­start induction­run, capacitor­start capacitor­run, and

polyphase induction motors. All of your responses to the following questions should be in the context of

these small motors.

B.1 Extrapolating Results. The Team will need to extrapolate findings from the analyzed motors to

other motors. Can you recommend a method of extrapolation that might be applied across

horsepower ratings and numbers of poles?

B.2 Shipments Estimate. Can you provide an estimate of the total national shipments for the CSIR,

CSCR, and polyphase induction motors? This would be your estimate of the total national

shipments for the US market, not your company’s shipments or proportion of those shipments.

B.3 Shipments Breakdown. Can you estimate the approximate percentage shipped in frame sizes

42, in 48, and in 56? Do you observe any trends in your customer orders for these frame sizes

(e.g., increasing, decreasing volumes)?

DOE will need to develop a distribution chain model to understand how motors move through the

market from manufacturer to end­user, as well as some of the final operating characteristics. DOE is

interested in understanding both the proportion (volume) of products that move through certain channels

and the mark­ups applied.

B.4 Distribution Chain. In the Determination Analysis, DOE estimated that the shipments from

motor manufacturers to original equipment manufacturers (OEMs) was 40%, from motor

manufacturers to distributors to OEMs was 25%, and from motor manufacturers to distributors to

end users was 35%. Do you agree with these national estimates? What are the typical mark­ups

by stakeholder in each of these channels?

B.5 End­Use Sectors. Which end­use sectors (e.g., industrial, commercial, agricultural) tend to

purchase motors using the three channels identified in B.4? If its easier, please respond to this

question by completing the following table.

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EERE-2007-BT-STD-0007 COMMENT 07.2
Table 12A­7. Apportioning End­use Consumers of Motors by Sales Channel

Sales Channel Industrial Commercial Agricultural Other Totals

OEMs 100%

Distributors to OEMs 100%

Distributors to End­users 100%

Totals 100% 100% 100% 100%

B.6 End­Use Application Operating Hours and Frame Size Apportionment. In the

Determination Analysis, DOE estimated the following annual operating hours by application

(these are repeated in the table below for convenience)? Do you agree with these national

average estimates? Do the average annual operating hours vary significantly by motor type or

size? Also, approximately what percentage of small motor shipments are used in the

applications listed below? Please complete the following table with your estimate of the

applications breakdown by frame size.

Table 12A­8. Operating Hours and Frame Size Apportionment

End­Use Application

Operating

Hours

/Year

Percentage Using...

Totals:

42­Frame 48­Frame 56­Frame

Air and gas compressors 800 100%

Commercial and Industrial HVAC /

refrigeration equipment 2500 100%

Commercial laundry machinery 2000 100%

Conveyors 3000 100%

Farm machinery 1000 100%

Food machinery 3000 100%

General industrial machinery 2000 100%

Industrial and commercial fans and blowers 5000 100%

Machine tools 2000 100%

Packaging machinery 3000 100%

Pumps and pumping equipment 3000 100%

Service industry machinery 1500 100%

Textile machinery 3000 100%

Woodworking machinery 2000 100%

Totals: 100% 100% 100%

12A­11

EERE-2007-BT-STD-0007 COMMENT 07.2
12A.4 PRELIMINARY MANUFACTURER IMPACT ANALYSIS

PART C. PRELIMINARY MANUFACTURER IMPACT ANALYSIS

C.1 Key Issues. What are the key issues for your company regarding any new energy conservation

standards for small electric motors?

C.2 Your Company’s Niches. What are your product lines, niches and relative strengths in the

small motors market?

C.3 Company Demographics. Where are your production facilities located, and what is the product

mix manufactured at each location? Does the bulk of your company’s small motor production

occur domestically? What are your employment levels at these facilities? Are there any

manufacturing or employment issues that DOE should be aware of in terms of producing more

energy efficient motors at your facility/facilities?

C.4 Materials and Material Prices. Are the materials necessary to build more energy­efficient

motors readily available? How would material price changes affect your company’s business?

C.5 Impacts. Generally how would new efficiency standards on small motors impact your customer

mix, distribution channels and corresponding profit margins? Please explain.

C.6 Capital Investment. What level of capital expenditure and product conversion costs would you

anticipate you may need to make at higher standard levels? Please describe these capital

investments and provide your best estimate of their respective magnitudes.

C.7 Small Businesses. To what extent will new standards require small businesses to acquire new

equipment or cause manufacturing process changes that could destabilize their business?

C.8 Facility Impacts. How would the imposition of new energy efficiency standards affect capacity

utilization and manufacturing assets at your domestic production facilities? Would a new

standard result in stranded capital assets? Would any facilities be closed or downsized? Added

or upgraded?

C.9 Depreciation. What are the depreciation periods for the three types of capital expenditures

(building, equipment, tooling)?

12A­12

EERE-2007-BT-STD-0007 COMMENT 07.2
C.10 Compliance Costs. What specific annual compliance costs (after the effective date) do you

anticipate incurring to comply with standards? Will they vary with standard level? Would these

costs vary over time?

C.11 Exports and Competition. Would new standards change your projected export sales? Would

new standards have an impact on the portion of the domestic market served by foreign

competition?

C.12 Industry Consolidation. In the absence of new standards, do you expect any industry

consolidation?

C.13 Competitive Positioning. How would new standards affect your ability to compete? Could

new standards disproportionately advance or harm the competitive positions of some firms?

C.14 IP Issues. Are there concerns over intellectual property, patent licensing or other related issue?

C.15 Impacts on Consumers. Could new standards result in disproportionate economic or

performance penalties for particular consumer/user subgroups? Beyond price and energy

efficiency, could new standards result in products that will be more or less desirable to

consumers due to changes in product functionality, utility or other features?

C.16 Regulatory Burden. Are there recent or impending regulations on small motors or related

products that do or will impose a cumulative burden on the industry? How might an energy

efficiency standard impact the cumulative regulatory burden faced by your company? What is

the total expected impact of those other regulations?

C.17 Federal Tax Incentives. Are there any federal tax credits or other incentive programs to

encourage you to produce energy efficient small motors (covered or subsidized for covered)?

12A­13

EERE-2007-BT-STD-0007 COMMENT 07.2