UNIT III:ENERGY EFFICIENT MOTORS

 Energy efficient motors

 Factors affecting efficiency, loss
distribution,
 constructional details-
Characteristics - variable speed,
variable duty cycle systems
 RMS hp- voltage van at ion-
voltage unbalance- over motoring
1  Motor energy audit.
In today’s power scenario, the gap between demand &
supply of electric energy is widening at the rate of
3%(approx.). Bridging this gap from supply side is
very difficult & expensive proposition. The only
viable way in handling these crises, instead of
capacity addition, is the efficient use of available
energy which is possible by use of energy efficient
devices.

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Electric motors are industry’s basic need. Electric motors
consume around 70% of the total electricity used in the
industrial sector. As motors are largest users of
electrical energy, even small efficiency improvements
can produce very large savings across the country.

Energy conservation measure taken by individual

consumers in this direction can improve the national
economy & benefit the environment on global scale.

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What is an Electric Motor?

• Electromechanical device that converts

electrical energy to mechanical energy
• Mechanical energy used to e.g.
• Rotate pump impeller, fan, blower
• Drive compressors
• Lift materials

• Motors in industry: 70% of electrical load

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How Does an Electric Motor Work?

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Three types of Motor Load
Motor loads Description Examples
Constant Output power varies Conveyors, rotary kilns,
torque loads but torque is constant constant-displacement
pumps

Variable Torque varies with Centrifugal pumps, fans

torque loads square of operation
speed

Constant Torque changes Machine tools

power loads inversely with speed

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Type of Electric Motors

Classification of Motors
Electric Motors

Alternating Current (AC) Direct Current (DC)

Motors Motors

Synchronous Induction Separately

Self Excited
Excited

Single-Phase Three-Phase Series Compound Shunt

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DC Motors – Components
• Field pole
• North pole and south pole
• Receive electricity to form
magnetic field

• Armature (Direct Industry, 1995)

• Cylinder between the poles

• Electromagnet when current goes through
• Linked to drive shaft to drive the load

• Commutator
• Overturns current direction in armature
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DC motors
• Speed control without impact power supply
quality
• Changing armature voltage
• Changing field current

• Restricted use
• Few low/medium speed applications
• Clean, non-hazardous areas

• Expensive compared to AC motors

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DC motors
• Relationship between speed, field flux and
armature voltage
Back electromagnetic force: E = KN
Torque: T = KIa

E = electromagnetic force developed at armature terminal (volt)

 = field flux which is directly proportional to field current
N = speed in RPM (revolutions per minute)
T = electromagnetic torque
Ia = armature current
K = an equation constant

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 DC motors
• Separately excited DC motor: field current
supplied from a separate source

• Self-excited DC motor: shunt motor

Speed constant
independent of load
up to certain torque

• Field winding parallel

with armature winding
• Current = field current Speed control:
+ armature current insert resistance
in armature or11
(Rodwell Int. field current
Corporation,
1999)
 DC motors
Self-excited DC motor: series motor
• Speed restricted to
Suited for high
5000 RPM
starting torque:
• Avoid running with
cranes, hoists
no load: speed
uncontrolled

• Field winding in series

with armature winding
• Field current =
armature current
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(Rodwell Int.
Corporation, 1999)
 Suited for high
DC compound motor starting torque if high
% compounding:
cranes, hoists

Good torque and

stable speed

Field winding in
series and
parallel with Higher %
armature winding compound in
series = high
starting torque

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AC Motors
• Electrical current reverses direction
• Two parts: stator and rotor
• Stator: stationary electrical component
• Rotor: rotates the motor shaft

• Speed difficult to control

• Two types
• Synchronous motor
• Induction motor

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(Integrated Publishing, 2003)
AC Motors – Synchronous motor
• Constant speed fixed by system
frequency
• DC for excitation and low starting
torque: suited for low load applications
• Can improve power factor: suited for
high electricity use systems
• Synchronous speed (Ns):

Ns = 120 f / P

f = supply frequency 15
P = number of poles
AC Motors – Induction motor
• Most common motors in industry
• Advantages:
• Simple design
• Inexpensive
• High power to weight ratio
• Easy to maintain
• Direct connection to AC power source

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 AC Motors – Induction motor
Components
• Rotor
• Squirrel cage:
conducting bars
(Automated Buildings)
in parallel slots
• Wound rotor: 3-phase, double-layer,
distributed winding

• Stator
• Stampings with slots to carry 3-phase windings
• Wound for definite number of poles
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 AC Motors – Induction motor
How induction motors work
• Electricity supplied to stator
• Magnetic field generated that moves around
rotor
Electromagnetics

• Current induced in rotor

• Rotor produces second

magnetic field that
opposes stator magnetic
field
Rotor
• Rotor begins to rotate Stator

(Reliance)
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 AC Motors – Induction motor

• Single-phase induction motor

• One stator winding
• Single-phase power supply
• Squirrel cage rotor
• Require device to start motor
• 3 to 4 HP applications
• Household appliances: fans, washing
machines, dryers

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AC Motors – Induction motor

• Three-phase induction motor

• Three-phase supply produces magnetic
field
• Squirrel cage or wound rotor
• Self-starting
• High power capabilities
• 1/3 to hundreds HP applications: pumps,
compressors, conveyor belts, grinders
• 70% of motors in industry!

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AC Motors – Induction motor
Speed and slip
• Motor never runs at synchronous
speed but lower “base speed”
• Difference is “slip”
• Install slip ring to avoid this
• Calculate % slip:

% Slip = Ns – Nb x 100
Ns

Ns = synchronous speed in RPM

Nb = base speed in RPM 21
 AC Motors – Induction motor
Relationship load, speed and torque
At 80% of full
At start: high speed:
current and highest “pull-
low “pull-up” out” torque
torque and current
drops

At full speed:
torque and
stator current
are zero

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Assessment of Electric Motors
Efficiency of Electric Motors
Motors loose energy when serving a load
• Fixed loss
• Rotor loss
• Stator loss
• Friction and rewinding
• Stray load loss

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Efficiency of Electric Motors
Factors that influence efficiency
• Age
• Capacity
• Speed
• Type
• Temperature
• Rewinding
• Load

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Efficiency of Electric Motors
Motor part load efficiency
• Designed for 50-100% load
• Most efficient at 75% load
• Rapid drop below 50% load

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Motor Load
• Motor load is indicator of efficiency
• Equation to determine load:

Load = Pi  HP x 0.7457

 = Motor operating efficiency in %

HP = Nameplate rated horse power
Load = Output power as a % of rated power
Pi = Three phase power in kW

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Motor Load
Three methods for individual motors
• Input power measurement
• Ratio input power and rate power at 100% loading
• Line current measurement
• Compare measured amperage with rated amperage
• Slip method
• Compare slip at operation with slip at full load

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 Motor Load
Input power measurement
• Three steps for three-phase motors

Step 1. Determine the input power:

Pi = Three Phase power in kW

V x I x PF x 3
Pi  V = RMS Voltage, mean line to line of 3 Phases
1000 I = RMS Current, mean of 3 phases
PF = Power factor as Decimal

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Motor Load
Input power measurement
Step 2. Determine the rated power:

0.7457 Pr = Input Power at Full Rated load in kW

Pr  hp x hp = Name plate Rated Horse Power
r r = Efficiency at Full Rated Load

Step 3. Determine the percentage load:

Pi Load = Output Power as a % of Rated Power

Load  x 100% Pi = Measured Three Phase power in kW
Pr Pr = Input Power at Full Rated load in kW

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Motor Load

Result Action
1. Significantly → Replace with more efficient,
oversized and properly sized models
underloaded
2. Moderately → Replace with more efficient,
oversized and properly sized models when
underloaded they fail
3. Properly sized → Replace most of these with
but standard energy-efficient models when
efficiency they fail

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Energy Efficiency Opportunities
1. Use energy efficient motors
2. Reduce under-loading (and avoid over-
sized motors)
3. Size to variable load
4. Improve power quality
5. Rewinding
6. Power factor correction by capacitors
7. Improve maintenance
8. Speed control of induction motor
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Energy Efficiency Opportunities
Use Energy Efficient Motors
• Reduce intrinsic motor losses
• Efficiency 3-7% higher
• Wide range of ratings
• More expensive but
rapid payback
• Best to replace when
existing motors fail

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(Bureau of Indian Standards)
Use Energy Efficient Motors
Power Loss Area Efficiency Improvement
1. Fixed loss (iron) Use of thinner gauge, lower loss core steel reduces
eddy current losses. Longer core adds more steel to
the design, which reduces losses due to lower
operating flux densities.
2. Stator I2R Use of more copper & larger conductors increases
cross sectional area of stator windings. This lower
resistance (R) of the windings & reduces losses due to
current flow (I)
3 Rotor I2R Use of larger rotor conductor bars increases size of
cross section, lowering conductor resistance (R) &
losses due to current flow (I)

4 Friction & Winding Use of low loss fan design reduces losses due to air
movement

5. Stray Load Loss Use of optimized design & strict quality control
procedures minimizes stray load losses
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(BEE India, 2004)
2. Reduce Under-loading
• Reasons for under-loading
• Large safety factor when selecting motor
• Under-utilization of equipment
• Maintain outputs at desired level even at low
input voltages
• High starting torque is required

• Consequences of under-loading
• Increased motor losses
• Reduced motor efficiency
• Reduced power factor

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2. Reduce Under-loading contd…
• Replace with smaller motor
• If motor operates at <50%
• Not if motor operates at 60-70%

• Operate in star mode

• If motors consistently operate at <40%
• Inexpensive and effective
• Motor electrically downsized by wire
reconfiguration
• Motor speed and voltage reduction but
unchanged performance
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 3. Sizing to Variable Load

• Motor selection based on

Motors have
‘service factor’
of 15% above
X • Highest anticipated load: expensive and risk
of under-loading
rated load
 • Slightly lower than highest load: occasional
overloading for short periods

• But avoid risk of overheating due to

• Extreme load changes
• Frequent / long periods of overloading
• Inability of motor to cool down
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4. Improve Power Quality
Motor performance affected by
• Poor power quality: too high fluctuations in
voltage and frequency
• Voltage unbalance: unequal voltages to three
phases of motor

Example 1 Example 2 Example 3

Voltage unbalance (%) 0.30 2.30 5.40

Unbalance in current (%) 0.4 17.7 40.0
Temperature increase (oC) 0 30 40

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4. Improve Power Quality contd..

Keep voltage unbalance within 1%

• Balance single phase loads equally
among three phases
• Segregate single phase loads and
feed them into separate
line/transformer

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 5. Rewinding
• Rewinding: sometimes 50% of motors
• Can reduce motor efficiency
• Maintain efficiency after rewinding by
• Using qualified/certified firm
• Maintain original motor design
• Replace 40HP, >15 year old motors instead of
rewinding
• Buy new motor if costs are less than 50-65%
of rewinding costs

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6. Improve Power Factor (PF)
• Use capacitors for induction motors
• Benefits of improved PF
• Reduced kVA
• Reduced losses
• Improved voltage regulation
• Increased efficiency of plant electrical system

• Capacitor size not >90% of no-load

kVAR of motor

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7. Maintenance
Checklist to maintain motor efficiency
• Inspect motors regularly for wear, dirt/dust

• Checking motor loads for over/under loading

• Lubricate appropriately

• Check alignment of motor and equipment

• Ensure supply wiring and terminal box and

properly sized and installed

• Provide adequate ventilation 41

8. Speed Control of Induction Motor
• Multi-speed motors
• Limited speed control: 2 – 4 fixed speeds

• Wound rotor motor drives

• Specifically constructed motor
• Variable resistors to control torque
performance
• >300 HP most common

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8. Speed Control of Induction Motor contd..

• Variable speed drives (VSDs)

• Also called inverters
• Several kW to 750 kW
• Change speed of induction motors
• Can be installed in existing system
• Reduce electricity by >50% in fans and pumps
• Convert 50Hz incoming power to variable
frequency and voltage: change speed
• Three types

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8. Speed Control of Induction Motor contd..

Direct Current Drives

• Oldest form of electrical speed control
• Consists of
• DC motor: field windings and armature
• Controller: regulates DC voltage to armature
that controls motor speed
• Tacho-generator: gives feedback signal to
controlled

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ENERGY EFFICIENCY PURPOSE:
 The purpose of energy efficient appliances and motors
is to be able to supply the same level of energy service
only using less energy.

 Efficient energy use is achieved primarily by means of

a more efficient technology or process rather than by
changes in individual behavior.

 Energy conservation reduces the energy consumption

and energy demand per capita and thus offsets some of
the growth in energy supply needed to keep up with
population growth.
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ENERGY EFFICIENT MOTORS:
Advantages:
 Save energy & money.

 Near uniform efficiency from 50% to 100% of full load

ensuring energy savings even at part load conditions
also.

 Short payback period.

 Substantial savings after payback period.

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How Much Energy They Consume as
Compared to Purchase Price
 Over a typical ten-year operating life, a motor
operating most of the time can easily consume
electricity valued at more than 50 times the motor’s
initial purchase price. This means that when you
spend $1,600 to purchase a motor that operates
continually, you may be obligating yourself to spend
more than $80,000 on electricity.
 Another example is that even at the relatively low
energy rate of $0.04/kWh, a typical 20-horsepower
(hp) continuously running motor uses almost $6,000
worth of electricity annually, about six times its
initial purchase price.
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Savings by Use of Efficient Motors
 Over half of all electrical energy consumed in the
United States is used by electric motors.
Improving the efficiency of electric motors and
the equipment they drive can save energy, reduce
operating costs, and improve our nation’s
productivity.
 The potential savings in system improvement
opportunities are very large - over 100 billion
kwh/year energy savings and $3 billion (U.S.)
annual energy cost savings opportunity with
existing and new technology by 2010.

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Saving Con.
Annual Value of a One-Point Efficiency Gain
(Based on $0.04/kWh, 8000 Hours of Use, Full Load)

Horsepower Annual Savings

5 $17
10 $32
20 $61
50 $142
100 $278
200 $537
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Savings Con.

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NEMA Premium® will become the
minimum efficiency standard for many
motors in 2010, making the U.S. standards
the highest in the world.

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Negative Environmental Impacts
 Appliances have to get energy from somewhere, and the energy
comes from power plants. These power plants are one main
source of air and water pollution. They also release radioactive
materials into the atmosphere.
 Used appliances also produce electronic waste, which are
discarded, surplus, obsolete, or broken electrical or electronic
devices.
 The processing of electronic waste in developing countries
causes serious health and pollution problems because electronic
equipment contains some very serious contaminants such as
lead, cadmium, beryllium, mercury, and brominated flame
retardants.
 Even in developed countries recycling and disposal of e-waste
involves significant risk to workers and communities and great
care must be taken to avoid unsafe exposure in recycling
operations and leaching of material such as heavy metals from
landfills and incinerator ashes.
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Phantom Loads
 The phantom load is the electricity consumed by a
device when it is turned off.
 For example, your television consumes electricity as
it waits for you to hit the “on” button on your
remote.
 Your clock uses up energy 24/7 to keep track of time.
 Devices that have a phantom load are sometimes
called “vampires.” These devices have a hidden
energy cost that most people are never even aware
of.
 Nationally, phantom loads make up about six
percent of our energy consumption. This translates
into billions of dollars spent and countless amounts
of pollution emitted into our air.
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How to Deal with Phantom Loads
 Unplug all devices when not in use.
 Alternatively, plug your devices into a power
strip and turn the strip off when you go to sleep.
 Be careful when using cube shaped transformers
that plug into the wall. They are 60-80%
inefficient when plugged in, so it is especially
important that these are on power strips.

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Improvements
 Increasing the thickness of the copper wires wound
around the core of the motor. This reduces both the
electrical resistance losses in the wires and the
temperature at which the motor operates.
 Using more and thinner high-quality steel sheets for
the main fixed and rotating parts of the motor. This
also minimizes electrical losses.
 Narrowing the air gap between the spinning and
stationary motor components, increasing the strength
of its magnetic field. This lets the motor deliver the
same output using less power.

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