Motors PDF

Motors
© Confederation of Indian Industry

Why to have focus on Motors?
Electric motors
consume
63-70% of the electricity
used by in
industry
Source: U.S. Department of Energy

LIFETIME COST OF AN ELECTRIC MOTOR
Purchase price
represents 2% of
motor life cost,
One Rewind
represents 0.7% of
cost
Electricity costs
accounts for
nearly 97%
Motors
Motor
Converts Electrical Energy into Mechanical
Energy
Drives a mechanical load
Types of mechanical loads
Constant torque, variable speed loads
Variable torque, variable speed loads

Types of Loads
Constant torque, Variable speed loads

Torque is constant irrespective of speed
Power is proportional to speed
Screw compressor, conveyors & feeders

Types of Loads
Variable torque, Variable speed loads

Torque α (speed)2
Power α (speed)3
Centrifugal pumps and fans
Common in all process
industries

TYPES OF MOTORS
DC Motors
Generally installed for
variable speed applications
Replaced by AC drives
AC MOTORS
Very common in
Industries
TYPES OF MOTORS
Slip ring induction
motors
Used in high starting
torque applications
Found in cranes, Mills,
large fans, etc

TYPES OF MOTORS
Squirrel cage
induction motors
Used in all general
applications
85% of the
industrial motors
are of squirrel cage
induction motors

Capacity of Motor - Horse Power ?
1 HP = 76 Kg-m per second

76 1 HP = 0.75 kW
Kg
Work - Force applied over a distance

Power – Rate of doing work

Operating Principle
When balanced three phase voltages are applied
to the windings of the stator, the resulting
currents in the windings produce a magnetic field
Lines of flux produced by the rotating magnetic
field cut the copper bars of the rotor, thus
inducing current in the rotor bars.
The interaction between the stator’s magnetic field and
the rotor’s currents results in rotational torque
The rotor then accelerates with its terminal speed
approaching that of the magnetic field

AC INDUCTION MOTOR
Primary winding connected to

“POWER SOURCE”
STATOR
Secondary winding carries

“INDUCED CURRENT”
ROTOR
Motor Efficiency
Effectiveness with which a motor
converts Electrical energy to

Output
Mechanical energy
Input
Out put Power

Efficiency = X 100
Input Power

Motor Losses
Copper Loss – I2R loss

Current dependent losses
Stator Cu loss
Rotor Cu loss
Iron loss – Voltage dependent
Hysteresis or magnetization loss
Eddy current loss

Motor Losses
Friction and windage losses –

mechanical losses
Friction at bearings
Friction offered by wind to rotor
movement
Stray load losses – difficult to estimate
Due to opposite rotor flux
Generally α (rotor current)2

Motor Power
P
Loss Model
WF
PCL
PI PO
Motor Load
PSL
PCU
Typical range
Hp horsepower 5 - 200 HP
Pwf windage/friction losses 2.6 - 0.3 %
Pcl core losses (magnetization) 5 - 2.5 %
Psl stray load losses 2.2 - 0.5 %
Pcu I2R losses (copper losses) 9 -3%
Pkl total losses 18.8 - 6.3 %
N motor efficiency (po/pi) 84 % - 94%

Range Of Losses In
AC Induction Motor
Range ( H.P ) % of Loss At FL

Efficiency %
1 - 10 14 - 35 65 - 86
10 - 50 09 - 15 85 - 91
50 - 200 06 - 12 88 - 94
200 - 1500 04 - 07 93 - 96
1500 & above 4 95 - 96
Types of Losses
Unavoidable losses
Avoidable losses
Focus on avoidable losses

Basic Formulas
Power = √3 V I Cos φ
Cos φ is power factor
Capacity α Torque
α Voltage 2

Motor Efficiency at Different Loads
Efficiency Vs Load
94%
70%
0 5 10 50 75 100
% Load
How to Find Out Motor Loading?
A 3-Ph IM rated for 75 kW, 415 V, 150A,

0.85 draws 30 kW & 75 A.
What is % loading on motor?
65 %
40 %
50 %
70 %

Performance of Motor at Partial Load
Motor loading is critical factor
Motor η and power factor varies with
% loading
For lightly loaded motors
Voltage related losses - high
Power factor is very low
More copper losses
Motor operates in less efficiency range

Voltage Optimisation
Capacity α Voltage 2
Impact on motor operating parameters
for voltage reduction:
Reduction in voltage dependent losses - Drop in

Magnetization current
Capacity reduces
PF improves
Load current drops
Load factor improves
Efficiency Improves
Motor Magnetization Losses Vs Motor
2.0 Voltage
1.8
Per unit magnetization losses 1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
.1 .2 .3 .4 .5 .6 .7 .8 .9 1.0
Per unit line voltage
Voltage Optimization
What are the effects of voltage optimization?

(Voltage 415 V --> 400 V)
100 HP Motor - 100 % Loading
100 HP Motor - 80% Loading
100 HP Motor - 50% Loading
Increase in Load Current

Decrease in Load Current – Optimum Level
Decrease in load current – Still Potential
Case study
Replace 380 V rated Motor with 415V Motor
15 kW, 380 V rated motor (imported) –

Raw & cooling water pump
Operated with 415V supply
Magnetiztion losses α V2

Action taken
Replace with 415V rated energy efficient motor
Savings achieved 8%
kW power consumption (380V motor) = 11.50 kW
kW power consumption (415V motor) = 10.56 kW
Reduction in kW = 0.94 kW
Total kW savings (4 motors) = 3.76 kW

Annual Saving - Rs 1.00 Lakhs

Investment - Rs 1.40 Lakhs
Payback - 17 Months

Optimization Of Lightly Loaded Motors
Options
Delta connection to permanent star
connection -Steady load application
Automatic star-delta-star converters- for
variable loads
Soft starter cum energy savers - High
Starting torque applications
Variable voltage devices
Down sizing
Overall voltage optimization

Options based on
Nature of load
Load factor
Economic option

Analysis of Load Pattern
Measure kW input to motor using Portable

Power Meter / Load Manager
Estimate % loading
Analyse Load pattern at different process
conditions
Record the minimum & maximum Loading

Delta & Star Motor Connection
L1
IL = √ 3 Ip VL
L1 VP =
√3
VL
V VL = VP
L2 L2
L3 L3
Delta connection Star connection

Convert Delta To Star Connection At
Lightly Loaded Motors
Motors normally operated in delta mode
Permanently Lightly loaded motors can be
operated in star mode
Effect on motor performance operating in star

mode
Reduction in voltage related Iron losses
Reduction in copper losses
Operates with improved P.F
Motor operating efficiency improves
CASE STUDY
Convert Delta To Star Connection At Root
Blower Motor
Rated kW - 30 kW
Actual load
Delta mode = 11 kW
Star mode = 9 kW
% Load = 36 %
Savings in kW = 2 kW
Annual Saving = Rs 0.6 Lakhs
Caution – Reset the OLR

Automatic Star-delta-star
Application - motors with variable loads
Automatic star-delta-star converter has load
sensor & Timer
Capacity ∝ V2
Principle of Voltage optimization
Load Sensor
Star Mode < 40% > 40% ∆ Mode

%L
Energy Saving Protection
CASE STUDY
Automatic Star Delta Star Starters for Belt
Conveyors
Most of the time lightly loaded

Subject to heavy load
Rated KW = 90.0 KW (3 nos)
Actual load = 35.0 KW
In star mode consumes = 32.0 KW
Savings in KW = 9.0 KW
Annual savings - Rs 2.8 Lakhs

Payback period - 5 months
Case Study
Loading of Motors – Varying
In a plant, if the loading of all the motors are less than 80%,
What is the method of Energy Conservation ?
Best method – Optimising the overall

Voltage of the plant.

Optimise The Plant Operating
Voltage-Overall
Plant operating voltage plays a critical role

in energy conservation
On line voltage optimising devices to
regulate the operating voltage
Magnetization losses vary exponentially
with the voltage

Optimise The Plant Operating
Voltage-Overall
Voltage optimization Potential will vary with
over all Loading pattern of all motors
To be implemented after analyzing the
loading pattern of all motors
Reduce Voltage from rated value – In steps
Monitor Energy Consumption
Arrive at Optimum Voltage
Case Study
Voltage Optimisation-Overall
Distribution Transformer : 2000 kVA, 11kV/433 V
Operating voltage : 428 – 430 V
LT Motors Loading : 20 – 80%
Average Load : 850 – 900 kW
Transformer tap position reduced from 3 (normal
tap) to 2
Optimized voltage : 417 – 419 V
Annual Savings : Rs 1.32 Lakhs

Role of Frequency in Process Plant
Fans, compressors & pumps are major loads
50 - 60 % power consumption
Majority of loads are centrifugal in nature
Power cons. ∝ Rpm3
10 - 20% over design is common
Excess head & capacity control
Controlled using dampers/valve
Energy inefficient methods of control

Role of Frequency in Process Plant
Variable frequency drives are ideal choice
Power plant (without grid synchronization)
Reduce the frequency and optimize
Majority of case low frequency is helpful to
reduce energy consumption
Reduction in Frequency – depends on
capacity utilization of Fans, pumps, Mills and
other drives
Applicable for power plants operating without
grid synchronization
Optimise operating frequency
A Case study from a Cement Plant
Has captive power plant – 45 MW

Operated in island mode
Operating frequency : 50 Hz
Studied all major equipment
Capacity utilization : 60 – 80%
Major fans controlled with GRR

TG @ 49.3 Hz frequency

Optimise operating frequency
Reduced the overall frequency to 49 Hz

in steps of 0.2 Hz
Observed the operating parameters
No effect on production
Found reduction in energy consumption

Energy Efficient Motor

Use of lower loss silicon
steel
Longer core
Thicker wires
Thinner laminations
Smaller air gap between
stator and rotor
Improved winding and
lamination designs to
minimise energy
consumption

Lesser slip
Copper instead of aluminum bars in
the stator
Improved fan design
Cooler operation & Increases motor
insulation life
1.15 service factor
Greater flexibility in handling voltage
variations and imbalances
High power factor
Eliminate need for PF correction
Energy Efficient Motors
New efficiency classes defined by IEC
Super premium Super premium
IE4
efficiency * efficiency
Premium
IE3 Premium
efficiency
High efficiency IE2 Comparable to EFF1
Standard
IE1 Comparable to EFF2
efficiency
IEC standard indicated a Super Premium class with

15% lower losses than the IE3
IE efficiency classes for 50 Hz 4-pole
motors

IE2 Vs IE3

Loading vs Efficiency
Motors are generally loaded between
50 – 80%
Due to Higher starting Torque
Varying process requirements
Efficiency of Energy Efficient Motors is

higher than conventional motors and
flat between 50 – 100% loading
Energy Efficient Motor – Part load
Operation
94 Energy efficient motor
90
80 Standard motor
76
5 10 50 100
% Loading
Part Load Efficiency Comparison
50 HP, 4 POLE MOTOR
110
105 EFF1
100
95
90
85 EFF2
80
75
% Efficiency
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0 25 50 75 100 125
% Load

Advantages of Energy Efficient Motor
Optimum efficiency
Longer life
Lower operating cost
Ability to operate at higher ambient
temperature

European Union Mandatory Standards
for Motors
Phase 1: Motors must meet the IE2 efficiency level
From 16 June, 2011
Phase 2: Motors with a rated output of 7.5 – 375 kW

must meet EITHER the IE3 efficiency level OR
From 1 January, 2015
the IE2 level if fitted with a variable speed drive
Phase 3: Motors with a rated output 0.75 – 375 kW must

meet EITHER the IE3 efficiency level OR the IE2
From 1 January, 2017
level if fitted with a variable speed drive

Indian Scenario
The standard is in line with IEC
Standard Recommend to Use of IE2 & IE3
motor
IE1 is obsolete from the standard
IE2 is recommended by standard from 30th
June 2011
IE3 is recommended by standard from 31st
Jan 2014

© ABB Group
When to Install EE Motors?
New Projects
EE Motors ideally suited
Rewinding of Old motors
In case of Normal Failure
Fit case for Replacement after rewound 5
times

Rewound Motors
Bearing failure
Rotor scratches stator
Air gap becomes uneven
Net torque developed is low
Causes drop in efficiency
Maximum 5 times motor can
undergo rewinding – normal
failure

Upgrading one, 0.75 kW motor
to a Premium Efficient motor ....
Every year will eliminate:
1 Drum 250 Kg of
of Oil coal from
from
being
or.... being
burned
burned
Up to 650 gms. of
carbon emissions
and.... from being
released into the
atmosphere

Case Study
Replace old motors with Energy Efficient
Motors
Implemented in one of the cement plants
Old motors
More than 20 years old
Rewound for many times
Reduction in efficiency
Replaced 9 numbers of motors

Payback period - 22 Months
Where Not to Install EE Motors?
Applications where EE motors cannot be

installed ?
EE Motors are not to be Installed for Intermittent

duty applications like crane, Hoist etc

Limitations of DC MOTORS
At higher speeds, brushes have
increasing difficulty in maintaining
contact
Brushes may create sparks, which limits
the maximum speed of the machine
Imperfect electric contact causes
electrical noise
Brushes eventually wear out and
require replacement
BLDC Motors
A brushless DC (BLDC) motor is a

synchronous electric Motor
powered by direct-current (DC) electricity
brush-system/commutator assembly is
replaced by an electronic controller
electronic controller can use position
information of the rotor, plus the desired
direction for the motor
In BLDC motors, current to torque and
voltage to rpm are linear
Two Configurations
Inner-Rotor Motors Outer-Rotor Motors

BLDC Motor control
Two components required for BLDC

motor control
Power is supplied through a switched
mode power supply which converts AC
to DC of 24 V or 48 V
PWM generation and control electronics

BLDC Motor control

Comparison DC Vs BLDC

Energy Efficient Ceiling Fan-Super fan
Super fan
Operates with BLDC motor
Least power consumption
High efficiency
Aerodynamic blade design

Why BLDC for ceiling fan ?
Ceiling fan is based on AC motors which

are power hungry
Speed is regulated through resistors
Inefficient control
Degradation of power factor
The proposed solution using the BLDC
motor is to keep the same air flow or
displacement
With less energy and improving the PF
BLDC Fan Vs Conventional Fan

BLDC Motor

Technical Specifications
Rated Voltage -230Vac

Rated Frequency -48Hz-52Hz
Power -35W
Power Factor -> 0.9
Speed -350rpm

Comparison
Power consumption in Watts
Speed Ordinary Fan Super fan*
Low 12 4
Medium 39 14
High 75 35
*Super fan delivers same or more air than ordinary fans

Features
Energy savings, more than 50%

Remote control
High air delivery
Power factor better than 0.9
LED Indication for remote operation
350 millions of fans will save Rs. 9000 crores in electricity bill every year

Sum-up
Sizing of the motor is critical and

important
Over sizing will result in
More losses
Lower efficiency
Undersizing will result in
Overloading
Overheating & failures
Optimal sizing will result in
Minimum losses
Maximum efficiency
Sum-up
Joint Ownership with the process team

New installations
Replacement – Rewound Motors
Low power ceiling fan

Thank you

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Motors

© Confederation of Indian Industry

Source: U.S. Department of Energy

© Confederation of Indian Industry

© Confederation of Indian Industry

Constant torque, Variable speed loads

© Confederation of Indian Industry

Variable torque, Variable speed loads

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

1 HP = 76 Kg-m per second

Work - Force applied over a distance

© Confederation of Indian Industry

© Confederation of Indian Industry

Primary winding connected to

Secondary winding carries

Effectiveness with which a motor

converts Electrical energy to

Out put Power

© Confederation of Indian Industry

Copper Loss – I2R loss

© Confederation of Indian Industry

Friction and windage losses –

© Confederation of Indian Industry

© Confederation of Indian Industry

Range ( H.P ) % of Loss At FL

© Confederation of Indian Industry

Cos φ is power factor

© Confederation of Indian Industry

A 3-Ph IM rated for 75 kW, 415 V, 150A,

© Confederation of Indian Industry

© Confederation of Indian Industry

Reduction in voltage dependent losses - Drop in

Per unit magnetization losses 1.6

What are the effects of voltage optimization?

Increase in Load Current

15 kW, 380 V rated motor (imported) –

© Confederation of Indian Industry

© Confederation of Indian Industry

Annual Saving - Rs 1.00 Lakhs

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

Measure kW input to motor using Portable

© Confederation of Indian Industry

© Confederation of Indian Industry

Effect on motor performance operating in star

Caution – Reset the OLR

Star Mode < 40% > 40% ∆ Mode

Most of the time lightly loaded

Annual savings - Rs 2.8 Lakhs

Loading of Motors – Varying

Best method – Optimising the overall

© Confederation of Indian Industry

Plant operating voltage plays a critical role

© Confederation of Indian Industry

Annual Savings : Rs 1.32 Lakhs

Controlled using dampers/valve

Energy inefficient methods of control

© Confederation of Indian Industry

Has captive power plant – 45 MW

© Confederation of Indian Industry