Introduction In todays power scenario we are facing a major power crunch.

Day by day gap between demand and supply of electric energy is widening. Bridging this gap from supply side is very difficult and expensive proportion. The only viable way in handling these crises, in addition to capacity addition, is the efficient use of available energy sources. Electric motors are industrys basic need. Industries consume about 50% of the power generated in the country and electric motors consume around 76% of the total electricity used in the industrial sector. Majority of the motive loads use squirrel cage induction motor as driving element. Most of the motors use in industry is oversized. Even when proper sized motors used, they are not fully loaded to their capacities. This result into poor efficiency which leads to more power consumption and energy cost .Therefore improvement of efficiency of the motor must be a part of any comprehensive energy conservation effort. This conservation is possible by using energy efficient motors in place of standard motors. As motors are the largest users of the electrical energy, even small efficiency improvements can produce very large saving across the country. Energy conservation measures taken by individual consumers in this direction will improve the national economy and benefit the environment on global scale.

Motor Efficiency History

Current Interest in Motor Efficiencies Began with the 1976 Energy Crisis. Premium Efficient Motors Introduced in 1980s. The National Electrical Manufactures Association (NEMA) first made a definition between Standards and Energy Efficient motors in MG1-1987 with their September 1990 revision. These Energy Efficiency motors efficiencies later became the standards for the Energy Policy Act of 1994 (EPAct). In October 1997, the Energy Policy Act of 1994 too effect mandating minimum efficiency levels for general purpose TEFC and OPD 1 - 200Hp (0.75150kW) 2, 4, 6 and 8 pole foot-mounted motors. This required that any EPAct motor sold in the United States comply with minimum nominal efficiency, testing and labeling standards. The consortium of Energy Efficiency (CEE) established premium efficiency guidelines used by many utilities for rebate programs in 1996. In mid-2001 NEMA and CEE harmonized their efficiency standards, establishing NEMA Premium efficiency standards for ODP and TEFC 1500Hp (0.75- 370kW) 2, 4, and 6 pole motors in low and medium voltage. The NEMA Premium standards first defined in NEMA MG1-1998, Rev 2 dose not differentiate between mountings configurations and all types of motors are covered.

Electric Motor Efficiency

Electric Motor Efficiency is the measure of its ability to convert kilowatt of electric power supplied to the motor terminal and the horse power of mechanical energy taken out of the motor at the rotating shaft. Efficiency (%) = Watts output ----------------- 100 Watts input
:

746 HP ----------------- 100 V I cos Input - Losses = ----------------- 100 Input

Ways to Save on Motor Energy Costs

Use Variable speed Drives (VSD) for Variable Loads Reduce the Load 9.1 Motor Size Motors should be sized to operate with a load factor between 65% and 100%. The common practice of oversizing results in less efficient motor operation. For rare peak loads, use a pony motor. 9.2 Operating Speed While the average speed of energy-efficient motors is slightly higher than the average speed of standard-efficiency motors for any given size, models of each type are available with a wide range of speeds. Installing a new motor with a higher speed can result in diminished energy savings. It is particularly important in centrifugal pump or fan applications to select replacement motors with a comparable full-load speed. 9.3 Inrush Current Avoid overloading circuits. Energy-efficient motors feature low electrical resistance and thus exhibit higher inrush currents than standard models. The inrush current duration is too short to trip thermal protection devices, but energy-efficient motors equipped with magnetic circuit protectors can sometimes experience nuisance trips during start-up.

What is an energy efficient motor?

An Energy efficient motor produces the same shaft output power (kW), but draws less input power (kW) than a standard (lower efficiency) motor. Hence EEM consumes less electricity than comparable standard motor for any given load. EEM are manufactured with higher quality materials and techniques; they usually have higher service factors and bearing lives, less waste heat output and less vibration.

Features of EEM:

Highest efficiency. Lower operating cost. Has high overloading cost. Suitable for operations at higher ambient temperature. Fewer power factor correction. Saving increases with time. Confirmation with NEMA standards of protection and control. Cooler and Quieter operation. Longer insulation life : EEMs winding run about 20C cooler which increases insulation life by 4 times. Improved bearing life: EEM bearing run about 10C cooler than standard motor bearing, which doubles the life. Less Starting thermal stress. Higher service factor. Better suited for energy management systems. EEM perform better under adverse conditions of abnormal voltage conditions like unbalanced voltages. Efficiency of EEM remains almost constant from 50% to 100% of load.

Energy Efficient or High Efficiency Motor Design

Efficiency is a measure of the effectiveness with which a motor converts electrical energy into mechanical energy, which is measured by watts input versus watts output. In the conversion process, watts are lost by transformation into heat, which is dissipated through the frame. To improve efficiency, watt losses must be reduced through optimized design, improved material selection and quality control Watts Loss Area: Iron. Stator. Rotor. Friction and Windage Losses. Stray Load Loss.

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

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

(Bureau of Indian Standards)

Energy Efficiency Opportunities

Use Energy Efficient Motors
Power Loss Area
1. Fixed loss (iron) 2. Stator I2R

Efficiency Improvement
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. 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) Use of larger rotor conductor bars increases size of cross section, lowering conductor resistance (R) & losses due to current flow (I) Use of low loss fan design reduces losses due to air movement Use of optimized design & strict quality control procedures minimizes stray load losses

3 Rotor I2R

4 Friction & Winding 5. Stray Load Loss

Energy Efficiency Opportunities

Minimising losses in a motor

Simply Stated: REDUCED LOSSES = IMPROVED EFFICIENCY 1. Iron Improved steel properties : Standard motors use low carbon laminated silicon steel for the rotor and stator. Such steel typically has electrical losses at 606 watts/kg. High efficiency motors are build with high grade silicon steel which typically reduces hysterisis and eddy current losses by half to only about 3.3 watts/kg. Thinner Laminations: Reducing lamination thickness in rotor and stator steel also lowers eddy current losses. Improved insulation between laminations, when applied with enhanced quality control further reduces these losses. The use of thinner lamination result into decrease in core loss from 10% to 25% depending on method of processing the lamination steel and the method of assembling the magnetic core. Longer core adds more steel to the design, which reduces the losses due to lower operating flux densities.

Energy Efficiency Opportunities

2.Stator and rotor IR. Increase conductor volume: Older standard motors employ aluminium or copper conductors of size no larger than that needed to deliver the required horsepower. High efficiency motors utilize bigger copper conductor to lower the winding resistance with the conductor sized 35% to 45% larger than needed to simply satisfy the motor output horsepower requirement. Modified slot design : To accommodate the larger volume of copper in the windings required additional slot insulation, the slot cross section area is increased.

Energy Efficiency Opportunities

Friction and Windage More Efficient fan design: Use of low loss fan design reduces due to air movement. Use of better quality bearing and lubricating material reduces friction losses. In EEM the heat producing losses are low hence it is possible to reduce ventilating requirements which in turn will reduce windage losses resulting into further improvement of the efficiency. EEM design incorporates a small cooling fan resulting into quieter operation

Energy Efficiency Opportunities

Stray Losses Use of optimized design and strict quality control procedures minimizes the stray losses. Proper proportioning of rotor and stator slots. Having Small slot opening. Using optimum air gap.

Energy Efficiency Opportunities

Air Gap Narrowing air gap: Air gap are optimized to reduce magnetizing current and associated losses resulting into improvement of power factor.

Energy Efficiency Opportunities

Energy Efficiency Opportunities

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

Energy Efficiency Opportunities

2. Reduce Under-loading
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

Energy Efficiency Opportunities

3. Sizing to Variable Load
Motors have service factor of 15% above rated load

Motor selection based on

X Highest anticipated load: expensive and risk of under-loading

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

Energy Efficiency Opportunities

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 Exampl e3

Voltage (%)

unbalance

0.30
0.4

2.30
17.7

5.40
40.0

Unbalance in current (%)

Temperature

30

40

Energy Efficiency Opportunities 4. Improve Power Quality

Keep voltage unbalance within 1% Balance single phase loads equally among three phases Segregate single phase loads and feed them into separate line/transformer

Energy Efficiency Opportunities

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

Energy Efficiency Opportunities

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

Energy Efficiency Opportunities

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

Energy Efficiency Opportunities

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

Energy Efficiency Opportunities

8. Speed Control of Induction Motor
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

Energy Efficiency Opportunities

8. Speed Control of Induction Motor
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

What Design Characteristics are Important?

9.1 Motor Size Motors should be sized to operate with a load factor between 65% and 100%. The common practice of oversizing results in less efficient motor operation. For rare peak loads, use a pony motor. 9.2 Operating Speed While the average speed of energy-efficient motors is slightly higher than the average speed of standard-efficiency motors for any given size, models of each type are available with a wide range of speeds. Installing a new motor with a higher speed can result in diminished energy savings. It is particularly important in centrifugal pump or fan applications to select replacement motors with a comparable full-load speed. 9.3 Inrush Current Avoid overloading circuits. Energy-efficient motors feature low electrical resistance and thus exhibit higher inrush currents than standard models. The inrush current duration is too short to trip thermal protection devices, but energy-efficient motors equipped with magnetic circuit protectors can sometimes experience nuisance trips during start-up.

Expected Savings

In many applications the load factor of the motor will range between 60% to 80%. The efficiency curve of standard motor is drooping in nature i.e there is a sharp fall in efficiency at partial loads. But the energy efficient motors have a flat efficiency curve and hence the fall in efficiency is marginal. Thus energy saving is significant even in part loads. Assessing cost effectiveness of energy efficient motors: Savings: Savings are calculated as follows : kW - out put of motor in kW E1 - efficiency of standard motor E2 - efficiency of energy efficient motor kW kW X= E1 E2 Savings = X (Working Hour's) (Working Days) (Tariff)

Load Vs Losses Graph , Benefits & Application

Higher efficiencies at operating level and consequently, reduction in electricity bill. Can take care of wider Supply variation and higher ambient. Suitable for service factor loads. Lower slip which enhances output of the end product.
Energy efficient motors are specially suited for industries which are power intensive and equipments which run on constant load for long duration.
Application:

Benefits of Energy Efficient Motors are as follows:-

Conclusion

As shows, the efficiency of three-phase induction motors can be improved through optimization of materials and operational parameters. If these improvements are realized, practically any motor that is operated more than just occasionally will, over the lifetime of the motor, yield savings equivalent to the purchase of several new motors. More detailed analyses are available from DKI13 and from the major motor manufacturers who also offer programs for selecting the best motors and drives for specific applications. Classifying motors into energy efficiency bands simplifies product selection and dispenses with the need for statutory control. The new labeling scheme is a major step forward as up until recently motor rating plates did not contain any information on power losses and efficiency. It would have been more expedient, however, to assign the label EFF1 to the lowest rather than the highest efficiency category, as this would have meant the EFF series could be readily extended up ward as future efficiency improvements are introduced. Recent developments in the USA have seen the production of motors whose losses are now lower than those stipulated in statutory regulations. As a result, these new high-efficiency motors have received the rather ungainly moniker NEMA Premium and only time will tell what awkward lexical construction will be created to describe the next phase of motor efficiency improvements. And with motors be coming ever more efficient, there is clearly going to be little need to extend the existing classification system in the other direction beyond EFF3.

Reference:

Energy Efficient Motor System By Steven Nadel A Textbook of Electrical Technology By B.L Theraja www.google.com www.ieee.org.in www.HEM.com

Along with saving money, energy efficient appliances and motors save the plant The energy used to run a product can be cut up to 80% There is a large potential to make a difference because all appliances energy usage can be cut Fridges, washers, dryers, cars Light bulbs, anything that plugs Into an outlet.

MAKING A DIFFERENCE

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.

THANK YOU FOR YOUR ATTENTION