super efficient motors
TRANSCRIPT
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SUPER-EFFICIENT MOTORS
Avalanche071
Need of the hour
AUTHORS
VAISHNAVI.V.BICHU (E & E) FARHANA. SOUDAGAR (E & E)
USN2GI05EE042 USN2GI05EE006
[email protected] [email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected] -
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CONTENTS
1.0INTRODUCTION2.0MOTOR UTILITY SEGMENTATION3.0WHAT DOES ENERGY EFFICIENCY MEAN?4.0 TYPES OF LOSSES
4.1POWER LOSS
4.2 MAGNETIC CORE LOSSES
4.3 FRICTIONS AND WINDAGE LOSS
4.4 STRAY LOAD LOSS
5.0 HOW HIGHER EFFICIENCY CAN BE ACHIEVED?
6.0 INNOVATIVE DESIGN
7.0 FACTORS TO BE CONSIDERED FOR ENERGY MANAGEMENT OF MOTORS
8.0 EFFICIENCY CONSIDERATIONS IN MOTOR PURCHASES
9.0 COMMON MISCONCEPTIONS ABOUT ENERGY EFFICIENT MOTORS
10.0 CRITERIA FOR USE OF ENERGY EFFICIENT MOTORS
11.0 STANDARDS PERSPECTIVE TO ENERGY EFFICIENT MOTORS
12.0 MARKET BARRIERS AND SOLUTIONS
13.0 CONCLUSION
REFRENCES
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ABSTRACT
Power scenario in the country calls forenergy crisis management. Industrialization and growth in
population is creating a void between demand and supply, and this void is deepening day by day. Limited
resources, huge capital investment limits increased generation. Fossil fuel based generation is harming the
environment. Hydel power is capital intensive and posesthreat to the ecological balance . The generating
cost is increasing day by day & thepower tariffs are on the rise. Unless the above crises are properly
managed power scenario will be bleak. Conservation of the energy is the call of the day.
There is a capital investment that can repay many times its original value over the next 20 years. At the
same time, it can improve equipment reliability, reduce downtime and repair costs, and result in lower
releases of carbon dioxide to the atmosphere. The investment is straightforward: install electric motors
having thehighest electrical energy efficiency commensurate with your needs. Energy-efficient motors pay
for themselves in a few years or sometimes even a few months, after which they will continue to pile up
savings worth many times their purchase cost for as long as they remain in service.
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1.0INTRODUCTION
Until the energy crises in the 1970s, most general-purpose motors were designed to
provide rated output and operating characteristics at reasonable cost, period. Efficient
operation was at best a secondary consideration. As energy prices began rising, however,
manufacturers began promoting improved motors they called "high-efficiency" and
"energy-efficient", although the terms were not specifically defined at the time.
Old-style "standard efficiency" motors remained popular because they generally cost less
than the new models. Purchasing agents were seldom inclined to spend a little more
money up front in order to save on energy costs later on. But today the story is entirely
different. Looking at the power scenario in the country, there exists a huge gap between
the demand & the supply, which is widening. The generating cost is increasing day by
day & the power tariffs are on the rise. This is affecting the profitability of all the
industries. Hence it is a trend in the industry to look for the opportunities of cost
reduction. The major cost components in an industry include material, labour & energy
costs. Material & labour cost reduction has its own limitations & a manufacturer does not
have a direct control many times. But the manufacturer himself can influence the energy
costs through energy conservation measures & effective energy management.
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2.0 MOTOR UTILITY SEGMENTATION
The figures of the motor purchases in 2003-04 will give an idea of this potential. About 5
million motors accounting to approximately 5 million kW have been sold in 2003-04.
(These figures are as reported by IEEMA & are approximated to round figures). The non-
reporting members also account for an additional 3-4 mil. KW.
Fractional HP motors account for over 85% of volume. These small motors are used
primarily in domestic appliances and are lightly and/or intermittently loaded. As a result
there is little potential for cost-effective energy savings. Direct current (DC) motors have
applications in the industrial sector. There are few DC motors in-service and most are
being phased out in favour of alternating current (AC) motors with inverter drive
systems. AC low-tension (or low voltage) motors are used by all end-user segments and
represent largest market, following fractional horsepower motors. AC high-tension (high
voltage) motors are used in the industrial sector and are designed for specific
applications. AC low-tension motors can be further classified into squirrel cage and slip
ring (wound rotor) motors. Slip ring motors are designed for specialized applications and
are limited in number.
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Fig 1
Squirrel cage induction motors are widely used and find applications in all segments of
the industry. The greatest impact from motor efficiency improvements point of view is in
the AC, low-tension, squirrel cage motor ranging in size between 0.75 kW to 37.5 kW.
Motors larger than 37 kW tend to be more efficient and are often customer designed for
specific application
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Total motors
4357400. Nos.
FHP motors
3900000 Nos.
DC motors
6500 Nos.
AC LT motors
450000 nos.
AC HT motors
900 Nos.
Slip ring
5000 nos.
Squirrel cage
445000 nos.
0.75-7.5kW
350000 nos..
11-37kW
75000 nos..
> 37 kW
20000 nos.
Fig 2
3.0 WHAT DOES ENERGY EFFICIENCY MEAN?
Electric motors are simply devices that convert electrical energy into mechanical energy.
Like all electromechanical equipment, motors consume some "extra" energy in order to
make the conversion. Efficiency is a measure of how much total energy a motor uses in
relation to the rated power delivered to the shaft.
A motor's nameplate rating is based on output horsepower, which is fixed for continuous
operation at full load. The amount of input power needed to produce rated horsepower
will vary from motor to motor, with more-efficient motors requiring less input wattage
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than less-efficient models to produce the same output. Electrical energy input is measured
in watts, while output is given in horsepower. One horsepower is equivalent to 746 watts.
There are several ways to express motor efficiency, but the basic concept and the
numerical results are the same. For example:
Efficiency, % =746 x Horsepower (output)
x 100Watts (input)
Efficiency, % =Watts (output)
x 100
Watts (input)
The ratio describes efficiency in terms of what can be observed from outside the motor,
but it doesn't say anything about what is going on inside the motor, and it is what's
happening inside that makes one motor more or less efficient than another. For example,
we can rewrite the equation as:
Efficiency, % =Watts (output)
X 100
Watts (output) + Watts (Losses)
Or its equivalent,
Efficiency, % =Watts (Input) - Watts (Losses)
x 100
Watts (Input)
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"Losses" stands for all the energy "fees" the motor charges in order to make its electrical-
to-mechanical energy conversion. Their magnitude varies from motor to motor and can
even vary among motors of the same make, type and size. In general, however, standard-
efficiency motors (pre-EPAct) have higher losses than motors that meet EPAct standards,
while NEMA Premium motors, or better, have lower losses still.
4.0 TYPES OF LOSSES
Energy losses in electric motors fall into four categories:
Power losses
Magnetic core losses
Friction and windage losses, and
Stray load losses.
Power losses and stray load losses appear only when the motor is operating under load.
They are therefore more importantin terms of energy efficiencythan magnetic core
losses and friction and windage losses, which are present, even under no-load conditions
(when the motor is running, of course).
Power losses, also called IR losses, are the most important of the four categories and can
account for more than one-half of a motor's total losses. Power losses appear as heat
generated by resistance to current flowing in the stator windings and rotor conductor bars
and end rings.
Stator losses make up about 66% of power losses, and it is here that motor manufacturers
have achieved significant gains in efficiency. Since increasing the mass of stator
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windings lowers their electrical resistance (and therefore reduces IR losses), highly
efficient motors typically contain about 20% more copper than standard efficiency
models of equivalent size and rating.
Fig 3A typical NEMA motor showing the components that can be modified to increase motor e fficiency
Rotor losses, another form of power losses, are also called slip losses because they are
largelybut not entirelydependent on the degree of slip the motor displays. Slip is
the difference in rpm between the rotational speed of the magnetic field and the actual
rpm of the rotor and shaft at a given load.
Where, S = Slip
N = Output speed under load and
Ns = Synchronous (no-load) speed, rpm
S =
Ns - N
Ns
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Fig 5 cross section of a die cast motor rotor
Copper has higher electrical conductivity than aluminum, and it would be an ideal
conductor bar material except for the fact that it is difficult to die cast. A process to
produce die-cast copper rotors has recently been developed and, when fully
commercialized, it will enable the production of motors with even higher efficiencies
than the best models currently available.
The fact that high-efficiency motors tend to have less slip (run faster) than standard-
efficiency motors must be taken into account in certain applications. For e xample, energy
consumption by centrifugal loads such as fans and rotary compressors is proportional to
the cube of rotational speed. If such loads are driven at the higher speed of a low-slip,
high-efficiency motor directly replacing a standard motor, energy consumption can
actually increase. This situation can sometimes be resolved by lowering rotational speed
with a variable-speed drive, gears or pulleys. There are other parameters, such as torque
or starting current, that can vary among motors of the same nominal horsepower. It is
important to properly engineer the application of any motor to the intended task.
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Magnetic core losses arise from hysteresis effects, eddy currents and magnetic saturation,
all of which take effect in the steel laminations. Magnetic losses can account for up to
20% of total losses. With proper design, use of better materials and stringent quality
control, these losses can be reduced considerably.
Fig 6 Three different efficiencies for the same horsepower rating. Top: standard-efficiency pre-
EPAct motor; lower left: EPAct -level motor; lower right: NEMA Premium efficiency motor. Notice
that the rotor and stator lengthen (and the amount of copper in the motor rises) as efficiency
increases. (Courtesy: Toshiba)
The most effective means to reduce hysteresis and saturation losses is to utilize steels
containing up to 4% silicon for the laminations in place of lower-cost plain carbon steels.
The better magnetic properties offered by silicon steels can reduce core losses by 10 to
25%. Reducing the laminations' thickness also helps: substituting 26-ga or 29-ga steel for
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The 24-ga steel found in standard-efficiency motors lowers core losses by between 15
and 25%. Lengthening the lamination stack, which reduces the flux density within the
stack, also reduces core losses. Eddy current losses can be reduced by ensuring adequate
insulation between laminations, thus minimizing the flow of current (and IR losses)
through the stack.
5.0HOW HIGHER EFFICIENCY CAN BE ACHIEVED
Fig 7
We have from the efficiency definition,
Efficiency = output / input
= Output / (output + losses)
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It is evident from the efficiency equation that efficiency will increase if the losses in the
motor are reduced. Hence the designers aim is to reduce the losses while designing the
energy efficient motor.
The different components of the total losses, its contribution & the measures adopted for
its reduction are as under-
Sr. No. Description of losses
% Age of total
losses
Measures adopted for reduction
1
Load losses or Copper
losses a. Stator
b. Rotor
55-60%
a. Suitable selection of copper
conductors for maximum material.
b. Specially designed rotors
2 Core losses 20-25%
Low watt loss material, thinner
laminations & control of process for
burr height.
3 Friction & windage losses 2-10% Optimum fan design
4 Stray losses 4-5%Optimum slot geometry; Minimum
overhang length
Table 1
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6.0INNOVATIVE DESIGN
Fig 8
Feature: Top terminal box at DE and parallel cooling fins. Benefit: 40% higher utilization of cooling airflow than conventional design with
side terminal box at the center of the frame and radial cooling fins.
Feature: Small fan diameter with respect to the fan cowl. Benefit: Optimal cooling air flow, lower fan losses and quite operation. Feature: Radial flow straight blade fan. Benefit: Cooling is independent of direction of rotation and motor is suitable for
bi-directional rotation
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Feature: Dual mounting holes at NDE. Benefit: Motor of high rating can be retrofitted in the existing foundation. Feature: Staggered skew rotor Benefit: No inherent axial thrust
7.0 FACTORS TO BE CONSIDERED FOR ENERGY MANAGEMENT OF
MOTORS
1. Proper selection of the motor.
The selection of motor as per the load requirements will have the bearing on the
energy consumption in case of a standard motor, as the efficiency tends to drop
marginally at partial loads.
2. Proper supply network.
The end user does not have a control over the supply conditions if he is not having a
captive power plant.
3. Energy efficient product.
However, using an energy efficient motor in the utility segments ranges mentioned above
will give a substantial savings.
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8.0 EFFICIENCY CONSIDERATIONS IN MOTOR PURCHASES
Industrial tariff levels have been increasing in the past and are forecast to continue to
increase in the future. Industrial companies, to remain competitive in world markets, will
have to seek greater efficiencies, including motor and motor system efficiency.
Table 2
Energy efficient motors are cost effective. A payback of 15 months is likely based on
economic analysis for a new motor purchase. The analysis evaluated a typical 15 kW, 4-
pole motor, with average operation of 8,000 hours per year, at current industrial tariff
rates. This analysis compared the energy efficient motors with the standard motor. As the
average operating hours and tariff levels increase the payback period declines.
Economic Analysis 15 kW Example
Payback Reduced with Longer Hours, Greater Load
1 5 k W (4 -p o le ) S t a n d a r d E n e r g y E f f i c ie n t
P r ic e ( R s ) : 1 7 , 7 0 0 2 1 ,4 2 0
% E ff ic ie n c y : 89 . 0 % 9 1 .8 %
P r ic e p re m iu m 3 5 4 0
O p e r a t io n - H o u rs 8 0 00 8 0 0 0
E n e rg y R a t e R s .4 / k W h r R s .4 / k W h r
E n e rg y C o s t ( R s / Y r) : 5 ,3 9 ,3 2 6 5 ,2 2 ,8 7 6
A n n u a l S a v in g s : N il R s .1 6 ,4 5 0 .
P a y b a c k f o r p r e m iu m : 2 .5 M
R e c o v e ry o f E n ti re c o s t o f E E M o t o r: 1 .2 5 Y
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9.0 COMMON MISCONCEPTIONS ABOUT ENERGY EFFICIENT MOTORS
Many misunderstandings have arisen concerning the characteristics of todays more
efficient motors. Some of them lead to unfair criticism and other equally inaccurate
notions. Lead users to expect more than these motors will delivers.
Misconception 1: An oversized motor is less efficient .
Many authorities continue to stress the need to match motor rating more closely to
actual load horsepower contending that oversized motors are inherently efficient. A
3HP load for example is more efficiently carried by an under loaded 5HP motor than
by a fully loaded 3HP machine
Misconception 2: a moreefficient motor also has high power factor.
Many motor design modifications may be made to increase efficiency. Some of them
will also increase their power factor, where as others will decrease it. Comparing
energy efficient machines with their less efficient predecessors shows that some do
have high power factor, some have lower power factor and some exhibit no change. If
power factor improvement is ever needed, an easy way to get it is with capacitor on
motor circuitAn economical corrective measure that is not available to improve
efficiency.
Misconception 3: more efficient motors run cooler.
Thats a fallacy. So is the reverse proposition. Cooler motors must be more efficient.
Temperature and heat is not the same thing so they should not be confused with each
other. Temperature ratings for insulation systems or motors are the same regardless of
motor efficiency.
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Misconception 4:An energy efficient motor develops less torque and may not
accelerate the load .
Lower rotor resistances, often used to achieve higher efficiencys, thus tend to reduce
motor accelerating torque, but its not the only influence. And the expected amount of
torque reduction is seldom harmful except for load such as full conveyors.
10.0 CRITERIA FOR USE OF ENERGY EFFICIENT MOTORS
It is a common notion that energy efficient motors are exorbitantly costly. It is a myth.
Actually they are about 15-20% costly. But the savings accrued ensures better payback
periods & the extra investment is justified.
There are three major criteria to be considered while using the energy efficient motors
which will have an impact on the payback period
1. New application and / or new installations.This is a most cost effective step. In this case only the differential amount between
E.E motor & standard motor is involved & hence the payback periods are as low as 6-
9 months
2. Replacement of failed motor with an E.E motor.In this case the cost of new motor is compared with the rewinding cost. Hence the
payback periods will be slightly high. It may range from 1-1.5 years. However, it
should be noted that every rewinding deteriorates the motor efficiency & the damage
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is cumulative. Hence it is always advisable to replace a failed motor with a better
product.
3. Retrofitting with Energy efficient motor.
This criterion will require a different approach. The identification of the prospective
motor for replacement will depend on lot of factors like load cycle, sizing of motor,
application etc. A number of organizations conduct energy audits through experts in
the field to identify the locations & plan a budget for energy conservation program. A
phased program is chalked out for replacement of existing motors with the E.E
motors.
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11.0 STANDARDS PERSPECTIVE TO ENERGY EFFICIENT MOTORS
The graph below gives a comparative picture of specified efficiencies for of motors up to
37kW as per different standards referred inIndia.
50
55
60
65
70
75
80
85
90
95
0.1
0.2
0.5 1. 2. 5. 1
118
. 30
kwratings
Efficie
ncies
IS 12615
IS 8789
IEEMA Std.19-2000
The current Indian Standard IS 8789 addresses efficiency criteria for standard motors in
India. Most of the motor manufacturers in India follow this standard & their efficiency
figures are bound by it. However, all the major ones provide much higher efficient
motors than specified by IS 8789. With the focus on high efficiency motors these days, it
was required that a more stringent standard be brought in to effect. IS 12615 which will
come into effect shortly addresses the issue & is applicable for high efficiency motors. Its
scope, at present covers 4 pole motors up to 37kW.
IEEMA has proposed voluntary standards for E.E motors (No.19 /2000). IEEMA
standard is based on European Union standard & energy Act of USA.
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13.0 CONCLUSION
The market for low-tension motors is vast and complex. In the Industrial sector the
awareness is increasing towards the need to save energy by use of Energy Efficient
Motors. Every element within the chain needs to gear up to push the use of energy
efficient motors & therein gain from the benefits out of it. In the agricultural sector, the
increasing use of submersible pumps present an opportunity to introduce Energy
Efficiency standards. Various institutions and organizations need to synergies their
initiatives & activities under Government thrust to impact a change in the market
Let all of us in the chain contribute our efforts for the cause of energy management
by promoting the use of ENERGY EFFICIENT motors.
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REFERENCES
1.Reference to books
Handbook of electrical engineeringS.L.Bhatia EncyclopediaWikepedia
2.Reference to articles
Siemens LtdOut of the world motors Bharat bijlee LtdEnergy efficient motors International copper promotion council (India)Efficiency of motors
3.Reference to an Internet source
www.wapa.gov/pubs/tchbrf/eemotors.htm
www.energy.ca.gov/process/pubs/motors.pdf
www.copper.org/application/electrical/energy/motor_text.html
www.nema.org/gov/energy/efficient/premium
WORD COUNT- ABSTRACT195
PAPER3080
http://www.wapa.gov/pubs/tchbrf/eemotors.htmhttp://www.wapa.gov/pubs/tchbrf/eemotors.htmhttp://www.energy.ca.gov/process/pubs/motors.pdfhttp://www.energy.ca.gov/process/pubs/motors.pdfhttp://www.copper.org/application/electrical/energy/motor_text.htmlhttp://www.nema.org/gov/energy/efficient/premiumhttp://www.nema.org/gov/energy/efficient/premiumhttp://www.nema.org/gov/energy/efficient/premiumhttp://www.copper.org/application/electrical/energy/motor_text.htmlhttp://www.energy.ca.gov/process/pubs/motors.pdfhttp://www.wapa.gov/pubs/tchbrf/eemotors.htm -
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