Electrical Motors

Training Session on Energy
Equipment
Electric Motors
Electrical Equipment/
Electric Motors
Presentation from the

“Energy Efficiency Guide for Industry in Asia”
www.energyefficiencyasia.org
1
© UNEP 2006
Training Agenda: Electric Motors
Introduction
Electric Motors
Types of electric motors

Assessment of electric motors
Energy efficiency opportunities
2
© UNEP 2006
Introduction
What is an Electric Motor?

Electric Motors
• 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 3
© UNEP 2006
Introduction
How Does an Electric Motor Work?

3
Electric Motors
4
2
(Nave, 2005)
4
© UNEP 2006
Introduction
Three types of Motor Load

Electric Motors
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
5
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Introduction
Electric Motors

6
© UNEP 2006
Type of Electric Motors
Classification of Motors
Electric Motors
Electric Motors
Alternating Current Direct Current (DC)

(AC) Motors Motors
Synchronous Induction Separately Self Excited

Excited
Single-Phase Three-Phase Series Compound Shunt
7
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DC Motors – Components
• Field pole
• North pole and south pole

Electric Motors
• 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 8
© UNEP 2006
DC motors
• Speed control without impact power

Electric Motors
supply quality
• Changing armature voltage
• Changing field current
• Restricted use
• Few low/medium speed applications
• Clean, non-hazardous areas
• Expensive compared to AC motors 9

© UNEP 2006
DC motors
• Relationship between speed, field

Electric Motors
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 10
© UNEP 2006
DC motors
• Separately excited DC motor: field current
supplied from a separate force

Electric Motors
• 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 or
(Rodwell Int. field current 11
Corporation, 1999)
© UNEP 2006
DC motors
Self-excited DC motor: series motor
Electric Motors
Suited for high

starting torque: • Speed restricted to
cranes, hoists 5000 RPM
• Avoid running with
no load: speed
uncontrolled
• Field winding in series
with armature winding
• Field current =
armature current
(Rodwell Int.
12
Corporation, 1999)
© UNEP 2006
DC motors
DC compound motor
Electric Motors
Suited for high Good torque and

starting torque if high stable speed
% compounding:
cranes, hoists
Higher %
compound in
Field winding in series = high
series and starting torque
parallel with
armature winding
13
© UNEP 2006
Classification of Motors
Electric Motors
Electric Motors
Alternating Current Direct Current (DC)

(AC) Motors Motors
Synchronous Induction Separately Self Excited

Excited
Single-Phase Three-Phase Series Compound Shunt
14
© UNEP 2006
AC Motors
• Electrical current reverses direction

Electric Motors
• Two parts: stator and rotor

• Stator: stationary electrical component
• Rotor: rotates the motor shaft
• Speed difficult to control

• Two types
• Synchronous motor
• Induction motor
15
(Integrated Publishing, 2003) © UNEP 2006
AC Motors – Synchronous motor

• Constant speed fixed by system

Electric Motors
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):
F = supply frequency
Ns = 120 f / P P = number of poles 16
© UNEP 2006
AC Motors – Induction motor

• Most common motors in industry

Electric Motors
• Advantages:
• Simple design
• Inexpensive
• High power to weight ratio
• Easy to maintain
• Direct connection to AC power source
17
© UNEP 2006

Components
Electric Motors
• 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
18
• Wound for definite number of poles © UNEP 2006

How induction motors work

Electric Motors
• 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 Rotor
field Stator
(Reliance)
• Rotor begins to rotate 19
© UNEP 2006

• Single-phase induction motor

Electric Motors
• 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
20
© UNEP 2006

• Three-phase induction motor

Electric Motors
• 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! 21
© UNEP 2006

Speed and slip

Electric Motors
• 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 = synchronous speed in RPM

Ns Nb = base speed in RPM
22
© UNEP 2006

Relationship load, speed and torque

Electric Motors
At 80% of full
At start: high speed: highest
current and “pull-out”
low “pull-up” torque and
torque current drops
At full speed:
torque and
stator current
are zero 23
© UNEP 2006
Introduction
Electric Motors

24
© UNEP 2006
Assessment of Electric Motors
Efficiency of Electric Motors

Motors loose energy when serving a load

Electric Motors
• Fixed loss
• Rotor loss
• Stator loss
(US DOE)
• Friction and rewinding
• Stray load loss
25
© UNEP 2006

Factors that influence efficiency

Electric Motors
• Age
• Capacity
• Speed
• Type
• Temperature
• Rewinding
• Load 26
© UNEP 2006

Motor part load efficiency

Electric Motors
• Designed for 50-100% load

• Most efficient at 75% load
• Rapid drop below 50% load
(US DOE) 27
© UNEP 2006
Motor Load
• Motor load is indicator of efficiency

Electric Motors
• Equation to determine load:
Load = Pi x  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
28
© UNEP 2006
Motor Load
Three methods for individual motors

Electric 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
29
load © UNEP 2006
© UNEP 2006
Motor Load
Input power measurement

Electric Motors
• 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 V = RMS Voltage, mean line to
Pi  line of 3 Phases
1000 I = RMS Current, mean of 3 phases
PF = Power factor as Decimal
30
© UNEP 2006
Motor Load
Input power measurement

Electric Motors
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
31
© UNEP 2006
Motor Load
Result Action
Electric Motors
→ Replace with more efficient,

1. Significantly properly sized models
oversized and
underloaded → Replace with more efficient,
2. Moderately properly sized models when
oversized and they fail
underloaded → Replace most of these with
3. Properly sized energy-efficient models when
but standard they fail
efficiency 32
© UNEP 2006
Introduction
Electric Motors

33
© UNEP 2006
Energy Efficiency Opportunities
1. Use energy efficient motors

2. Reduce under-loading (and avoid over-

Electric Motors
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
34
© UNEP 2006
Use Energy Efficient Motors

• Reduce intrinsic motor losses

Electric Motors
• Efficiency 3-7% higher

• Wide range of ratings
• More expensive but
rapid payback
• Best to replace when
existing motors fail (Bureau of Indian Standards)
35
© UNEP 2006
Use Energy Efficient Motors

Power Loss Area Efficiency Improvement

Electric Motors
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 & Use of low loss fan design reduces losses due to air
Winding movement
5. Stray Load Loss Use of optimized design & strict quality control
procedures minimizes stray load losses
36
(BEE India, 2004)
© UNEP 2006
2. Reduce Under-loading
• Reasons for under-loading

Electric Motors
• 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
37
• Reduced power factor
© UNEP 2006
2. Reduce Under-loading
• Replace with smaller motor

Electric Motors
• 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 38
© UNEP 2006
3. Sizing to Variable Load

• Motor selection based on

Motors have
Electric Motors
‘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
39
• Inability of motor to cool down
© UNEP 2006
4. Improve Power Quality

Motor performance affected by

Electric Motors
• 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 40
© UNEP 2006
4. Improve Power Quality

Electric Motors
Keep voltage unbalance within 1%

• Balance single phase loads equally
among three phases
• Segregate single phase loads and
feed them into separate
line/transformer
41
© UNEP 2006
5. Rewinding
• Rewinding: sometimes 50% of motors

Electric 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%
42
of rewinding costs
© UNEP 2006
6. Improve Power Factor (PF)

• Use capacitors for induction motors

Electric 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 43
© UNEP 2006
7. Maintenance
Checklist to maintain motor efficiency

Electric Motors
• 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
44
© UNEP 2006
8. Speed Control of Induction Motor

• Multi-speed motors
Electric 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
45
© UNEP 2006

• Variable speed drives (VSDs)

Electric Motors
• 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
46
• Three types
© UNEP 2006

Direct Current Drives

Electric Motors
• 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
47
© UNEP 2006
Training Session on Energy
Equipment

Electric Motors
Electric Motors
THANK YOU
FOR YOUR ATTENTION
48
© UNEP 2006
Disclaimer and References
• This PowerPoint training session was prepared as part of

the project “Greenhouse Gas Emission Reduction from
Industry in Asia and the Pacific” (GERIAP). While
Electrical Systems/
Electric motors
reasonable efforts have been made to ensure that the

contents of this publication are factually correct and
properly referenced, UNEP does not accept responsibility
for the accuracy or completeness of the contents, and shall
not be liable for any loss or damage that may be occasioned
directly or indirectly through the use of, or reliance on, the
contents of this publication. © UNEP, 2006.
• The GERIAP project was funded by the Swedish
International Development Cooperation Agency (Sida)
• Full references are included in the textbook chapter that is
49
available on www.energyefficiencyasia.org
© UNEP 2006

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Training Session on Energy

Presentation from the

Types of electric motors

What is an Electric Motor?

• Electromechanical device that converts

• Motors in industry: 70% of electrical

How Does an Electric Motor Work?

Three types of Motor Load

Motor loads Description Examples

Variable Torque varies with Centrifugal pumps, fans

Constant Torque changes Machine tools

Types of electric motors

Alternating Current Direct Current (DC)

Synchronous Induction Separately Self Excited

Single-Phase Three-Phase Series Compound Shunt

• North pole and south pole

• Receive electricity to form

• Armature (Direct Industry, 1995)

• Cylinder between the poles

• Speed control without impact power

• Expensive compared to AC motors 9

• Relationship between speed, field

flux and armature voltage

E = electromagnetic force developed at armature terminal (volt)

supplied from a separate force

• Self-excited DC motor: shunt motor

Suited for high

Suited for high Good torque and

Alternating Current Direct Current (DC)

Synchronous Induction Separately Self Excited

Single-Phase Three-Phase Series Compound Shunt

• Electrical current reverses direction

• Two parts: stator and rotor

• Speed difficult to control

AC Motors – Synchronous motor

• Constant speed fixed by system

AC Motors – Induction motor

• Most common motors in industry

AC Motors – Induction motor

AC Motors – Induction motor

How induction motors work

• Electricity supplied to stator

• Current induced in rotor

• Rotor produces second

AC Motors – Induction motor

• Single-phase induction motor

• One stator winding

AC Motors – Induction motor

• Three-phase induction motor

• Three-phase supply produces magnetic

AC Motors – Induction motor

Speed and slip

• Motor never runs at synchronous

% Slip = Ns – Nb x 100 Ns = synchronous speed in RPM

AC Motors – Induction motor

Relationship load, speed and torque

Types of electric motors

Efficiency of Electric Motors

Motors loose energy when serving a load

Efficiency of Electric Motors

Factors that influence efficiency

Efficiency of Electric Motors

Motor part load efficiency

• Designed for 50-100% load