Motors: Efciency.....................................................135
138
Motors: Starter Sizes ................................................136
Motors: Service Factor.............................................136
Motors: Useful Equations ........................................137
Motors: Relative Costs .............................................137
Motors: Overloading ................................................138
134
Steam Turbines: Steam Rate ...................................
Steam Turbines: Efciency ......................................138
Gas Turbines: Fuel Rates.........................................139
Gas Engines: Fuel Rates ..........................................141
Gas Expanders: Available Energy...........................141
 Drivers 135

Table 1 from the GPSA Engineering Data Book1 Table 2

compares standard and high efciency motors. Table 2 Synchronous vs. Induction 3 Phase, 60 Hertz,
from GPSA compares synchronous and induction motors. 2,300 or 4,000 Volts
Table 3 from Evans2 shows the effect of a large range of
speeds on efciency.

Table 1
Energy Evaluation Chart
NEMA Frame Size Motors, Induction

Table 3
Full Load Efciencies

*Synchronous motors, 1.0 PF

1. GPSA Engineering Data Book, Gas Processors

Suppliers Association, Vol. 1, 10th Ed.
2. Evans, F. L., Equipment Design Handbook for
Reneries and Chemical Plants, Vol. 1, 2nd Ed., Gulf
Publishing Co., 1979.
136 Rules of Thumb for Chemical Engineers
Here are motor starter (controller) sizes.
Polyphase Motors
Over the years, oldtimers came to expect a 1015%
service factor for motors. Things are changing, as shown
in the following section from Evans.1
For many years it was common practice to give stan-
dard open motors a 115% service factor rating; that is, the
motor would operate at a safe temperature at 15% over-
load. This has changed for large motors, which are closely
tailored to specic applications. Large motors, as used
here, include synchronous motors and all induction
motors with 16 poles or more (450 rpm at 60 Hz).
New catalogs for large induction motors are based on
standard motors with Class B insulation of 80C rise by
resistance, 1.0 service factor. Previously, they were 60C
rise by thermometer, 1.15 service factor.
Service factor is mentioned nowhere in the NEMA
standards for large machines; there is no denition of it.
There is no standard for temperature rise or other char-
acteristics at the service factor overload. In fact, the stan-
dards are being changed to state that the temperature rise
tables are for motors with 1.0 service factors. Neither
standard synchronous nor enclosed induction motors
have included service factor for several years.
Today, almost all large motors are designed specically
for a particular application and for a specic driven
machine. In sizing the motor for the load, the hp is usually
selected so that additional overload capacity is not
required. Therefore, customers should not be required to
Single Phase Motors
McAllister, E. W., Pipe Line Rules of Thumb Handbook,
3rd Ed., Gulf Publishing Co., 1993.
pay for capability they do not require. With the elimina-
tion of service factor, standard motor base prices have
been reduced 45% to reect the savings.
Users should specify standard hp ratings, without
service factor for these reasons:
1. All of the larger standard hp are within or close to
15% steps.
2. As stated in NEMA, using the next larger hp avoids
exceeding standard temperature rise.
3. The larger hp ratings provide increased pull-out
torque, starting torque, and pull-up torque.
4. The practice of using 1.0 service factor induction mo-
tors would be consistent with that generally followed
in selecting hp requirements of synchronous motors.
5. For loads requiring an occasional overload, such as
startup of pumps with cold water followed by con-
tinuous operation with hot water at lower hp loads,
using a motor with a short time overload rating will
probably be appropriate.
Induction motors with a 15% service factor are still
available. Large open motors (except splash-proof ) are
available for an addition of 5% to the base price, with a
specied temperature rise of 90C for Class B insulation
by resistance at the overload horsepower. This means the
net price will be approximately the same. At nameplate
 Drivers 137

hp the service factor rated motor will usually have less
than 80C rise by resistance.
Motors with a higher service factor rating such as
125% are also still available, but not normally justiable.
Most smaller open induction motors (i.e., 200 hp and
below, 514 rpm and above) still have the 115% service
factor rating. Motors in this size range with 115% service
factor are standard, general purpose, continuous-rated,
60 Hz, design A or B, drip-proof machines. Motors in this
size range which normally have a 100% service factor are
totally enclosed motors, intermittent rated motors, high
slip design D motors, most multispeed motors, encapsu-
lated motors, and motors other than 60 Hz.
Evans, F. L., Equipment Design Handbook for Reneries
and Chemical Plants, Vol. 1, 2nd Ed., Gulf Publishing
Co., 1979.

The following equations are useful in determining the where

current, voltage, horsepower, torque, and power factor for
AC motors: E Volts (line-to-line)
I Current (amps)
Full Load I [hp(0.746)]/[1.73 E (eff.) PF] PF Power factor (per unit percent PF/100)
(three phase) eff Efciency (per unit percent eff./100)
[hp(0.746)]/[E (eff.) PF] hp Horsepower
(single phase) kW Kilowatts
kVA input IE (1.73)/1,000 (three phase) kVA Kilovoltamperes
IE/1,000 (single phase)
kW input kVA input (PF)
hp output kW input (eff.)/0.746
Torque (rpm)/5,250 Evans, F. L. Equipment Design Handbook for Reneries
Full Load Torque hp (5,250 lb.-ft.)/rpm and Chemical Plants, Vol. 1, 2nd Ed., Gulf Publishing
Power Factor kW input/kVA input Co., 1979.

Evans gives handy relative cost tables for motors based

on voltages (Table 1), speeds (Table 2), and enclosures
(Table 3).

Table 1 Table 2
Relative Cost at Three Voltage Levels Relative Cost at Three Speeds
of Drip-Proof 1,200-rpm Motors of Drip-Proof 2,300-Volt Motors
138 Rules of Thumb for Chemical Engineers

Table 3
Relative Cost of Three Enclosure
Types 2,300-volt, 1,200-rpm Motors
Evans, F. L., Equipment Design Handbook for Reneries
and Chemical Plants, Vol. 1, 2nd Ed., Gulf Publishing
Co., 1979.

*Does not include blower and duct for external air supply.
**With double tube gas to water heat exchanger. Cooling water within
manufacturers standard conditions of temperature and pressure.

When a pump has a motor drive, the process engi- horsepower. The motor must have the capacity to handle
neer must verify that the motor will not overload this.
from extreme process changes. The horsepower for a
centrifugal pump increases with ow. If the control valve
in the discharge line fully opens or an operator opens
the control valve bypass, the pump will tend to run Branan, C. R., The Process Engineers Pocket Handbook,
out on its curve, giving more ow and requiring more Vol. 2, Gulf Publishing Co., 1978.

The theoretical steam rate (sometimes referred to as the
water rate) for stream turbines can be determined from
Keenan and Keyes1 or Mollier charts following a constant
entropy path. The theoretical steam rate1 is given as
lb/hr/kw which is easily converted to lb/hr/hp. One word
of cautionin using Keenan and Keyes, steam pressures
are given in PSIG. Sea level is the basis. For low steam
pressures at high altitudes appropriate corrections must
be made. See the section on Pressure Drop Air-Cooled
Air Side Heat Exchangers, in this handbook, for the equa-
tion to correct atmospheric pressure for altitude.
The theoretical steam rate must then be divided by the
efciency to obtain the actual steam rate. See the section
on Steam Turbines: Efciency.
1. Keenan, J. H., and Keyes, F. G., Theoretical Steam
Rate Tables, Trans. A.S.M.E. (1938).
2. Branan, C. R., The Process Engineers Pocket
Handbook, Vol. 1, Gulf Publishing Co., 1976.

Evans1 provides the following graph of steam turbine Smaller turbines can vary widely in efciency depend-
efciencies. ing greatly on speed, horsepower, and pressure condi-

Figure 1. Typical efciencies for mechanical drive
turbines.
Gas turbine fuel rates (heat rates) vary considerably,
however Evans1 provides the following fuel rate graph for
initial estimating. It is based on gaseous fuels.
Figure 1. Approximate gas turbine fuel rates.
Drivers 139
tions. Very rough efciencies to use for initial planning
below 500 horsepower at 3,500 rpm are
Some designers limit the speed of the cheaper small
steam turbines to 3,600 rpm.
1. Evans, F. L., Equipment Design Handbook for
Reneries and Chemical Plants, Vol. 1, 2nd Ed., Gulf
Publishing Co., 1979.
2. Branan, C. R., The Process Engineers Pocket
Handbook, Vol. 1, Gulf Publishing Co., 1976.
The GPSA Engineering Data Book2 provides the
following four graphs (Figures 25) showing the
effect of altitude, inlet pressure loss, exhaust pres-
sure loss, and ambient temperature on power and heat
rate.
GPSA2 also provides a table showing 1982 Performance
Specications for a worldwide list of gas turbines, in their
Section 15.
1. Evans, F. L., Equipment Design Handbook for
Reneries and Chemical Plants, Vol. 1, 2nd Ed., Gulf
Publishing Co., 1979.
2. GPSA Engineering Data Book, Gas Processors
Suppliers Association, Vol. 1, 10th Ed.
 Figure 2. Altitude Correction Factor. Figure 3. Inlet Loss Correction Factor.

Figure 4. Exhaust Loss Correction Factor. Figure 5. Temperature Correction Factor.

 Drivers 141

Here are heat rates, for initial estimating, for gas

engines.
Evans, F. L., Equipment Design Handbook for Reneries
and Chemical Plants, Vol. 1, 2nd Ed., Gulf Publishing
Co., 1979.

Figure 1. Approximate gas engine fuel rates.

With high energy costs, expanders will be used more results. Equation 1 can be used to see if a more accurate
than ever. A quickie rough estimate of actual expander rating is worthwhile.
available energy is For comparison, the outlet temperature for gas at
critical ow accross an orice is given by
P2
K 1 K

H C p T1 1 05 (1)
P1 P 2
K 1 K

T2 T1 2 T1 (3)
P1 K 1
where
The proposed expander may cool the working uid
H Actual available energy, Btu/lb below the dew point. Be sure to check for this.
Cp Heat capacity (constant pressure), Btu/lb F The expander equation (Equation 1) is generated
T1 Inlet temperature, R from the standard compressor head calculation (see
P1, P2 Inlet, outlet pressures, psia Compressors, Horsepower Calculation) by:
K Cp /Cv
1. Turning [(P2/P1)(K 1)K 1] around (since work
To get lb/hr-hp divide as follows: h)
2. Substituting Cp (1.9865/Mol.wt.)[K/(K 1)]
2 545 (1.9865/1,544)R[K/(K 1)]
H 3. Cancelling 1.9865/1,544 with 779 ftlb/Btu
4. Assuming Z 1
A rough outlet temperature can be estimated by 5. Using a roundhouse 50% efciency

P H
K 1 K

T2 T1 2 (2)
P1 Cp

For large expanders, Equation 1 may be conservative. Branan, C. R., The Process Engineers Pocket Handbook,
A full rating using vendor data is required for accurate Vol. 1, Gulf Publishing Co., 1976.