2012

Nishat
Mills
LTD

Submitted by : Muhammad Gulraiz Ahmed

NFC Institute Of Engineering & Fertilizer

Research Faisalabad
(affiliated with UET LHR)

[INTERNSHIP REPORT]
Electrical Engineering (power)
 In the name of
ALLAH
The Gracious and The Benevolent

1
 Acknowledgements

First of all the whole praise to ALMIGHTY ALLAH, the creator of

the universe and anything in this universe. He made us super creature,
blessed us to accomplish this work. We are very thankful to Allah
Almighty, Who has provided us such an opportunity to gain
knowledge in Ibrahim Fibers Limited. It was a great experience to do
internship over here. We learnt many things practically which we
have learnt theoretically earlier. We also pay our gratitude to the
Almighty for enabling us to complete this Internship Report within
due course of time.

Words are very few to express enormous humble obligations to our

affectionate Parents for their prayers and strong determination to
enabling me to achieve this job.

We would like to thank all the administration engineers, operators and

officials for helping us and for their kind behavior.

2
 Introduction
Nishat Group

billion (US$ 5 billion), it ranks amongst the top five business houses
of Pakistan. The group has strong presence in three most important
business sectors of the region namely Textiles, Cement and Financial
Services. In addition, the Group also has reasonable market share in
Insurance (Adamjee and Security General), Power Generation, Paper
products ( Nishat Shoaiba Paper Mills) and Aviation
( Phonix Aviation). It also has the distinction of being one of the
largest players in each sector. The Group has a remarkable position in
the market as good as any multinationals operating locally in terms of
its quality of products, services and management skills.Nishat Group
is one of the leading and most diversified business groups in South
East Asia with fixed/ current assets of over Rs.300

Executive Summary

Nishat has grown from a cotton export house into the premier
business group of Pakistan with 5 listed companies, concentrating on
4 core businesses; Textiles, Cement, Banking and Power Generation.
Today, Nishat is considered to be at par with multinationals operating
locally in terms of its quality products and management skills.

I recently have done my internship in Nishat Mills Limited, in which I

got training from each of its department. The internship basically
revolved around the product knowledge training. The system, the
style of working & the commitment of the employees in NML is
really exemplary.

The difference between the success & failure is doing things right and
doing things nearly right, & NML has always tried for success & that
is why it is known to be one of the leading organizations in Pakistan.
Irrespective of all these positive points of Nishat Mills Limited, I have

3
noticed a few areas where the improvement can really increase the
efficiency of NML.

In this report I have given a very brief review of what I have seen
during our internship I have mentioned all these as I have made an
internship as according to the schedule. I also mentioned about the
Textile industry in Pakistan and vision of its industry. Then I have
done a detailed SWOT analysis as well as PEST Analysis.

Then I have discussed about my learning in the whole internship that

is all about the Textile Terminologies and process of the productions.
I have made it possible to write each and every thing that I have learnt
there. I have all my practical efforts in the form of this manuscript
that’s the asset for my future career.

Vision Statement

To transform the Company into a modern and dynamic yarn, cloth

and processed cloth and finished product manufacturing Company
that is fully equipped to play a meaningful role on sustainable basis in
the economy of Pakistan. To transform the Company into a modern
and dynamic power generating Company that is fully equipped to
play a meaningful role on sustainable basis in the economy of
Pakistan.

4
Mission Statement

To provide quality products to customers and explore new markets to

promote/expand sales of the Company through good governance and
foster a sound and dynamic team, so as to achieve optimum prices of
products of the Company for sustainable and equitable growth and
prosperity of the Company.

5
Company Profile

Nishat Mills Limited is the flagship company of Nishat Group. It was

established in 1951. It is one of the most modern, largest vertically
integrated textile company in Pakistan. Nishat Mills Limited has
198,120 spindles, 655 Toyota air jet looms. The Company also has
the most modern textile dyeing and processing units, 2 stitching units
for home texitle, one stitching unit for garments and Power
Generation facilities with a capacity of 89 MW. The Company’s total
export for the year 2011 was Rs. 36.015 billion (US$ 416 million).
Due to the application of prudent management policies, consolidation
of operations, a strong balance sheet and an effective marketing
strategy, the growth trend is expected to continue in the years to
come. The Company's production facilities comprise of spinning,
weaving, processing, stitching and power generation.

Quality Policy

We work together as a team for implementation and continual

improvement of total quality system in order to achieve satisfaction of
our internal and external customers.

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 Board of Directors

As on April 05, 2012

1 Mian Umer Mansha Director/CEO/Chairman

2 Mian Hassan Mansha Director
Mr. Khalid Qadeer
3 Qureshi Director
Mr. Muhammad
4 Azam Director
5 Syed Zahid Hussain Director (Nominee NIT)
Ms. Nabiha
6 Shahnawaz Cheema Director
7 Mr. Maqsood Ahmad Director

Power Generation
(MESSAGE FROM CEO)

Mobilizing and generating affordable and environment-friendly

energy resources is one of the key challengers for any nation in
today's world. Today the top priority for Pakistan is Energy and
Power Generation. Presently, Out of around 162 million population
only 65-70% has access to electricity.

To Enter into power generation business is one of the diversified

decision of Nishat Group with the vision to enhance its Investment
into Energy Sector. Nishat Power Ltd. (NPL) a public limited
company was incorporated in February 2007 under the Companies
Ordinance for setting up power plant under the Power Policy 2002 on
Build, Own and Operate ("BOO") basis. Its a 200 MW Combined
Cycle Power Plant based on Reciprocating Engine Technology. The

7
primary fuel of the Plant is Residual Furnace Oil ("RFO") and its
uninterrupted supply is guaranteed by SHELL Pakistan. The Plant
Configuration is eleven (11) proven Engine sets of type 18v46
manufactured by WARTSILA of Finland and eleven (11) generating
sets, One (1) Heat Recovery Steam Turbine with generator.As per the
Power Purchase Agreement, the NTDC has contracted to purchase the
total net generation capacity of 195.26 MW produced by NPL for a
period of 25 years at US cents 12.1253 per KWh. As the plant will
operate on residual furnace oil, a Fuel Supply Agreement ("FSA") has
been signed between the Company and Shell Pakistan Limited for a
period of ten years after the commencement of commercial
production.The entire plant, machinery and equipment required for
the project has been procured from Wartsila Finland Oy. Whereas,
Wartsila Pakistan (Private) limited has been appointed for the
construction, erection, installation testing and commissioning of the
entire project. We have also awarded Wartsila Pakistan an Operations
& Maintenance Contract for our Plant.The total cost of the project
including interest during the construction period is around PkR17.704
billion.

Major Consideration of the Project were:

The Project would offer significant relief locally in the transmission

system of Lahore, as it would bypass long transmission lines and
potential stepdown transformer bottlenecks. There is currently no
significant power generation inside this area

The plant generation would be consumed very close to the generation

site, thus also reducing substantial transmission losses

The Project has been finalized and commissioned on a fast-track basis

within 18 months as a power generation plant based on reciprocating
engine single fuel RFO fired technology

It is hoped that NPL's power project, the RFO based power plant
under Power Policy 2002, shall serve as role model for others to
follow.
8
 Safety Precautions

In order to avoid the hazards on the plant, company train their

employees for the Safe handling and operation of materials and units
installed on plant. So for this company follow following steps:

Authorization

Even a small mistake on the plant can cause a serious damage so

MMM (man, machine, material) is very important.

nting out and

also some

crossing the roads and also tanks with explosive materials are present
at different places and anything hitting them may cause a serious
danger.

workers and as a result, their work may be ignored.

for every unit some guider is provided for the specific period of time
and we are not allowed to go in any area according to our desire.

other to prevent injury of workers.

computer control
systems to prevent the tripping of systems as they are very sensitive.

9
water in that area is of very high conductivity.

for the workers.

material for the safe handling and storage of the materials.

ded for the safe
operations.

overcoming fire.

Safety Measures:
Safety measures are activities and precautions taken to improve
safety, i.e. reduce risk related to human health. Common safety
measures include:
o Root cause analysis to identify causes of a system failure and
correct deficiencies.
o Visual examination for dangerous situations such as emergency
exits blocked because they are being used as storage areas.
o Visual examination for flaws such as cracks, peeling, loose
connections.
o Chemical analysis
o X-ray analysis to see inside a sealed object such as a weld, a
cement wall or an airplane outer skin.
o Destructive testing of samples
o Stress testing subjects a person or product to stresses in excess
of those the person or product is designed to handle, to
determining the "breaking point".

10
o Safety margins/Safety factors. For instance, a product rated to
never be required to handle more than 200 pounds might be
designed to fail under at least 400 pounds, a safety factor of two.
Higher numbers are used in more sensitive applications such as
medical or transit safety.
o Implementation of standard protocols and procedures so that
activities are conducted in a known way.
o Training of employees, vendors, product users
o Instruction manuals explaining how to use a product or perform
an activity
o Instructional videos demonstrating proper use of products
o Examination of activities by specialists to minimize physical
stress or increase productivity
o Government regulation so suppliers know what standards their
product is expected to meet.
o Industry regulation so suppliers know what level of quality is
expected. Industry regulation is often imposed to avoid potential
government regulation.
o Self-imposed regulation of various types.
o Statements of Ethics by industry organizations or an individual
company so its employees know what is expected of them.
o Drug testing of employees, etc.
o Physical examinations to determine whether a person has a
physical condition that would create a problem.
o Periodic evaluations of employees, departments, etc.
o Geological surveys to determine whether land or water sources
are polluted, how firm the ground is at a potential building site,
etc.

11
Different Safety Signs
Safety signs are used for indication of the hazard involved while
carrying out the certain action. They are very helpful in for the subject
as they give clear guideline about the hazard that one could face at the
site where they are erected. Some different safety signs are:

In safety there is a rule of triple M.

 Man safety
 Machine safety
 Material safety

Man safety
In safety the first thing is man safety. Man safety is one of
the important things between the rules of safety. Man safety
means how to safe man in working area (plant).Mask, safe-
guard, gloves etc are provided for safety. Also no use of mobile

12
Machine safety
Machine safety is also important. The trouble shoot,
maintenance of temperature is the important one. No use of
mobile near to machine because safety of tripping and matching
of frequency.

Material safety
The safety of material is also important. The thing like
sand is safe according to its way of safety. Other things like
PTA, MEG are store according to its conditions.

Power Distribution
The feeder lines are fed to the panels situated there which are
connected to each other with bus couplers along with VCB breakers.
From there, these lines are fed to Transformer Room where the
voltage is stepped down from 11KVA to 415V. The lines from the
transformers are fed to LVD Room in the form of bus wires. The bus
wires are fed to the panels in LVD Room where the panels are
connected in the form of Ring Main System along with Power Factor
Control and ACCB Breakers for safety purpose. From there, the
power is supplied further as per requirement.

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MCC Room
The purpose of this room is to control the speed of the motors hence
controlling the output of the SPG/DL-1 section. The speed is
controlled through inverters which in turn are controlled through
PLCs via Control Room.
The explanation of different terms and the equipment mentioned
above will be explained after giving the summary of each section.
MCC is the motor control centre which is controlling the all the
motors and pumps connected in the specific area. In MCC room the
panels which are controlling the Motors parameters the technology
which is using in MCC room is the one of the modern technology
which the inverters based.
The inverter work is converts the voltage waves into one form to the
other. The main two inverters are using in the MCC room of polyester
plant are the following:

AC to AC inverters
DC to AC inverters

The main purpose of the invertors is that many motors which are
using in the plant are proportional to the frequency and the power we
having the frequency of 50 Hz so that by using invertors we can vary
the frequency of the power given to the motor. We known t the speed
is directly proportional to the frequency we apply.

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 UTILITIES

Soft Water

Fresh raw water is pumped from ground and is transported to the

water plant. In plant they are further pumped to gravel bed in a closed
vessel. Small portions of Hydro-chloric acid (HCl) are added to the
filtered water kill bacteria and to lower pH value. Then it passes
through bag filter which consists of series of fibers to deposit gravel
on them. The water that passes the laboratory test is termed as Soft
water, and this is the major production of plant. The soft water
produced is then decarbonised. Decarbonisation is a process in which
air is pumped into water to remove carbon content.

Daemon Water
The soft water is passed through the bed of mixed cation and anion
bed and it become demineralised. Daemon water is then stored in
another vessel (4010-V05). Daemon water is used in chilled water
circuit, boiler house etc.

Drinking Water
Soft water from the storage vessel and some small amount of raw
water is passed through the bed of calcium hydrolit. Drinking water
produced is then stored in drinking vessel.

15
Boilers

Boiler house have 3 boilers. All boilers are of fire tube types
having three passes and a super heater. Water is accumulated in
the shell and it surrounds the tubes. Fire is passed through first
pass where combustion take place, from first pass end it enters
the second pass from behind, leave the second pass from front
and the fire rises to the super heater then it enters the third pass,
exhaust gases leave the boiler at boiler rear face to the exhaust
chimney erected outside the boiler house.

There are basically two types of boilers:

 Fire tube boiler
 Water tube boiler
Fire tube boiler

The name fire tube is very descriptive. The fire, or hot flue gases from
the burner, is channeled through tubes that are surrounded by the fluid
to be heated. The body of the boiler is the pressure vessel and
contains the fluid. In most cases this fluid is water that will be
circulated for heating purposes or converted to steam for process use.

Every set of tubes that the flue gas travels through, before it makes a
turn, is considered a "pass". So a three-pass boiler will have three sets
of tubes with the stack outlet located on the rear of the boiler.

Fire tube Boilers are:

 Relatively inexpensive
 Easy to clean
 Compact in size
 Available in sizes from 600,000 btu/hr to 50,000,000 btu/hr
 Easy to replace tubes
16
  Well suited for space heating and industrial process
applications

Disadvantages of Fire tube Boilers include:

 Not suitable for high pressure applications 250 psig and

above
 Limitation for high capacity steam generation

Three pass Fire tube boilers are used in the IFL. There are 3 fire tube
boilers are used in IFL. One is stand by while 2 are in operation.

Water Tube Boiler

A Water tube design is the exact opposite of a fire tube. Here the
water flows through the tubes and are incased in a furnace in which
the burner fires into. These tubes are connected to a steam drum and a
mud drum. The water is heated and steam is produced in the upper
drum. Large steam users are better suited for the Water tube design.
The industrial watertube boiler typically produces steam or hot water
primarily for industrial process applications, and is used less
frequently for heating applications.

Water tube Boilers are:

 Available in sizes that are far greater than the fire tube
design. Up to several million pounds per hour of steam.
 Able to handle higher pressures up to 5,000 psig
 Recover faster than their fire tube cousin

17
  Have the ability to reach very high temperatures

Disadvantages of the Water tube design include:

 High initial capital cost

 Cleaning is more difficult due to the design
 No commonality between tubes
 Physical size may be an issue

Fuel for boiler:

 Natural gas (mostly used)
 Furnace oil (stand by)
The steam at 25 bar pressure is then divided in to 3 different pressures
 25-bar , 10-bar , 6-bar

18
 Parts Of Boiler:

Evaporator –

A liquid vapor refrigerant mixture enters the evaporator at state point

1. Liquid refrigerant is vaporized to state point 2 as it absorbs heat
from the system cooling load.The vaporized refrigerant flows into the
compressor first stage.

19
Compressor first stage –

Refrigerant vapor is drawn from the evaporator into the first stage
compressor. The first stage
impeller accelerates the vapor increasing its temperature and pressure
to state point 3.

Compressor second stage –

Refrigerant vapor leaving the first stage compressor is mixed with

cooler refrigerant vapor from the economizer. This mixing lowers the
enthalpy of the vapor entering the second stage. The second stage
impeller accelerates the vapor, further increasing its temperature and
pressure to state point 4.

Condenser –

Refrigerant vapor enters the condenser where the system cooling load
and heat of compression are rejected to the condenser water circuit.
This heat rejection cools and condenses the refrigerant vapor
to a liquid up to point 5.

Economizer and refrigerant orifice system –

Liquid refrigerant leaving the condenser at state point 5 flows

through the first orifice and
enters the economizer to flash a small amount of refrigerant a an
intermediate pressure labeled P1. Flashing some liquid refrigerant
cools the remaining liquid to state point 8. Another benefit of flashing
refrigerant is to increase the total evaporator Refrigeration Effect from
RE’ to RE. The economizer provides around 4 percent energy savings
compared to chillers with no economizer. To complete the operating
cycle, liquid refrigerant leaving the economizer at state point 8 flows

20
through a second orifice. Here refrigerant pressure and temperature
are reduced to evaporator conditions at state point 1. An innovative
design feature of the CVGF chiller is maximizing the evaporator heat
transfer performance while minimizing refrigerant charge
requirements. This is accomplished by the Trane-patented falling film
evaporator design. The amount of refrigerant charge required in
CVGF is less than that in comparably sized chillers of flooded
evaporator design.

Process

The evaporator is basically shell & tube heat exchanger in which the
chilled water is in the tube side & the refrigerant (Freon) is on the
shell side. The heat exchanger used here is a 1-2 pass heat exchanger.
The wc (chilled water) stream from the process (11-12oC) enters the
evaporator in the tubes & is discharged at a temperature of 6-7oC. It is
present in the liquid form & when the WC stream passes through the
evaporator tubes, the refrigerant gets heat from the water and
evaporates.

21
The vapors of the refrigerant are sent to the two-stage compressor.
The compressor should be of such capacity that it should intake same
amount of vapors from the evaporator as being produced in it if the
capacity is low then the pressure in the evaporator will increase &
thus the saturation temperature of refrigerant will increase. When the
vapors are compressed their temperature & pressure increases.
The compressed stream is sent to the condenser in the tubes, where
cooling water is circulated for the cooling purpose in the shell side.
Here the vapors are discharged at the same pressure but at lower
temperature & sent to the economizer. A nozzle is fitted in the
economizer, which acts as an expansion valve. Here the vapors are
sprayed so their pressure decreases due to sudden expansion cooling
occurs & most of the vapors go to liquid form. From the economizer
these streams are discharged.
 To the evaporator (in liquid form)
 To the evaporator (in the vapor form)
To the 2nd stage of compressor as an inter cooler (in vapor form)

Cooling Tower
Types of cooling towers

Cooling towers are designed and manufactured in several types:

1. ATMOSPHERIC
2. MECHANICAL DRAFT

 FORCED DRAFT
 INDUCED DRAFT

1: Atmospheric

The atmospheric cooling towers utilize no mechanical fan to create air

flow through the tower; its air is derived from a natural induction flow
provided by a pressure spray.

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2: Mechanical Draft

Mechanical draft towers uses fans (one or more) to move large

quantities of air through the tower. They are two different classes:

 Forced draft cooling towers

 Induced draft cooling towers

The air flow in either class may be cross flow or counter flow with
respect to the falling water. Cross flow indicates that the airflow is
horizontal in the filled portion of the tower while counter flow means
the air flow is in the opposite direction of the falling water.

The counter flow tower occupies less floor space than a cross flow
tower but is taller for a given capacity. The principle advantages of
the cross flow tower are the low pressure drop in relation to its
capacity and lower fan power requirement leading to lower energy
costs.

Forced Draft

The forced draft tower, shown in the picture, has the fan, basin, and
piping located within the tower structure. In this model, the fan is
located at the base. There are no louvered exterior walls. Instead, the
structural steel or wood framing is covered with paneling made of
aluminum, galvanized steel or asbestos cement boards.

23
During operation, the fan forces air at a low velocity horizontally
through the packing and then vertically against the downward flow of
the water that occurs on either side of the fan. The drift eliminators
located at the top of the tower remove water entrained in the air.
Vibration and noise are minimal since the rotating equipment is built
on a solid foundation. The fans handle mostly dry air, greatly
reducing erosion and water condensation problems

24
 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

Three types of Motor Load

Motor loads Description Examples

Constant torque Output power varies but Conveyors, rotary kilns,

loads torque is constant constant-displacement
pumps

Variable torque Torque varies with square Centrifugal pumps, fans

loads of operation speed

Constant power Torque changes inversely Machine tools

loads with speed

25
Classification of Motors

Electric
Motors

Alternating Direct
Current (AC) Current (DC)
Motors Motors

Synchron Inductio Separate Self

ous n ly Excited
Excited

Single- Three- Serie Compou Shunt

Phase Phase s nd

DC motors
 Speed control without impact power supply quality
• Changing armature voltage
• Changing field current
 Restricted use
• Few low/medium speed applications
• Clean, non-hazardous areas
 Expensive compared to AC motors

26
Relationship between speed, field 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

 Separately excited DC motor: field current supplied from a

separate force
 Self-excited DC motor: shunt motor
 DC compound motor

AC Motors – Synchronous motor

 Constant speed fixed by system 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):

27
 Ns = 120 f / P
F = supply frequency
P = number of poles
 Most common motors in industry
 Advantages:
• Simple design
• Inexpensive
• High power to weight ratio
• Easy to maintain
• Direct connection to AC power source

Components

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  Rotor
• Squirrel cage:
conducting bars
in parallel slots
• Wound rotor: 3-phase, double-layer, distributed winding
 Stator
• Stampings with slots to Electromagnetics
carry 3-phase windings
• Wound for definite
number of poles

Rotor

Stator
How induction motors work
• Electricity supplied to stator
• Magnetic field generated that moves around rotor
• Current induced in rotor
• Rotor produces second magnetic field that opposes stator
magnetic field
• Rotor begins to rotate
(Reliance)

 Single-phase induction motor

• One stator winding
• Single-phase power supply
• Squirrel cage rotor

29
 • Require device to start motor
• 3 to 4 HP applications
• Household appliances: fans, washing machines, dryers

 Three-phase induction motor

• 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!

Speed and slip

• 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
Ns = synchronous speed in RPM
Nb = base speed in RPM

30
Efficiency of Electric Motors
Motors loose energy when serving a load
• Fixed loss
• Rotor loss
• Stator loss
• Friction and rewinding
• Stray load loss

(US DOE)

Factors that influence efficiency

• Age
• Capacity
• Speed
• Type
• Temperature
• Rewinding

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 • Load
Motor part load efficiency
• Designed for 50-100% load
• Most efficient at 75% load
• Rapid drop below 50% load

(US DOE)
Motor Load
• Motor load is indicator of efficiency
• Equation to determine load:

Load = Pi x  HP x 0.7457

 = Motor operating efficiency in %

HP = Nameplate rated horse power

32
Load = Output power as a % of rated power
Pi = Three phase power in kW

Three methods for individual 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 load

Input power measurement

• Three steps for three-phase motors

Step 1. Determine the input power:

V x I x PF x 3
Pi 
1000

Pi = Three Phase power in kW

V = RMS Voltage, mean line to
line of 3 Phases
33
I = RMS Current, mean of 3 phases
PF = Power factor as Decimal

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

34
 Action
→ R
eplace with more
efficient, properly sized
models
→ R
eplace with more
efficient, properly sized
models when they fail
→ R
eplace most of these with
energy-efficient models
when they fail

Result
1. Significantly
oversized and
underloaded
2. Moderately
oversized and
underloaded
3. Properly sized
but standard
efficiency

35
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

36
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

37
 Use Energy Efficient Motors
Power Loss Area Efficiency Improvement

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
Winding air movement

5. Stray Load Loss Use of optimized design & strict quality

control procedures minimizes stray load losses

38
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

• 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

39
3. Sizing to Variable 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

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

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 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 0 30 40
(oC)

Keep voltage unbalance within 1%

• Balance single phase loads equally among three
phases
• Segregate single phase loads and feed them into
separate line/transformer

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

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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

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

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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

• 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

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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

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