Chapter-05

Energy Efficient Motors

5.1 Motor Horse Power

Horsepower (hp) is the name of several units of measurement of power, the rate at which work
is done. Electrical power is rated in horsepower or watts. A horsepower is a unit of power
equal to 746 watts or 33,0000 lb-ft per minute (550 lb-ft per second). A watt is a unit of
measure equal to the power produced by a current of 1 amp across the potential difference of
1 volt. The watt is the base unit of electrical power. Motor power is rated in horsepower and
watts. Horsepower is used to measure the energy produced by an electric motor while doing
work. The most common conversion factor, especially for electrical power, is 1 hp = 746 watts.

Steam engineer James Watt coined the term horsepower back in the 1700s. It refers to his
theory that one horse can do 33,000 foot-pounds of work in a minute, i.e. it can move 1,000
pounds of coal (or some other object) 33 feet in a minute. In theory, a 300-horsepower engine
is able to perform the work of 300 horses in the same amount of time. Most countries use
horsepower to measure the output of gasoline-powered engines. But some countries (like
Australia) prefer to use kilowatts to measure the output of gasoline engines.

To convert kilowatts to horsepower, we multiply the number of kilowatts by 1.34. For example
80 kilowatts is roughly equivalent to 107 horsepower.

5.1.1 Relationship between Horse Power and Watts:

Mathematically the horse power of a motor and the electrical power are related by

Electric Power of a Motor P

Hp   w (1)
746 746

The electric power of a motor Pw depends upon the type of motor, whether it is a dc or an ac
motor. Accordingly any of the following expressions can be substituted for ‘Electric Power of a
Motor’ in equation (1).

DC Motor
Electric power of a motor can be expressed as:

m  V  I
Pw  kW (2)
1000

Where Pw = power (kW); ηm = motor efficiency; V = voltage (Volts); I = current (amps)

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AC Motor
Single Phase
 m  V  I  cos 
Pw  kW (3)
1000
where cos = Power Factor

Two Phase Four Wire

 m  2  V  I  cos 
Pw  kW (4)
1000

Three Phase
 m  1.73  V  I  cos 
Pw  kW (5)
1000

Example: The horse power of a 230 V dc electrical motor with 85% efficiency pulling 10 amps
can be calculated as:
  V  I 0.85  230  10
Hp  m   2.62 Hp
746 746

Example: What is the horsepower of a 230 V motor pulling 4 amps and having 82% efficiency?
  V  I 0.82  230  4
Hp  m   1 Hp
746 746

Example: Calculate the horsepower of a 230 V 50Hz motor pulling 8 amperes at 0.85 lagging
power factor and having 85% efficiency?
  V  I  cos  0.85  230  8  0.85
Hp  m   1.78 Hp
746 746

Example: Calculate the current drawn by a 10 HP electric motor with operating 240 V at 0.88
lagging power factor and having 90% efficiency?
746  Hp 746  10
I   39 A
 m  V  cos 0.90  240  0.88

To calculate the horsepower of a motor when the speed and torque are known, apply this
formula:
Motor speed in rpm  TorqueT 
Hp 
5252cons tan t 

Example: What is the horsepower of a 1725 rpm motor with a FLT 3.1 lb-ft?
1725  3.1
Hp   1 Hp
5252

5.1.2 Standard Horsepower Ratings:

Standard horsepower ratings of electrical motors - 1 to 4000 hp are indicated below:

1, 1 1/2, 2, 3, 5, 7 1/2, 10, 15, 20, 25, 30, 40, 50, 60, 75, 100, 125, 150, 200, 250, 300, 350, 400,
450, 500, 600, 700, 800, 900, 1000, 1250, 1500, 1750, 2000, 2250, 2500, 3000, 3500, 4000

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5.1.3 Classification of Horsepower:

The following definitions have been widely used:

Mechanical horsepower = 33,000 ft-lbf/min
hp(I) = 550 ft·lbf/s
= 745.699872 W
Metric horsepower = 75 kgf·m/s
hp(M) - also PS, ''cv, hk, pk, ks or ch = 735.49875 W
Electrical horsepower
hp(E)
The horsepower used for electrical machines is defined as = 746 W
exactly 746 W. The nameplates on electrical motors show their
power output, not their power input
Boiler horsepower
hp(S)
One boiler horsepower unit, or BHP, is equal to a boiler thermal =33,475 BTU/h
output of 33,475 Btu/h (9.811 kW), which is the energy rate = 9,809.5 W
needed to evaporate 34.5 lb (15.65 kg) of water at 212 °F (100
°C) in one hour. The unit is not current outside of North America
Hydraulic horsepower = flow rate (US gal/min) ×
pressure (psi) × 7/12,000
or
= flow rate (US gal/min) ×
pressure (psi) / 1714
= 550 ft·lbf/s
= 745.699872 W

In certain situations it is necessary to distinguish between the various definitions of horsepower

and thus a suffix is added: hp(I) for mechanical (or imperial) horsepower, hp(M) for metric
horsepower, hp(S) for boiler (or steam) horsepower and hp(E) for electrical horsepower.
Hydraulic horsepower is equivalent to mechanical horsepower. The formula given above is for
conversion to mechanical horsepower from the factors acting on a hydraulic system.

5.2 Energy Efficient Motors:

Power scenario of today faces major power crunch. The gap between demand and supply of
electric energy is widening at the rate of 3%. Bridging this gap from supply side is very difficult
and expensive proposition. The only viable way in handling such crisis, in addition to capacity
addition, is the efficient use of available energy. One of the possible ways is the use of Energy
Efficient Electrical Machines.

Electric motors are industry’s primary requirement. They consume around 70% of the total
electricity used in the industrial sector. As motors are the largest users of electrical energy, even
small efficiency improvements can produce very large savings across the country. The efficiency
of an electric motor can only be improved through a reduction in motor losses. Improvements
in the design, materials, and construction have resulted in efficiency gains of 2 to 6 percent,
which translates into a 25 percent reduction in losses. A small gain in efficiency can produce
significant energy savings and lower operating costs over the life of the motor. Consequently,
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the higher purchase price of high-efficiency motors (15 to 30 percent) can, in most cases, be
recovered in 2 years through cost savings in energy and operation. Because energy-efficient
motors are a proven technology in terms of durability and reliability, their use should be
considered for new installations, major modifications, replacement of failed motors or those
that require rewinding, or extreme cases of oversized or under-loaded motors. Energy
conservation measures taken by individual consumers in this direction can improve the national
economy and benefit the environment on the global scale.

According to IEEMA, over two million motors are produced in India each year that together
have an energy saving potential of more than 5 billion kWh of power if replaced with IE3
motors. Considering the investment for a 600MW power plant these energy-efficient motors
have the potential to save nearly Rs 3,500 crore for the country as a whole.

An energy efficient motor (EEM) is one that produces same shaft output power but draws less
input power than a standard motor. Energy-efficient motors are higher quality motors, with
increased reliability and longer manufacturer’s warantees, providing savings in reduced
downtime, replacement and maintenance costs. Hence EEM motor consumes less electricity
than comparable standard motor.

EEMs must conform to following Standards:

 IS 12615-2011
 IS 325-1996
 IEC 60034 – 30 (2008)
 IEEMA : 19-2000; NEMA EPACT EFFICIENCY VALUES (for NEMA motors) IEEMA 19-2000
standard covers kW ratings only up to 160kW. Energy efficient motors up to 450 kW are
also available.

The International Electrotechnical Commission (IEC; in French: Commission électrotechnique

internationale) is a non-profit, non-governmental international standards organization that
prepares and publishes International Standards for all electrical, electronic and related
technologies – collectively known as “electrotechnology". IEC standards cover a vast range of
technologies from power generation, transmission and distribution to home appliances and
office equipment, semiconductors, fibre optics, batteries, solar energy, nanotechnology and
marine energy as well as many others. The IEC also manages three global conformity
assessment systems that certify whether equipment, system or components conform to its
International Standards. Its head quarters is in Geneva, Switzerland.

What does The IS: 12615-2011 for Energy Efficient Motors Stand For?
The Indian Standard IS: 12615-2011 replaces the earlier IS:12615-2004. With this change, the
efficiency classes eff2 and eff1 are no longer valid. This new standard defines new
"International Efficiency" classes similar to IEC 60034-30 (2008). The IS:12615-2011 defines
efficiency values for a motor to be classified as energy efficient. This standard covers single
speed, three phase, 50Hz, Cage Induction Motors that:
 Have rated voltage ≤1000V;
 Have a rated output 0.75kW ≤ PN ≤ 375kW;
 Have either 2, 4 or 6 poles;
 Meet frame size to output relation as stipulated in IS:1231 (for outputs covered by this
standard);
 Are rated on the basis of either duty type S1 (continuous duty) or S3 (intermittent

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 periodic duty) with rated cyclic duration factor of 80% or higher
 Are capable of operating direct on-line;
 Are designed for operation on virtually sinusoidal and balance voltage conditions as
defined in 7.2.1 of IS/ IEC 60034-1;
 Designed for an ambient temperature not exceeding 40°C and altitude not exceeding
1000m;
 Have degree of protection IP44 or superior;
 Have method of cooling IC411 in accordance with IS 6362 (Part 0/Sec0):1995 / IEC
60034-6(1991);
 Have service factor not exceeding 1.0.
 This standard also stipulates that for a motor to be classified as energy efficient, it must
meet as a minimum, efficiency class IE2. The losses and efficiency for motors
conforming to this standard have to be determined as per IEC 60034-2-1(2007)

5.2.1 Opportunities for Selection of Energy-efficient motors:

There are three general opportunities for choosing energy-efficient motors: 1) when
purchasing a new motor, 2) in place of rewinding failed motors, and 3) to retrofit an operable
but inefficient motor for energy conservation savings. In addition, Energy-efficient motors
should be considered in the following instances:
 For all new installations
 When major modifications are made to existing facilities or processes
 For all new purchases of equipment packages that contain electric motors, such as air
conditioners, compressors, and filtration systems
 When purchasing spares or replacing failed motors
 Instead of rewinding old, standard-efficiency motors
 To replace grossly oversized and under-loaded motors
 As part of an energy management or preventative maintenance program
 When utility conservation programs, rebates, or incentives are offered that make energy-
efficient motor retrofits cost-effective
 When utility rebates are offered that make high-efficiency motor retrofits even more cost
effective

5.2.2 Typical Features (specifications) of EEM:

Table-1 gives salient features of a typical energy efficient motor.
Table-1: Salient features of EEM
Standards IS:12615, IS:325, IS:1231, IS:2223
Mounting : Foot (B3), flange (B5), face (B14), and Combination
Voltage : 415V,  10% or as required
Frequency : 50Hz,  5% or as required
Ambient : 450C
Altitude : Upto 1000m above mean sea level
Enclosure : Totally Enclosed Fan Cooled (TEFC)
Protection : IP55
Insulation Class : Class F insulation with temperature rise limited to
class B

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5.2.3 Performance of EEM:
In many applications, the load factor of the motor range between 60% to 80%. The efficiency
curve of a 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 partloads. Figures below show
the performance characteristics of ‘Hindustan’ 11 kW/4P and ‘Crompton Greaves’ 15 kW/4P
standard and energy efficient motor. Efficiencies are measured at different loading conditions.
The efficiencies of energy efficient motors are higher than the standard motors.

100
90 91 91
90 82
87 89 89
80
70 75
% Efficiency

60
50
40
30
Eff1
20
Eff2
10

25 50 75 100
% Load
Fig5.1. Comparison of performances of 11 kW/4P EEM (Hindustan)

Fig5.2: Comparison of performances of 15 kW/4P EEM (Compton Greaves)

% Efficiency

Fig.5.3: Standard and High Efficiency Motor performance

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5.2.4 Payback Time:
 Efficiency of standard motor (Hindustan): 89.0%
 Efficiency of EEM (Hindustan): 91.0 %
 Motor power: 11.0 kW
 No. of hours of operation per annum: 5000 hrs
 Energy saved per annum @ Rs.4.0/kWh: Rs. 5432.77
 Additional cost of EEM: Rs. 2700.00
 Payback period: 6 months

5.2.5 Special design Features: Higher efficiencies are achieved by following special features:
 Low loss special grade of thinner laminations. This reduces the Iron loss even at partial
loads.
 Thicker conductors and more copper contents reduce copper loss due to lower
resistance.
 Longer core length, reduced and uniform air gap between stator and rotor to reduce
stray losses .
 Special design of fan and fan cover to reduce windage losses

5.3 Efficiency measurement of an electric motor:

The efficiency of an electric motor is determined by the amount of useful power it produces
compared to the amount of energy required to operate it. The figure below illustrates how a
Crompton Greaves Energy efficient motors effectively turns 1000 units of electrical power into
mechanical power. Since motor efficiency is commonly expressed as a percentage. Efficiency in
this case would be 94%.

Fig.5.4: Sankey diagram showing energy use in Electric Motors

Assessment of Cost Effectiveness of Energy Efficient Motors: The savings are calculated by:

Savings  X working hoursworking daystariff 

 kW kW 
where X     ; E1 = Efficiency of Standard Motor; E2 = Efficiency of Energy Efficient
 E1 E 2 
Motor; kW = Output of motor in kW

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Alternatively annual energy savings can also be estimated using,
 1  1
E S  hp  L  0.746  hr  C  

 Eeem E std

Where, ES Savings = Expected annual dollar savings; hp = Motor rated horsepower; L = Load
factor (percentage of full load/100); hr = Annual operating hours; C = Average energy costs
(Rs/kWh); Estd = Standard motor efficiency rating, %; Eeem = Energy-efficient motor efficiency
rating, %; 0.746 = Conversion from horsepower to kW units

Simple Payback (in years)

For a new motor purchase,
Price - Utility rebate for EEM
Payback 
Annual Savings

When calculating the simple payback for replacing an operating motor,

Motor Price  Installation Charge - Utility rebate for EEM
Payback 
Annual Savings

Example: A 3.7 kW 4 pole motor in frame ND112M has the following specifications:
Standard motor eff2 = 85% at Rs. 7215/-; Energy efficient motor eff1 = 88.3% at Rs.9380/-;
Working hours per day = 16; Number of working days in a year = 300; Cost of power is
Rs.4.5/kWh. Compute the savings and payback period.

 3.7 3.7 
X     0.1626
 0.883 0.85 

Savings  0.162616300 4.5  Rs.3512.16 / year

Additional investment for EEM = 9380-7215= Rs. 2165/-

Additional Investment 2165

Payback period    1.5 months(approx)
Savings 3512 .16

5.4 Benefits and Application of EEMs:

Listed below are some benefits of using energy efficient motors:
 Saves Energy: Improved efficiency is available from 60 % to 100 % load. The efficiency
curve is almost flat resulting in higher energy savings as in most of the cases the motor
is not always fully loaded.
 Cost Reduction: The special design features also result in lower operating
temperatures, which enhance the life of motor and reduce the maintenance costs.
 Environment friendly: These motors have inherently low noise and vibration and help
in conservation of environment.
 Improvement in System Efficiency: The higher power factor reduces the currents in the
cables supplying power to motor and this reduces cable loss, improving the system
efficiency sometimes by even 2 %. Sometimes this allows even a lower cable size saving
tremendously on capital costs.

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  Reduced number of Capacitors: Saving is also made by reducing capacitors required to
improve power factor.
 Energy efficient motors come with higher power factor. This is usually due to the
special exclusive designs available (Crompton Greaves EEM)
 Short payback period and substantial savings after payback period.

Applications:
 Energy efficient motors are specially suited for industries, which are power intensive,
and equipment, which run on constant load for long duration.
 The benefits of using these motors are maximum in continuous duty applications like
Blowers, Compressors, Fans, Exhausters Pumps etc.

5.5 Examples of EEMs manufactured in India:

Crompton Greaves has now developed a complete family of high

efficiency motors confirming to Eff level 1 standards of IEEMA : 19-
2000 and other applicable standards in Europe and rest of the world.
These motors are available in TEFC construction for use in safe areas
and also in flameproof enclosure for use in Hazardous areas.

The Havells range of premium energy efficient motors are the first of
its kind in India. Havells IE3 & IE2 motors conform to IS 12615:2011
and IEC 60034-30:2008 and are suitable for continuous operation,
where high energy saving is essential

Siemens: Made in India, #MovingIndia: In 2012, Siemens launched its range of award-
winning energy efficient motors in India. As of now, there are 150,000+ of these motors
running across the world. Siemens is the first manufacturer in India to introduce the
complete range of IE2 and IE3 motors. By promoting, the usage of only “High Efficiency”
motors as per the new Indian Standard IS12615:2011,we envision transforming the
energy consumption scenario in industries

Exercise Questions
1. Write a descriptive note on Energy Efficient Motors.
2. With the help of a neat graph explain the comparison of efficiency vs horsepower of standard and energy
efficient motors.
3. What are the benefits and applications of EEMs?
4. Write descriptive notes on determining savings and payback period of EEMs.
5. Mention typical features of EEMs.
6. How do EEMs help in energy conservation?

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