Electrical Motors

Motors – EE Opportunities and
Latest Technologies
Confederation of Indian Industry

CII – Godrej Green Business Centre, Hyderabad, India
Why to have focus on motors ??
*Source:- International Copper Association
2 © Confederation of Indian Industry

Capacity of Motor - Horse Power ?
1 HP = 76 Kg-m per second

76 Kg 1 HP = 0.75 kW
Work - Force applied over a distance

Power – Rate of doing work
© Confederation of Indian Industry
Motor Efficiency
Effectiveness with which a motor
converts Electrical energy to
Mechanical energy Output
Input
Out put Power
Efficiency = X 100
Input Power

Motor Losses
Range ( H.P ) % of Loss At FL

Efficiency %
1 - 10 14 - 35 65 - 86
10 - 50 09 - 15 85 - 91
50 - 200 06 - 12 88 - 94
200 - 1500 04 - 07 93 – 96
1500 & 4 95 - 96
above

Why your motors are becoming less Energy Efficient?
• Over Sized / Under loaded Motors

1
• Improper Supply Voltage

2
• Use of Less Efficient Motors

3
• Poor Power Factor

4
• Rewinding of Motors
5
Performance of Motor at Partial Load
 Motor loading is critical factor

 Motor  and power factor varies
with % loading
 For lightly loaded motors
 Voltage related losses - high
 Power factor is very low
 More copper losses
 Motor operates in less efficiency
range
How to Find Out Motor Loading?
 A 3-Ph IM rated for 75 kW, 415 V, 150A, 0.85 power
factor and 92% draws 30 kW & 75 A.
 What is % loading on motor?
 65 %
 40 %
 50 %
 37 %

Analysis of Loading Pattern
 Analysis of Load Pattern
 Measure kW input to motor using Portable Power Meter / Load Manager
 Estimate % loading
 Analyse Load pattern at different process conditions
 Record the minimum & maximum Loading

Analysis of Loading Pattern
 Analysis of Load Pattern
Measure kW input to motor using Portable Power
Meter / Load Manager
Estimate % loading
Analyse Load pattern at different process conditions
Record the minimum & maximum Loading
Optimization Of Lightly Loaded Motors
 Options Based on  Options
 Nature of load  Delta connection to permanent star connection
 Steady load application
 Load factor
 Automatic star-delta-star converters
 Economic option  variable loads
 Soft starter cum energy savers
 High starting torque applications
 Variable voltage/frequency devices
 Down sizing
 Overall voltage optimization

Delta & Star Motor Connection
L1

Convert Delta To Star Connection at Lightly Loaded Motors
 Motors normally operated in delta mode

 Motors operating at less than 40% loading can be
operated in star mode
 Effect on motor performance operating in star
mode
 Motor operating efficiency improves
 Reduction in voltage related Iron losses
 Reduction in Cu losses

Case Study - Delta to Star Conversion
Before:
U1 V2
MOTOR
415V
2.15KW U2 V1
W1 W2
415V
DELTA CONECTION OF MOTOR


After: V1
230V
MOTOR
415V
V2
U2
1.23KW W2
U1
W1
STAR CONNECTION OF MOTOR

Delta mode Star mode Power saving in Energy saving per

S.NO Equipment Rated kw kw annum in kwh
Cost Saving
power power
1 COOLING FAN - 1 3.7 2.15 1.23 0.92 7286 Rs 35000
2 COOLING FAN - 2 3.7 2.07 1.16 0.91 7207 Rs 34500
TOTAL 14494 Rs 69 500
*Run hours taken 330days @ 24Hrs per day

Automatic Star-delta-star
 Application - motors with variable loads

 Automatic star-delta-star converter has load sensor & Timer
 Capacity  V2
 Principle of Voltage optimization
Load Sensor
Star Mode < 40% %L

> 40%  Mode
Energy Saving Protection

In a plant, if the loading of all the motors are less than 80%,
What is the method of Energy Conservation ?
Best method – Optimizing the overall Voltage of the plant.

Optimise The Plant Operating Voltage-Overall
 Plant operating voltage plays a critical
role in energy conservation
 On line voltage optimizing devices to
regulate the operating voltage
 Magnetization losses vary
exponentially with the voltage

Motor Magnetization Losses Vs Motor Voltage
 Methodology to be adopted
 Voltage optimization Potential will vary with over all Loading
pattern of all motors
 To be implemented after analyzing the loading pattern of all motors
 Reduce Voltage from rated value – In steps
Per unit magnetization losses

 Monitor Energy Consumption
 Arrive at Optimum Voltage

Case Study- Overall Voltage Optimization
 Distribution Transformer : 2000 kVA, 11kV/433 V
 Operating voltage : 428 – 430 V
 LT Motors Loading : 20 – 80%
 Average Load : 850 – 900 kW
 Transformer tap position reduced from 3 (normal tap) to 2
 Optimized voltage : 417 – 419 V
Annual Savings : Rs 1.32 Lakhs

Energy Efficient Motor


 Lesser slip
 Copper instead of aluminum bars in the stator
 Improved fan design
 Cooler operation & Increases motor insulation life
 1.15 service factor

 Greater flexibility in handling voltage variations and imbalances
 High power factor

 Eliminate need for PF correction

Energy Efficient Motors
New efficiency classes defined by IEC -60034

Super premium
IE4 Super premium efficiency
efficiency *
Premium
IE3 Premium
efficiency
High efficiency IE2 Comparable to EFF1
Standard
IE1 Comparable to EFF2
efficiency
IEC standard indicated a Super Premium class with 15% lower losses than the IE3
©Confederation
© Confederationof of Indian
Indian Industry
Industry
IE efficiency classes for 50 Hz 4-pole motors

European Union Mandatory Standards for Motors
Phase 1: Motors must meet the IE2 efficiency level
From 16 June, 2011
Phase 2: Motors with a rated output of 7.5 – 375 kW must meet

EITHER the IE3 efficiency level OR the IE2 level if fitted
From 1 January, 2015
with a variable speed drive
Phase 3: Motors with a rated output 0.75 – 375 kW must meet

EITHER the IE3 efficiency level OR the IE2 level if fitted
From 1 January, 2017
with a variable speed drive
©Confederation
© Confederationof of Indian
Indian Industry
Industry
Indian Scenario..
 The standard is in line with IEC

 Standard Recommend to Use of IE2 & IE3 motor
 IE1 is obsolete from the standard
 IE2 is recommended by standard from 30th June 2011
 IE3 is recommended by standard from 31st Jan 2014
© ABB Group
When to Install EE Motors?
 New Projects
 EE Motors ideally suited
 Rewinding of Old motors
 In case of Normal Failure
 Fit case for Replacement after rewound 5 times

Upgrading one, 0.75 kW motor to a Premium Efficient motor ....
Every year will eliminate:

1 Drum of
Oil from 250 Kg of
being coal from
burned or.... being
burned
and....
Up to 650 gms. of carbon

emissions from being
released into the atmosphere
Case Study-Replace old motors with Energy Efficient Motors
 Implemented in one of the Automobile plant

 Old motors
 More than 20 years old
 Rewound for many times
 Reduction in efficiency
 Replaced 9 numbers of motors
Annual Saving - Rs 14.0 Lakhs

Investment - Rs 25.0 Lakhs
Payback period - 22 Months

Savings Calculation
Annual
Rated Old New Load Operatin Monetary Savings
Savings Energy
Power Efficiency Efficiency Factor g hrs (INR)
Savings
7.5 85.73 90.4 0.75 0.33 8000 2711 Rs 0.20 Lakhs

Permanent Magnet Synchronous Motor

 Features
 Online starting
 No drive required
 Lossless excitation
 High efficiency- IE4 standard
 No rotor losses
 Runs at synchronous speed
 Starting torque similar to IE2 motors and starting current 90% of IE2
motors
 Can be used with a drive for higher savings than IE2 motor

BLDC Motors
 A brushless DC (BLDC) motor is a synchronous electric Motor

 powered by direct-current (DC) electricity
 brush-system/commutator assembly is replaced by an electronic controller
 electronic controller can use position information of the rotor, plus the desired
direction for the motor
 In BLDC motors, current to torque and voltage to rpm are
linear

Energy Efficient Ceiling Fan-Super fan
 Ceiling fan is based on AC motors which are power hungry

 Speed is regulated through resistors
 Inefficient control
 Degradation of power factor
 The proposed solution using the BLDC motor is to keep the same air
flow or displacement
 With less energy and improving the PF
 Aerodynamic blade design

BLDC Fan Vs Conventional Fan

BLDC Motor

Technical Specifications
 Rated Voltage -230Vac Power consumption

in Watts
 Rated Frequency -48Hz-52Hz
Ordinary Super
 Power -35W Speed Fan fan*
 Power Factor -> 0.9
Low 12 4
 Speed -350rpm
Medium 39 14
High 75 35
*Super fan delivers same or more air than ordinary fans

BLDC in Air Handling Units
System is a combination of all the conventional Motor functions given below
1. Motor Without Maintenance

2. FAN
3. Inbuilt VSD
4. Functionality of Starter Panels
5. Voltage and Current Protections.
6. Harmonic Filtration.
7. Power Factor Correction
8. Communication Channels for BMS
9. 30-40 % energy savings

What is the new technology ?
Conventional System Intelligent System
Motion Produced by Slip created in rotor and stator Motion Produced by Opposite Magnetic Field created in
rotor and stator
 Motor Efficiency at varying load 40-80%  Motor Efficiency at varying load 92-95%
 Motor Efficiency full load 80 -85%  Motor Efficiency full load >95%
 Power Factor at drive level 0.6 to 0.8  Power Factor at drive level Close to unity

Technology Implementation through Retrofit



ABB Ability – Smart Sensors
 Smart Sensor
 ABB Ability Smart Sensor is like a fitness wristband
for electric motors
 FitS easily to the surface of a motor, without wiring
or machining
 Collects operational data and health information of
the motor
 The sensor takes a measurement every hour, and
has a memory for a month
 The data is analyzed by the powerful algorithms
Can be used for old and new motors of ABB motors and non-ABB motors
https://www.youtube.com/watch?v=iSR80gkbvCg&feature=youtu.be
Smart Sensors- Monitoring
 Motor health manifests as  Motor activity shows as:

 Bearings condition – e.g.  Energy consumption
lubrication issues, damaged
 Vibration levels
elements
 Temperature
 Cooling condition – e.g.
dirty fan cover  Operating hours
 Rotor condition – e.g.

cracked bars or short circuit
rings
 Airgap condition – e.g.
eccentricity, bent shaft
Smart Sensors – Benefits
 Safe remote monitoring

 Proactive maintenance
 Reduce downtime
 Save energy
 Reduce maintenance cost

Sum-up….
 Sizing of the motor is critical and important
 Over sizing will result in
 More losses
 Lower efficiency
 Under sizing will result in
 Overloading
 Overheating & failures
 Optimal sizing will result in
 Minimum losses
 Maximum efficiency

Sum-up
 Joint Ownership with the process team

 Energy Efficient Motor
 New installations
 Replacement – Rewound Motors
 Low power ceiling fan

Solar Mill
The SolarMill Generates :

 Daytime energy from the sun and wind. 1 Module =250kWp
Solar +350kWp Wind
 Day & Night energy from the wind.
 Energy even on cloudy days.
 More energy on hot sunny days due to cooling
effect on solar panels by wind.
 Standing at about 1 meter height, Solar Mill meets
building code requirements.
 3 Vertical-Axis Wind Turbines coupled to 3
permanent magnet generators
 On-Board “Smart” Electronics include dynamic
Maximum Power Point Tracking (MPPT) and
connectivity
Solar Mill
 Solar Mill Assembly:

 3 Vertical Axis Turbines mounted
on a single base.
 Cut-in wind speed – 2 m/s & Cut-
out wind speed – 18 m/s.
 Turbines (Savonius) produce energy
by accepting winds coming from
any direction.
 Designed for both On-Grid and Off-
Grid applications.
Solar Mill
13kW- Residence, 10kW- Sidvin Plastech,

Shamshabad Shameerpet
5kW- GreenAssets,
5kW- Dexler, Bangalore
Dehradun
Thank You….

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Motors – EE Opportunities and

Confederation of Indian Industry

*Source:- International Copper Association

2 © Confederation of Indian Industry

1 HP = 76 Kg-m per second

Work - Force applied over a distance

Effectiveness with which a motor

converts Electrical energy to

Mechanical energy Output

© Confederation of Indian Industry

Range ( H.P ) % of Loss At FL

5 © Confederation of Indian Industry

• Over Sized / Under loaded Motors

• Improper Supply Voltage

• Use of Less Efficient Motors

• Poor Power Factor

 Motor loading is critical factor

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

 Motors normally operated in delta mode

© Confederation of Indian Industry

DELTA CONECTION OF MOTOR

15 © Confederation of Indian Industry

STAR CONNECTION OF MOTOR

16 © Confederation of Indian Industry

Delta mode Star mode Power saving in Energy saving per

1 COOLING FAN - 1 3.7 2.15 1.23 0.92 7286 Rs 35000

2 COOLING FAN - 2 3.7 2.07 1.16 0.91 7207 Rs 34500

TOTAL 14494 Rs 69 500

*Run hours taken 330days @ 24Hrs per day

 Application - motors with variable loads

Star Mode < 40% %L

Energy Saving Protection

Best method – Optimizing the overall Voltage of the plant.

© Confederation of Indian Industry

© Confederation of Indian Industry

 To be implemented after analyzing the loading pattern of all motors

 Reduce Voltage from rated value – In steps

Per unit magnetization losses

 Arrive at Optimum Voltage

© Confederation of Indian Industry

Annual Savings : Rs 1.32 Lakhs

© Confederation of Indian Industry

© Confederation of Indian Industry

 1.15 service factor

 High power factor

© Confederation of Indian Industry

New efficiency classes defined by IEC -60034

High efficiency IE2 Comparable to EFF1

© Confederation of Indian Industry

Phase 1: Motors must meet the IE2 efficiency level

From 16 June, 2011

Phase 2: Motors with a rated output of 7.5 – 375 kW must meet

Phase 3: Motors with a rated output 0.75 – 375 kW must meet

 The standard is in line with IEC

 IE1 is obsolete from the standard

 IE2 is recommended by standard from 30th June 2011

 IE3 is recommended by standard from 31st Jan 2014

© Confederation of Indian Industry

Every year will eliminate:

Up to 650 gms. of carbon

 Implemented in one of the Automobile plant