Electrical Motors

Dr.P.Dharmalingam

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 Classification of Electric Motors

Electric Motors

Alternating Current (AC) Direct Current (DC)

Motors Motors

Synchronous Induction Separately Self Excited

Excited

Single-Phase Three-Phase Series Compound Shunt

• Motors are categorized on the basis of input supply, construction and operation principles

• Electromechanical device that

converts electrical energy to
mechanical energy

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Motor Efficiency

% Load vs. Power factor, Efficiency

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 Induction Motor Characteristics

The actual speed, which the motor operates, will be less than
the synchronous speed. The difference between synchronous
and full load speed is called slip and is measured in percent. It
is calculated using this equation:

•Induction Motor never runs at synchronous speed but lower “base speed”
•Difference is “slip”

AC MOTOR SIZE
Frame size is directly related to base RPM,
for a given Horsepower
Example: 15 HP motors of different base speeds

Base RPM 3600 (2-pole) 1800 (4-pole) 1200 (6-pole)

Frame Size 215 254 284

Torque 22.5 lb-ft 45 lb-ft 67.5 lb-ft

Amps 18.5 18.7 19.3

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Three types of Motor Load

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

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Motor Load Types: Constant Torque Load

Ex: Conveyors, Extruders,

and Hoists

Motor Load Types: Constant horsepower Load :

Ex: Metalcutting tools operating over wide speed

range, mixer, extruder and special machines where
operation at low speed may be continuous

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 Motor Load Types: Variable torque load

Energy Audit in motors

Motor Load Survey

of all identified key equipments measurement of
electrical parameters compare with the design
load and calculate % loading

Opportunities would include reshuffling of motors,

replacing with energy efficient motors, Rewinding
vs new motor

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Factors affecting motor operation

• Factors affecting motor operation are

Duty and loading
Power supply-voltage, phase, frequency, regulation
Mechanical arrangement: motor and coupling to
drive equipment, bearings and lubrication
Speed and power requirement
Method of starting and speed control
Frequency of starting

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Assessment of Electric Motors

Factors that influence efficiency

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

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 Assessment of Electric Motors

Motor part load efficiency

• Designed for 50-100% load
• Most efficient at 75% load
• Rapid drop below 50% load 19

Motor Load Survey: Methodology

Large industries have a massive population of LT motors
Load survey is to identify improvement options
Sl. Equipment / Motor Rating Measurements Reading Operating %
Starter
No. Motor Location KW RPM Amps type Volt Amps KW PF KVAR KVA Hz Condition Load

Open Ciruit Cold

1 Water Pump 1 40.5 1440 70 SD 416 39.4 19.5 0.6 21 28.70 48.3 No load

Open Ciruit Cold

2 Water Pump 1 40.5 388 52.1 29 0.8 21 36 48.7 Load 72

Open Ciruit Hot Sump

3 Pump 1 17.7 32 DOL 420 18.5 9.00 0.66 10.3 13.7 48.2 No load

Open Ciruit Hot Sump

4 Pump 1 17.7 420 25.0 14.2 0.78 11.3 18.2 48.1 Load 80

Open Ciruit Cooling

5 Tower Fan 5.5 410 15.6 5.16 0.46 10.3 11.2 48.1 Load 94

Closed Ciruit Cold

6 Water Pump 2 110 225 SD 413 156 91.7 1.00 0 56 48.4 Load 83

Closed Circuit Return

7 water Pump 2 48 1480 82 DOL 416 62.6 33.8 0.78 28.1 43.5 49.4 Load 70

Closed Circuit Cooling

8 Tower Fan 1 30 420 33 18.1 0.75 15.9 24.1 48.0 Load 60

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 Energy Efficiency Opportunities

1. Use energy efficient motors

2. Reduce under-loading (avoid over-sized
motors)
3. Power factor correction by capacitors
4. Rewinding
5. Improve Voltage unbalance
6. Speed control of induction motor
7. Optimize transmission efficiency
8. Improve maintenance
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1.Use Energy Efficient Motors

• Efficiency 3-7% higher

• Best to replace when existing motors fail

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Case Study - Energy Efficient Motors:

Input kW Output - kW Delivered kW

Case-1Existing 47.2 42.5 23.37
standard motor Motor Pump
Eff. 90% Eff. 55%

Case-2 Replaced Input kW Output - kW Delivered kW

44.7 42.5 23.37
with Energy
Efficient motor Motor Pump

Eff. 95% Eff. 55%

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 2. Reduce Under-loading
Problem
• 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
Solution
• Replace with smaller motor
• If motor operates at <50%
• 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
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 Before

After
Replacement of oversized motors.

Operation of Under-Loaded Delta-Connected Motors in Star Connection

1. If a motor is oversized and

continuously loaded below 30%
of its rated shaft load, the motor
can be permanently connected
in Star.

2. If the motor is normally loaded

below 30% but has a high
starting torque requirement, then
the motor can be started with a
suitable starter and, after
overcoming the starting inertia,
be automatically switched from
Delta to Star, using timer
control or current sensing.

3. If the load is below 30% most of

the time, but if the load exceeds
50% some times, automatic
Star-Delta changeover
Switches (based on current or
load sensing) can be used.

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 Effect of over sizing
Why are motors often oversized?
 Original design requires 7kW
 Engineer adds in 10% for contingency - 7.7kW
 Selects next standard size motor - 11kW
 Over rating = 57%

To meet 7.5 kW load if the motor selected is 7.5 /11 /15 kW then the variations in energy
consumption is as shown in Table below: -

Parameter Case 1 Case 2 Case 3

Motor Load 7.5 kw at F.L. 10 kw at 3/4 load 15 kw at ½ load

Required load 7.5 7.5 7.5

Motor EFF (%) 88 84 79

Motor input kw 8.5 9.0 9.5

Unit consumed kwh 42500 45000 47500

% increase -- 5.8 11.76

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 3.Power Factor Correction in motor
• When power factor is improved and the reactive
power component is reduced, the total current flow in
the system is reduced.
• Capacitor size not >90% of no-load kVAR of motor

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3. Maintain High Power Factor

Table 2.5 Capacitor Ratings for Power Factor Correction by Direct
Connection to Induction Motors
Motor Rating Capacitor rating (kVAr) for Motor Speed
(HP) 3000 1500 1000 750 600 500
5 2 2 2 3 3 3
7.5 2 2 3 3 4 4
10 3 3 4 5 5 6
15 3 4 5 7 7 7
20 5 6 7 8 9 10
25 6 7 8 9 9 12
30 7 8 9 10 10 15
PF capacitor improves power factor from the point of installation backto the generating side.
If PF capacitor is installed at the starter terminals of the motor, it won't improve the
operating PF of the motor

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 4. Motor Rewinding

Motor burning rate • Population of rewound motors

• < 10 HP : 60 – 100 Nos per year
• >10 HP : 5 Nos per year
Major reasons
- Electrical overloading
- Mechanical / bearing failure
- Oil leaks & Water leaks while cleaning
Rewinding Quality
• Motor rewinding carried out by outside
contractor
• No load current is checked for rewound motor
if < 40% load , accepted with 6 months
guarantee
if > 40% load motor is returned for rework
may exceed 50 %
• Rewinding can reduce motor
efficiency and reliability.
• Majority of the users would
wish to rewind the motor.
• Rewind-versus-replace
decision
• Compare of no load current and
stator resistance per phase of a
rewound motor with the original
no-load current and stator
resistance at the same voltage
to assess the efficacy of
rewinding.

Minimize Rewind Losses

• Rewinding can reduce motor efficiency and reliability.

• Majority of the users would wish to rewind the motor.
• During a motor failure or in the stripping of the winding
from the stator core prior to rewinding, high
temperatures can occur. These temperatures can, in many
cases, affect the electrical characteristics of the stator
core steel and result in increased iron losses and lower
motor efficiency

• Rewinding population?No of times rewinded?

• Replacement policy?
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 5. Improve Voltage unbalance
Motor performance affected by
• 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

Keep voltage unbalance within 1%

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

6. Speed Control of Induction Motor

• 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
 RPM = (f x 120) / p
Need for VFD

 Torque α speed2
 Power α speed3

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 USE OF VARIABLE SPEED DRIVE (VSD)

• Electric motors drive fan, compressors, pumps, conveyors

and many other devices
• While processes are required to operate at varying
capacities, many motors operate at a single speed
– Change in Flow /Head requirements
– Over capacity pumps
– Check for all Pump/Fans where ever Damper control is used Presently.
• Many devices use valves or dampers to adjust fluid flow
and have the following characteristics
– Flow rate proportional to the motor speed
– Torque proportional to the square of motor speed
– Power proportional to the cube of motor speed
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Size to variable load

To determine the right choice for a variable speed drive
The load patterns should be thoroughly studied before exercising the
option of VSD. In effect the load should be of a varying nature to demand
a VSD

Figure 5.3 Example of an excellent variable speed Figure 5.4 Example of a poor variable speed
drive candidate drive candidate

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 Potential area for VFD

• Pumps/Fans
• Change in Flow /Head requirements
• Over capacity pumps
• Check for all Pump/Fans where ever Damper
control is used Presently.
• VSD proved economical even at flow requirement
is75 to 85 % of rated capacity. ( Operating Hours )
• The same Induction motor can be used.

Case Study:
VARIABLE SPEED DRIVE FOR BOILER COMBUSTION FANS

• Existing situation
– 50 HP centrifugal fan to supply combustion air to the boiler
– An actuator varies the amount of air and fuel to the burner
– Air flowrate controlled by inlet dampers
– Load profile of the fan and power consumed with damper control shown below

Air Power
kW kWh
Flowrate Operating Consumption (kW)
Fraction Hours Damper VSD Savings Savings
(%)
100 1 000 37 37 0 0
80 2 000 40 30 10 20 000
65 3 000 35 20 15 45 000
50 1 000 33 10 23 23 000

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 7.OPTIMIZE TRANSMISSION EFFICIENCY
Transmission equipment including shafts, belts, chains, and
gears should be properly installed and maintained. When
possible, use flat belts in place of V-belts. Helical gears are
more efficient than worm gears; use worm gears only with
motors under 10 hp. As far as possible it is better to have a
direct drive thus avoiding losses in transmission system.

 IMPROVING DRIVE TRANSMISSION EFFICIENCY :

 Direct drive most preferred least transmission losses.
 V- belts have transmission efficiency 85 - 90%.
 Modern flat belts(using nylon and chrome leather sandwiched
material ) have 96 to 98 % transmission efficiency.
 Transmission efficiencies of gear drives:
> Spur Gear : Cast teeth : 93%
Cut teeth : 96%
> Bevel Gear : Cast teeth : 92%
Cut teeth : 95%
> Worm Gear : thread 30o : 85-95%
thread 15o : 75- 95 %

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8. Improve 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

Improve maintenance
Conduct Hot Spot survey

Loose Contact in 3-Ph Supply

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 Flat Busbar connection

Conclusion
Conduct
Motors survey
Harmonics survey
Thermography survey
Electrical energy monitoring
Electrical energy balance by utility

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