2021 14th IEEE International Conference on Industry Applications Tu3Track B.

Induction Motors Assessment: A Substitution Case

Analysis
Jonathan Muñoz Tabora, V.B. Andrade, Cleydson M. Lima, C.C. M. de Moura Carvalho, Ulisses J. Paixão, J.C.A. da Silva,
M.E. de Lima Tostes, Edson Ortiz de Matos and Ubiratan Holanda Bezerra
2021 14th IEEE International Conference on Industry Applications (INDUSCON) | 978-1-6654-4118-6/21/$31.00 ©2021 IEEE | DOI: 10.1109/INDUSCON51756.2021.9529738

Amazon Energy Efficiency Excellence Center (CEAMAZON)

Federal University of Pará (UFPA)
Belém, Pará, Brazil
jonathan_mt24@hotmail.com, vinioneborges@gmail.com, cleydsonmatos12@hotmail.com, carminda@ufpa.br,
upaixaojr.eng@gmail.com, jamillyazevedo123@gmail.com, tostes@ufpa.br, ortiz@ufpa.br, ubiratan.fapespa@gmail.com

Abstract—Currently, 70% of the electric motors installed
globally are unregulated (IE0) and standard efficiency (IE1)
motors. With higher efficiencies existing commercially, as well
as the minimum efficiency requirements for commercial sales,
the replacement of old/non-efficient electric motors can bring
great savings in economic and ecological terms. This work
presents a technical and economic analysis carried out for the
substitution of electric motors classes IE0 and IE1 in a pumping
system at the Federal University of Pará. The results highlight
the importance of measurement before making substitutions,
and the considerations to be made aiming for greater energy and
economic savings.
Keywords—Energy efficiency, voltage variations, power
quality, induction motors, motor substitution.
I. INTRODUCTION (HEADING 1)
Brazil has approximately 20 million installed electric
motors in the industrial, commercial, and residential sectors
that represent between 24-30% of the total energy generated
[1], [2]. Many of these installed motors have already reached
their useful life and have been rewound multiple times. In
2008 the IEC 60034-30-1 [3] defined a classification to
harmonize the different efficiency classes on the market (IE1,
IE2 & IE3 efficiency classes), the latest edition defined the
IE4 class as the maximum efficiency.
A report presented in 2017 showed that more than 70% of
the motors installed are class IE0 (unregulated) and class IE1
(standard efficiency) [4]. Currently more than 80 countries
have adopted the Minimum Energy Performance Standards
[5], with which the minimum efficiency classes to be
manufactured and commercialized are defined according to a
series of conditions. In Brazil, the minimum efficiency class
to be commercialized from March 2019 is the IE3 class [6].
For the replacement of motors, different considerations
must be carried out, both technical and economic, such as the
hours of operation, the type of application, the payback period,
among others. Papers analyzing substitution between
technologies have been presented in [7]–[9].
For the replacement, different methods can be used
according to the available information: from power and
current measurements, slip method, to the induction motor
modeling, aiming to estimate the electric motor output load
percentage, and from there, to carry out technical and
economic feasibility studies [10], [11].
However, for the replacement, other factors such as the
power quality of the supply must be considered in case it is
necessary to derate the motor output power due to unbalanced
voltages, harmonics, or voltage variations among other
disturbances that impact on its operation [9], [12], [13] .
This work presents the technical and economic analysis for
the replacement of electric motors classes IE0 and IE1 in a
pumping system of the Federal University of Pará. The main
contributions of this work are a procedure to evaluate if the
replacement of an electric motor is economically feasible, as
well as considerations related to power quality and connected
load aiming at the correct dimensioning of the proposed
motors.
II. PUMPING SYSTEM DESCRIPTION
A. Existing Electric Motors
The Federal [14] University of Pará has two pumping
systems, each of them is composed for two induction motors
(IM’s) and supplied by the main cistern, from where the water
is distributed to the basic and professional sectors in the
UFPA. Water to the main cistern is supplied by a submersible
pump of 60 hp. Figure 1 shows photographs of the two
pumping systems. The professional sector system (Fig 1a)
works with 10 hp electric motors, but the basic sector (Fig 1b)
works with 20 hp electric motors. The operating voltage of
both the systems is 380 V supplied by an exclusive electric
transformer for the water treatment station.
(a) (b)
Fig. 1. Pumping systems electric motors for the (a) Professiona sector and
(b) basic sector in the UFPA.
Each set of motors have the same nameplate
characteristics, and the nominal nameplate data are
summarized in Table I. The efficiency values of the motors of
14.92 kW were sought in the efficiency classification of the
IEC 60034-30-1, and it is among the IE1 (Standard efficiency)
classification. The set of 7.46 kW motors, on the other hand,
has no information regarding the efficiency and power factor
values, being an old motor, and was classified as a class IE0
motor (non-regulated).

978-1-6654-4118-6/21/$31.00 ©2021 IEEE 783 ISBN 978-1-6654-4118-6

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 TABLE I. ELECTRIC MOTORS DATA

IM Nameplate data Professional Sector Basic Sector

Output Power (kW) 14.92 7.46

Nominal Speed (rpm) 1760 1730

Efficiency 0.902 Non-Available

Power Factor 0.82 Non-Available

Nominal Current (Amps
30.5 16
- 380 V)
IEC Class IE1 IE0

Fig. 3. Power quality analyzer for electric motors consumption

B. Methodology
For the study, the methodology presented in Figure 2 was
used. Initially, the nameplate data of each installed motor were
collected, as well as the maintenance information and number
of rewinds of each motor. With this information, the IM’s
efficiency class was verified based on the IEC 60034-30-1
standard.
Then measurement campaigns were carried out aiming to
observe the operating cycle, motor output load, and quality of
supply, to verify if additional considerations are necessary for
the replacement of the electric motors. Finally, an economic
analysis was carried out considering the payback of the
investment as well as the minimum efficiency level for the
proposed electrical motors based on the IEC 60034-30-1.
measurement.
III. MEASUREMENTS RESULTS AND ANALYSIS
A. Basic Sector Pumping System
The basic sector pumping system consists of two motor
pumps with an output power of 10 hp (7,457 kW) in parallel.
Figure 4 shows the variation of the input power of the motors
for each day. It can be seen that although the average power
value varies between 3-4 kW, there are times when the
demand exceeds 6 kW, reaching a maximum of 6.3 kW,
throughout the week. The line current of the motors did not
exceed their rated value (16 A), with maximum values of 13
A, as shown in Figure 5.

Fig. 4. Input power measured for the 10 hp electric motor in the basic sector
pumping system.

Fig. 2. Methodology Flowchart for the IM’s substitution case analysis

C. Operation and Measurement

The pumping systems operate permanently, with two
pumps for each set, in order to allow maintenance. The
actuation of each system is with electric floats, with which an
operation cycle with frequent starts / stops is expected.
To verify the cycle of operation and consumption of the
analyzed systems, power quality analyzers were installed for
each system, from the manufacturer HIOKITM model
PW3198. It is important to mention that the measurements
were carried out in a pandemic period, in which UFPA
operates without students.
The measurements were performed in the period between
28/08/2020 and 11/09/2020. Figure 3 presents the power
quality analyzers installed in the electric motor panel. Fig. 5. Input line currents measured for the 10 hp electric motor in the basic
secto pumping system.

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 The power factor, shown in Figure 6, remained at 0.70
within the analyzed period, being the lowest when compared
to the electric motors in the professional sector.

Fig. 8. Input line currents measured for the 20 hp electric motor in the
professional sector pumping system.

Fig. 6. Power factorv vaiation for the 10 hp electric motor in the basic secto
pumping system.

B. Professional Sector Pumping System

The Pumping System for the professional sector has two
electric motors with 20 hp (14.92 kW) of output power,
measurements were made at the electric motor and the results
of the input power are shown in Figure 7.
It can be observed that there are points (periods) in which
the electric motor operates above its nominal value, varying
mainly between 10-15 kW, and reaching powers up to 20 kW,
which represents an overload in the motor, and which can
result in a decrease in its useful life.

Fig. 9. Power factor variation for the 20 hp electric motor in the basic sector
pumping system.

C. Power Quality Analysis

As can be seen in Figures 5 and 8, the line currents present
a slight unbalance, in this way the line voltages of the motor
control panel were also analyzed and are presented in Figure
10. It can be observed that there is a small voltage unbalance,
but it turns out to be less than 1% so no adjustment should be
made for substitution between electric motors according to the
National Electrical Manufacturers Association (NEMA).

Fig. 7. Input power measured for the 20 hp electric motor in the basic secto
pumping system.

To better analyze this fact, the variation of the nominal

current is shown in Figure 8. It can be observed that there are
periods when the current exceeds the nominal value of 30 A,
reaching maximum currents of 36 A. The service factor of the
motors in the system is 1.15, which means that they can
operate during certain periods with overloads of up to 15%,
but currently overloads of up to 19% have been found based
on the measurements performed. The power factor, shown in
figure 9, showed small variations over the analyzed period,
with values greater than 0.80 close to the nominal value.
Fig. 10. Voltage magnitude vaiation for the electric motor input.

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 However, a variation in voltage magnitudes can also be within the Green hourly tariff modality. According to ANEEL
observed, with values higher than the nominal motor plate Normative Resolution 414 (2010), the tariff modalities of
voltage (380 V). The NEMA and IEC standards define the group A are characterized by the binomial invoice with the
maximum and minimum values allowed for electric motors in application of monetary values for the consumption of active
±10% in relation to nominal voltage on the nameplate. Within power (kWh) and demand charge (kW). In this way, it is
this range, it is expected that the IM can operate satisfactorily possible to simulate energy expenditure [16].
without compromising its useful life. Figure 11 presents those
limits. A measurement campaign was performed from 08/28 to
09/03 to estimate consumption and demand. The average daily
In Zone A, the motor may present increases in core losses, consumption of 136.8 kWh was provided during peak hours
and consequently slight increases in temperature, however and 858.2 kWh during off-peak hours. Fig. 12 shows the
without significantly affecting its operation. Then in Zone B, estimated monthly values.
the motor can present considerable increases in temperature,
as well as decreases in the power factor, so if it is not possible Estimated monthly energy consumption
to improve the power quality of the supply, the derating of the
electric motor must be considered. Energy consumption at peak 4104,45 kWh
Energy consumption off-peak 25746,91 kWh
Demand charge

Demand at peak 68,20 kW

Demand off-peak 69,30 kW

Fig. 12. Estimated monthly consumption and demand.

The maximum demand recorded in the analysis period was

69.3 kW. Considering the billing method for the Green tariff
modality, and that the amounts due to the pumping system are
components of the university invoice, the demand billed will
be considered equal to the registered demand. Thus, for billing
purposes, we have the following values shown in Fig. 13.

Monthly energy bill

Tariff
Consumption tariff at peak 2,7057 R$/kWh
Fig. 11. Voltage variation zones for NEMA and IEC Standards. Copied from
[15] off-peak 0,2867 R$/kWh
Demand tariff 29,75 R$/kW
As it is observed in Figure 10, in some small periods the
motors operate with voltages of up to 420 V, which represents Payment
more than 10% of voltage variation exceeding the values Consumption at peak R$ 11.105,42
recommended by the aforementioned standards. The main
cause is the suspension off the activities at UFPA due to the off-peak R$ 7.381,64
pandemic, which results in low load and consequently, in Demand R$ 2.061,68
overvoltage.
Total without tax R$ 20.548,73
The voltage variation in this case results in an increase in Total with tax R$ 29.114,10
the positive sequence component. Efficiency in the electric
motor is directly proportional to the positive sequence Fig. 13. Estimated monthly energy bill.
component of voltage, while the power factor varies
proportionally inversely, which can be observed on days Based on the consumption cost calculation, shown in
28/08 and 01/09 where voltages were up to 420 V and the Figure 13, the pumping system represents for the Federal
power factor values presented the lowest values, and vice University of Pará a cost of approximately R$ 20,548.73
versa. without tax or R$ 29,114.10 with tax each month, and
In this way, it is expected that in these operating conditions approximately R$ 246,584.77 and R$ 349,369.18 over the
the efficiency of the motor will present small increases while year without and with taxes, respectively. The following
the power factor the oppositive behaviour. section will show an analysis of the expected savings from
replacing existing motors with more efficient electric motors.
Because the overvoltage is mainly caused by the low load
present in the University, it was recommended to change the
transformer tap position while the currently load profile IV. SUBSTITUTION ANALYSIS
persists.
In order to analyze the feasibility of substitution between
D. Pumping Systems Electric Bill technologies, as well as the characteristics of existing ones,
As UFPA is served by the energy concessionaire with a this section shows the analysis of the economy to be obtained
supply voltage equal to 13.8 kV, it is in group A, currently with substitution of the presented IM’s. For this purpose,

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 budgets were requested based on the measurements made, as
well as considering the efficiency of the existing electric
motors and the proposed ones. The annual savings from
substitution can be calculated using equations (1-3) [12]:
𝟏𝟎𝟎 𝟏𝟎𝟎
𝒌𝑾𝒔𝒂𝒗𝒆𝒅 = 𝑷𝒐𝒖𝒕 ∗ 𝑳 ∗ ( − )
𝑬𝑶𝑴 𝑬𝑵𝑴
𝒌𝑾𝒉𝒔𝒂𝒗𝒊𝒏𝒈𝒔 = 𝒌𝑾𝒔𝒂𝒗𝒆𝒅 ∗ 𝒉𝒓
𝑻𝒐𝒕𝒂𝒍 𝑺𝒂𝒗𝒊𝒏𝒈𝒔
= 𝒌𝑾𝒔𝒂𝒗𝒆𝒅 ∗ 𝟏𝟐 ∗ 𝑴𝒐𝒏𝒕𝒉𝒍𝒚 𝒅𝒆𝒎𝒂𝒏𝒅 𝒄𝒉𝒂𝒓𝒈𝒆
+ 𝒌𝑾𝒉𝒔𝒂𝒗𝒊𝒏𝒈𝒔
𝑹$
∗ 𝒆𝒏𝒆𝒓𝒈𝒚 𝒄𝒉𝒂𝒓𝒈𝒆 ( ) (𝟑)
𝒌𝑾𝒉
Where 𝒌𝑾𝒔𝒂𝒗𝒆𝒅 is the decrease in motor input power,
𝑷𝒐𝒖𝒕 , are the nominal motor plate power in kW, L is the
percentage of motor load, hr are the hours of operation,
𝒌𝑾𝒉𝒔𝒂𝒗𝒊𝒏𝒈𝒔 represents the annual energy savings, 𝑬𝑶𝑴 and
𝑬𝑵𝑴 are the old and new electric motors efficiency.
The total annual savings are calculated using equation (3),
with a demand according to the percentage that the motors
represent in the maximum demand, and the costs in (R$/kWh)
at peak and off-peak periods.
A. Basic Sector
According to the measurements presented, it was observed
that the 10 hp motors are correctly dimensioned with the
measured load. In this way, it is only proposed to replace the
existing IE0 class IM’s with IE3 class IM’s, the minimum
efficiency allowed within Brazil.
Figure 14 presents the savings obtained with the
replacement of the two 10 hp electric motors. The efficiency
values for the new motor were obtained from the
manufacturer's manuals, while for the old motor they were
estimated, initially considering an efficiency lower than that
of an IE1 class motor for the same power, also applying a
reduction factor due to the fact that they have been rewound
more than twice. The hours of operation were estimated based
on the measurement period, also considering the peak and off-
peak hours with the respective rates.
Fig. 14. Payback period for the substitution of two 10 Hp IM’s.
Annual savings of R$ 2,791.00 can be obtained with the
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substitution of both electrical motors. With an individual
initial cost of R$ 4,597.00/electric motor, it can be seen that it
takes less than two years to pay the initial cost for one electric
motor in the pumping system and 3.29 years the total pumping
system. Based on the estimated useful life of the IM’s at that
output power, an economy of up to R$ 25,000 can be obtained
(𝟏)
with the replacement, as presented.
B. Professional Sector
(𝟐)
As presented, the existing 20 hp IM’s are operating at a
load higher than the nominal power, which results in greater
losses, an increase in temperature and consequently a
reduction in their useful life. The electric motors have a
nominal power of 20 hp and according to the measurements is
recommended one of 30 hp, so different factors must be
considered for replacement, as detailed below:
• The estimated service life of the IM in operation, for
this it is necessary to review the time it has in
operation to compare with the estimated time of the
electric motor according to the rated power. If the
electric motor has more than its expected useful life,
the maintenance history should be consulted to check
if it has already been rewound and from there,
estimate the remaining useful life.
• Check the savings to be obtained by replacing it with
a more efficient electric motor, but with greater
power, to check if it is more feasible to let the old
motor reach its useful life, then install a more
efficient electric motor, or substitute the existing
motor for a new higher efficiency immediately.
To analyze the feasibility of the substitution, we will use
(4) [13]. For the replacement to be attractive, the cost of the
new engine must be less than the remaining life of the existing
engine multiplied by the economy of the new engine each
year.
𝑰𝑵𝑬𝑾 𝑴𝑶𝑻𝑶𝑹 < 𝒕𝒖𝒔𝒆𝒇𝒖𝒍 𝒍𝒊𝒇𝒆 𝑶𝑳𝑫 𝑴𝑶𝑻𝑶𝑹 ∗ 𝑬𝑵𝑬𝑾 𝑴𝑶𝑻𝑶𝑹 (𝟒)
Where 𝑰𝑵𝑬𝑾 𝑴𝑶𝑻𝑶𝑹 is the cost of the proposed new electric
motor engine, 𝒕𝑼𝒔𝒆𝒇𝒖𝒍 𝒍𝒊𝒇𝒆−𝑶𝑳𝑫 𝑴𝑶𝑻𝑶𝑹 , is the estimated lifetime
of the existing motor in years and 𝑬 𝑵𝑬𝑾 𝑴𝑶𝑻𝑶𝑹 , the economy
of the proposed new efficient motor.
The savings from replacing the old motor can be calculated
using the equations in (1-3), but for efficiency, the value for
the measured load factor in the undersized old motor and that
of the proposed electric motor was considered. With these
values, the replacement payback calculation was performed
and is shown in Figure 15. Estimated annual savings of R$
7,352.00 can be obtained with the substitution of both
electrical motors. With an individual initial cost of R$
12,829.00/electric motor, it can be seen that it takes less than
two years to pay the initial cost for one electric motor in the
pumping system and 3.48 years the total pumping system.
Using equation (4) we can analyze the feasibility of
replacing with a higher power electric motor, as presented
below:
𝑹$ 𝟏𝟐, 𝟖𝟐𝟗 < (𝟏, 𝟕) (𝑹$ 𝟕. 𝟑𝟓𝟐, 𝟕𝟐)
787
 If the time until the next rewind is more than 1.7 years, the
replacement would not be profitable, and it is better to wait for
the existing motor to need maintenance (rewind) to replace it
with a new one. If the period is shorter, the replacement is
viable and with a three-year payback period for the two 30 hp
electric motors, as presented in Figure 15, and with a total
economy of more than R$ 60,000.00 through its useful
estimated life.
Fig. 15. Payback period for the substitution of two 30 Hp IM’s.
V. CONCLUSIONS
The present work analyzed the pumping system of the
water treatment station in the UFPA. Based on measurements,
and analyzes, some conclusions and considerations were
made:
1. It was observed that the existing electric motors have
efficiency classes of IE0 and IE1, also having been
rewound more than once. Actually, and according to
the current regulation, the minimum efficiency class
in Brazil is the IE3 class, whereby the replacement
for more efficient IM’s can bring great energy and
economic savings.
2. The operating cycle of the pumps is being controlled
by electric level floats, whereby the motors have an
operating cycle with frequent starts/stops. As well as
with operations of more than 97% of the time during
peak hours, in which the energy cost is 10 times the
cost during off-peak hours, whereby the use of
variable speed drivers can avoid/decrease the
operating time in these periods, as well as operations
at reduced speeds can translate into even greater
savings.
3. The existing pumping system represents
approximately R$ 20,548.73 or R$ 29,114.10 each
month and approximately R $ 246,584.77 or R$
349,369.18 throughout the year without and with
taxes, respectively. With the implementation of
substitution for more efficient motors of IE3 class,
annual savings of up to R$ 21,450 can be obtained
annually in the pumping systems of the basic, and
professional sectors, with a 2-year payback for both
pumping systems.
Based on the previous one, the feasibility of replacing the
old/non-efficient existing motors with motors can be
highlighted, as well as the implementation of automation
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actions through variable speed drivers to optimize the system
operation
VI. FUTURE WORKS
The replacement of electric motors can bring great savings
in the current pumping system, however, greater savings than
those presented above can be obtained with the
implementation of an automated system. The existing electric
motors have only soft starters in their mechanisms, so the
implementation of a variable speed system can bring great
benefits.
To verify this fact, we can see Figure 15, which shows the
power variation in each of the system's pumps (10 hp, 20 hp
and 60 hp). It can be seen that they have a frequent
stop/starting cycle; this behavior is due to the activation pump
system through electric floats installed in the water reservoirs.
Fig. 16. Start/stop cycle for the 3 pumping systems installed in the UFPA.
To optimize the operation, it is important to understand
how the water demand works during the day, what time occurs
the highest consumption, the speed to fill the reservoir, etc.
With this information it is possible to implement a system with
more sensors that indicate different levels such as 50%, 85%
and 100%, for example. So, when below 50% for example, the
system goes into operation at full capacity, between 85% -
100%, at reduced speed, saving energy; and when it reaches
100% it turns off.
It will also be considered the avoid/reduction of the
operating time of systems during peak hours, in which the cost
in R$/kWh is 10 times the energy cost during off-peak hours.
However, with the main water users outside the
University, due to the pandemic, the energy and economic
analysis with the implementation of these systems will be
presented in future works.
ACKNOWLEDGMENT
This work was developed with the support of the Federal
University of Pará, through the Energy Management and
Efficiency research project, as well as with the support of the
the Brazilian National Council of Scientific and
Technological (CNPq), in part by the Coordenação de
Aperfeiçoamento de Pessoal de Nível Superior – Brasil
(CAPES) – Finance Code 001 as well as the Paulo Freire
Program and the Honduras Presidential Program 20/20
Scholarships
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