A Technical Seminar Report

On
“ EFFICIENT ENERGY MOTORS ”
Submitted in partial fulfilment of the requirement for Seminar
course
Bachelor of Technology in Electrical & Electronics Engineering
M.VIJAYKUMAR (208P5A0205)

Under the supervision of

Mrs. P Swetha

Department of Electrical & Electronics Engineering

AAR Mahaveer Engineering College
Hyderabad 500005
2022-2023

DEPARTMENT OF Electrical & Electronics ENGINEERING

(AAR MAHAVEER ENGINEERING COLLEGE)ESTD: 2010

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 DEPARTMENT OF ELECTRICAL &
ELECTRONICS ENGINEERING

CERTIFICATE
This is to certify that the technical seminar report entitled “
EFFICIENT ENERGY MOTORS ” which is being submitted by
M.VIJAYKUMAR [208P5A0205] in partial fulfillment for the award
of the Degree of BACHELOR OF TECHNOLOGY in
ELECTRICAL & ELECTRONICS ENGINEERING of
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY is a
record of the bona fide work craned out by them under our guidance and
supervision.

SEMINAR COORDINATOR HEAD OF THE

DEPARTMENT
Mrs.P.SWETHA Mrs.Dr N.EASHWARAMMA
(Asst. professor, EEE) (Professor, EEE Department)

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 ACKNOWLEDGEMENT
I would like to express my deep-felt appreciation and gratitude to
Mrs.P.SWETHA, Associate professor, Department of EEE, technical seminar
supervisor, for her skilful guidance, constant supervision, timely suggestions, keen
interest and encouragement in completing the individual seminar within the
stipulated time.

I express my profound sense of gratitude to Mrs.Dr.N.EASHWARAMMA

Professor,Head of Department, EEE, who has served as a host of valuable
corrections and for providing me time and amenities to complete this seminar.

I am also thankful to Dr.G. SATISH BABU, Principal of our college and the
management of AAR MAHAVEER ENGINEERING COLLEGE for providing
an excellent academic environment in the college.

I also wish to express my gratitude to the Members of Staff and all other who
helped me throughout this path.

M.VIJAYKUM
AR [208P5A0205]

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 ABSTRACT

An Energy Efficient Motor (EEM) is a motor that gives you the same
output strength by consuming less power. A Standard motor efficiency is the ratio
of mechanical power output to equivalent electrical power input to the motor. An
Energy efficient motor utilizes the improved design and high quality materials to
reduce the motor running losses, therefore improves the overall efficiency.
Generally standard motors are compromised between Efficiency, endurance,
starting torque and initial cost. On the contrary, EEM competes on Efficiency but
not price. This paper presents an overview about energy-efficient motor
technologies, namely Energy Efficient Motors (EEMs), Variable Speed Drives
(VSDs), efficient transmission systems, etc. It also identifies the main barriers to
the penetration of those technologies as well as the strategies which can be used to
overcome those barriers and contribute to making efficient purchase decisions,
accelerating the penetration of energy efficient motor technologies.

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 INDEX
CONTENTS PAGE
NO

CHAPTER 1: INTRODUCTION 07
CHAPTER 2: DESCRIPTION (8-17)
2.1 : Motor Technology 08
2.2 : Construction Of Energy Efficient Motor 09
2.3 : Motor System 12
2.4 : Need Of Energy Efficient Motor 14
2.5 : Factors Affecting The Motor Efficiency 16
CHAPTER 3: NEED OF ENERGY EFFICIENCY MOTOR (18-
19)
3.1 : Motor Life Cycle. 18
3.2 : Efficiency Elevation Factors 19
CHAPTER 4: ADVANTAGES AND DISADVANTAGES 20
4.1 Advantages
4.2 Disadvantages
4.3 Applications
CHAPTER 5 : CONCLUSION 21
5.1 Conclusion
5.2 Future Scope
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5.3 Reference

LIST OF FIGURES
Table 1 :Types Of Induction Motors
Table 2 :Materials Used For Construction Of Motors
Table 3 : Efficiency Class
Table 4 : Energy Efficiency Reduction After Motor Repairs
Table 5 : Applications
Figure 1 :Construction Of Energy Efficiency Motor
Figure 2 : Lose Reduction
Figure 3 : Motor System
Figure 4 : Block Diagram Of Motor System
Figure 5 : Comparison Between Standard And EEM Motors

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 CHAPTER 1
Introduction
Electric motors convert electrical energy into motion and are found everywhere in homes,
offices, buildings and factories. However, motors do not convert all the electrical energy to
usable mechanical energy because some of it is lost as heat during the conversion process. At a
motor system level, the energy losses are much greater due to additional inefficiencies in the
mechanical and hydraulic components. Motor repairs, if carried out unprofessionally, are a
source of further energy losses.
Establishing appropriate policy measures can drive markets to adopt robust performance
standards, promote professional motor repair practices, and encourage efficiency improvements
in the overall systems that are driven by motors.
Specifically, these motors are defined as general purpose, three-phase electric induction
motors with two, four or six poles; rated output between 0.75 kW – 375 kW (i.e. 1 HP to 500
HP); rated voltage up to 1000 Volts at 50 Hz or 60 Hz; and continuous duty operation.
An energy efficient motor (EEM) is a motor that gives you the same output strength By
consuming lesser amounts of power. EEM is manufactured using the same frame as a Standard
motor, but they have some differences:
1. Higher quality and thinner steel laminations in the stator
2. More copper in the winding
3. Optimized air gap between the rotor and the stator
4. Reduced fan losses
5. Closer machining tolerances
6. High quality aluminum used in rotor frame

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 CHAPTER 2
Discription
This chapter deals with the overall introduction of the efficient energy motors

2.1 :Motor technology

Table:1 types of induction Motors

There are several electric motor technologies, as shown in Table 1, induction motors are the
most common due to the simplicity of their construction, ruggedness and low-cost. This guide
focuses on general purpose induction motors and the systems driven by these motors, as show in
Figure 3. The target motors represent 10 percent of motors in the global market, yet account for
68 per cent of the electricity used by motors.

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2.1.1 : Material used for construction of Motors:

Table 2
At the end of life of an induction motor, the Cast iron, steel, aluminium, copper, stainless Steel
and brass parts, which constitute more Than 98 per cent of the material content, are Fully
recyclable.
The recycling of metals not only conserves Valuable natural resources, but also requires Less
energy than extracting the respective Metal from its ore.
Apart from metals, an electric motor uses a Small quantity of rubber and plastic for the Fan and
terminal board, which are recyclable As well. The electronic printed circuit boards, Electrolytic
capacitors and semiconductor Devices used in variable speed drives should Be handled in
accordance with regulationsCovering e-waste.80

2.2 : Construction Of Efficient Energy Motor(EEM):

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The energy efficiency of induction motors can be improved by incorporating the design improvements
shown in Figure 1, as well as through improved manufacturing practices. In practice, motor
manufacturers typically take the lowest cost pathway to achieve the MEPS that has been adopted for a
market. They use a combination of design improvements that depend on the prevailing costs of the
materials

Figure.1 :construction of EEM

A relatively small improvement in the energy efficiency percentage is equivalent to a substantial
reduction of energy losses. By way of illustration, in the example of a 45 kW, 4 pole, 50 Hz motor, the
difference in the efficiencies of IE4 and IE1 motors is only 3.7 per cent, but this is equivalent to a 47 per
cent reduction in energy losses, as can be seen in Table 3

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 Table 3
Improvements in induction motor design have ensured a steady reduction of losses and Increases
in energy efficiency over the years. Figure 2 shows the progressive reduction of Losses in the
best available design of a 45 kW, 4-pole induction motor since 1960. It shows That any motor
built in 1990, if still in operation, would be less efficient than IE1, the lowest Efficiency class
today. This underscores the energy savings potential from the replacement Of old motors and the
risks of locking-in motor inefficiency given their long life.

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 Figure :2
2.2.1 : Energy Efficiency Reduction after Motor Repairs
Motors fail in service for various reasons. The most common cause is a failure of the Bearings
due to the mechanical vibrations Or shocks from misalignment of shafts or Improper assembly.
Bearings also fail due to Under- or over-lubrication or contamination Of the lubricant.
The second most common cause is The failure of the coil insulation due to Overheating caused
by overloads, poor Ventilation, contamination, or power Quality issues such as unbalanced
voltages And currents. This could also happen if The motor has previously been repaired Poorly.
There are other causes of motor Failures as well such as mechanical damage, And a mismatch
between the motor’s Characteristics and the starting torque Requirements of the load.
If a spare motor is readily available, the Failed motor may be replaced and the driven Equipment
can go back into operation. The maintenance department must decide Whether to repair or
replace the motor Depending on the extent of damage, the Previous repair history of the motor,
and the Relative costs of repair versus replacement.

Table : 4

2.3 :Motor Systems

A motor is a component of a larger system That is comprised of (see Figure 3):
• Power Equipment:

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 The distribution Transformer, which feeds the low-voltage Bus, switchgear, meters, protection,
Command and control.
• Optional Starter or Variable Speed Drive:
When the motor operates at a fixed-Speed, power is drawn directly from the Main power supply. If a lot
of power is Needed to start a fixed-speed motor, an Additional soft-start may be incorporate In the
system. When the speed of the Motor needs to vary, an electronic speed Controller (alternatively known
as a Variable speed drive, variable frequency Drive, inverter or converter) is used.
• Mechanical Transmission:
The motor Shaft may be coupled directly to the Driven equipment through a coupling, A gearbox, a
belt and pulley, or a chain And sprocket arrangement. There could Additionally be an electromagnetic
clutch For decoupling and a drum or disc brake For stopping quickly.
• Driven Equipment:
This could be a water Or an air pump, a fan, a gas compressor, A conveyor to move materials, or some
Type of production machine.
• Mechanical Controls and Process Components:
The remainder of the Process can include pipes to carry Liquids or gases, and valves, throttles And
dampers to control the flow of Liquids or gases.

Figure :3

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 Figure :4
2.4 : Need of Energy Efficiency Motor :
In the future, the cost of energy will increase due to environmental problems and limited Resources.
The electric motors consume a major part of the electric energy in industries. Thus, implementing
energy efficient motor could save a significant amount of electricity. It would also reduce the production
of green-house gases and push down the total Environmental cost of electricity generation. Also, these
motors can reduce maintenance Costs and improve operations in industry. Efficient energy use is
achieved primarily by Means of a more efficient technology or process rather than by changes in
individual Behavior
An EEM produces the same shaft output power, but uses less input power than a standard Efficiency
motor. A standard motor is a compromise between efficiency, endurance, Starting torque, and initial cost.
Standard motor generally competes on price, not Efficiency. On the contrary, EEM competes on
efficiency, not price. Shortly, EEM is Needed
a) When there is a new installation or modification to your plant.
b) When old motors are damaged and need rewinding.
c) When existing motors are underloaded or overloaded.
d) While protecting other devices.

WAYS OF IMPROVING EFFICIENCY

The various ways of improving efficiency includes:
a) Reduction of iron losses
b) Reduction of flux density
c) Usage of low loss magnetic material
d) Reduction of stator and rotor copper losses
e) Increasing the copper section i.e., the stator slot area or rotor bar section
f) Increasing stator yoke

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g) Reducing rotor diameter
h) Increasing the speed of starting current
i) Reducing the starting torque
j) Increasing core length for maintaining the starting torque
k) the thickness of the copper wires wound around the core of the motor. This reduces both the
electrical resistance losses in the wires and the temperature at which the motor operates.
l) Using more and thinner high-quality steel sheets for the main fixed and rotating parts of the
motor. This also minimizes electrical losses.
m) Narrowing the air gap between the spinning and stationary motor components, increasing the
strength of its magnetic field. This lets the motor deliver the same output using less power.

Figure:5

Electric motors are of utmost importance in industrial as well as agriculture sector. These motors
found their application as constant speed drives with very low rating as well as variable speed
drives with very high rating. Energy efficiency and energy conservation are very closely related
to each other. With increase in demand of energy and due to uncertainties in oil supply and
fluctuating price of conventional fuels, efficiency and conservation of energy has become an
important aspect of industrial as well as rural development. A large amount of electrical energy is
consumed by induction motor used for irrigation in rural sector and industrial purpose in urban
sector. In country like India agriculture and industrial sector is developing rapidly, in same way
electrical energy consumption is increasing. A study indicated that a 5 per cent improvement in
overall efficiency of induction motor would save enough energy that would be comparable to
energy produced by a new power plant of few hundred megawatts.

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Energy-efficient motors are the ones in which, design improvements are incorporated specifically
to increase operating efficiency over motors of standard design. Design improvements focus on
reducing intrinsic motor losses. Improvements include the use of lower-loss silicon steel, a longer
core (to increase active material), thicker wires (to reduce resistance), thinner laminations,
smaller air gap between stator and rotor, copper instead of aluminum bars in the rotor, superior
bearings and a smaller fan, etc. Energy-efficient motors now available in India operate with
efficiencies that are typically 3 to 4 percentage higher than standard motors.

The suitable selection of copper conductor size will reduce the resistance. Reducing the motor
current is the most readily accomplished by decreasing the magnetising component of current.
This involves lowering the operating flux density and possible shortening of air gap. Rotor I2 R
losses are a function of the rotor conductors (usually aluminium) and the rotor slip. Utilisation of
copper conductors will reduce the winding resistance. Motor operation closer to synchronous
speed will also reduce rotor I2 R losses. Core losses are those found in the stator-rotor magnetic
steel and are due to hysterisis effect and eddy current effect during 50 Hz magnetisation of the
core material. These losses are independent of load and account for 20 – 25 per cent of the total
losses. The hysterisis losses which are a function of flux density, are to be reduced by utilising
low loss grade of silicon steel laminations. The reduction of flux density is achieved by suitable
increase in the core length of stator and rotor. Eddy current losses are generated by circulating
current within the core steel laminations. These are reduced by using thinner laminations.

Friction and windage losses result from bearing friction, windage and circulating air through the
motor and account for 8 – 12 per cent of total losses. These losses are independent of load. The
windage losses also reduce with the diameter of fan leading to reduction in windage losses. Stray
load losses vary according to square of the load current and are caused by leakage flux induced
by load currents in the laminations and account for 4 to 5 per cent of total losses. These losses are
reduced by careful selection of slot numbers, tooth/slot geometry and air gap.
Energy efficient motors cover a wide range of ratings and the full load efficiencies are higher by
3 to 7 per cent. The mounting dimensions are also maintained to enable easy replacement. As a
result of the modifications to improve performance, the costs of energy-efficient motors are
higher than those of standard motors. The higher cost will often be paid back rapidly in saved
operating costs, particularly, in new applications or end-of-life motor replacements.

2.5 :Factors effecting the Motor Efficiency:

Load Variation
Most electric motors are designed to run at 50 per cent to 100 per cent of rated load, the
maximum efficiency is achieved usually near 75 per cent of rated load. Thus, a 10-hp motor has
an acceptable load range of 5 to 10 hp with maximum efficiency is at 7.5 hp. A motor’s efficiency
tends to decrease dramatically below about 50 per cent of the rated load. However, the range of
efficiency varies with individual motors and tends to extend over a broader range for larger
motors. A motor is considered under loaded when it is in the range where efficiency drops
significantly with decreasing load.Overloading of motors can decrease efficiency. Many motors
are designed with a service factor that allows short time overloading.

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Power Factor
Power factor is an important attribute relating to efficiency of AC induction motors. As the load
on the motor comes down, the magnitude of the active current reduces. However, there is no
corresponding reduction in the magnetising current, which is proportional to supply voltage with
the result that the motor power factor reduces, with a reduction in applied load. Induction motors,
especially those operating below their rated capacity, are the main reason for low power factor in
electric systems. Motors, like other inductive loads, are characterized by power factors less than
one. As a result, the total current draw needed to deliver the same real power is higher than for a
load characterised by a higher PF. An important effect of operating with a PF less than one is that
resistance losses in wiring upstream of the motor will be higher, since these are proportional to
the square of the current. Thus, both a high value of PF close to unity are desired for efficient
overall operation in a plant.

Effect of Harmonics
Harmonics are ac voltages and currents with frequency that are integer multiples of the
fundamental frequency. In earlier years, harmonics were not prevalent in most of the industries
due to balance linear loads using three phase induction motors along with incandescent lighting,
resistivity etc., but the rapid advancement of power electronics in industrial application makes
industrial loads non-linear type. These non-linear loads draw non-sinusoidal current from the
sinusoidal voltage waveform. The distortions thus produced in the voltage and current waveforms
from the sinusoidal waveforms are called harmonic disorders.Harmonics are generated due to
increasing number of non-linear loads occurred when the system voltage is linear but the load is
non-linear, the current will be distorted and become non-sinusoidal. The actual current will
become higher than the current measured by an ammeter or any other measuring instrument at the
fundamental frequency. It also occurred when the supply system itself contains harmonics and the
voltage is already distorted, the linear loads will also respond to such voltage harmonics and draw
harmonic currents against each harmonic present in the system and generate the same order of
current harmonics. When the system voltage and loads are both non-linear (a condition which is
more common) the voltage harmonics will magnify and additional harmonics will be generated,
corresponding to the non-linearity of the load and hence will further distort an already distorted
voltage waveform.

Energy Efficiency and Environment

It is well known that environment and efficiency are closely interlinked with each other. Electric
drive systems are largely responsible for the largest part of the electricity consumption.
Therefore, an increase in efficiency in motor will result in large energy savings and reduction in
CO2 emission into our environment. Machine designers over many years have tried their best to
respond to the need for improved efficiency of induction motors. Real driver for the evolution of
higher efficiency motor is to save the environment through reduction of energy consumption. An
improvement in energy efficiency will lead to reduction of CO2 emissions. Today, in India
millions of the induction motors are manufactured every year and they combined to consume
about 50 per cent of the total energy generated. By improving the efficiency, considerable amount
of energy can be saved and it also leads to save environment because to meet the load of these
machines power generating stations are releasing millions of tons of greenhouse gases into the
atmosphere every year. There is requirement of sustaining the constantly increasing demand of

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energy and at the same time reducing environmental pollution, then automatic increase in the
efficiency of energy conversion will have to substantially improve in order to produce more
power from the same or less material.

CHAPTER : 3
3.1:MOTOR LIFE CYCLE
Motor efficiency details:
Standard Eff3
Improved Eff2
Energy efficient Eff1
Eff1 motors are expensive to buy, be deployed for 24/7 working. Eff2 motors can be Installed in
all cases.
DIRECT SAVINGS and PAYBACK ANALYSIS
In many new installations, the extra cost of a premium-efficiency motor is justified by The energy
and demand savings.
Consider a new application of a 50 hp motor with the following specifications:
• 6,000 hours of annual use at 75% load
• Cost of electricity = $.06/kWh
• Demand charge = $70/kW-yr
• Efficiency of EPAct motor = 93.9% at 75% load
• Efficiency of premium-efficiency motor = 94.8% at 75% load
• Extra list cost of premium-efficiency motor = $470
• Price is 65% of list
• Actual extra cost = $305
The yearly savings afforded by the premium-efficiency motors are as follows:
• Demand savings = 50 hp x (1/0.939 -1/0.948) x 0.75 x 0.746 kW /hp = 0.283kW
• Energy savings = 0.283 kW x 6,000 hr/yr = 1,697 kWh
• Cost savings = $.06/kWh x 1,697 kWh + $70/kW-yr x 0.283 kW = $122/year
• Simple payback period = $305/$122 = 2.5 years
The most common method used by equipment buyers to evaluate conservation Investments is the
simple payback, or the time that it will take for the savings to pay back The cost of the in-
vestment. The simple payback is calculated by dividing the incremental Cost of the efficient
equipment by the value of the expected annual energy savings. For Example, if an efficient motor
costs $500 more than a standard motor and is expected to Save $400/year, the simple payback
will be 1.25 years. The use of the simple payback Introduces some errors into the calculation by

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assuming that inflation is zero and utility Rates are constant. It also ignores the life of the
measure. A device with a 6-month payback May seem like a good investment, but it’s not if it
lasts only 8 months. Because of the Short payback requirements of most motor users, however,
and the relatively low cost of Installing efficient motors and drives, the errors in simple payback
analysis are generally Minor.

3.2EFFICIENCY EVALUATION FACTOR

Efficiency evaluations attempt to relate the results obtained from a specific programme To
the resources expended to maintain the programme. Efficiency evaluations are Receiving
increasingly greater attention as programmes must compete with the limited Resources.
Energy efficiency index

1.Cooling tower
A)Fan efficiency
B) Cooling efficiency
C) Water loss of cooling tower

2. Heat exchanger
A)Surface heat flux iintensity.
B) End temperature difference
C)Power and heat ratio

3. Water pump
A)Pump efficiency
B)Water loss of pump
C)Operating efficiency

4.Pipe
A) Surplus coefficient of pipe
B)Coefficient of heat loss

5. Valve
A) Surplus coefficient of valve

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 CHAPTER :4
4.1 :Advantages :
1) EEM has a lower slip so they have a higher speed than standard motors.
2) EEM can reduce maintenance costs and improve operations in industry due to Robustness
and reliability. It is of low cost than standard motor.
3) Increasing the productivity.
4) Efficiencies are 3% to 7% higher compared with standard motors.
5) Design improvements focus on reducing intrinsic motor losses.

4.2: Disadvantages:
1) High initial cost .

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 4.3: Applications :

TABLE 5

CHAPTER:5
5.1:Conclusion
Higher efficiency motors (HEMs or EEMs) are preferred than that of standard efficiency
motors, because increased efficiency saves significant amount of energy consumed and therefore
saves energy bill, costs incurred over maintenance of the standard motor . However EEMs may
not always lead to lower power consumption.Sometimes there would be an increase in energy
consumption rather than a decrease due to the smaller slip in selecting a suitable motor. So
proper selection of high efficiency motors must be made according to the type of application and
energy required. One should be careful in choosing proper rating, always avoiding over-sized
motors.

5.2 : Future scope :

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 ● Environmental: Increased efficiency can lower greenhouse gas (GHG) emissions and
other pollutants, as well as decrease water use.
● Economic: Improving energy efficiency can lower individual utility bills, create jobs,
and help stabilize electricity prices and volatility.
● Utility System Benefits: Energy efficiency can provide long-term benefits by lowering
overall electricity demand, thus reducing the need to invest in new electricity generation
and transmission infrastructure.
5.3:reference :
● IEEE
● Research gate
● United for Efficiency
● WWW.aceee.org

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