ESR ea ELECTRIC MOTORS Prepared for Bureau of Energy Etficiency, Indian Renewable Energy Development Agency, (under Ministry of Power, Government of India) Cote 4A, East Court, Hal no.4, 2 Floor, NBCC Tower, 1 Floor, India Habitat Centre, Bhikaji Cama Place, Lodhi Road, New Delhi ~ 110066. New Delhi - 110003, yy Devki Energy Consultancy Pvt. Ltd., 405, Ivory Terrace, RC. Dutt Road, Vadodara ~ 380007, India. 2006CONTENTS 1 INTRODUCTION. 4.1 Bacxerouno 12 CLassincamion oF MovORS 2 FUNDAMENTALS. 2.1 PRINCIPLE oF OPERATION 21.1 Speed, Torque and Power 21.2 Load Considerations. 213 Power Factor. 21a Eficiony. 215 Torque d Curent vs. Spoed Charactosics of Motors io 22” moron Loaome 1 23° PoweRLosses m Morons: rH 24 EFFECT OF VOLTAGE UNBaLANGE On MOTOR PERFORMANCE 12 3 SELECTION & EFFICIENT OPERATION OF MOTORS. 2.1 IMpORTANGE OF MoToR RUNNING CoST- LIFE CYCLE Costs: 14 22 Motor Raia SuavEY. 4 33 Sropmin IDLE/REDUNDANT RunniniG OF MOTOR BrivEN EQUIPMENTS 18 2.4 ProPERSiaNG oF MoToRS 16 ‘34.1 Operation of Under-Leaded Delta Connected ators in Siar Connection. 7 342 __Usoof Electronic Sot Starters 19 45 Sevection & APPLicaTION oF Hich ErficichcY MOTORS 20 351 Design 20 352 Eficency Standards. 20 353 ANoleof Caution 21 354 Estimation of energy saving 21 2.6 MOTOR MAINTENANCE & REWINDING 2 26.1 Proper Lubrication 22 362 Bells and Pulleys 2 363 Bearings 23 B64 Rewinding 2 365 Maintonance of histo 24 3.7 Dave TaansMission, 24 ‘27.1 Belt Daves. 24 372 Gear Drives 25 38” AppuicaTion oF AaiUSTARLE SPEED ORWES 26 38.1 Enorgy saving by use of ASDs. 28 38.2 Some issues or Consideration When Using Electronic Ac Variable Speed Drives a 4 INTEGRATED SYSTEMS APPROACH. 4.1 Puwpne Systems 29 42 Coupnesseo Ain 30 43° Rermicenarion & Ain-Conornionina 31 5 CASE STUDIES. 5.1. SWTCHING OFF IDLE/REDUNDANT OPERATION OF MOTOR DRIVEN EQUIPMENT. Py B11 Case Study-1: Thermostat based operation of cooking tower fan 3 5.2. Marowine WoTOR Witt THE DRIVEN LOAD 3 521 Case Study-2: Operation in STAR connection for under loaded motors. 35 522 Case Study-3: Use Of Electronic Soft Starters on Conveyors System 36 5.2 UseoF HigH EFFICIENCY MoTORS. a 33.1 Case Study 4: Replacement of ination’ Motor by High Eicioncy Motor 37 33.2 Case Study-5 : Replacement of ineticint, Oversized Moter with High Etcioney Motor. a7 533 Case Study-6: High effcioncy motor mn place of standard motors when replacing equipments 38 5.41 IMPROVE DRIVE TRANSMISSION EFFICIENCY 0 54.1 Case Study-7: Flat Belt in Place of V Batt Ar compressor: 39 54.2 Case Study: High efciony planetary gears in place of worm gears. 40 5.5 IMPROVEMENT IN MOTOR DRIVEN SYSTEMS a 55.1 Case Sudy-9: Proper Sizing of Pumps. 41 55.2 Case Sudy-10: Use of variable hequency diva for @ Cooling Tower Pump. 43 REFERENCES.List of figures Figure 1.1 Sector-nise break up of electricty consumption in motor crven systems Figure 12: Classiication of electric motors ‘Figure 21: Induction motor principle. Figure 22: Aluminium Foto. Figure 23: Vector dagrara Figure 24: Power lacor correcion by use of capacitors Figure 25: Motor effelency and power factor Figure 26: Torque & Curent vs. Speed Figure 27: Current loading .vs. Shaft loading Figure 2.:Motor esses Figure 29 Elect of voltage unbalanee on maior losses, ‘Figure 8.1: Star-Delta Operation of mator. Figure 3.2: Energy Saving Potential by Use of Sot Starter with Enargy Saving Feature Figure 3.3: Adjustable requency drive system schematic List of Tables Table 2.1 Load Charactritios Table 22Motor Loss Categories Table 23: fect of vollage and trequencyvariaon on motor pevormance Table 3.1 importance of Running Cost of Motor Driven Equipment Table 2: nereased Costs Duo To Oversized Motor Table 23:Values Of Performance Characteristic Of 4 Pole Energy Elicit Induction Motors Table 24: Losses in V Bete Table 3.5: Efficiency of Gear Drives Table 5.1: Energy saving by use of sofas Table 5 2: Energy Saving by use of high efceney motors Table 6:3: Motors Tested Table 5:4: Tabi of Savings Summary Table 5.5: Group replacement of pumps Table 5.6: Spectcaton and power consumplion of ew pumps 2 1 4 7 2 2s i 38 0 2 2