ENERGY EFFICIENT MOTORS

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 Efficiency & loss distribution
 Motor performance

 Power factor

 Voltage variation

 Motor load

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 Motor Energy Audit
• Drive power is huge- think big,
• Motors are part of a system –think systems,
• Optimize the applications &process-deliver service,
• The further the downstream savings, the higher is
the upstream benefits-start downstream,
• Pursue integration package of savings
opportunities rather than isolated measures
because many savings are inter –dependent –
integrate measures

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 Contd..,

• Collection of nameplate details of motor and load equipment

• Measurement of voltage, current, power, apparent power, power factor,
frequency and annual operating hours for major loads.
• Calculation of load factor for major loads.
• Checking for light loads on large motors
• Check if valves are always used for flow control in pumps, fans and blowers.
• Check if flow from pumps, fans and blowers are changing continuously.
• Check if the set discharge pressure is at the lowest permissible limit of
operation in the compressor.
• Check for proper maintenance of major equipment i.e. cleaning measuring
temperature, dust, vibration, noise, lubrication and coupled condition.

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 Power factor correction at motor end

• Capacitors connected in parallel (shunted) with

the motor are typically used to improve the
power factor
• The impacts of PF correction include reduced
KVA demand (and hence reduced utility demand
charges), reduced I2R losses in cables upstream
of the capacitor (and hence reduced energy
charges), reduced voltage drop in the cables
04/16/2022 5
 Contd..,
• The size of capacitor required for a particular
motor depends upon the no-load reactive KVA
(KVAr) drawn by the motor
• Required capacitive kVAr increases with
decrease in speed of motor, as the
magnetizing current requirement of a low
speed motor is more compared to the high
speed motor for the same HP.

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 Follow the sequence:
• MCQ1:
• The following sequence of steps can help plants identify the
best opportunities for motor system improvements.
• Plant Profile
• Motor Size and Hours of Operation
• _________________
• Keep Records

Options:
• Screen with Data Acquisition and Analysis
• Plant orientation
• Management system
• Load

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 Answer: MCQ1
• Screen with Data Acquisition and Analysis
Justification:
Because:
After identifying the most energy-intensive motor systems, the user can start collecting
operating data on the motors and the systems slated for improvements. The data can
be acquired by measuring the electrical power supplied to the motor and, in some fluid
systems, by measuring the fluid power generated by a pump or fan.

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 Task 1: Efficiency Opportunities:

• Describe at least seven efficiency

opportunities that address both component
and system issues. Each one details a specific
opportunity for improving motor system
performance???

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 Answer:
• Assessing Motor and Drive System Operating Conditions

• Establishing a Motor Management Program

• Providing Basic Maintenance

• Selecting the Right Motor

• Using Variable Frequency Drives

• Addressing In-Plant Electrical Distribution and

Power Quality Issues

• Using the Service Center Evaluation Guide

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Efficiency Opportunity No. 2 for motors

• Establishing a Motor Management Program:

Most industrial facilities rely heavily on motor systems to
maintain or support production, these systems are often
overlooked as manageable assets. A formal motor management
program expands on the assessment activities:
• Assessing Motor and Drive System Operating Conditions, by
defining strategies that support proactive, cost-effective planning.
• These strategies include instituting repair/replace and purchasing
policies.
• Establishing a motor inventory, tracking motor life, creating a
spares inventory.
• A schedule for required maintenance.

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 MCQ 2:
The benefits of implementing a motor management Plan include

• Greater motor reliability

• Improve overall system performance
• ____________
• Options:
• Improve load factor
• Improve torque load
• Lower the Energy Cost

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 Task # 3

• Engineers frequently specify motors that are

larger than needed to meet system
requirements in order to ensure that the
existing motor/drive assembly can support
anticipated increases in capacity. What are the
consequences of oversizing motors???
• Time 15 mintes
• Group 4

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 Answer:
• Lower efficiency
• Higher motor/controller costs
• Higher installation costs
• Lower power factor
• Increased operating costs.

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 Simple Calculation of Annual Electricity cost
Annual energy costs = (motor full-load brake horsepower) x (0.746 kW/hp) x (1/motor efficiency)
x (annual hours of operation) x (electricity cost in $/kWh) x load factor
 
Assumptions:
 
Cost of electricity = $0.05/kWh
 
Load factor = 65%
 
Motor efficiency = 95%
 
Example:
 
Motor full-load hp = 100 hp
 
Annual hours of operation = 8,760 hours (3-shift, continuous operation)
 
Annual electricity costs =
 
(100 hp) x (0.746 kW/hp) x (1/0.95) x (8,760 hours) x ($0.05/kWh) x .65 = $22,356
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 Replace V-Belts with Cogged or Synchronous Belt Drives for motor

• The majority of belt drives use V-belts. V-belts use a trapezoidal

cross section to create a wedging action on the pulleys to
increase friction and improve the belt’s power transfer
capability. Joined or multiple belts are specified for heavy loads.
• V-belt drives can have a peak efficiency of 95% to 98% at the
time of installation.
• Efficiency is also dependent on pulley size, driven torque, under
or over-belting, and V-belt design and construction. Efficiency
deteriorates by as much as 5% (to a nominal efficiency of 93%)
over time if slippage occurs because the belt is not periodically
re-tensioned.

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 Cogged Belts & Synchronous Belts
• Cogged belts have slots that run perpendicular to the belt’s
length. The slots reduce the bending resistance of the belt.
Cogged belts can be used with the same pulleys as equivalently
rated V-belts. They run cooler, last longer, and have an
efficiency that is about 2% higher than that of standard V-belts.
• Synchronous belts (also called timing, positive-drive, or high-
torque drive belts) are toothed and require the installation of
mating toothed-drive sprockets.
Synchronous belts offer an efficiency of about 98% and
maintain that efficiency over a wide load range. In contrast, V-
belts have a sharp reduction in efficiency at high torque due to
increasing slippage. Synchronous belts require less
maintenance and retensioning, operate in wet and oily
environments, and run slip-free. But, synchronous belts are
noisy, unsuitable for shock loads, and transfer vibrations.
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Example: 1
Description:
• For centrifugal fans and pumps, which exhibit a strong
relationship between operating speed and power, synchronous
belt sprockets must be selected that take into account the
absence of slippage. Operating costs could actually increase if
slippage is reduced and a centrifugal load is driven at a slightly
higher speed. 
• Synchronous belts are the most efficient choice. However,
cogged belts may be a better choice when vibration damping is
needed or shock loads cause abrupt torque changes that could
shear a synchronous belt’s teeth. Synchronous belts also make
a whirring noise that might be objectionable in some
applications.

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 Example : 1
Individual task:
• A continuously operating, 100-hp, supply-air fan
motor (93% efficient) operates at an average load
of 75% while consuming 527,000 kWh annually.
What are the annual energy and dollar savings if a
93% efficient (η1) V-belt is replaced with a 98%
efficient (η2) synchronous belt? Electricity is priced
at $0.05/kWh. Use this formula:
• Energy Savings= Annual Energy Use x (1 – η1/η2 )

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 Solution: Example 1
• Energy Savings= Annual Energy Use x (1 –
η1/η2 ) = 527,000 kWh/year x (1 – 93/98)
= 26,888 kWh/year

• Annual Cost Savings = 26,888 kWh x

$0.05/kWh = $1,345

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 Motors drive a lot of things

pumps

Vents, blowers

Hydraulics
Compressors
Conveyors
…
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 Motor data acquisition
Data to collect
Working time Number of shifts
Working place
Number of places
Energy Total: year, month
consumption
Diurnal variation: working day, weekend
Motor Age
Rated power
Type of application (pump, vent, conveyor,..)
Operating hours / year
Mean utilisation (load factor)
Controller
Gear type
Maintenance interval (gear, motor)
..
Detailed analysis V, A, P, cos p, n, Hz
Sound, vibration
Heat radiation, surface temp.
Dirt, damage, lubrication

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 efficiency & losses
efficiency as a function of load factor for 3-
phase induction motor

supplied
electric
energy

mechanical
output

Losses:
• Iron losses
• Winding losses
• Rotor losses
• Friction and ventilation
• Load depending additional losses

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 Type plate / name plate
Type plate provide efficiency data
+ efficiency is the ration of shaft output to
electric input
+ h = Pshaft / Pelectr. = Pshaft / (UN·IN·√3·cos j)
+ h efficiency [-]
+ Pshaft = PN = Pmech = rated power on the name
plate [kW]
 motor’s mechanical output rating – that
is it’s ability to deliver the torque needed
for the load at rated speed
+ UN rated voltage [V]
+ IN rated current [A]
+ cos j power factor [-] h = 1.5 kW / (380 V · 3.4 A · √3 · 0.79) = 0.848
h = 1.5 kW / (415 V · 3.4 A · √3 · 0.85) = 0.722
+ Partial load reduces efficiency Which one is true?

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 Type plate / name plate
Type plate provide efficiency data
+ efficiency is the ration of shaft output to
electric input
+ h = Pshaft / Pelectr. = Pshaft / (UN·IN·√3·cos j)
+ h efficiency [-]
+ Pshaft = PN = Pmech = rated power on the name
plate [kW]
 motor’s mechanical output rating – that
is it’s ability to deliver the torque needed
for the load at rated speed
+ UN rated voltage [V]
+ IN rated current [A]
+ cos j power factor [-] h = 1.5 kW / (380 V · 3.4 A · √3 · 0.79) = 0.848
h = 1.5 kW / (415 V · 3.4 A · √3 · 0.85) = 0.722
+ Partial load reduces efficiency Which one is true?

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 More details

Further reading:
http://
electrical-engineering-porta
l.com/19-essential-informa
tion-you-can-find-on-motor
-nameplate h = 1.5 kW / (400 V · 2.9 A · √3 · 0.87) = 0.85
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 New motor efficiency classes
+ Since June 2011: IEC Standard 60 034-30 (von International
Electrotechnical Commission – IEC)
 IE4: Super premium efficiency
 IE3: Premium efficiency
 IE2: High efficiency (comparable to EFF1 of the older system)
 IE1: Standard efficiency (comparable to EFF2 of the older system)
Efficiency curve for partial load

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 Energy savings when changing motors
+ @ 0.12 EUR/kWh

Motor Power, kW Load Op. hours, Efficiency Annual Investm.

factor h cost of Cost, EUR
electr.,
EUR
IE2 15 75 % 4,500 90.6 % 6,705 700
IE3 15 75 % 4,500 92.1 % 6,596 900
Difference 109 -200
ROI 1.8 years

Life expectancy 0.75 – 1.1 kW 1.1 – 11 kW 11 – 110 kW 110-370 kW

Years 10 12 15 20

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 Effects of voltage variations on
motors
+ voltage drops cause
change in
• motor efficiency
• power factor
• running current
• temperature
+ If motor terminal
voltage is below the
rated voltage it will
draw more current than
the rated current which
will ultimately result in
the overheating of the
motor winding and thus
reduces life of the
motor.

Source: www.motorsanddrives.com
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 Voltage unbalance
+ 1 % is ok
+ Beyond 1 % it causes
current unbalances, and
thus losses (heat)

Source: http://www.csanyigroup.com/motor-operation-efficiency-under-abnormal-conditions
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 Rewinding
Frequent Rewind Motors
+ each rewinding decreases the efficiency of the motor by 2-3 %, in
worst cases 5-8 %.
+ If old motors run even after their designed life, repeatedly repair
cost of these motors will be very high and will be more than the
replacement cost.
Recommendations:
+ Frequent rewind motors should be replace with high efficiency
motors.
+ Motor burnning record should be maintained with proper
identification of the motors.

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 Motor list
Location Name/Descr. Op. Age / V A P.F. Rated Meas Load
hours, h Year Power, . %
kW Powe
r, kW
EG 1, B2 Compressor 1 6,700 1981 400 120 .85 75 70.67 94
EG 3, B22 Compressor 2 5,300 2002 400 165 .85 90 97.17 108

EG 1, Line 1 Dying drum 1 4,500 1999 390 14 .85 24 8.04 33

EG 1, Line 2 Dying drum 2 6,300 2010 390 18 .85 15 10.33 69
EG 2, … Wet blue drum 4,000 2002 398 20 .85 24 11.72 49
.. Paddle 4,000 n.a. 395 11 .85 10 6.4 64
.. Blower 8,760 2010 400 10 .85 7.46 5.89 79
EG 1, B3 R O Plant 6,700 2012 400 42 .85 37 24.73 67

+ Estimate total consumption

+ Over / undersized motors
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Quick test for assessment of motors
+ http://www.ie-guide.com/de/energysavingscalculator
+ Quick (and dirty): 1-2-3 Test
 Criteria 1: Age of the motor (see type plate or general data)
 Criteria 2: Rated power
 Criteria 3: Operating hours (VSD, controller, machin op.hrs. counter, estimation)

Age, yrs <5 < 10 < 15 < 20 > 20

Power, kW > 1,500 < 1,500 < 500 < 150 < 50
Operating hours, h/y < 2,000 < 3,000 < 4,000 < 5,000 > 5,000
Rating points 1 2 3 4 5
+ Judgement:
Total
 > 10 points: change motor quickly
 6 < 10 points: evaluate a possible change more detailed
 < 5 points: no changes required

Source: topmotors.ch
Motor efficiency tool

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 And whats beyond the motor?
+ Optimising potentials for the motor itself are rather limited.
+ Much more can be achieved in the system that the motor is
driving.

Savings potential
Total system Large

• Pipes dimensioning Drive chain Medium

• Armatures, Valves
• Storages • VSD Motor Small
• Operating hours • Gear box
• Pumps • Dimensioning
• (power system) • Vents • IE class

Quelle: Markus Blesl, Alois Kessler: Energieeffizienz in der Industrie, Springer Verlag,
2013
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 E.g. drive chain
+ Missalignment of motor and load ~10 %
+ Sufficient heat sinks (ventilation)
+ Drive type
Efficiency Max. speed ratio
(nM/nD)
Direct 100 % 1
Flat belt 96-98 % 5
Tooth belt 96-98 % 8
Chain 96-98 % 6
Spur gear 95-98 % 7
Bevel gears 95-98 % 5
V-belt 90-95 % 8-10
(< 1 kW: 75 %)
Worm gear 50-96 % 50

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 Pumps (& Vents)
+ Studies indicate that the
• average pumping efficiency in manufacturing plants can be less than
40 %
• with 10 % of pumps operating below 10 % efficiency.
+ Oversized pumps and the use of throttled valves were identified as
the two major contributors to the loss of efficiency.
+ Energy savings in pumping systems of between 30 % and 50 %
could be realised through equipment or control system changes.
+ A pump’s efficiency can also degrade during normal operation due
to wear by as much as 10 % to 25 % before it is replaced.
+ Efficiencies of 50 % to 60 % or lower are quite common.

http://www.sustainability.vic.gov.au/~/
media/resources/documents/services%20and%20advice/business/srsb%20em/resources%20and%20tools/srsb%20em%20best%
20practice%20guide%20pump%202009.pdf 38
 Variable frequency drives
+ Motor-driven systems are often designed to handle peak loads that
have a safety factor.
+ This often leads to energy inefficiency in systems that operate for
extended periods at reduced load. (load factors of 60 %)
+ The ability to adjust motor speed enables closer matching of motor
output to load and often results in energy savings.
+ Hence adding a variable frequency drive (VFD) to a motor-driven system
can offer potential energy savings in a system in which the load vary
with time.
+ Energy is saved by reducing motor speed according to load
+ Best results provide control loops with sensors (e.g. frequency =
function of temperature, air quality or pressure)
+ Best suitable for drive systems with low static load, optimised control
range 30 – 75 % of load

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Variable frequency drives – practical issues

VFD have electronics that

+ need proper set up (large nr. of parameters to be set) !
+ provide additional analysis 
 Energy consumption meter
 Operating hours
 …
+ Energy saving calculation tool
 http://energysave.abb-drives.com/#/main

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 Other advantages
+ Electric advantages:
 Reduction of start up current
 Effective and detailed motor protection
 Reduction of reactive load
+ Mechanical advantages:
 Brake and acceleration control for rotating masses
 Demand controlled production
 Optimising working conditions for pumps / vents

VFD offer a great chance to energy performance increase.

BUT it doesn‘t end with VFD – the complete system needs to be
looked at and optimised.