Introduction
What is an Electric Motor?
Electromechanical device that converts
electrical energy to mechanical energy
Mechanical energy used to e.g.
Rotate pump impeller, fan, blower
Drive compressors
Lift materials
Motors in industry: 70% of electrical
load
Introduction
How Does an Electric Motor Work?
3
4
(Nave, 2005)
Introduction
Three types of Motor Load
Motor loads
Description
Examples
Constant
torque loads
Output power varies
but torque is constant
Conveyors, rotary kilns,
constant-displacement
pumps
Variable
torque loads
Torque varies with
square of operation
speed
Centrifugal pumps, fans
Constant
power loads
Torque changes
inversely with speed
Machine tools
Type of Electric Motors
Classification of Motors
Electric Motors
Alternating Current
(AC) Motors
Synchronous
Induction
Single-Phase
Three-Phase
Direct Current (DC)
Motors
Separately
Excited
Series
Self Excited
Compound
Shunt
Type of Electric Motors
Classification of Motors
Electric Motors
Alternating Current
(AC) Motors
Synchronous
Induction
Single-Phase
Three-Phase
Direct Current (DC)
Motors
Separately
Excited
Series
Self Excited
Compound
Shunt
Type of Electric Motors
AC Motors
Electrical current reverses direction
Two parts: stator and rotor
Stator: stationary electrical component
Rotor: rotates the motor shaft
Speed difficult to control
Two types
Synchronous motor
Induction motor
(Integrated Publishing, 2003)
UNEP2006
Type of Electric Motors
AC Motors Synchronous motor
Constant speed fixed by system
frequency
DC for excitation and low starting
torque: suited for low load applications
Can improve power factor: suited for
high electricity use systems
Synchronous speed (Ns):
Ns = 120 f / P
F = supply frequency
P = number of poles
Type of Electric Motors
AC Motors Induction motor
Most common motors in industry
Advantages:
Simple design
Inexpensive
High power to weight ratio
Easy to maintain
Direct connection to AC power source
Type of Electric Motors
AC Motors Induction motor
Components
Rotor
Squirrel cage:
conducting bars
in parallel slots
(Automated Buildings)
Wound rotor: 3-phase, double-layer,
distributed winding
Stator
Stampings with slots to carry 3-phase windings
Wound for definite number of poles
UNEP 2006
Type of Electric Motors
AC Motors Induction motor
How induction motors work
Electricity supplied to stator
Magnetic field generated that moves around
rotor
Electromagnetics
Current induced in rotor
Rotor produces second
magnetic field that
opposes stator magnetic
field
Rotor begins to rotate
Rotor
Stator
(Reliance)
Type of Electric Motors
AC Motors Induction motor
Single-phase induction motor
One stator winding
Single-phase power supply
Squirrel cage rotor
Require device to start motor
3 to 4 HP applications
Household appliances: fans, washing
machines, dryers
Type of Electric Motors
AC Motors Induction motor
Three-phase induction motor
Three-phase supply produces magnetic
field
Squirrel cage or wound rotor
Self-starting
High power capabilities
1/3 to hundreds HP applications: pumps,
compressors, conveyor belts, grinders
70% of motors in industry!
Type of Electric Motors
AC Motors Induction motor
Speed and slip
Motor never runs at synchronous
speed but lower base speed
Difference is slip
Install slip ring to avoid this
Calculate % slip:
% Slip = Ns Nb x 100
Ns
Ns = synchronous speed in RPM
Nb = base speed in RPM
13
Type of Electric Motors
AC Motors Induction motor
Relationship load, speed and torque
El
At start: high
current and
low pull-up
torque
At full speed:
torque and
stator current
are zero
At 80% of full
speed: highest
pull-out
torque and
current drops
Assessment of Electric Motors
Efficiency of Electric Motors
Motors loose energy when serving a load
Fixed loss
Rotor loss
Stator loss
Friction and rewinding
Stray load loss
(US DOE)
Assessment of Electric Motors
Efficiency of Electric Motors
Factors that influence efficiency
Age
Capacity
Speed
Type
Temperature
Rewinding
Load
Assessment of Electric Motors
Efficiency of Electric Motors
Motor part load efficiency
Designed for 50-100% load
Most efficient at 75% load
Rapid drop below 50% load
(US DOE)
Assessment of Electric Motors
Motor Load
Motor load is indicator of efficiency
Equation to determine load:
Load =
HP
Load
Pi
Pi x HP x 0.7457
= Motor operating efficiency in %
= Nameplate rated horse power
= Output power as a % of rated power
= Three phase power in kW
Assessment of Electric Motors
Motor Load
Three methods for individual motors
Input power measurement
Ratio input power and rate power at 100%
loading
Line current measurement
Compare measured amperage with rated
amperage
Slip method
Compare slip at operation with slip at full
load
19
Assessment of Electric Motors
Motor Load
Input power measurement
Three steps for three-phase motors
Step 1. Determine the input power:
V x I x PF x 3
Pi
1000
Pi
V
I
PF
= Three Phase power in kW
= RMS Voltage, mean line to
line of 3 Phases
= RMS Current, mean of 3 phases
= Power factor as Decimal
Assessment of Electric Motors
Motor Load
Input power measurement
Step 2. Determine the rated power:
0.7457
Pr hp x
r
Pr
hp
r
= Input Power at Full Rated load in kW
= Name plate Rated Horse Power
= Efficiency at Full Rated Load
Step 3. Determine the percentage load:
Pi
Load
x 100%
Pr
Load = Output Power as a % of Rated Power
Pi
= Measured Three Phase power in kW
Pr
= Input Power at Full Rated load in kW
21
Assessment of Electric Motors
Motor Load
Result
1. Significantly
oversized and
underloaded
2. Moderately
oversized and
underloaded
3. Properly sized
but standard
efficiency
Action
Replace with more efficient,
properly sized models
Replace with more efficient,
properly sized models when
they fail
Replace most of these with
energy-efficient models when
they fail
Energy Efficiency Opportunities
1. Use energy efficient motors
2. Reduce under-loading (and avoid oversized motors)
3. Size to variable load
4. Improve power quality
5. Rewinding
6. Power factor correction by capacitors
7. Improve maintenance
8. Speed control of induction motor
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Energy Efficiency Opportunities
Use Energy Efficient Motors
Reduce intrinsic motor losses
Efficiency 3-7% higher
Wide range of ratings
More expensive but
rapid payback
Best to replace when
existing motors fail
(Bureau of Indian Standards)
24
Energy Efficiency Opportunities
Use Energy Efficient Motors
Power Loss Area
Efficiency Improvement
1. Fixed loss (iron)
Use of thinner gauge, lower loss core steel reduces
eddy current losses. Longer core adds more steel to
the design, which reduces losses due to lower
operating flux densities.
2. Stator I2R
Use of more copper & larger conductors increases
cross sectional area of stator windings. This lower
resistance (R) of the windings & reduces losses due to
current flow (I)
3 Rotor I2R
Use of larger rotor conductor bars increases size of
cross section, lowering conductor resistance (R) &
losses due to current flow (I)
4 Friction &
Winding
Use of low loss fan design reduces losses due to air
movement
5. Stray Load Loss
Use of optimized design & strict quality control
procedures minimizes stray load losses
(BEE India, 2004)
Energy Efficiency Opportunities
2. Reduce Under-loading
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
26
Energy Efficiency Opportunities
2. Reduce Under-loading
Replace with smaller motor
If motor operates at <50%
Not if motor operates at 60-70%
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
Energy Efficiency Opportunities
3. Sizing to Variable Load
Motors have
service factor
of 15% above
rated load
Motor selection based on
X Highest anticipated load: expensive and risk
of under-loading
Slightly lower than highest load: occasional
overloading for short periods
But avoid risk of overheating due to
Extreme load changes
Frequent / long periods of overloading
28
Inability of motor to cool down
Energy Efficiency Opportunities
4. Improve Power Quality
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)
30
40
29
UNEP 2006
Energy Efficiency Opportunities
4. Improve Power Quality
Keep voltage unbalance within 1%
Balance single phase loads equally
among three phases
Segregate single phase loads and
feed them into separate
line/transformer
30
Energy Efficiency Opportunities
5. Rewinding
Rewinding: sometimes 50% of motors
Can reduce motor efficiency
Maintain efficiency after rewinding by
Using qualified/certified firm
Maintain original motor design
Replace 40HP, >15 year old motors instead of
rewinding
Buy new motor if costs are less than 50-65%31
UNEP 2006
of rewinding costs
Energy Efficiency Opportunities
6. Improve Power Factor (PF)
Use capacitors for induction motors
Benefits of improved PF
Reduced kVA
Reduced losses
Improved voltage regulation
Increased efficiency of plant electrical system
Capacitor size not >90% of no-load
kVAR of motor
32
Energy Efficiency Opportunities
7. 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
Energy Efficiency Opportunities
8. Speed Control of Induction Motor
Multi-speed motors
Limited speed control: 2 4 fixed speeds
Wound rotor motor drives
Specifically constructed motor
Variable resistors to control torque
performance
>300 HP most common
Energy Efficiency Opportunities
8. 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
Three types
35
Energy Efficiency Opportunities
8. Speed Control of Induction Motor
Direct Current Drives
Oldest form of electrical speed control
Consists of
DC motor: field windings and armature
Controller: regulates DC voltage to armature
that controls motor speed
Tacho-generator: gives feedback signal to
controlled
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Induction Motors
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