MBEYA UNIVERSITY OF

SCIENCE AND TECHNOLOGY

• INDUSTRIAL ENERGY MANAGEMENT

• LECTURE SEVEN
• ELECTRIC MOTORS

1
 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
2
 What is an Electric Motor?

•An electric motor is an electromechanical

device that converts electrical energy to
mechanical energy. The mechanical energy can
be used to perform work such as rotating a
pump impeller, fan, blower, driving a
compressor, lifting materials etc.
•It is estimated that about 70% of the total
electrical load is accounted by motors only.
That is why electric motors are termed as
“Work Horse” in an industry. 3
Introduction

How Does an Electric Motor Work?

3

4
2
(Nave, 2005)

4
 How Does an Electric Motor Work?

• The general working mechanism is the same for all

motors and shown in the figure
1.An electric current in a magnetic field will experience a force.
2.If the current carrying wire is bent into a loop, then the two
sides of the loop, which are at right angle to the magnetic
field, will experience forces in opposite directions.
3.The pair of forces creates a turning torque to rotate the coil.
(note: a “torque” is the force that causes the rotation)
4.Practical motors have several loops on an armature to provide
a more uniform torque and the magnetic field is produced by
electromagnet arrangement called the field coils

5
Introduction

Three types of Motor Load

Motor loads Description Examples
Constant Output power varies Conveyors, rotary kilns,
torque loads but torque is constant constant-displacement
pumps

Variable Torque varies with Centrifugal pumps, fans

torque loads square of operation
speed

Constant Torque changes Machine tools

power loads inversely with speed

6
 Three types of Motor Load

In understanding a motor it is important to

understand what a motor load means. Load refers
to the torque output and corresponding speed
required. Loads can generally be categorized into
three groups:
•Constant torque loads are those for which the
output power requirement may vary with the
speed of operation but the torque does not vary.
Conveyors, rotary kilns, and constant-
displacement pumps are typical examples of
constant torque loads.
7
 Three types of Motor Load

• Variable torque loads are those for which the

torque required varies with the speed of
operation. Centrifugal pumps and fans are
typical examples of variable torque loads
(torque varies as the square of the speed).
• Constant power loads are those for which the
torque requirements typically change
inversely with speed. Machine tools are a
typical example of a constant power load

8
Type of Electric Motors

Classification of Motors
Electric Motors

Alternating Current Direct Current (DC)

(AC) Motors Motors

Synchronous Induction Separately Self Excited

Excited

Single-Phase Three-Phase Series Compound Shunt

9
 Classification of Motors

Motors are categorized in a number of types

based on the input supply, construction and
principle of operation. We will start at looking
at various forms of the DC motor such as shunt
and series, followed by the AC motors
including synchronous and induction motors.

10
 Type of Electric Motors

DC Motors – Components
• Field pole
• North pole and south pole
• Receive electricity to form
magnetic field

• Armature (Direct Industry, 1995)

• Cylinder between the poles

• Electromagnet when current goes through
• Linked to drive shaft to drive the load

• Commutator
• Overturns current direction in armature 11
 DC Motors – Components

Direct-Current motors, as the name implies, use a

direct-unidirectional current. A DC motor is
shown in the figure and has three main
components:
•Field pole. Simply put, the interaction of two
magnetic fields causes the rotation in a DC motor.
The DC motor has field poles that are stationary
and an armature that turns on bearings in the
space between the field poles. A simple DC motor
has two field poles: a north pole and a south
pole.
12
 DC Motors – Components

• The magnetic lines of force extend across the

opening between the poles from north to
south. For larger or more complex motors
there are one or more electromagnets. These
electromagnets receive electricity from an
outside power source and serve as the field
structure.

13
 DC Motors – Components

• Armature. When current goes through the armature,

it becomes an electromagnet. The armature,
cylindrical in shape, is linked to a drive shaft in order
to drive the load. For the case of a small DC motor,
the armature rotates in the magnetic field
established by the poles, until the north and south
poles of the magnets change location with respect to
the armature. Once this happens, the current is
reversed to switch the south and north poles of the
armature.

14
 DC Motors – Components

• Commutator. This component is found mainly

in DC motors. Its purpose is to overturn the
direction of the electric current in the
armature. The commutator also aids in the
transmission of current between the armature
and the power source.

15
Type of Electric Motors

DC motors
• Speed control without impact power
supply quality
• Changing armature voltage
• Changing field current

• Restricted use
• Few low/medium speed applications
• Clean, non-hazardous areas

• Expensive compared to AC motors 16

 DC motors

•The main advantage of DC motors is speed

control, which does not affect the quality of power
supply. It can be controlled by adjusting:
•the armature voltage – increasing the armature
voltage will increase the speed
•the field current – reducing the field current will
increase the speed.

17
 DC motors

• DC motors are available in a wide range of sizes, but

their use is generally restricted to a few low speed,
low-to-medium power applications like machine
tools and rolling mills because of problems with
mechanical commutation at large sizes. Also, they
are restricted for use only in clean, non-hazardous
areas because of the risk of sparking at the brushes.
• DC motors are also expensive relative to AC motors.

18
Type of Electric Motors

DC motors
• Relationship between speed, field
flux and armature voltage
Back electromagnetic force: E = KN
Torque: T = KIa

E = electromagnetic force developed at armature terminal (volt)

 = field flux which is directly proportional to field current
N = speed in RPM (revolutions per minute)
T = electromagnetic torque
Ia = armature current
K = an equation constant
19
 Type of Electric Motors

DC motors
• Separately excited DC motor: field current
supplied from a separate force

• Self-excited DC motor: shunt motor

Speed constant
independent of load
up to certain torque
• Field winding parallel
with armature winding
• Current = field current Speed control:
+ armature current insert resistance
in armature or
(Rodwell Int. field current
Corporation, 1999) 20
 DC motors

•If field is supplied from a separate source it is

called as separately excited DC motor.
•(Click once) In a shunt motor, the field winding
(shunt field) is connected in parallel with the
armature winding (A) as shown in the. The total
line current is therefore the sum of field current
and armature current

21
 DC motors

• The following can be said about the speed

of shunt motors:
• (Click once) The speed is practically constant
independent of the load (up to a certain torque
after which speed decreases) and therefore
suitable for commercial applications with a low
starting load, such as machine tools
- (Click once) Speed can be controlled by either
inserting a resistance in series with the
armature (decreasing speed) or by inserting
resistance in the field current (increasing 22
 Type of Electric Motors

DC motors
Self-excited DC motor: series motor
Suited for high
starting torque: • Speed restricted to
cranes, hoists 5000 RPM
• Avoid running with
no load: speed
uncontrolled
• Field winding in series
with armature winding
• Field current =
armature current

(Rodwell Int.
Corporation, 1999) 23
 DC motors
•In a series motor, the field winding (shunt field) is
connected in series with the armature winding (A) as
shown in the figure. The field current is therefore equal to
the armature current.
•(Click once) The following can be said about the speed of
a series motor
•Speed is restricted to 5000 RPM
•It must be avoided to run a series motor with no load because
the motor will accelerate uncontrollably
•(Click once) Series motors are suited for applications
requiring a high starting torque, such as cranes and hoists
24
 Type of Electric Motors

DC motors
DC compound motor
Suited for high Good torque and
starting torque if high stable speed
% compounding:
cranes, hoists
Higher %
compound in
Field winding in series = high
series and starting torque
parallel with
armature winding

25
 DC motors

•A DC compound motor is a combination of shunt and

series motor. In a compound motor, the field winding
(shunt field) is connected in parallel and in series with the
armature winding (A) as shown in the figure.
•(Click once) For this reason this motor has a good starting
torque and a stable speed.
•(Click once) The higher the percentage of compounding
(i.e. percentage of field winding connected in series), the
higher the starting torque this motor can handle.
•(Click once) For example, compounding of 40-50% makes
the motor suitable for hoists and cranes, but standard
compound motors (12%) are not. 26
Type of Electric Motors

Classification of Motors
Electric Motors

Alternating Current Direct Current (DC)

(AC) Motors Motors

Synchronous Induction Separately Self Excited

Excited

Single-Phase Three-Phase Series Compound Shunt

27
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
28
(Integrated Publishing, 2003)
 AC Motors

•Alternating current (AC) motors use an electrical

current, which reverses its direction at regular
intervals.
•An AC motor has two basic electrical parts: a
"stator" and a "rotor". The stator is in the
stationary electrical component. The rotor is the
rotating electrical component, which in turn rotates
the motor shaft.

29
 AC Motors
• The main advantage of DC motors over AC motors is that
speed is more difficult to control for AC motors. To
compensate for this, AC motors can be equipped with variable
frequency drives but the improved speed control comes
together with a reduced power quality.
• There are two types of AC motors: synchronous (see figure)
and induction. The main difference between the synchronous
motor and the induction motor is that the rotor of the
synchronous motor travels at the same speed as the rotating
magnetic field.

30
 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):
F = supply frequency
Ns = 120 f / P P = number of poles
31
 AC Motors – Synchronous motor

•A synchronous motor is an AC motor, which runs

at constant speed fixed by frequency of the system.
•It requires direct current (DC) for excitation and
has low starting torque, and synchronous motors
are therefore suited for applications that start with
a low load, such as air compressors, frequency
changes and motor generators.
•Synchronous motors are able to improve the
power factor of a system, which is why they are
often used in systems that use a lot of electricity.
32
 AC Motors – Synchronous motor

• This motor rotates at a synchronous speed,

which is given by the following equation
• Ns = 120 f / P
• Where:
• f = frequency of the supply frequency
• P= number of poles

33
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

34
 Type of Electric Motors

AC Motors – Induction motor

Components
• Rotor
• Squirrel cage:
conducting bars
(Automated Buildings)
in parallel slots
• Wound rotor: 3-phase, double-layer,
distributed winding

• Stator
• Stampings with slots to carry 3-phase windings
• Wound for definite number of poles 35
 An induction motor has two main electrical
components as shown in the figure
Rotor. Induction motors use two types of rotors:
•A squirrel-cage rotor consists of thick conducting
bars embedded in parallel slots. These bars are
short-circuited at both ends by means of short-
circuiting rings.

36
• A wound rotor has a three-phase, double-layer,
distributed winding. It is wound for as many poles as
the stator. The three phases are wired internally and
the other ends are connected to slip-rings mounted
on a shaft with brushes resting on them.
• Stator. The stator is made up of a number of
stampings with slots to carry three-phase windings. It
is wound for a definite number of poles. The
windings are geometrically spaced 120 degrees apart

37
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 Rotor

field Stator

(Reliance)
• Rotor begins to rotate
38
 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
39
 AC Motors – Induction motor

Induction motors can be classified into two main groups:

single-phase and three-phase induction motors
Single-phase induction motors. These only have one
stator winding, operate with a single-phase power supply,
have a squirrel cage rotor, and require a device to get the
motor started. This is by far the most common type of
motor used in household appliances, such as fans,
washing machines and clothes dryers, and for applications
for up to 3 to 4 horsepower.

40
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!
41
 AC Motors – Induction motor

Induction motors can be classified into two main

groups:
•Single-phase induction motors. These only have
one stator winding, operate with a single-phase
power supply, have a squirrel cage rotor, and
require a device to get the motor started. This is by
far the most common type of motor used in
household appliances, such as fans, washing
machines and clothes dryers, and for applications
for up to 3 to 4 horsepower.
42
 AC Motors – Induction motor

• Three-phase induction motors. The rotating

magnetic field is produced by the balanced three-
phase supply. These motors have high power
capabilities, can have squirrel cage or wound rotors
(although 90% have a squirrel cage rotor), and are
self-starting. It is estimated that about 70% of
motors in industry are of this type, are used in, for
example, pumps, compressors, conveyor belts,
heavy-duty electrical networks, and grinders. They
are available in 1/3 to hundreds of horsepower
ratings.
43
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 = synchronous speed in RPM

Ns Nb = base speed in RPM
44
 AC Motors – Induction motor

In practice however, the motor never runs at synchronous speed

but at a lower “base speed”. The difference between these two
speeds is the “slip”, which increases with higher loads. Slip only
occurs in all induction motors. To avoid slip, a slip ring can be
installed, and these motors are called “slip ring motors”. The
following equation can be used to calculate the percentage slip
% Slip = Ns – Nb x 100
Ns
Where:
Ns = synchronous speed in RPM
Nb = base speed in RPM

45
 Type of Electric Motors

AC Motors – Induction motor

Relationship load, speed and torque
At 80% of full
At start: high speed:
current and highest “pull-
low “pull-up” out” torque
torque and current
drops

At full speed:
torque and
stator current
are zero
46
 AC Motors – Induction motor

The figure shows the typical torque-speed curve of

a three-phase AC induction motor with a fixed
current. When the motor:
•(Click once) Starts there is a high starting current
and low torque (“pull-up torque”).
•(Click once) Reaches 80% of the full speed, the
torque is at its highest level (“pull-out torque”) and
the current begins to drop.
•(Click once) Is at full speed, or synchronous speed,
the torque and stator current drop to zero.
47
 Assessment of Electric Motors

Efficiency of Electric Motors

Motors loose energy when serving a load
• Fixed loss
• Rotor loss
• Stator loss
• Friction and rewinding (US DOE)

• Stray load loss

48
 Efficiency of Electric Motors

•The efficiency of a motor can be defined as “the ratio

of a motor’s useful power output to its total power
intput.”
•Motors convert electrical energy to mechanical
energy to serve a certain load. In this process, energy is
lost as shown in the figure.
•The efficiency of a motor is determined by intrinsic
losses that can be reduced only by changes in motor
design and operating condition. Losses can vary from
approximately two percent to 20 percent.
49
Assessment of Electric Motors

Efficiency of Electric Motors

Factors that influence efficiency
• Age
• Capacity
• Speed
• Type
• Temperature
• Rewinding
• Load 50
 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) 51
 Efficiency of Electric Motors

•There is a clear link between the motor’s efficiency and

the load. Manufacturers design motors to operate at a 50-
100% load and to be most efficient at a 75% load.
•But once the load drops below 50% the efficiency
decreases rapidly as shown in the figure. Operating motors
below 50% of rated loads has a similar, but less significant,
impact on the power factor. High motor efficiencies and
power factor close to 1 are desirable for an efficient
operation and for keeping costs down of the entire plant
and not just the motor.
52
Assessment of Electric Motors

Motor Load
• Motor load is indicator of efficiency
• Equation to determine load:

Load = Pi x  HP x 0.7457

 = Motor operating efficiency in %

HP = Nameplate rated horse power
Load = Output power as a % of rated power
Pi = Three phase power in kW
53
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 54
 Motor Load

There are three methods to determine the motor load for

motors operating individually:
•Input power measurement. This method calculates the
load as the ratio between the input power (measured with
a power analyzer) and the rated power at 100 % loading.
•Line current measurement. The load is determined by
comparing the measured amperage (measured with a
power analyzer) with the rated amperage. This method is
used when the power factor is not known and only the
amperage value is available. It is also recommended to use
this method when the percentage loading is less than 50%
55
 Motor Load

• Slip method. The load is determined by comparing

the slip measured when the motor is operating with
the slip for the motor at full load. The accuracy of
this method is limited but it can be used with the use
of a tachometer only (no power analyzer is needed).
• Because the input power measurement is the most
common method used, only this method is described
for three-phase motors.

56
Assessment of Electric Motors

Motor Load
Input power measurement
• Three steps for three-phase motors

Step 1. Determine the input power:

Pi = Three Phase power in kW

V x I x PF x 3 V = RMS Voltage, mean line to
Pi = line of 3 Phases
1000 I = RMS Current, mean of 3 phases
PF = Power factor as Decimal

57
 Motor Load

When available, “direct-read” power

measurements are used to estimate motor part-
load. The measurements can be used in three
different formula. (click once) To begin with, one
can use this equation to determine the input
power.

58
Assessment of Electric Motors

Motor Load
Input power measurement
Step 2. Determine the rated power:

0.7457 Pr = Input Power at Full Rated load in kW

Pr = hp x hp = Name plate Rated Horse Power
r r = Efficiency at Full Rated Load

Step 3. Determine the percentage load:

Pi
Load =
Load = Output Power as a % of Rated Power
x 100% Pi = Measured Three Phase power in kW
Pr Pr = Input Power at Full Rated load in kW

59
Assessment of Electric Motors

Motor Load

Result Action
→ Replace with more efficient,
1. Significantly properly sized models
oversized and
underloaded → Replace with more efficient,
2. Moderately properly sized models when
oversized and they fail
underloaded → Replace most of these with
3. Properly sized energy-efficient models when
but standard they fail
efficiency 60
Energy Efficiency Opportunities

1. Use energy efficient motors

2. Reduce under-loading (and avoid
over-sized 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
61
 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)

62
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 & Use of low loss fan design reduces losses due to air
Winding movement

5. Stray Load Loss Use of optimized design & strict quality control
procedures minimizes stray load losses

(BEE India, 2004) 63

 Use Energy Efficient Motors

•Energy-efficient motors have design improvements that

specifically seek to increase operating efficiency for the
five power loss areas: fixed, stator, rotor, friction &
winding, and stray load loss (note: these were explained in
earlier slide)
•(It is suggested to give one example only) This table
depicts the energy efficiency areas achieved incase of
energy efficient motors. For example, looking at the power
loss area “iron”, the efficiency improvement is 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.
64
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 65
 Reduce Under-loading
Under-loading is probably the most common cause
of inefficiencies for several reasons:
•Equipment manufacturers tend to use a large
safety factor when selecting the motor.
•Equipment is often under-utilized. For example,
machine tool equipment manufacturers provide for
a motor rated for the full capacity load of the
equipment. In practice, the user may rarely need
this full capacity, resulting in under-loaded
operation most of the time.
66
 Reduce Under-loading

• Large motors are selected to enable the output to

be maintained at the desired level even when
input voltages are abnormally low.
• Large motor are selected for applications
requiring a high starting torque but where a
smaller motor that is designed for high torque
would have been more suitable.
• (Click once) Under-loading increases motor losses
and reduces motor efficiency and the power 67
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 68
 Replace with smaller motors
•When replacing an oversized motor with a smaller motor,
it is also important to consider the potential efficiency
gain. Larger motors namely have inherently higher rated
efficiencies than smaller motors. Therefore, the
replacement of motors operating at 60 – 70% of capacity
or higher is generally not recommended. On the other
hand there are no rigid rules governing motor selection
and the savings potential needs to be evaluated on a case-
by-case basis. For example, if a smaller motor is an energy
efficient motor and the existing motor not, then the
efficiency could improve. 69
• Operate in star mode (from delta mode)
• For motors that consistently operate at loads below
40% of the rated capacity
• Inexpensive and effective measure.
• Motor is electrically downsized: involves re-
configuring the wiring of the three phases of power
input at the terminal box.

70
• Leads to a voltage reduction by factor ‘√3’, but
performance characteristics as a function of load
remain unchanged. Thus, motors in star mode have a
higher efficiency and power factor when in full-load
operation than partial load operation in the delta
mode.
• Possible only for applications where the torque-to-
speed requirement is lower at reduced load. Should be
avoided if the motor is connected to a production
facility with an output that is related to the motor
speed (as the motor speed reduces in star mode). 71
 Energy Efficiency Opportunities

3. Sizing to Variable Load

• Motor selection based on
Motors have
‘service factor’
of 15% above
X • Highest anticipated load: expensive and risk of
under-loading
rated load
✓ • 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
• Inability of motor to cool down 72
 Sizing to Variable Load
•Motor selection based on
•the highest anticipated load makes the motor more expensive
as the motor would operate at full capacity for short periods
only, and it carries the risk of motor under-loading.
•the load duration curve of a particular application is a better
alternative. This means that the selected motor rating is slightly
lower than the highest anticipated load and would occasionally
overload for a short period of time. (Click once) This is possible
as manufacturers design motors with a service factor (usually
15% above the rated load) to ensure that running motors above
the rated load once in a while will not cause significant damage.
•(
73
 Sizing to Variable Load

• Click once) The biggest risk is overheating of the motor,

which adversely affects the motor life and efficiency
and increases operating costs. Overheating can occur
with:
• Extreme load changes, such as frequent starts / stops, or high
initial loads
• Frequent and/or long periods of overloading
• Limited ability for the motor to cool down, for example at
high altitudes, in hot environments or when motors are
enclosed or dirty
74
 Sizing to Variable Load
• A criteria in selecting the motor rating is therefore
that the weighted average temperature rise over the
actual operating cycle should not be greater than the
temperature rise under continuous full-load
operation (100%).
• Where loads vary substantially with time, speed
control methods can be applied in addition to proper
motor sizing (will be explained later)

75
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) 0 30 40
76
 Improve Power Quality
•Motor performance is affected considerably by the quality
of input power, which is determined by the actual volts and
frequency compared to rated values. Fluctuation in voltage
and frequency much larger than the accepted values has
detrimental impacts on motor performance.
•Voltage unbalance can be even more detrimental to motor
performance and occurs when the voltages in the three
phases of a three-phase motor are not equal.
•Several factors can affect voltage balance: single-phase
loads on any one phase, different cable sizing, or faulty
circuits. An unbalanced system increases distribution system
losses and reduces motor efficiency. 77
 Improve Power Quality
• An example of the effect of voltage unbalance
on motor performance is shown in the table.
Give one example: small voltage unbalances
are acceptable but, for example, a voltage
unbalance of 5.4% results in a temperature
increase of 40oC!!!

78
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

79
 Improve Power Quality
•The voltage of each phase in a three-phase system
should be of equal magnitude, symmetrical, and
separated by 120°. Phase balance should be within
1% to avoid derating of the motor and voiding of
manufacturers’ warranties.
•Voltage unbalance can be minimized by:
•Balancing any single phase loads equally among all the
three phases
•Segregating any single phase loads which disturb the
load balance and feed them from a separate line /
80
transformer
 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%
of rewinding costs 81
 Rewinding

•It is common practice in industry to rewind burnt-out

motors. The number of rewound motors in some
industries exceeds 50% of the total number of motors.
Careful rewinding can sometimes maintain motor
efficiency at previous levels, but in most cases results in
efficiency losses.
•Rewinding can affect a number of factors that contribute
to deteriorated motor efficiency: winding and slot design,
winding material, insulation performance, and operating
temperature.
82
 Rewinding
• When rewinding motors it is important to consider
the following:
• Use a firm that ISO 9000 certified or is member of an
Electrical Apparatus Service Association.
• Motors less than 40 HP in size and more than 15 years old
(especially previously rewound motors) often have
efficiencies significantly lower than currently available
energy-efficient models. It is usually best to replace them.
It is almost always best to replace non-specialty motors
under 15 HP.

83
 Rewinding
• If the rewind cost exceeds 50% to 65% of a new
energy-efficient motor price, buy the new motor.
Increased reliability and efficiency should quickly
recover the price premium.

84
 Rewinding
• (Optional) The impact of rewinding on motor
efficiency and power factor can be easily assessed if
the no-load losses of a motor are known before and
after rewinding. Information of no-load losses and
no-load speed can be found in documentation of
motors obtained at the time of purchase. An
indicator of the success of rewinding is the
comparison of no load current and stator resistance
per phase of a rewound motor with the original no-
load current and stator resistance at the same
voltage.
85
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 86
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
87
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

88
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 89
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
90
 THANK YOU
FOR YOUR ATTENTION

91