Welcome to the world of Siemens Energy Saving Motors!

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Motor the Main Energy Consumer

The largest user of electrical energy in the industry is an

Electric Motor!!!

Electric Motors contribute to almost 74% of industrial

electrical consumption.
~ 100% of agricultural power

The integral HP-AC Polyphase motors consume 75% of the

energy consumed by motors

MUM/A&D/SD Motors
Energy Consumption of Motors : Application Wise

11% 16 %
5%
9% 1

18 %
9%

32%

1 Blo wers and Fans 2 Co mp resso rs 3 Pump s 4 M achine To o ls

5 DC Drives 6 Fractio nal HP 7 Other AC Drives

MUM/A&D/SD Motors
The operating costs are what count!

Utility Investment Operating Cost Per Month Operating Cost As % Of Investment

2,50,000 2,000 [ 1%

Maruti Car

50,000 500 [ 1%
Personal Computer

20,000 200 [ 1%

Washing Machine

20,000 20,000
100 %
Electric Motor 20 HP

MUM/A&D/SD Motors
The operating costs are what count!
Life cycle costs for a useful life of 3000 Hr/annum

MUM/A&D/SD Motors
 Energy Efficient Motors – How do you identify one?

A motor which consumes the least power is energy efficient, right?

A motor which draws higher current is NOT energy efficient, right?
A motor which draws higher no-load current cannot be energy efficient, right?

WRONG!!!

Surprised?

MUM/A&D/SD Motors
 Energy Efficient Motors – The myths dispelled

A motor which consumes the least power is energy efficient, right? – Wrong!!!

A motor that is switched off consumes the least power (zero), but since it does
not produce any output, also has zero efficiency.

Similarly a motor which draws a higher current or a higher no load current does
not necessarily mean that it is NOT energy efficient as will be proved later.

A higher no-load current only means a poorer power factor. And that does NOT
mean a bad motor.

MUM/A&D/SD Motors
 Power Factor or Efficiency? (1)

Once the magnetic circuit of an induction motor (The slot geometry, no. of slots
and core packet dimensions etc.) is finalised, the efficiency and power factor of
the motor can be improved at the cost of the other. This means that either the
motor has a better power factor at the cost of the efficiency or vice versa.

Since power factor contributes only to the line losses and secondly as it can be
improved externally at the system level, we at Siemens believe in building into
the motor higher efficiency than a higher power factor.

A poor power factor motor draws a higher no-load current. Yes, but we do not
intend running motors on no-load, do we?

MUM/A&D/SD Motors
 Power Factor or Efficiency? (2)

A poor power factor motor may even draw a higher current when loaded, but
when it comes to losses or energy efficiency…
High efficiency Motor Std. Efficiency motor
Motor Type
Output (kW) 160 160
Voltage (V) 415 415
Power Factor 0.86 0.9
Efficiency 95.8% 95.3%
Rated Current 271 260
11A more current
Input Power (kW) [Power consumption] 167.01 167.89
Losses in Motor (kW) [Input - Output] 7.01 7.89

Cable resistance for a length of 100 m at 20°C (240mm² Al Cable) 0.013 0.013
Losses in cable 2.86 2.64

Total Losses 9.87 10.53

0.66kW more losses
Total Consumption 169.87 170.53
kWH Savings (per day) 15.84
Yearly Savings (assuming 300 days, Rs. 4/- per kWH) Rs. 19008

MUM/A&D/SD Motors
 Power Factor or Efficiency? (3)

More reasons why there is no point in concentrating on a higher PF Motor…

Motor load may not have much effect on the system power factor, this is true
when…

Most of the induction motor load is represented by large, high speed motors with
inherently better PF and hence PF of a few smaller motors won’t mean much.

Motors are only a part of inductive load responsible for PF deterioration, there are
other inductive devices as well. [Welding Transformers, chokes, solenoid operated
mechanisms]

High Motor Power factor is wasted if the motor runs much of the time at reduced
load

MUM/A&D/SD Motors
 Efficiency of Motors

Efficiency for any machine/device is defined as the ratio of output of the

machine to the input to the machine.

Thus by definition, efficiency denoted by the Greek letter η can be expressed

as:

Output Output
η= η=
Input Output + Losses
Therefore … to increase efficiency reduce losses.

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 Typical motor loss distribution for a 4 Pole motor – (1)

Core (Wc) Losses :

25% Friction and Windage
(Wfw) losses: 15%

Stator I²R (Ws)

Losses : 34%

Rotor I²R (Wr)

Losses : 21%

Stray Load (Wl)

losses : 5%

MUM/A&D/SD Motors
 Efficiency of Motors - How to reduce losses (1a)

Type of Loss Constitutes of Ways to reduce them

Friction Losses Using properly selected bearings
Mechanical Losses
Windage Losses Optimising Fan Design
Hysteresis Using low loss Electrical Grade steel
Iron Losses
Eddy Current Losses in Lamination Reduce Lamination thickness
Stator Copper Loss Reduce Stator Winding Resistance
Ohmic Losses
Rotor Copper Loss Reduce Rotor Winding Resistance

Reducing Lamination thickness is not feasible beyond a certain limit due to

mechanical strength limitations.
Reducing stator and rotor winding resistance results in increase in starting
current and decrease in starting torque and increase in speed.

MUM/A&D/SD Motors
The Siemens Concept of Effective Efficiency

Generally the efficiency of a motor decreases as the load on the motor

decreases.
This requires motors to be designed for specific application.
It is advantageous for the client to be able to use the same motor across various
applications.
For this the efficiency should remain constant over a certain load variation.
Modern Energy Efficiency criteria insist on FL and 75%FL efficiency being
declared.
We at Siemens have been concentrating on this right from the beginning.

All our 1LA0 Series Standard Motors have constant efficiency from 100%FL to
60%FL.

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 Electrical design Philosophy

Maximize Efficiency
kVA
kVAR ∝ Power Factor

φ
kW ∝ Efficiency

To minimize net cash outflow of customer in way of electricity bills.

Since power factor contributes only to the line losses and secondly as it can be
improved externally at the system level, we at Siemens believe in building into
the motor higher efficiency than a higher power factor.

MUM/A&D/SD Motors
Energy Efficient Motors – Indian Standards

The IS 12615 stipulates efficiency requirements for energy efficient motors. It

covers TEFC motors rated 0.12 kW to 37kW in 4P only.
Table 1 of IS:12615

Output Efficiency Output Efficiency This standard is under revision and a draft of
kW % kW % IEEMA 19-2000 is already under circulation.
0.12 52 5.5 85
0.18 55 7.5 87
0.25 58
0.37 63 9.3 87 This new standard will cover motors 0.37kW to
160kW in 2,4 and 6P and upto 132kW in 8P.
0.55 70 11 88
0.75 73 15 89
1.1 75 18.5 90
1.5 77 22 90 The international Standard CEMEP covers
2.2 80 30 91
motors only from 1.1kW to 90kW in 2 and 4P.
3.7 84 37 91

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 Efficiency Class on Name Plate

Name Plate - 1LA0 as per eff2

Name Plate - 1LA7 as per eff2

Siemens indicates the efficiency class on the rating plate of the motor.

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 Efficiency Classification as per CEMEP

Background - Introduction of efficiency classes acc. to CEMEP

To implement measures for improving the efficiency levels of electrical
drives. Motive: To reduce the emission of CO2.

CEMEP prescribes efficiency classification for 2-pole and 4-pole motors in

the power range from 1.1 to 90 kW. Efficiency is subdivided into three
classes so that 2 characteristics define the three classes:
- "eff1" (High-efficiency motors)
- "eff2" (Improved-efficiency motors)
- "eff3" (Standard motors)

1)CEMEP = European Commitee of Manufacturers of Electrical Machines and Power Electronics; Efficiency determined as before
according to EN 60034-2

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 Efficiency Classification as per CEMEP

Trend

[%] 95

90

85

80

75

[kW]
70
1 10 100
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 CEMEP- Motors Covered and Efficiency Values

Output 2 Pole 4 Pole

Efficiency Class Efficiency Class
kW EFF3 EFF2 EFF1 EFF3 EFF2 EFF1
Efficiency in %
1.1 < 76.2 76.2 82.8 < 76.2 76.2 83.8
1.5 < 78.5 78.5 84.1 < 78.5 78.5 85.0
2.2 < 81 81.0 85.6 < 81 81.0 86.4
3.0 < 82.6 82.6 86.7 < 82.6 82.6 87.4
4.0 < 84.2 84.2 87.6 < 84.2 84.2 88.3
5.5 < 85.7 85.7 88.6 < 85.7 85.7 89.2
7.5 < 87 87.0 89.5 < 87 87.0 90.1
11.0 < 88.4 88.4 90.5 < 88.4 88.4 91.0
15.0 < 89.4 89.4 91.3 < 89.4 89.4 91.8
18.5 < 90 90.0 91.8 < 90 90.0 92.2
22.0 < 90.5 90.5 92.2 < 90.5 90.5 92.6
30.0 < 91.4 91.4 92.9 < 91.4 91.4 93.2
37.0 < 92 92.0 93.3 < 92 92.0 93.6
45.0 < 92.5 92.5 93.7 < 92.5 92.5 93.9
55.0 < 93 93.0 94.0 < 93 93.0 94.2
75.0 < 93.6 93.6 94.6 < 93.6 93.6 94.7
90.0 < 93.9 93.9 95.0 < 93.9 93.9 95.0

MUM/A&D/SD Motors
Super Efficiency Motors

Motor Type Frame Output kW Efficiency %

1SE0 163-4YK80 160 M 9.3 92.0
1SE0 163-4YL80 160 M 11 92.5
1SE0 166-4YK80 160 L 13 93.0
1SE0 166-4YL80 160 L 15 93.0
1SE0 183-4YL80 180 M 18.5 93.0
1SE0 186-4YL80 180 L 22 93.0
1SE0 207-4YL80 200L 30 93.5
1SE0 220-4YL80 225S 37 94.0
1SE0 223-4YL80 225M 45 94.2

MUM/A&D/SD Motors
Energy efficient motor replacement program (1)

Determining if your motors are properly loaded

You should perform a motor load and efficiency analysis on all of your major working
motors as part of your preventative maintenance and energy conservation program.
It is recommended that you survey and test all motors operating over 1000 hours per
year. Using the analysis results, divide your motors into the following categories:
• Motors that are significantly oversized and under loaded—replace with more
efficient, properly sized models at the next opportunity, such as scheduled plant
downtime.
• Motors that are moderately oversized and under loaded—replace with more
efficient, properly sized models when they fail.
• Motors that are properly sized but standard efficiency—replace most of these with
energy-efficient models when they fail.

MUM/A&D/SD Motors
Energy efficient motor replacement program (2)

Determining Motor loading:

Operating efficiency and motor load values must be assumed or based on field
measurements and motor nameplate information. The motor load is typically derived from a
motor’s part-load input kW measurements as compared to its full-load value (when kW or
voltage, amperage, and power factor readings are available).

3 ⋅ Vav ⋅ I av ⋅ cos ϕ / 1000

% Loading = ⋅ 100
kW rated / η
Where,
Vav, Iav are the average line voltage and line current across the three phases,
kW rated is the nameplate rated kW and η is the declared rated efficiency

Beware ! Current is not a reliable measure of loading of a motor.

MUM/A&D/SD Motors
Current is not a very reliable measure of loading of a motor

100% Current, Efficiency and PF as %

90% of rated Vs Load
80%
Values (% of rated va

As you can see that due to

70%

60%

50% drastic drop in PF at part

40% loads, the current does not
30% drop linearly and hence
20% estimating loading of motor
10%
by measuring currents does
0%
0 20 40 60 80 100 not give you correct idea of
Load (% of rated)
the loading.
kW % of rated Efficiency % of rated
PF % of rated Current % of rated

MUM/A&D/SD Motors
Efficiency of rewound motors

Significant increase in motor losses and consequent reduction in efficiency can

result from poor/improper rewinding practice.
•Core loss can increase due to damage to insulation of lamination
•Stator copper loss can increase due to use of incorrect wire sizes
•Losses can also increase due to distortion in air gap

A study reveals that Electrical Consumption can increase by

5 – 8% in small motors and by
2 - 3% in large motors

MUM/A&D/SD Motors
Precautions while Rewinding a failed Motor

Conduct No load test before and after rewinding

Check Winding Resistance before and after rewinding

MUM/A&D/SD Motors
 Energy Saving by using Variable Speed Drives (1)

Where can a motor driven by a Variable Speed Drive help in saving energy?

Fans, pumps, blowers etc., where the load varies depending upon the flow rate are the
most popular applications which result in energy savings when Variable Speed Drives are
used.

Fans & pumps - the requirements:

• Maintain the set flow rate based on the inputs.
• The flow rate may vary as per the process demands.

The methods of achieving this are by :

1. Conventional methods
2. Variable speed drives

MUM/A&D/SD Motors
 Energy Saving by using Variable Speed Drives (2)

1. Conventional methods :
Pumps : valve control (open/close)
Fans : dampers/vanes (open/close)
(Inlet/outlet/by-pass)

In this case, the flow control is achieved by diverting / resisting a part of the fluid flow.

The pumping rate does not decrease 1:1 for a decrease in flow rate.

2. By using a variable speed drive:

Fans as well as centrifugal pumps have T α N² characteristics

Since P α N x T, and T α N²
P α N3

MUM/A&D/SD Motors
Energy Saving by a VFD Driven Motor (1)

Throttling Element Variable Speed Drive

H Delivery head H Delivery head
Pump/ Compressor
A3 characteristic Pump / Compressor
H3 A2 characteristic
H2
B1
A1
H1
H1
n2 nn

B2

H2
Resistance to n3
the flow B3
H3

MUM/A&D/SD Motors
Energy Saving by a VFD Driven Motor (2)

Throttling Element Variable Speed Drive

P1
P2
P1

P3 Power input Pump /

Compressor
power P
Pump / Compressor P2
power
P
P3

Q3 Q2 Q1
Q3 Q2 Q1
Quantity of flow Q

MUM/A&D/SD Motors
Energy Saving by a VFD Driven Motor (3)

Throttling Element Variable Speed Drive

Pump / Compressor
power P If you want 60% Flow…
By conventional
P2
throttling method,
energy consumed would
P3 be between 60-65%.
P2 By Speed reduction
method energy
Energy consumed would be
P3
Savings around 21.6%
A straight saving of
Q3 Q2 Q1
Quantity of flow Q around 40%!!!

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Vote of thanks

Thank You !

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