DOL Group of Companies

In your service since 1978

Products || Services || Customised Solutions

T : +91 022 2760 7542 | E : info@dolgroup.in | www.dolgroup.in

 Frame work of the presentation

•Introduction and Company Profile

•Energy Conservation Act – What it is and its Provisions

•Energy Efficient Motors

•Energy Management through Motors

 Introduction
Name: Milind Raje

Education: B.E (Electrical); MBA (Administration)

Professional Experience: 30+ years

17 years Siemens Ltd (9 years in Motors Testing- Factory; 7 years in Sales and
Marketing
09 years – International Copper Association – Commodity Marketing
05 years – Dol Motors – Sales and Operations

Additional Activities – ISO Auditor

Sustainability Practitioner and Assessor
 Company Profile

Products Services Customised Solutions

● MV MOTORS - (Fr. ● REPAIRS & ● METERING

315 to Fr. 630 | 690V REFURBISHMENT SOLUTIONS
to 11kV |150kW to (Up to 15MW, 13kV) ● SOLAR
6000kW) ● SMART MOTOR ● ENERGY AUDITS &
● LV MOTORS - (Fr. KIT™ CONSULTATION
200 to Fr. 315 | 15kW ● RETROFITS
to 200kW)
● GEARBOXES
● TRACTION MOTORS
● WIND GENERATORS
 Timeline - DOL Group
2005 - LV 2013 - Two new 2018 - MV
1978 - Motor plants of total 4500 Motor
Formation of Manufacturing Sq. Mt. Manufacturing
Organization Begins Commissioned Begins

2002 - 1.25 MW Wind 2012 - Customized 2017 - SMART Motor 2019 -

Generators Job work, Solutions Division Kit™ Launched Expansion to
Power Plant Added New Verticals
Refurbishment with
Siemens/Alstom Begins
Products | Services | Customised Solutions
 Frame work of the presentation

•Introduction and Company Profile

•Energy Conservation Act – What it is and its Provisions

•Energy Efficient Motors

•Energy Management through Motors

 Energy Conservation Act
• Policy – EC Act enacted in 2001
• Implementation – Bureau of Energy Efficiency under the Ministry of
Power constituted

• Regulations
- Manufacturers – Standards and Labels for Products
- End Users - Mandatory Energy Audits for Designated
consumers

• Facilitation – Energy Managers and Energy Auditors, Energy

Service Companies, Finance options etc.

• Incentives, Rewards and penalties

 Frame work of the presentation

•Introduction and Company Profile

•Energy Conservation Act – What it is and its Provisions

•Energy Efficient Motors

•Energy Management through Motors

Energy Saving Potential in
India
Segmental Energy Saving Potential

Economy as a whole. Up to 23%

Agriculture Up to 30%
Industrial Up to 26%
Transport Up to 20%
Domestic & Commercial Up to 20%
Energy Saving Opportunities

• Thermal

• Fuels

• Electrical

• Materials

• Etc etc
 110/220 kV
Heat Generation with a 10/20 kV
purpose.
110 kV Industry
6 ~ 20 kV 15 kV
Power Generation
Railways
20 kV
200/400 kV
230/440 V

Power Transformer Distribution Transformers

Domestic
& Commercial
Heat Generation as wastage of energy.
Source: Thyssen Krupp
Energy Saving Potential using Energy Efficient
Equipment

• Generation – boilers, turbines, alternators etc.

Non Conventional sources of energy

• Transmission and Distribution - Transformers, Cables, OH wires etc.

• End Use - Motors & Pumps, Domestic equipment like Air conditioner and
refrigerators, Fans, Lighting, etc. etc.

Saving one unit is much cheaper than generating one unit.

 Why Energy Efficient Motors
•There is a huge gap between the demand & supply of electric power

•Almost 70% of the electricity is consumed by motors.

•Ever increasing energy cost reduces profits of the industry.

•Operating cost is much more than the initial price of the motor.
 Interesting fact about motors
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 19500
98%
Electric Motor 20 HP
Source : Siemens
The operating costs are what count!

12 yrs 15 yrs 20 yrs

The low cost of buying can be deceptive

 How to Improve Efficiency

Efficiency = Output
Input

= Output
Output + Losses

Since output is going to remain constant,

what we can reduce are LOSSES.
Source: Siemens
 Losses in Motors

55 - 60% Stator I2R Suitable selection of Copper Conductors for Max

Active Material
Rotor I2R Specially designed Al-die cast Rotors

20 - 25% Core Losses Low watt Loss Material

Thinner Laminations
Burr height

2 - 12% Friction & Windage Optimum design of Fan

4 - 5% Stray Optimum Slot Geometry

Minimum Overhang Length
Source : Siemens
 Frame work of the presentation

•Introduction and Company Profile

•Energy Conservation Act – What it is and its Provisions

•Energy Efficient Motors

•Energy Management through Motors

 Selection process frame work

First purchases Existing motors

New Project Expansion Replacement Retrofit

Projects / Consultants Plant Personnel

Top Management/Financers
 New Motor Purchase
Economics
15 kW (4-pole) Standard Energy Efficient
Price (Rs): 17,700 21,420

% Efficiency: 89.0% 91.8%

Price premium 3720
Operation-Hours 8000.00 8000

Energy Rate Rs.4/kWhr Rs.4/kWhr

Energy Cost (Rs/Yr): 5,39,326 5,22,876

Annual Savings: Nil Rs.16,450.

Payback for premium: 2.7 M

Recovery of Entire cost of EE Motor: 1.25 Y

Payback Reduced with Longer Hours, Greater Load

Energy management – Existing
Motors
•Make a census of existing motors in the plant

•Based on existing motor data,grade motors on the basis of

hours of running, life & no. of rewinding

•Classify the motors for energy intensiveness

•Identify motors if necessary for study

•Make a techno commercial report

•Make a proposal for motor replacement plan

Comprehensive Assessment of
Motors

Level A – Desk Top Analysis

Level B - Field Testing
Level C - Condition Monitoring
Level A - Desk Top Analysis
1. Motor Inventory with Name Plate details
Comprehensive Motor Inventory
Client: Date
Class of
Plant Location Tag No Make Sl.No Frame kW Volts Amps Hz PF Eff% rpm Insulatio Bearing DE Bearing NDE

Decision Tool 1. Helps in spare parts management

Level A - Desk Top Analysis
Running Data

Decision Tool 2 - Helps in sizing, relocation, repair

 Level A - Desk Top Analysis
3. Critical Motor Identification

Decision Tool 3-Retrofit, replacement, condition monitoring

Level B - Field Tests - No Load tests

NO Load Test - Data to be measured

Voltage Current I/P Power Resistance No-Load temp

P.F Hz
(Volt) (Amp.) (watt) L-L (Ω) RPM RC (°C )

R - Phase
C
Y - Phase

B - Phase

Average
Level B - Field Tests -Load tests

Load Test - Data to be measured

Voltage Current Input KW Resistance Load temp

P.F Hz
(Volt) (Amp.) (watt) L-L (Ω) (RPM) RH (°C )

R - Phase

Y - Phase

B - Phase

Average
Level B - Field Tests -Loss Calculations
Loss Calculation
Stator Copper Loss at No - Load =
watt
(No-load current2 X Rcold / phase)
Stator Copper loss
Stator Copper Loss at Load =
watt
(load current2 X RHot / phase)
Iron + Friction + Windage losses
Constant Loss watt
(No Load Input in watt - No Load Stator Copper Loss)
Stray Losses % Stray loss as per SLL of rated O/P watt
Slip = (Ns-NLoad)
%
Ns
Rotor I/P = (I/P at Load - Stator Copper Loss at load -
Rotor Copper loss watt
Constant Loss - Stray Losses)

Rotor Copper Loss = Rotor I/P x Slip watt

Total Losses = stator copper loss at load + constant loss
watt
+ stray loss + rotor copper loss
 Level B - Field Tests -Efficiency
Estimation
Efficiency = Output / Input
=(Input – Losses) / Input

 Input Measured in Load test

 Losses calculated after load, no load test

Thus efficiency can be estimated

Level C – Condition Monitoring
1. Maintenance Evolution Continuous
Monitoring
Root cause
Failure analysis Best in
Class
Condition
Monitoring Proactive

Scheduled
Predictive
Spared
inventory
Preventive

Reactive
Thank You! for your
valuable time

DOL Group of Companies

Head Office : R-965/R-958 MIDC, Rabale, Navi Mumbai - 400 701
T : +91 22 2760 7542, +91 22 2760 6458 | E : info@dolgroup.in | www.dolgroup.in |