Energy Efficiency Avenues In Indian Industries

Presented by R.K. Paul Senior General Manager- Marketing (Motor) M:+91 9810 622 768 Email: ravinder.paul@bharatbijlee.com
Date and Place of Presentation in Arial Italic 11 pt

Consumption of electricity by Sector

Why Energy Conservation

High Cost of generation per MW compared to saving of energy. Government of India taking initiative towards energy conservation. Win-Win situation for both the user and supplier of energy efficient equipments. Since 2003, there has been a rise of 12.5% in the amount of electricity consumption in commercial sector. Energy is like raw material for many energy intensive industries like Steel,Paper,Textile and so on.

Initiatives taken By Govt. of India

Energy Conservation Act already in place since 2001. Energy Conservation Building Code- 2007(ECBC) also in place. This code mentions about HVAC System and motors. Energy Audit companies being shortlisted & set up by BEE to conduct Energy Audits and consultation on profit sharing basis.

Sectors Covered By Energy Conservation Act

Aluminium Iron & Steel Pulp & Paper Sugar Chemicals Port Trust Petrochemicals Commercial buildings Ferilizers Cement Chlor Alkali Textile Railways Transport Power Stations

Note : Number of sectors already purchasing high efficiency motor and reaping the fruits of low electricity bills and also conserving energy

Regulatory Interventions
The Government of India has identified the importance of energy conservation in light of the huge gap between the demand & supply of power. The Government of India had constituted the Bureau of Energy Efficiency (BEE) as the authority responsible for the implementation of the Act. The EC Act identifies energy intensive industries and establishments as Designated Consumers (DCs) who are required to Appoint or designate an Energy Manager (EM) in their plant. Get energy audit conducted by an accredited Energy Auditor (EA) Implement techno-economically viable recommendations for energy conservation Comply with fixed norms of specific energy consumption Submit reports on the measures taken in a specified format. BEE is implementing a labeling program, in preparation to introduction of Minimum Energy Performance Standards (MEPS) for appliances and equipment.

Energy Efficient Motors- A National Priority

70% of all electrical energy consumed in India is used for driving electric motors. 55% of which is consumed by industrial motors

National Standard for Energy Efficient Motors

IS: 12615

Specifies two Efficiency Levels eff 2 (Imp. Eff.) eff 1 (High Eff.)

Covers Motors From 0.37KW to 160KW (Upto Fr 315 L)

eff1 efficiency levels are higher than eff2

Both Eff1 and Eff2 are higher than nominal values specified in IS8789:1996

IS 12615: 2004 (First revision) -Superior to existing Std. IS 8789

To be considered as energy efficient, a motor must conform to one of the following efficiency levels specified in IS 12615: Improved Efficiency (eff 2) High Efficiency (eff 1) eff1 efficiency levels are higher than those of eff2. Both eff1 & eff2 are higher than the nominal values specified in IS 8789: 1996.

Range of Energy Efficient Motors

Efficiency Class eff-1,High Efficiency

Efficiency Class eff-2,Improved Efficiency
Eff 2 motors are offered ex-stock by few manufacturers. Most of manufacturers offer a complete range of eff 1 motors against specific orders with a lead time of 8 to 10 weeks. Fast moving ratings are available of the shelf in case of Bharat Bijlee.

Comparison of efficiencies of Standard & Energy Efficient Motors

Output 4 Pole
0.75 kW 1.5 kW 3.7 kW 11 kW 18.5kW 37 kW 75 kW

IS 8789
71.0% 76.0% 83.0% 85.5% 87.0% 88.5% Not specified

eff 2 as per IS 12615

73.0% 78.5% 84.0% 88.4% 90.0% 92.0% 93.6%

eff 1 as per IS 12615

82.5% 85.0% 88.3% 91.0% 92.2% 93.6% 94.7%

110 kW
160 kW

Not specified
Not specified

94.4%
95.0%

95.2%
95.8%

Salient Features of Eff1 Motors

Efficiency

Equals to IS:12615 Nearly flat load curve from 60% to 100% FL

Design

Increased Copper Section Longer Core Length Low Loss Magnetic Material Stamping Special Stator/ Rotor Stamping Design

Why does IS 12615 specify two efficiency levels?

User has the option to go for eff1 motor and save energy but at higher initial cost. It is strongly recommended to go for eff1 motor when utilization is high. The standard is hence user friendly since it has provided two levels of efficiency. This is in line with other international standards like CEMEP.

How is motor Efficiency Improved

Reduce (1)Iron Loss Reduce (2)Copper Loss

Reduce Stator Cu Loss

Reduce Flux Density Low Loss Magnetic matl. Increase Copper Section

Reduce Rotor Cu Loss

Increase Rotor bar section Increased Starting current Torque

Stator slot area Reduce Rotor Diam

Increase Stator Yoke

Reduced S t a r t i n g

Efficiency improvement to eff1 by use of Low Loss Stamping & increased Fe and Cu
11 kW 1500 rpm eff 2 eff1 Low Loss + increased Stamping Cu & Fe
Iron losses Friction & Windage 400 W 120 W 330 W 120 W 250 W 120 W

Constant Losses Load related Losses Total Losses Efficiency

520 W 840 W 1360 W 89%

450 W 750 W 1200 W 90.2%

370 W 650 W 1020 W 91.5%

Why is the Energy Efficient motor more expensive?

eff 1 motors are generally priced 5 - 15 % higher than eff 2 motors. More laminations - longer core length and/or High Grade (low loss) laminations More Copper

Rs.

Life Cycle Cost of Motor

In one year, a motor consumes energy equivalent to 10 to 20 times its purchase price. Many consumers in India especially OEMs purchase cheap motors having low efficiency values.

Initial Cost of an 11 kW 4Pole motor is only 4% in the first year of operation

Assumptions:

Efficiency Eff2 : 89.0% Energy cost: Rs 5 per kWh Working: 8000 hrs pa

Energy Efficient Motors have a Flat Efficiency Vs Load Characteristic

Motor rating is selected for max. load conditions and next preferred rating Most motors operate on an average around 75% load.
Efficiency Comparison
95 90 85 80 75 70 65 60 25%

Efficiency is almost same from 60% to 100% load in a well designed EE motor

50%

75%

100%

Motor As per IS 8789 Energy Efficient Motors

Energy savings increase at partial loads due to Flat efficiency vs Load Characteristic

11kW-4 Pole eff 2 motor Vs eff1 motor.

Load Working Hrs. p.a. Eff of eff 1 Eff of eff 2 100% 3000 91.5% 89 75% 3000 91.5% 89% 50% 2000 89.5% 86%

Difference in input power (kW)

0.338

0.338
Rs 4056

0.50
Rs 4000

Energy saving p a @ Rs 4.0 per kwH Rs 4056

Total Energy saving per annum : Rs. 12112

Additional Price of eff-1 motor over eff2 motor : Rs. 2627

Payback Period is 2.6 Months

Eff1 motor gives further savings over an eff2 motor

Eff2
Purchase Price of 11kW/4P motor Rs Efficiency Energy consumption p.a. for 8000 Hrs @ Rs 4 per kWH 17509 89.0% 3,95,504

Eff1
20135 91.5% 3,84,700

Energy Saving Rs
Additional purchase price Rs

10804
2626

Pay Back Period of eff1 motor is 2.9 months for a 15% price increase over eff2 motor

Energy Efficient-Increased Safety & Flame Proof Motors

Bharat Bijlee offers Flame Proof and Increased Safety motors conforming to eff2 as standard

Eff 1 motors can also be offered against customer requirement with a lead time of 8 to 10 weeks.

In a few eff1 outputs next higher frame size is required.

Need for High Efficiency Motors

Use of High efficiency motors in sectors like Fertilizers / Sugar / Central Airconditioning units and AHUs/etc, will allow considerable energy saving at locations with high usage.

The use of high efficiency motors helps to reduce the power consumption. (Example in next slide)

The following table will provide insights on energy savings on usage of energy efficient (eff-1) motors against (eff-2), or any other standard motor.

The ratings in the table correspond to the requirement of a modern building project, whose enquiry has come up with Bharat Bijlee

Rating

Efficiency

Qty of

Annual Purchase Price Savings (Approx) Rs. Price

Difference (Rs.) 565 613 816 1046 1438 1681 2731 2682 3335

PayBack Period

HP 1.5 2 3 5 7.5 10 12.5 15 20

Pole 4 4 4 4 4 4 4 4 4

KW 1.1 1.5 2.2 3.7 5.5 7.5 9.3 11 15

eff2 78 80 82 85 86 87 88 89 90.2

eff1 83.8 85 86.4 88.3 89.5 90.3 90.5 91.5 92.2

Motors 1 1 1 1 1 1 1 1 1

Rs. 1969.9 2205.9 2732.6 3253.6 5001.9 6300.8 5838.8 6753.9 7214.6

Eff-2 3755 4108 5427 6944 9570 11176 17317 17891 22232

Eff-1 4319 4721 6243 7990 11008 12857 20048 20573 25568

Months 3.44 3.34 3.58 3.86 3.45 3.20 5.61 4.77 5.55

30
40 100

4
4 4

22
30 75

91.8
92 94

92.8
93.2 94.7

1
1 1

5164.9
8397.1 11795.4

33416
45077 123421

36756
49586 129594

3340
4509 6172

7.76
6.44 6.28

Replacement Vs Rewinding -11 kW 4 pole motor

Eff of Old Motor to be rewound or replaced New motor Efficiency Purchase Price of new motor Rs Rewinding Cost Rs Additional Cost Rs Efficiency of old motor IS 8789 eff2 16000 4000 12000 85.5% eff2 eff1 19200 4600 14600 88.4%

Efficiency after rewinding ( less 1.5%)

Efficiency of new motor Saving by replacement with new eff2 motor For 5000 Hrs @ Rs 4.0 per kWH (Rs) Pay back period :

83.0%
88.4% 0.809 kW 16180 8.9 Months

86.9%
91.0% 0.570 kW 11406 15.4 Months

Replace old eff 2 motor with eff1 motor & get Payback in 15 months Replace old IS8789 motor with eff2 motor & get payback in 9 months

Nameplates - Marking of Efficiency

Manufacturer Name
3 ph. Induction motor
Type MH16M4734 Fr 160M

Manufacturer Name
3 ph. Induction motor
Type MA16M433 M/c. No
Fr 160M

MADE IN INDIA
Hz 50

MADE IN INDIA
Hz 50

Insl Cl F

Insl. Cl F Duty S1

M/c. No

.
A 19.7 rpm 1460 EFF-1

Duty S1 Eff % 91.5 P f 0.85

A 20.5 rpm 1450 EFF-2

Volts 415 kW/HP 11/15

Volts 415

Eff % 89.0 P f 0.84

kW/HP 11/15

A High Efficiency Motor

A Standard Motor (Improved Efficiency)

The EE motors are clearly labeled EFF-1 or EFF-2

Inrush current
Energy-efficient motors feature low electrical resistance and thus exhibit higher inrush currents than standard models. The inrush current duration is too short to trip thermal protection devices

Advantages- Apart from Higher Efficiency

Less maintenance and longer life time due to lower temperature in windings and bearings Higher reliability due to lower losses. Better tolerance to thermal stresses resulting from stalls or frequent starting. Increased ability to handle overload conditions. Better resistance to abnormal operating conditions, such as under and over voltage or phase unbalance. Higher tolerance to poorer voltage and current wave shapes.

Design Factor to be considered..

Motor Size. Size motors for efficiency. Motors should be sized to operate with a load factor between 65% and 100%. The common practice of oversizing results in less efficient motor operation. For example, a motor operating at a 35% load is less efficient than a smaller motor that is matched to the same load The Next figure explains the same.

To Add..
Energy savings are more at partial loads because Energy Efficient motors have a Flat Efficiency Vs. Load Characteristic Payback period of eff2 motor over IS-8789 motor is approx 1500 working hrs. Payback period of eff1 motor over eff2 motor is approx 2500 working

hrs.

How to Determine Cost effectiveness?

The cost effectiveness of an energy-efficient motor in a specific situation depends on several factors, such as
Motor price Efficiency rating Annual hours of use Percent full load Energy rates Cost of installation and downtime, The availability of utility rebates or other incentives.

Advantages of Using High Efficiency Motors

To save energy this is a national priority

To reduce operating cost Increased Profits To reduce harmful greenhouse gas emissions

When Should I Consider an Energy-Efficient Motor?

Most motors should be replaced with an energy-efficient model if they operate over 1500 hours per year. In general, energy-efficient motors should be

considered in the following circumstances:

New installations, both separate and as part of packages such as HVAC systems

When major modifications are made to a facility or a process

Instead of rewinding old motors, use high-efficiency motors Existing motors are under loaded or overloaded.

As part of a preventive maintenance or energy conservation plan

Intermittent duty applications.?

Intermittent duty motors are typically used in crane, hoist, valve actuators and other applications with frequent starts. In these applications, motors are designed for low starting losses rather than low running losses.

For intermittent duty applications EE motors are not the best choice

Problems in field testing

Efficiency measurement at site is unreliable.

One needs to decouple the load in order to measure no load losses. Variable voltage supply required in order to maintain rated voltage.

We recommend measurement of kWh using a energy meter and compare two motors. Measurement of current is not a reliable indicator. Current is not directly proportional to input power because power factor varies with load and voltage.

Who should Help in promoting Eff1 Motors?

Finance Help Are there any financing or leasing schemes for EE Motors? Yes, IREDA and other financial companies such as ICICI, IDBI etc. have schemes that can help you to acquire EE motors. (courtesy web site of COPPER international copper Promotion council India)

Energy Efficient Motors & Carbon Credits

Lower energy consumption means lesser burning of natural resources Thus lower pollution. Better efficiency means lower operating costs, hence improved bottom lines. Opportunity to participate in World Carbon Credit Market, which stands for just 6% in India (against 71% in China) at an estimated value of US $ 64 billion as per World Bank Estimate for 2007. (Source Economic Times)

Bharat Bijlee manufactures Energy Efficient motors conforming to eff1 or eff2 of IS 12615 Bharat Bijlees Standard Ex stock Motors conform to eff2 of IS 12615

Inferior motors conforming to IS 8789 are not manufactured by Bharat Bijlee

Summary & Conclusion

There exists a national standard IS 12615: 2004 (Revision 1) for energy efficient three phase induction motors from 0.37kW to 160 kW

Energy savings are more at partial loads because Energy Efficient motors have a Flat Efficiency Vs. Load Characteristic

Payback period of eff2 motor over IS-8789 motor is approx 1500 working hrs.

Payback period of eff1 motor over eff2 motor is approx 2500 working hrs.