High Energy Efficient Motors

Hemanth kumar
Interactive Workshop on Rotating Electrical Machines
08 Sept 2012

Indian center of ICA to promote Copper applications in India.

ICA - INTERNATIONAL COPPER ASSOCIATION

A Not -for- profit Global Organization
Registered in New York, USA. 31 Offices in 24 countries.
Members Account for Over 80% of World Copper Production.

ICPCI is driven by the objective to

promote the beneficial usage of
copper
for
safety,
health,
environment and energy savings

Presentation Structure

1.

Why HEM s in the Industry

2.

Policies & Regulation

3.

Supply chain involvement

4.

HEM implementation in Industries - End Users involvement (Demand

Side Management)

5.

Conclusion

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Sector wise energy consumption

Others
10%
Com m ercial
4%
Industrial
41%

Dom estic
19%

Agri
26%

Sector wise Energy Saving potential

Conservation
potential (%)

Energy Handled
by Motors (%)

Industrial Sector

Up to 25

70 - 75 %

Agriculture Sector

Up to 30

20 25 %

Domestic Sector

Up to 20

23%

Commercial Sector

Up to 30

Sector

45%

Motor Market scenario (2011)

17,200 MW
(81%)
Low Tension
(LT) Motors

AC Motors

IHP Motors

Motor Industry

2.865 Mn units
(100%)

2.86 Mn units
(99.9%)

2.855 Mn units
(99.8%)

DC Motors

5,300 units
(0.2%)
FHP Motors

2.85 Mn units
(99.8%)

High Tension
(HT) Motors

5,200 units
(0.2%)

Product of Interest

4,000 units
(0.1%)
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*Order of magnitude estimates

Source: Primary Research, IEEMA

Presentation Structure

1.

Why HEM s in the Industry

2.

Policies & Regulation

3.

Supply chain involvement

4.

HEM implementation in Industries - End Users involvement (Demand

Side Management)

5.

Conclusion

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Barriers to penetration of HEM

1.
2.
3.
4.

Lack of knowledge/ awareness with users

Non availability of EE motors
Confusion EE motor definition
Need to have focused market transformation

Higher initial cost

Low demand; high price
Lesser working hours
Lack of technology

1.
2.

Poor power quality in rural sector

Application limitations

HEMs Implementation

Towards increasing
penetration of HEM s

Policies
Regulation
Standards

Supply
Chain

Marketing
Promotion

Policy initiative EC Act 2001

9 Energy intensive
sectors recognized
Energy manager
mandatory for
designated
consumers
Annual energy
audits mandatory
S & L identified as a
thrust area

Standards scenario International

(Before Harmonization, 2008)
EPACT

Legislation
Three-phase induction
motors
0.75 to 150kW
60Hz
2, 4, and 6 pole
Specifies minimum
efficiencies
Testing to IEEE-112b

CEMEP Agreement

Voluntary
Three-phase induction
motors
1.1 to 90kW
50 Hz
2 and 4 pole
Efficiency labelling

Testing to IEC60034-2

11

Efficiency Levels
(quantitative comparison)

USA

Europe

India

EPACT

CEMEP

IS 12615

Motor Rating

EPACT

NEMA premium

Eff1

Eff2

Eff1

Eff2

1.1

84

86.5

83.8

76.2

83.8

76.2

2.2

84

86.5

86.4

81

86.4

81

3.7(4kW)

87.5

89.5

88.3

84.2

88.3

84

5.5

87.5

89.5

89.2

85.7

89.2

85.7

7.5

89.5

91.7

90.1

87

90.1

87

Efficiencies as per International Standards

AS PER IEC 60034-30

Sr . No

Rating

IE1 (equivalent eff2)

IE2 (equivalent eff1)

IE3

1.1

75

81.4

84.1

2.2

79.7

84.3

86.7

3.7 (4)

83.1

86.6

88.6

5.5

84.7

87.7

89.6

7.5

86

88.7

90.4

Global scenario

Efficiency Levels

Premium Efficiency

Efficiency Classes
IEC 60034-30
Global 2008
IE3

High Efficiency

IE2

Standard Efficiency

IE1

Testing Standard
IEC 60034-2-1
incl. stray load losses
2007
Low Uncertainty

Medium Uncertainty

Performance Standard
Mandatory MEPS
Policy Goal
USA 2011
Canada 2011
Europe* 2015 (>7.5 kW), 2017
USA
Canada
Mexico
Australia
New Zealand
Korea
Brazil
China 2011
Switzerland 2011
Europe 2011
China
Brazil
Costa Rica
Israel
Taiwan
Switzerland
bold means in effect
*) IE3 or IE2+VSD

Indian Standards Scenario

IS 8789 : Performance of Standard motors
Covers 37 kW ( 2P,4P,6P,8P)
Efficiency levels lower than eff2
Small manufacturers comply
Large manufacturers provide higher efficiency
IS 12615 (2004) : Performance of EE motors
Covers 160 kW (4 P), 132kW (6 P) and 110kW (8 P)
Two efficiency levels defined : eff1 & eff2
Large manufacturers voluntarily provide > eff2
Test Method followed 60034-2
IS 12615 (2011) : Newly implemented
New Efficiencies levels (IE1, IE2 & IE3)
Method of Testing of Stray Load Loss changed
15

New Standard IS 12615:2011

Harmonization of Indian standard IS 12615:2004 to the new global IEC

standard for efficiency classes of industrial motors (IEC 60034-30). The
final draft was approved and the new standard IS 21615:2011 published
in August 2011

New Standard IS 12615:2011

Recommends that the Minimum Efficiency Performance Standards (MEPS)
for industrial motors be IE2 and further proposes IE3 as minimum efficiency
performance from Jan 2014

IS12615 - Past & Present

IS12615: 2004

IS12615: 2011

IS12615: MEPS
shall be IE3 by
Jan 2014

1st revision of IS:12615-1989

Extends the range of motors
(covers 2P and 4P motors from
0.37kW 160kW,
6P motors from 0.37 132kW
and 8P motors from 0.37 110
kW)

2nd revision of IS:12615-1989

Efficiency Levels Eff1 & Eff2

(IEC60034-30)

MEPS - IE2

Test Method - 60034-2

Extends the range of motors (covers 2P,4P

and 6P motors from 0.37kW 375kW)
Test Method: IEC 60034-2-1 (IS15999:2011)
Efficiency Levels IE1, IE2 & IE3
(IEC60034-30:2008)
Additional parameters like breakaway
torque, current & Full load speed & Full load
current are included.

Standards and labels

Standard
Prescribes Energy performance of manufactured
products (Minimum Energy Performance Standards,
MPES).

Label
Information on products energy performance
(usually in the form of energy use, efficiency, or
energy cost)
Give consumers the data necessary to make
informed purchases

Current Labeling Plan

for motors
MEPS should be at Eff2(-) level

Eff1 would be an endorsement label

Consider efficiency at 100% loading
Include 2 pole motors & 4 pole motors

Label contents
Parameters spelt out in clause 20.1a of IS 325 :
1996
BEE logo, license number & Efficiency class
marking

Revision of the labeling plan is under progress

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Government initiative for

energy efficiency

BEE Motor labels for

IE 1 (Eff2) & IE 2 (Eff1)

New efficiency
standard under
IS 12615:2011

21

Market Share by Efficiency

EPAct92

MEPS2006

70% by
2014

Standard motors dominate global market , about 90% global market share
High efficiency motors will take over market eventually due to mandatory standards
US will lead premium market

Prepared for ICA by Peter Liu, E&E, May 2008

Mandatory MEPS pushes market much faster than voluntary program

Presentation Structure

1.

Why HEM s in the Industry

2.

Policies & Regulation

3.

Supply chain involvement

4.

HEM implementation in Industries - End Users involvement

(Demand Side Management)

5.

Conclusion

Efficiency is a differentiator for Major

Motor manufacturers
IE3
IE2 (Eff1)

Min benchmark

IE1 (Eff2)

Voluntarily adopted

Forced to follow

Eff3
Major
manu.

Small/medium
scale manu.

Future aim

Education of all the elements

Motor Manufacturer - Supply

Dealer

O.E.M

Consultants
influence
Contractor

End User - Demand

Push
I
N
F
L
U
E
N
C
E
Pull

Presentation Structure
1.

Why HEM s in the Industry

2.

Policies & Regulation

3.

Supply chain involvement

4.

HEM implementation in Industries - End Users involvement

(Demand Side Management)

5.

Conclusion

HEM Implementation At Consumer End

Towards increasing
penetration of HEM s

Awareness
creation

Awareness
Seminar

Conviction

Desk Top
Audit
Analysis

Adoption

Field Audits
Demonstration

27

Life cycle cost

Induction motors account for >100 times their first
purchase cost during their life time
Therefore , Negotiate the life cycle cost

DSM Opportunities to Adopt HEM

1. First purchases

New Project

Expansion

Existing motors

2. Replacement

Projects / Consultants

Top Management/Financers
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3. Retrofit

Plant Personnel

Motor Management Programme

Comprehensive and light predictive assessment and

Decision Tools

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First Step Desktop Audit

Comprehensive Motor Inventory
Client:

Date

Plant

Class of
Insulatio Bearing DE Bearing NDE

Location Tag No

Make

Sl.No

Frame kW

Volts Amps Hz

PF

Eff% rpm

Decision tool- spare & parts management

Second step Desktop Audit

Decision Tool- Sizing, relocation, repair..

Third step Desktop Audit

Decision Tool- Retrofit, replacement,

continuous condition monitoring.

Economic Analysis

For a 15kW Motor, with Efficiencies IE1 (88.7%) & IE3 motor (92.1%)
For an application with operation of 8000hrs in year & Energy tariff of Rs 5 per kWH.
The total energy Cost annually for operating IE1 is

INR 6,76,437 /-

The total energy cost annually for operating IE3 is

INR 6,51,465/-

The annual savings by using IE3 instead of IE1 is

INR 24,971/-

The premium price paid for IE3 with respect to IE1 is Rs. 16000/-

The premium cost is recovered in 6 months, & The entire cost of IE3 motor is
recovered in 2 years.
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Right Sizing of Motor

Over Sized motor
Motor out put 37 kW,4P
Name plate Eff 92%
Measured in put 19 kW
Measured losses 2.1 kW
Calculated out put 16.9kW
Load factor 45%
Motor efficiency 89%
Efficiencies at partial
loads always poor

Sized SEE motor

Motor out put 22 kW, 4P
Name plate Eff 93%
Measured in put 18.1 kW
Measured losses 1.2 kW
Calculated out put 16.8 kW
Load factor 76%
Motor efficiency 93%
Energy saved 0.9 units per hour;
@8000 hours/annum is 7200
units
Source: Power House

Textile Ring Frame

(Higher Output motor)
Motor Decision Process during modernisation of textile mill for production augmentation
( Actual measurement done with same ring frame but increased spindle speed)
Parameter
Motor rating
Maximum spindle speed(RPM)
Total cycle duration (min.)
Units consumed (KWh)
Total Production per cycle (kg)
Units / kg (Kwh / kg)
Machine avail. Time per year (min)
Total doffs / year
Production / year (kgs)
Extra production / year

Existing Motor Replacement Motor

34 kW 91% eff 45KW , 94 %
18983
20198
153
146
72.86
78.26 + 7.5%
51.52
51.4
1.414
1.523
520560
520560
3402.35
3565.48
175289.22
183265.64
7976.42
+ 4.5%

Cost of 45 kW motor
Net Extra revenue calculated

Rs.1,13,500 (2500 USD)

Rs.1,00,930(2240 USD)

Based on the extra revenue figures management decided

to modernize 56 ring frames with higher kW motors
Source: Power House

Textile Ring Frame Energy Audit

Field Efficiency Testing on ring frame during the energy Audit of the factory
Parameter
Motor rating (kW)
Motor Efficiency
Measured input
Calculated Output
Load factor
Efficiency at load factors
Units consumed per year (8000hrs)
Units saved
Saving @ Rs.3.5

Existing Motor Replacement Motor

45
34
93.50%
94.70%
25.3
24
22.586
78.26
50.0%
67%
89.300
94.600
221628
210240
11388.00
39858.00

Additional benefit of kVA reduction given by the distribution company (Approx. Rs 6000)
Approx, saving per motor Rs.46000
Approx. cost of 34kW motor Rs. 95000
Payback

2 years

Management decided to replace 50 motors in a phased

manner
Source: Power House

Presentation Structure
1.

Why HEM s in the Industry

2.

Policies & Regulation

3.

Supply chain involvement

4.

HEM implementation in Industries - End Users involvement

(Demand Side Management)

5.

Conclusion

To conclude .
ONE Unit saved = TWO Units Generated
Conserving 1,000 kWh will Reduce 0.9 ton CO2 (greenhouse gas)

coal from being burned

and...

Carbon
emissions
from being
released
into the
atmosphere

Upgrading one, 1 HP motor to a high Efficient motor ...

Adoption of High Energy Efficient Motors

Saves

" Energy & Environment"

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Thank you
For more information please contact
hemanth.kumar@copperalliance.asia
Raje_milind@icpci.org

E Mail info_copper@icpci.org
Website www.copperalliance.org

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Phone- +91 22 66937989

Fax- +91 22 66939282