Energy Conservation Measures In Industrial Drives Through Selection, Operation and Maintenance.

M.G.Morshad, Deputy Chief Engineer / Electrical maintenance / Thermal station II Neyveli Lignite Corporation Ltd

INTRODUCTIONThe need for energy conservation dose not requires any explanation. The simple logic is - energy saved is equivalent to energy generated. But the question is - how much energy can be saved? Right answer - the energy, which is being wasted, can only be saved. Energy waste is always associated with improper selection, operation and maintenance of equipments. But financial constraint and reliability - are the two factors, which industry is always concerned about, get top priority neglecting energy account intentionally or unintentionally. Energy conservation is an effort to consider the factor of selection, operation and maintenance seriously and arrest energy waste as much as possible without disturbing reliability and increasing financial burden. Electrical motor (industrial, commercial, domestic and agriculture) alone consumes about 70% of country's total generated power (83000MW). If, by effective energy conservation it is possible to improve the efficiency of drive system by 0.5%, electrical power amounted to 83000 x 0.7 X 0.005 = 290 MW can be saved or alternately generated every day. This huge potential for power generation through energy conservation is much more economical, viable and practical than obtaining similar amount of power from renewable source like solar, wind, tidal etc. Therefore, considering the present energy situation energy conservation is not merely an option but compulsion, which have to be adopted without any compromise for prolonging the life of our modern civilization beyond the estimated limit. Energy losses in electrical motorMainly three phase induction motors are used for industrial application and the typical percentage of losses and their root causes are found as shown in the table TYPICAL % OF LOSSES ROOT CAUSE OF THE LOSSES I2R losses minimum at no Stator Copper (I2R) loss 35 to 40% load. It increases with the increase of motor load and additionally with temperature I2R losses in bar and end rings virtually zero at no load. Increases as the square of Rotor Loss 15 to 20% the load and additionally as the temperature increases. Rotor conductor size, material and temperature rise FACTOR AFFECTING THESE LOSSES Stator conductor size, material and temperature rise

TYPE OF LOSSES

Rotor core losses due to main flux are virtually zero.

Core loss a) Hysteresis 15 to 20%

a)

Energy

expended

by a) Type and quality of magnetic material

reversal of magnetic flux

b) I2R losses in core steel b) Quality of lamination cause by circulating current used for core induced by the flux reversal. Addition load losses in stator

b) Eddy current

Stray load loss

10 to 15%

and rotor mainly caused by leakage flux and high

Manufacturing and design methods

frequency pulsation. a) Friction losses 5 to 10% a) Viscous flow of the Selection / design of and fan and bearings

lubrication in bearings b) Air resistance

b) Windage losses

turbulence in cooling fans

Rated efficiency of motor is decided during design stage and cannot be improved further, whereas operating efficiency, which mainly depends on operating condition is possible to improved by proper selection, operation and maintenance.

SELECTION
1) Proper sizing of motor Convinced by the general perception that higher size is more reliable, there is always a tendency to prefer oversize motor. Such practice not only increases the investment cost but also causes tangible amount of energy loss. For successful acceleration of load, motor capacity must always be higher than load capacity. In centrifugal pump type load (low starting torque) it is normally kept 25% higher - considering other aspect like temporary overload due to higher frequency, over discharge, and future expansion of load. Based on this calculation - a pump of capacity 13.8 KW at 1465-rpm

requires 13.8 + 13.8 x 0.25 = 17.25KW motor. Since motors are available with standard capacity and frame, only two capacities i.e. 18.5 KW and 22 KW are available in this frame and the appropriate size of motor for driving the pump should be considered 18.5 KW. Instead of that, if 22 KW is selected - it becomes oversize for the pump and the financial burden for selecting oversized motor can be calculated as shown in the table. REQUIRED MOTOR Motor capacity Motor frame Motor loading % Motor efficiency Motor input Motor loss Power loss in oversized motor Energy loss / day 18.5 KW 180M (13.8/18.5) x100 = 75% 92% 13.8 / 0.92 = 15 KW 15 - 13.8 = 1.2 KW ********** *********** OVERSIZED MOTOR 22 KW 180L (13.8 / 22) x100 = 62% 90% 13.8 / 0.90 = 15.33 KW 15.33 -13.8 = 1.53 KW 1.53 -1.2 = 0.33 KW 0.33 x 24 = 7.92 Unit

REQUIRED MOTOR Energy loss / year Energy cost @ Rs 2.50 / year Energy cost in five years Motor cost (Rs 2500/KW) Difference in motor cost Interest - for 5 Years Cumulative financial loss in 5 years 2) Energy efficient motor ************* Rs 46250 /************ *********** ************

OVERSIZED MOTOR 7.92 x 300 = 2376 Units 2376 x 2.50 = Rs 5940/Rs 29700/Rs 55000/Rs 8750/Rs 6550 /8750 +6550 + 29700 = 45000

There are some drives like conveyor belt, where high starting torque is required for successful acceleration of load. In such case motor capacity must be at least 30% higher than load capacity and designer normally prefer 35% higher - considering other aspects like temporary overload and future expansion of load. Based on this calculation - for driving a conveyor belt of capacity 3.5 KW, motor capacity 5.5KW is preferred. Such unavoidable over sizing [(3.5/5.5) x100= 63% loading] always causes energy loss due to partial loading of motor. There are two basic advantages in energy efficient motors - a) Motor full load efficiency is 1 to 2% higher than standard motor and b) This efficiency remains more and less unchanged till 50% of loading. The effective energy saving for replacing standard 5.5 KW motor with similar

capacity energy efficient motor can be found as shown in the table Type of motor Motor Capacity Motor Loading % Operating efficiency Motor loss Power saving Energy saving / day Energy saving / year Cost saving (Rs 2.50) / year Motor cost (Rs 2500/ KW) Difference in cost Pay back period 3) Variable Speed Drive (VSD) Conventionally, throttling / re-circulation in pump and damper control in fan / blower are used for controlling out let flow. Such methods always increase the system resistance and consume about 12.5% more power at 50% of flow. The energy waste due to throttling or damper control can be avoided by selecting following methods for flow control a) For higher head pump - Recirculation through NRV (instead of valve less recirculation) b) For lower head pump - Variable Speed motor (instead of throttling) c) For fan and blower - Variable speed motor (instead of damper control) Standard motor 5.5 KW (3.5/5.5) x100 = 63% 82% (3.5/0.82) - 3.5 = 0.76 KW *************** **************** **************** **************** Rs 13750/Rs 2750 /************** Energy efficient motor 5.5KW (3.5/5.5) x100 = 63% 83% (3.5/0.83) - 3.5 = 0.71 KW 0.76 - 0.71 = 0.05 KW 0.05 x24 = 1.2 Units 1.2 x 300 = 360 Units 360 x 2.50 = Rs 900/Rs 16500/************** Three years

4) Soft starter To avoid over sizing and harmful starting, motor for high inertia load like heavy conveyor belt is provided with fluid coupling. Transmission loss due to slip is a permanent feature in this type of coupling. The slip is normally found 3% at full load and increases with the decreases of load. Such load dependent slip in coupling always causes energy loss - particularly in conveyor belt type load where uniformity in loading can never be maintained and average loading level is normally found less than 50%. Soft starter limits the starting current by controlling terminal voltage and helps to achieve starting alike fluid coupling with direct coupling. Therefore, by starting motor through soft starter, fluid coupling can be replaced with direct coupling and some amount of energy can be saved. The typical energy saving for replacing fluid coupling with direct coupling can be calculated as shown in the table Fluid coupling Motor capacity At Ave. 60% motor loading Approximate slip in coupling Transmission efficiency Motor out put Motor efficiency Motor input Motor loss Energy saving Energy saving / day Energy saving / year Cost of the energy / year 45 KW 27 KW 7% 93% 29 KW 89% 32.58 5.58 KW ********* ********** ********* ********* Direct coupling 45 KW 27KW 0 100% 27KW 89% 30.33 KW 3.33 KW 2.25KW 54 Units 16200 Units RS 40500 /-

Soft starter also can find out optimum operating voltage required for a particular loading condition. Utilizing this feature, soft starter applies the minimum terminal voltage during idle running and saves considerable amount of energy. 5) High slip motor for pump & blower operation Since the power input in centrifugal type pump, fan and blowers is proportional to (Speed) 3, power consumption in motor gets increased with the increase of operating speed. Full load speed of motor for a particular specification varies from manufacture to manufacturer. Selecting lower speed motor (high slip) for such application some amount of energy can be saved. The energy saving potential of high slip motor for pump application can be calculated as shown in the table Selected motor capacity Rated speed of the motor Slip of the motor Pump input power (PN3)

67 KW 1490 RPM 0.66% 49.00 KW

67KW 1485 RPM 1% 48.51 KW

Discharge (Q N) Outlet pressure (H N2) Motor input power ( 87%) Motor current Energy saving Energy saving / year Cost saving / year 6) Rewinded motor

109.26 m3/h 15.78 Ksc 56.32 KW 50.84 A ****** ******* ********

108.9 m3/h 15.68 Ksc 55.75KW 50.33 A 56.32-55.75=0.57KW 0.57X24x300 = 4104 Units 4104 X 2.50 = Rs 10260 / -

After rewinding, efficiency of all types of motors gets reduced by 2 to 3 %. Energy loss due to lower efficiency can only be avoided if rewinded motors are discarded completely. But considering financial constraints involves with such practices, it is never recommended and rewinded motors are allowed to run with extra energy losses. The financial loss for rewinded motor can be calculated as shown in the table New motor Capacity Motor out put at 75% loading Operating efficiency Motor loss Extra energy loss / day Extra energy loss / year Cost of energy / year Motor cost Cost saving for rewinding Extra energy cost in 5 years 110 KW 82.5KW 92% 7.71 KW ********* ********* ********** Rs 2,75000 *********** ********* Rewinded motor 110KW 82.5KW 89% 10.19 KW 59.6 units 17880 units Rs 44700 Rs 40000 (Rewinding cost) Rs 2,35000 / Rs 2,23500 /-

Energy waste in rewinded motor can be avoided by proper planning such as - a) Using only for less running hours drive. b) Keeping as emergency reserve for temporary use. c) Discarding as and when operating cost of rewinded motor becomes equal to the cost of new motor. 4) Unidirectional motor cooling fan Normally bi directional fan is used for cooling motor. The efficiency of this type of fan is very poor (30%) and therefore needs more fins area for delivering required quantity of air. The air resistance encountered by more fins area virtually increases the windage loss in motor.

Bi-directional Fan

Unidirectional Fan

Alternatively, efficiency of unidirectional fan is very high (80%). It needs minimum fins area for delivering same quantity of air and reduces the windage loss in motor. Energy saving potential of unidirectional fan can be calculated as shown in the table Bi-directional Fan Motor capacity Speed Rated efficiency of the motor Rated loss Rated windage loss (8%) Efficiency of the fan Power consumption by fan Power saving Energy saving / day Energy saving / year Cost of energy / year 160KW 1485 rpm 95.3 % 7.89 KW 6.31 KW 30% 4.41 KW ****** ****** ****** ****** Unidirectional Fan 160 KW 1485 rpm 95.3 % 7.89 KW 6.31 KW 80% 1.26 KW 3.14 KW 75.36 Units 22608 Units Rs 56520 /-

Therefore by knowing the Direction Of Rotation of machine, unidirectional cooling fan may be preferred for saving unwanted windage loss in motor. 4) Higher size cable Since the DC resistance in cable decreases with the increases of size, energy loss in higher size cable is always found less. Therefore, by providing higher size cable some amount of energy can be saved as shown in the table Standard size Motor capacity Full load current of Operating current of motor Cable size Length of the cable DC resistance in cable I2R loss Energy saving Energy saving / day Energy saving / year (300 days) Cost saving / year Cost of the cable Difference in cost Pay back period 15KW 28 Amps 22 Amps 3C AL 10 mm 0.3Km 0.92 Ohms 445.3 W ******* ******* ******** ********* Rs 12000/********** **********
2

Higher size 15KW 28 Amps 22 Amps 3C Al 16mm 0.3Km 0.57 Ohms 275.8 W 0.17 KW 4.08 Units 1224 Units Rs 3060/Rs 15000/Rs 3000/0.98 years
2

Highest size 15KW 28 Amps 22 Amps 3C Al 25mm2 0.3Km 0.36 Ohms 174.2 W 0.27 KW 6.48 Units 1944 Units Rs 4860/Rs 18000/Rs 6000/1.2 years

8) Proper bearing selectionIn small motor mainly shield or sealed bearings are used. Improper selection of theses bearings may result in increase of bearing friction and causes energy loss. Shielded bearing for high speed motor (2 and 4 pole) and sealed bearing for low speed motor may be preferred to avoid such energy loss. 9) High grade lubricantsFriction in bearing mainly depends on viscosity of the lubricants. There is some high-grade grease available in market, which offers less friction. The application of such grease in a 2 pole 45 KW motor is found to have saved 200-watt of power.

OPERATION
1) Power qualityRated Voltage - It should be maintained within +/- 5% of operating voltage. Voltage above 5% increases core loss by 2%. Similarly voltage below 5% increases copper loss by 10%. Voltage imbalance - It should be within a tolerance of 1%. Voltage imbalance of 3.5% increases motor temperature rise by 14%, which interns increases the motor loss. High Power Factor - Motor operating PF should always be maintained as high as possible to avoid distribution loss. Rated frequency - Motor should be operated as close as to the rated frequency (50Hz.). Higher frequency of 1% increases the pump input by 3%. Low harmonic content - Harmonic content increases the core loss in motor. Therefore it should be maintained as low as possible. 2) Over current Mechanical overload, high friction in bearings / gearbox or high core loss are some primary reasons that may increase the motor operating current more than normal. Such over current proportionally increases the copper loss in motor. 3) Hot running Motor temperature may increase due to over current, improper cooling or high ambient temperature. High temperature always increases the motor winding resistance in cyclic manner and increases copper loss.

MAINTENANCE
1) Periodical maintenance Blocked ventilation, high friction in bearing due to defect or low grease, looseness in bearing retainer, end shields etc are some flaws motor generally develop in course of long service and causes increase in energy loss. Such losses can be avoided by periodical greasing, cleaning and overhauling of motor.

2) Condition monitoring Any abnormality like high current, hot running, vibration, sound or noise always involves with energy loss and therefore condition monitoring can be initiated for detecting and analyzing such abnormalities at initial stage for avoiding energy loss as well as unforeseen break down. 3) Quality overhauling and erection Poor overhauling and erection (alignment) also causes energy loss due to friction. It can be detected by seeing no load current, noise and vibration level. Therefore after each overhauling and erection those parameters need to be corrected for avoiding any energy loss.

CONCLUSIONS
Energy waste in motor is always found lower than total waste in system. Therefore, for effective energy conservation - energy waste in other components of system like gearbox & coupling, pump& pipeline etc. are also to be considered along with motor. Such thing can be achieved only through teamwork and industry determined to conserve energy must follow the road map decided by the team. Convention 1) One year = 300 days (82% PLF). 2) Energy cost =Rs 2.50 per unit ******************************************************************************************************** ADDRESS Office M.G.MORSHAD/ Deputy Chief Engineer (Electrical Maintenance) Thermal Station II / Neyveli Lignite Corporation Ltd. Neyveli / Tamil Nadu / Pin - 60780 Residence - M.G.MORSHAD Qr No 139/D Type II Block 7 NLC township Neyveli / Tamil Nadu / Pin - 60780 Ph No - 04142- 269753 E-mail - morshad@sancharnet.in