Energy Efficiency Aspects

of Electric Motors
Load Efficiency
Three-phase squirrel-cage induction motors comprise a considerable
percentage of the electrical load in the United States. Design, operation, and
maintenance of these machines is well described in some of the articles
already published. This article focuses on their energy efficiency aspects.

Energy Efficiency Aspects of Motors (photo credit: stiavelli.com)

Induction motors typically range in full load efficiency from about 87% to
94%. This efficiency is very difficult to measure accurately in the field,
requiring a dynamometer and other specialized equipment. Fortunately,
energy saving projects associated with electric motors do not require actual
efficiency of a given motor to be established.

One of the foremost opportunities for energy savings is to implement a

program of replacing – rather than rewinding – induction motors at failure.
Rewinding a damaged induction motor is a common practice in industry, but
studies have proven that rewinding an induction motor drops its efficiency by
a couple percentage points. Multiple rewinds can further reduce the
efficiency of the rewound motor.

While a drop in efficiency from 89% to 88% seems insignificant, a quick

estimate reveals that this reduction can be costly. A standard efficiency 20
hp motor operating 8000 hours annually, for example, costs about $7000
per year to operate at an average electricity rate of 7 ¢/kWh. Once this
motor fails, the least-cost option for returning it to service is typically
rewinding.

The incremental cost of replacing this failed motor with an  energy-efficient
motor, however, is only $430. This amount assumes considers the
rewound cost, and  the labor necessary to perform the motor change-
out,  as sunk costs.

The annual energy savings associated with replacing the failed motor with an
energy-efficient model, at a new efficiency of 92.9%, is approximately $510.
The simple payback for the replacement, therefore, is less than one year.

Figure 1 – Electric motors are efficient

machines, even at partial load

Figure 2 – But power factor drops off

sharply at half load
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Energy-efficient motor programs are applicable to any AC motor installations

utilizing NEMA Design B induction motors. Since the programs are based on
replacement at failure, the full savings potential is realized after three years
or more.
Published efficiencies of typical rewound, standard, and energy-
efficient three-phase induction motors.

HP Rewound Efficiency Standard Efficiency Energy Efficient Efficiency

1 69.7% 70.7% 82.6%
2 79.5% 80.5% 83.4%
3 79.4% 80.4% 86.6%
5 81.4% 82.4% 88.3%
8 83.1% 84.1% 90.0%
10 85.1% 86.1% 91.1%
15 85.5% 86.5% 92.0%
20 87.3% 88.3% 92.9%
25 88.0% 89.0% 93.5%
30 88.1% 89.1% 93.7%
40 88.7% 89.7% 94.2%
50 90.0% 91.0% 94.4%
60 89.9% 90.9% 94.7%
75 90.4% 91.4% 94.9%
100 90.4% 91.4% 95.4%
125 90.6% 91.6% 95.3%
150 91.5% 92.5% 95.7%

Motor Rewinding Process (VIDEO)

What is the rewind scenario if a motor fails? Read more about rewind
“rules of thumb” .
Cant see this video? Click  here to watch it on Youtube.
Reference:  Electrical Energy Management – Bill Brown, P.E., Square D
Engineering Services