Enhance Energy Efficiency through

IE3 motors adoption

• Ace Enablers LLP, Chennai

• Demand Aggregator and Empaneled Energy Auditing

Agency under EESL’s NMRP
Global Electricity consumption by end use

Source: IEA 2016

World Energy
Outlook
 • IS 325 - Implemented in 1978…….. Now revised as IS/IEC:60034-1

• B) IS 4889 - Performance & efficiency… Now revised IS:15999-2-1/2011

Indian • C) IS 12615: 2004 - Eff2: Improved Efficiency & Eff1: High Efficiency levels

Standards - • D) IS 12615: 2011 - IE1 as standard efficiency- Not adopted (only for reference)
• IE2 as High efficiency

Overview • IE3 as Premium efficiency

• E) IS 12615: 2018 - IE1, IE3, IE3, IE4 (Super Premium Efficiency) Latest
• covering 2, 4, 6 & 8 pole from 0.12 to 1000 kW

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Towards a Worldwide Common Efficiency Standard

In 2008, IEC came up with a new standard - the IEC 60034-30

• to eliminate differences in efficiency standards the world over
• to enable user to compare motor efficiency with a common reference

IE4 Nema Premium Plus

• Worldover except North
America
• Metric dimensions are NEMA Premium (IE3)
used
IE3 EISA 2007
from 12/2010
NEMA Energy Efficient
EFF1 IE2 EPAct (IE2)
up to 12/2010

EFF2 IE1 • North America with the

core regions US,
Canada and Mexico
IEC 60034-30 • Dimensions in inches
IEC World Applicable the World over! NEMA World
IS: 12615/2011
 Various losses in Motors- Typical
Stator I²R Core (Wc) Losses Friction and
(Ws) Losses Windage
(Wfw) losses

2 pole 4 pole
Losses
average average
Losses in in Stator - WCuS 26% 34%
Electrical I²R losses
Components in Rotor - WCuR 19% 21%

Losses in Hysteresis Loss

Core losses
Magnetic 19% 21%
(WFe) Eddy Current
Components
Loss
Frictional
Losses in
Mechanical Losses WFr
Mechanical 25% 10%
Losses Windage Losses
Components
- WWind
Losses due to
asymmetrcal Stray load
11% 14%
and leakage losses (Wl)
Rotor I²R Stray Load (Wl) fluxes
(Wr) Losses losses
 Efficiency comparison with Stray loss

• Example:
250 kW, 4-pole, 50 Hz
IE2 Other losses…
Former determination New determination

Stray load losses, Stray load losses,

lump sum 0,5%
of input power individually measured
Efficiency  [%]

96,0%
The efficiency
95,5%
values decline, but
the motor stays the
same
physically!

IS:12615/2004 IS: 12615/2011

Efficiency comparison as per IS:15999-2-1/2011

IS: 12615/2004 Stray loss assumed as 0.5% of output IS: 12615/2011 Stray loss actually measured

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Desktop Audit for apple-to-Apple comparison

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Desktop Audit - proposal
Global Standard for
induction motors

• IEC: 60034-30/2008 – IE1, IE2 & IE3

• MEPS- IE2
• IEC:60034-30-1/2014- IE2, IE3 & IE4
• MEPS- IE3

• India
• IS:12615/2011- IE2 & IE3
• No MEPS
• IS:12615/2018- IE2, IE3 & IE4
• MEPS- IE2
Quality control order- Induction motors- IE2
with ISI marking mandatory from 01.01.2018
 Induction Motors Replacement

• The Quality control order has ensured that IE2 is the ‘minimum efficiency performance standard’
(MEPS) in India through manufacturers, importers and distributors.
• Motivating industries to replace old less than IE1-Eff2 motors will support the ‘NMEEE’- National
mission for energy efficiency enhancement program by BEE.
• Being a voluntary initiative, industries need to be guided and supported to undertake the old and
inefficient motor replacement program.
• What if IE3 becomes the minimum efficiency in 5 years time? Industries must be encouraged to
adopt IE3 now itself, if any voluntary replacement program is undertaken.
• EESL has brought ‘National motor Replacement program’ to retrofit old motors with IE3 on the
national level.
Induction Motors in India
Motor Market scenario – (2015-16)
Product of Interest- 93% are
LT, Sq. Cage Motors

Low Tension
(LT) Motors

13.46 Lakhs units

AC Motors

IHP Motors 14.40 Lakhs units Low Tension

Slip ring Motors

14.44 Lakhs units 6,000 units

Motor Industry (25%) DC Motors

Flame proof Motors

57.49 Lakhs units 4000 units
(100%) FHP Motors 84000 Units

HT Motors
43.05 Lakhs units
(75%)
4000 units

Source IEEMA 2015-16

Data does not include FHP, LV Slip ring, Flame proof, MV, MV Slip ring and DC Motors
Source: EUP Lot 11 Motors, Report No. 3, Analysis of existing technical and market information, ISR-
University of Coimbra, Aníbal T. de Almeida et al, April 2007
Small & Medium size motors up to 30 kW can be replaced for name
plate efficiencies and simple payback

❖Nearly 95% of the LT motors are below 30 kW, as per IEEMA statistics.
❖Only 5% of the motors fall under 37 kW and above and also include HT motors.
❖Engineered selection is critical for these 5% of the population to ensure long service life and optimum utilization.
❖These 5% of the population contribute nearly 40% of the total energy use through motor system.
How to address the potential?

Motors management can be approached under three categories. Motors,

Motor systems and the end use applications.

Matching the speeds of the old and new motors is critical to match the flow,
pressure and power of the driven load such as the Fan, Pumps & compressors.
 How to prepare a site for replacement?

▪ Inventory preparation- Prepare a comprehensive list of all the plant motors and group
them in to small, medium and large category. The list must contain the make, year of
manufacture and the plant location too.
▪ Initial load survey- Electrical data must be measured to fix the load factor, hours of
operation and payback estimate
▪ Key motor identification- Based on the age, load factor and the history of rewind/repair,
key motors can be identified and prioritized for replacement program.
▪ DESKTOP audit for motors up to 30 kW to compare old motors with new IE3 on apple-to-
apple basis and invest on the basis of payback
▪ System analytical approach for motors over 30 kW to include other system components
and VFD, if warranted.
Banswara Syntex Ltd., Rajasthan- Case study
Motors in B/R, Simplex, H. Plant, Ring frames, Doubling etc
Case study- Humidification plant
Case study- Humidification plant
Compressor Motors
Annual Energy saving

1.21 x 24 x 350 x Rs.5 = 50870/- per annum

EESL- M&M case study…….. Eff2 vs IE3
 CONTACT: EMAIL:
ace@aceenablers.com
J. SRINIVASAN

Thank you

MOBILE- +91 SRINIVASAN JEYARAM

9962056206 JEYARAM SRINIVASAN

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