ˆ Checking periodically for proper alignment of the motor and the driven equipment.

Improper alignment can cause shafts and bearings to wear quickly, resulting in damage
to both the motor and the driven equipment.

ˆ Ensuring that supply wiring and terminal box are properly sized and installed. Inspect
regularly the connections at the motor and starter to be sure that they are clean and
tight.

f)- Age

Most motor cores in India are manufactured from silicon steel or de-carbonized cold-rolled
steel, the electrical properties of which do not change measurably with age. However, poor
maintenance (inadequate lubrication of bearings, insufficient cleaning of air cooling passages,
etc.) can cause a deterioration in motor efficiency over time. Ambient conditions can also
have a detrimental effect on motor performance. For example, excessively high temperatures,
high dust loading, corrosive atmosphere, and humidity can impair insulation properties;
mechanical stresses due to load cycling can lead to misalignment. However, with adequate
care, motor performance can be maintained.

10Nov 2023

g)- Rewinding Effects

Figure 2: Can You Repair a Burned-Out Electric Motor? YES motors can be repaired by rewinding

9
 The electric motor rewind process involves replacing old windings with new ones to restore
the motor’s optimal efficiency. Technicians ensure the insulation can handle temperatures
up to 200 degrees Celsius. Also use best quality insulation materials to guarantee optimal
performance.

It is common practice in industry to rewind burnt-out motors. The population of rewound

motors in some industries exceed 50% of the total population. Careful rewinding can some-
times maintain motor efficiency at previous levels, but in most cases, losses in efficiency
result. Rewinding can affect a number of factors that contribute to deteriorated motor effi-
ciency : winding and slot design, winding material, insulation performance, and operating
temperature. For example, a common problem occurs when heat is applied to strip old wind-
ings : the insulation between laminations can be damaged, thereby increasing eddy current
losses. A change in the air gap may affect power factor and output torque.

7. Energy Efficient Transformers

Most energy loss in dry-type transformers occurs through heat or vibration from the core. The
new high-efficiency transformers minimise these losses. The conventional transformer is made up
of a silicon alloyed iron (grain oriented) core. The iron loss of any transformer depends on the
type of core used in the transformer. However the latest technology is to use amorphous material
– a metallic glass alloy for the core (see Figure 10.9). The expected reduction in energy loss over
conventional (Si Fe core) transformers is roughly around 70%, which is quite significant. By using
an amorphous core– with unique physical and magnetic properties- these new type of transformers
have increased efficiencies even at low loads - 98.5% efficiency at 35% load.
Electrical distribution transformers made with amorphous metal cores provide excellent op-
portunity to conserve energy right from the installation. Though these transformers are a little
costlier than conventional iron core transformers, the overall benefit towards energy savings will
compensate for the higher initial investment. At present amorphous metal core transformers are
available up to 1600 kVA.

8. Energy Efficient Lighting Controls

a)- Occupancy Sensors

10
 Occupancy-linked control can be achieved using infra-red, acoustic, ultrasonic or microwave
sensors, which detect either movement or noise in room spaces. These sensors switch lighting
on when occupancy is detected, and off again after a set time period, when no occupancy
movement detected. They are designed to override manual switches and to prevent a situation
where lighting is left on in unoccupied spaces. With this type of system it is important to
incorporate a built-in time delay, since occupants often remain still or quiet for short periods
and do not appreciate being plunged into darkness if not constantly moving around.

b)- Timed Based Control

Timed-turnoff switches are the least expensive type of automatic lighting control. In some
cases, their low cost and ease of installation makes it desirable to use them where more
efficient controls would be too expensive.

c)- Daylight Linked Control

Photoelectric cells can be used either simply to switch lighting on and off, or for dimming.
They may be mounted either externally or internally. It is however important to incorporate
time delays into the control system to avoid repeated rapid switching caused, for example, by
fast moving clouds. By using an internally mounted photoelectric dimming control system,
it is possible to ensure that the sum of daylight and electric lighting always reaches the
design level by sensing the total light in the controlled area and adjusting the output of the
electric lighting accordingly. If daylight alone is able to meet the design requirements, then
the electric lighting can be turned off. The energy saving potential of dimming control is
greater than a simple photoelectric switching system. Dimming control is also more likely to
be acceptable to room occupants.

d)- Localized Switching

Localized switching should be used in applications which contain large spaces. Local switches
give individual occupants control over their visual environment and also facilitate energy
savings. By using localized switching it is possible to turn off artificial lighting in specific
areas, while still operating it in other areas where it is required, a situation which is impossible
if the lighting for an entire space is controlled from a single switch.

11
9. Should I repair or replace my electric motor?

Repairing an existing motor is clearly much better for the planet than simply discarding it,
however, replacement is sometimes the only option. There are many factors to review when
considering repairing or replacing your electric motor. Some elements include pricing, lead times,
condition of the electric motor, past history, and more. Below are some general guidelines that
should be considered when working with customers to determine if they should repair or replace
their electric motor.

a)- How critical is your electric motor?

Does the failed electric motor result in your production being ground to a halt, or is it on
a machine that you only use occasionally? If your production is down due to this motor
failure, your company is losing money. The criticality of your motor to your production line
impacts how you will decide to repair or replace your electric motor. This will be discussed
further in regards to the cost of repair vs replace, as well as the lead time of the replacement
motor.

Do you have a spare on hand? If you have a spare electric motor on hand for your failed
motor, it is going to alleviate some of your decision making below because you are not pressed
for time. If you do not have a spare, it is important to know how to decide repair or replace
when thinking about cost and lead time. It is strongly recommend having a spare on hand
for critical machines. However, it is understand that sometimes it is not financially feasible
for some companies to have a spare for their equipment.

b)- Electric Motor Repair or Replace: Price

Whenever there is an electric motor in our repair shop, investigation on the cost of new for
the customers has to be done. Costomers shoud always be provided with options so that he
can make an informed decision on whether to repair or replace. Generally, when the cost of
repair is 50% to 80% the cost of new, replacement is recommended. This is a wide guideline,
but there are many factors that go into this decision, such as lead time, energy savings, like
for like replacement and etc.

Please keep in mind that one should make sure that the motor replacement option is suitable
for your application. Occasionally we witness cost saving methods in the form of finding
a cheap replacement from a less reliable manufacturer versus a higher cost – high quality

12
 manufacturer. If you choose to go this route, understand that the lifetime and reliability of
your motor may be negatively affected and that it can result in higher maintenance costs
down the line.

Another factor that can impact the price in this decision is the condition of the motor. If
the failed motor requires a simple overhaul, the cost of repair might beat the guideline of
50 to 80% cost of new. However, if a motor requires a complete overhaul (think rewinding,
machining work, and etc.) the cost of repair very well may exceed the cost of new.

Does size matter? Once a standard motor is below a certain size, it is more economical to
replace than to repair. Generally speaking, any standard AC induction T frame motors at
or below 50 to 75 are more economical to replace. Our experienced motor experts will help
you with this determination.

c)- Electric Motor Repair or Replace: Lead Time

Finding out the lead time of a replacement motor or repairing your motor is important in
your decision making. If there is a replacement motor readily available and its cost is not
excessively high compared to repair cost, it’s an easy decision to replace. On the other hand,
if the lead time for new is longer than the lead time for a repair, you need to take a step
back to evaluate. Here’s an example situation:

i- Cost of downtime per hour= $1,000/Hour

ii- Standard Hours per week= 40/Week

iii- Cost of New= $10,000, 4 weeks lead time

iv- Cost of Repair= $20,000, 1 week lead time

v- Cost of new, including lost production would equal: $10,000+($1,000*(40*4))=$170,000

vi- Cost of repair, including lost production would equal: $20,000+($1,000*(40*1))=$60,000

d)- Electric Motor Repair or Replace: Other Factors

While Price and Lead time are the leading factors, some other conditions to think about
include energy savings, specifications of a replacement motor, past repair history, and how
often this motor has failed in the past.

ˆ Energy Savings

13
 Motor manufacturers strive to improve energy efficiencies on their product.
Age can often be a contributing factor towards the severity of any damage, should you
experience it. If your motor does seem to be showing signs it might be failing, it should
be determine if repair or replacement solution is the best for you.
If your failed motor is really old, the new motor very well may have better energy
efficiencies than your old one. Replacing your motor in this case may lead to energy
savings.

ˆ Criticality of the motor

If an underperforming electric motor puts your operation at risk of imminent service
or production interruption, electric motor replacement might be the most appropriate
option and could save you time and money in the long run by minimising production
line downtime.

ˆ Size of the motor

The size of a motor can influence the cost of a potential replacement but we will always
try and offer an electric motor repair solution first. As a rule of thumb, if the cost of
repair is less than the cost of replacement, then we would always go ahead with electric
motor repair.

ˆ Extent of the damage

If the extent of the damage to your motor is not too significant, then we would always
advise going for electric motor repair. It is a much more cost-effective and environmen-
tally friendly solution, especially if only certain parts of the motor need repairing. We
can also give advice about what might have caused the damage in the first place and
help you provide a preventative solution that will ensure many more years of trouble-free
operation.

ˆ Replacement Motor Specifications

While the replacement motor’s nameplate specifications may be the same as your old
motor, the size of the actual motor itself may be different (smaller). The smaller size
of the new motor may make it difficult for your team to install it in the original appli-
cation. Double check the dimensions of the motor and its frame with your Dreisilker
representative.

e)- In Conclusion

14
 There are many factors that go into deciding whether to repair or replace your electric
motor. Our experience motor experts help many customers every day to make this important
decision. We’ll help you figure our pricing and lead time, as well as consider any other factors
that may impact your decision. Call us today if you have questions about electric motor repair
or replace.

f)- Case study 1 (as Assignment/CA1 to be submitted /presented in 2 weeks

Read the following Paper by M. Hasanuzzaman, N. A. Rahim and R. Saidur on

Analysis of Energy Savings for Rewinding and Replacement of Industrial Motor and try to
get the main results.

g)- Case study 2: Power Factor Correction Solutions for Electric Motors (as Assign-
ment/CA1 to be submitted /presented in 2 weeks The he following Paper by John
Ware on

POWER FACTOR CORRECTION (pfc) could help.The emphasis should be on the correc-
tion of linear and nonlinear loads as well as the effect of the harmonics.

h)- Some Calculations

Case1 Determine the energy and cost savings by replacing a 10 kW motor that has current
efficiency of 70% by a new premium motor that has efficiency of 92%. The yearly
operational hours are 6000.

Case2 The audit team measured the current, voltage, power factor, and rotational speed of 20
kW motor as 28 A, 400 V, 0.85, and 1475 rpm respectively. The rated speed is 1450
rpm Determine the motor efficiency! Also, determine the energy, cost savings, and pay
back period if this motor is replaced by a new one that costs 1000 $ and has efficiency
of 90% (assume it operates for 6000 hrs per year, and the tariff is $ 0.09/kWh).

10. Summary: steps of Energy Audit of Electric Motors

The rational sequence in every action of energy audit of a system consists in the following
steps:

ˆ Clear identification, description and modelling of the system under assessment

ˆ Identification of basic operational parameters and measurement

15
 ˆ Comparison of performance data with those of Best Available Technologies and/or
Reference Performance Values

ˆ Identification of specific Energy Efficiency Measures applicable for upgrading the system

ˆ Cost-effectiveness assessment of Energy Efficiency Measures set identified

ˆ Final Reporting to decision makers

This basic scheme must be tailored on the specific needs of the client. The Energy Audit
theory foresees various schemes, depending on various targets that the client agrees with the
auditor

16