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Day by day gap between demand and supply of electric energy is widening. Bridging this gap from supply side is very difficult and expensive proportion. The only viable way in handling these crises, in addition to capacity addition, is the efficient use of available energy sources. Electric motors are industrys basic need. Industries consume about 50% of the power generated in the country and electric motors consume around 76% of the total electricity used in the industrial sector. Majority of the motive loads use squirrel cage induction motor as driving element. Most of the motors use in industry is oversized. Even when proper sized motors used, they are not fully loaded to their capacities. This result into poor efficiency which leads to more power consumption and energy cost .Therefore improvement of efficiency of the motor must be a part of any comprehensive energy conservation effort. This conservation is possible by using energy efficient motors in place of standard motors. As motors are the largest users of the electrical energy, even small efficiency improvements can produce very large saving across the country. Energy conservation measures taken by individual consumers in this direction will improve the national economy and benefit the environment on global scale.
Features of EEM:
Highest efficiency. Lower operating cost. Has high overloading cost. Suitable for operations at higher ambient temperature. Fewer power factor correction. Saving increases with time. Confirmation with NEMA standards of protection and control. Cooler and Quieter operation. Longer insulation life : EEMs winding run about 20C cooler which increases insulation life by 4 times. Improved bearing life: EEM bearing run about 10C cooler than standard motor bearing, which doubles the life. Less Starting thermal stress. Higher service factor. Better suited for energy management systems. EEM perform better under adverse conditions of abnormal voltage conditions like unbalanced voltages. Efficiency of EEM remains almost constant from 50% to 100% of load.
Efficiency is a measure of the effectiveness with which a motor converts electrical energy into mechanical energy, which is measured by watts input versus watts output. In the conversion process, watts are lost by transformation into heat, which is dissipated through the frame. To improve efficiency, watt losses must be reduced through optimized design, improved material selection and quality control Watts Loss Area: Iron. Stator. Rotor. Friction and Windage Losses. Stray Load Loss.
Efficiency Improvement
Use of thinner gauge, lower loss core steel reduces eddy current losses. Longer core adds more steel to the design, which reduces losses due to lower operating flux densities. Use of more copper & larger conductors increases cross sectional area of stator windings. This lower resistance (R) of the windings & reduces losses due to current flow (I) Use of larger rotor conductor bars increases size of cross section, lowering conductor resistance (R) & losses due to current flow (I) Use of low loss fan design reduces losses due to air movement Use of optimized design & strict quality control procedures minimizes stray load losses
3 Rotor I2R
Simply Stated: REDUCED LOSSES = IMPROVED EFFICIENCY 1. Iron Improved steel properties : Standard motors use low carbon laminated silicon steel for the rotor and stator. Such steel typically has electrical losses at 606 watts/kg. High efficiency motors are build with high grade silicon steel which typically reduces hysterisis and eddy current losses by half to only about 3.3 watts/kg. Thinner Laminations: Reducing lamination thickness in rotor and stator steel also lowers eddy current losses. Improved insulation between laminations, when applied with enhanced quality control further reduces these losses. The use of thinner lamination result into decrease in core loss from 10% to 25% depending on method of processing the lamination steel and the method of assembling the magnetic core. Longer core adds more steel to the design, which reduces the losses due to lower operating flux densities.
2.Stator and rotor IR. Increase conductor volume: Older standard motors employ aluminium or copper conductors of size no larger than that needed to deliver the required horsepower. High efficiency motors utilize bigger copper conductor to lower the winding resistance with the conductor sized 35% to 45% larger than needed to simply satisfy the motor output horsepower requirement. Modified slot design : To accommodate the larger volume of copper in the windings required additional slot insulation, the slot cross section area is increased.
Friction and Windage More Efficient fan design: Use of low loss fan design reduces due to air movement. Use of better quality bearing and lubricating material reduces friction losses. In EEM the heat producing losses are low hence it is possible to reduce ventilating requirements which in turn will reduce windage losses resulting into further improvement of the efficiency. EEM design incorporates a small cooling fan resulting into quieter operation
Stray Losses Use of optimized design and strict quality control procedures minimizes the stray losses. Proper proportioning of rotor and stator slots. Having Small slot opening. Using optimum air gap.
Air Gap Narrowing air gap: Air gap are optimized to reduce magnetizing current and associated losses resulting into improvement of power factor.
Consequences of under-loading
Increased motor losses Reduced motor efficiency Reduced power factor
Slightly lower than highest load: occasional overloading for short periods
But avoid risk of overheating due to
Extreme load changes Frequent / long periods of overloading Inability of motor to cool down
Voltage (%)
unbalance
0.30
0.4
2.30
17.7
5.40
40.0
Temperature
30
40
Buy new motor if costs are less than 50-65% of rewinding costs
9.1 Motor Size Motors should be sized to operate with a load factor between 65% and 100%. The common practice of oversizing results in less efficient motor operation. For rare peak loads, use a pony motor. 9.2 Operating Speed While the average speed of energy-efficient motors is slightly higher than the average speed of standard-efficiency motors for any given size, models of each type are available with a wide range of speeds. Installing a new motor with a higher speed can result in diminished energy savings. It is particularly important in centrifugal pump or fan applications to select replacement motors with a comparable full-load speed. 9.3 Inrush Current Avoid overloading circuits. Energy-efficient motors feature low electrical resistance and thus exhibit higher inrush currents than standard models. The inrush current duration is too short to trip thermal protection devices, but energy-efficient motors equipped with magnetic circuit protectors can sometimes experience nuisance trips during start-up.
Expected Savings
In many applications the load factor of the motor will range between 60% to 80%. The efficiency curve of standard motor is drooping in nature i.e there is a sharp fall in efficiency at partial loads. But the energy efficient motors have a flat efficiency curve and hence the fall in efficiency is marginal. Thus energy saving is significant even in part loads. Assessing cost effectiveness of energy efficient motors: Savings: Savings are calculated as follows : kW - out put of motor in kW E1 - efficiency of standard motor E2 - efficiency of energy efficient motor kW kW X= E1 E2 Savings = X (Working Hour's) (Working Days) (Tariff)
Higher efficiencies at operating level and consequently, reduction in electricity bill. Can take care of wider Supply variation and higher ambient. Suitable for service factor loads. Lower slip which enhances output of the end product.
Energy efficient motors are specially suited for industries which are power intensive and equipments which run on constant load for long duration.
Application:
Conclusion
As shows, the efficiency of three-phase induction motors can be improved through optimization of materials and operational parameters. If these improvements are realized, practically any motor that is operated more than just occasionally will, over the lifetime of the motor, yield savings equivalent to the purchase of several new motors. More detailed analyses are available from DKI13 and from the major motor manufacturers who also offer programs for selecting the best motors and drives for specific applications. Classifying motors into energy efficiency bands simplifies product selection and dispenses with the need for statutory control. The new labeling scheme is a major step forward as up until recently motor rating plates did not contain any information on power losses and efficiency. It would have been more expedient, however, to assign the label EFF1 to the lowest rather than the highest efficiency category, as this would have meant the EFF series could be readily extended up ward as future efficiency improvements are introduced. Recent developments in the USA have seen the production of motors whose losses are now lower than those stipulated in statutory regulations. As a result, these new high-efficiency motors have received the rather ungainly moniker NEMA Premium and only time will tell what awkward lexical construction will be created to describe the next phase of motor efficiency improvements. And with motors be coming ever more efficient, there is clearly going to be little need to extend the existing classification system in the other direction beyond EFF3.
Reference:
Energy Efficient Motor System By Steven Nadel A Textbook of Electrical Technology By B.L Theraja www.google.com www.ieee.org.in www.HEM.com
Along with saving money, energy efficient appliances and motors save the plant The energy used to run a product can be cut up to 80% There is a large potential to make a difference because all appliances energy usage can be cut Fridges, washers, dryers, cars Light bulbs, anything that plugs Into an outlet.
MAKING A DIFFERENCE
The purpose of energy efficient appliances and motors is to be able to supply the same level of energy service only using less energy. Efficient energy use is achieved primarily by means of a more efficient technology or process rather than by changes in individual behavior.