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CIGRE 2014

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A Novel Technique for Refurbished Induction Motors Efficiency Estimation Based on

No-Load Tests
Maher Al-Badri
Pragasen Pillay
Concordia University
Canada

SUMMARY
Induction motors are the most widely used in the industry. They use two-thirds of the total energy
utilized by industry in the industrialized countries [1], and hence, contribute to the global
environmental problem which is represented by the emission of greenhouse gases [2]. Several
Canadian and U.S. utilities took serious steps in implementing demand side management programs [3]
to reduce both greenhouse gas effects and the cost of power that feeds this tremendous population of
electric motors.
The precise estimation of efficiency of refurbished motors or any existing motor is crucial in industries
for energy savings, auditing and management. Full-load and partial load efficiency can be determined
by using the dynamometer procedure which is expensive and available only in well-equipped
laboratories. An inexpensive and easily applied procedure for efficiency estimation is of importance in
the field. This research presents a proposed method for estimating refurbished induction motors fullload efficiency that could be applied successfully in electric motor service centers. The method
requires only a DC test (including stator winding cold temperature), nameplate details, and RMS
readings of no-load input power, voltage, and current.
This research aims to develop an algorithm for induction motors efficiency estimation that can be
applied easily in any electric motor service center. To do so, the research team decided to make
technical visits to a few of those centers in North America to determine the facilities available in such
workshops and to design an algorithm that matches those workshops technical environment.
The proposed efficiency estimation algorithm starts with the DC test to obtain the cold DC resistance
of the stator winding. The temperature of the cold stator winding should be measured and recorded as
well. The stator winding DC resistance and the corresponding temperature are essential values to be
used in the algorithm.
The next stage will be reading and recording the nameplate data.
Then, the machine should be run with no load coupled to the shaft and the following RMS values of
the input voltage, input current, and input power should be read and recorded.
The above mentioned values will be fed to a user-friendly software based on a spreadsheet which is
designed to handle the necessary calculations and provide values for the estimated efficiency with
illustrative graphs. Visual Basic programming was used in designing the software.
An important assumption was implemented within the calculation. The assumption is that mechanical
rotational losses which are assumed to have the same value during both no-load and the full-load
conditions [4]. The assumption is made because there is no way to separate core losses with friction
and windage losses as the proposed technique works with only one no-load operating voltage.

ma_albad@encs.concordia.ca

Stray load loss and full-load temperature are assumed based on IEEE Std. 112-2004 [5] and IEC
60034-2-1 [6] formulas. Seven induction motors of different power ratings (3-150 hp) were tested for
efficiency estimation using the proposed technique. By comparing the estimated efficiencies with the
measured values of the seven motors a maximum deviation of 1.679% and minimum deviation of
0.361% were noticed. The problem of having 1.679% deviation from the measured value was
investigated and it was found that the two assumed values of stray load loss and full-load temperature
have a large impact on the accuracy of the technique.
The measured values of the stray load loss and full-load temperature were used instead of the assumed
ones and a big difference in the estimated efficiencies accuracy occurred. By using the measured
values, the maximum deviation became 0.49% and the minimum deviation was 0.09% for the seven
motors under test.
Hydro-Qubec which is one of the largest power companies in North America offered to contribute to
the research by providing an extremely valuable database of a large number of induction machines
with power rating range 1-500 hp [7]. Another set of data is received from the Canadian BC Hydro
[8]. The data has been implemented in the software. Experimental and field tests of 192 induction
motors showed very promising results.
The software is under assessment by several power companies in Canada.

KEYWORDS
Induction-Motor, greenhouse-gases, Method A, DC-Test, Nameplate, Stray-Load-Loss, full-LoadTemperature, No-Load-Test, Mechanical-Rotational-Losses.

1. THE PROPOSED ALGORITHM

The algorithm is designed to work with very limited inputs and only one operating point. The
measurements needed are only three quantities, line-to-line voltage, line current, and total input
power. The RMS values of these quantities are required. Hence, only conventional instrumentations
are needed which are usually used in motor repair workshops.
The efficiency estimation procedure is detailed as follows:
A.

DC Test

,
The stator winding lead-to-lead resistance is measured among the three phases of the motor (i.e.
). The DC resistance of the stator winding should be determined by using a DC resistance test
that complies with section 5.4 of IEEE Std 112-2004 [5] and section 8 of CAN/CSA Std C392-11
[9].
is calculated according to (1)
The average lead-to-lead dc resistance
(1)
During the measurement, the temperature
is measured and recorded. The temperature has to be
measured during the DC resistance test using the recommended instruments in section 4.4 of IEEE Std
112-2004 and section 8 of CAN/CSA Std C392-11.
B.

Nameplate Details

Nameplate details are necessary part of the algorithm. The rated voltage, rated current, rated power,
rated speed, number of poles, efficiency, insulation class, NEMA design, and winding configuration
should all be read and recorded.
C.

Performing the No-Load Test

The motor should be run with no load coupled to the shaft at rated or close to rated voltage, with rated
frequency shown on the nameplate. The input power reading should stabilize, and the RMS values of
input voltage, input current, and input power will be read and recorded.

D.

Stator Resistance Correction for Temperature

The stator resistance

should be corrected to the full-load temperature
according to (2) and
based on insulation class of the machine and Table I (if full-load temperature rise is not available) as
recommended in IEEE Std 112-2004.
(2)
where
is 234.5 for 100% IACS conductivity copper.
Table I. Rated temperature for efficiency calculations [5]
Temperature in C
Total temperature
Class of
insulation system including 25C reference ambient
A
75
B
95
F
115
H
130
E.

Estimation of Stator Copper Loss at room temperature

Stator Copper Loss at room temperature

can be calculated by using (3).

(3)

F.

Mechanical Rotational Losses Estimation

Mechanical rotational losses

can be estimated as in (4).

(4)

G.

Estimation of full-load input power

can be estimated by using nameplate values of full-load output power

Full-load input power
and full-load efficiency
as in (5).
(5)
H.

Estimation of Stray Load Loss

Based on experimental and field tests done on a wide range of machines of different power ratings (1500 hp), it has been found that, for motors of ratings larger than 40 hp, the value of Stray Load Loss
can be better estimated by applying International Standard IEC 60034-2-1 computing
methodology using (6). On the other hand, motors of ratings less than 40 hp, the stray load loss will be
better assumed according to Table II.
(6)
Table II. Assumed Values for Stray Load Loss [5]
Machine Rating Stray Load Loss Percent
(kW)
of Rated Load

I.

1 - 90

1.8%

91 - 375

1.5%

376 - 1850

1.2%

1851
and greater

0.9%

Estimation of full-load Stator Copper Loss

Full load Stator Copper Loss

can be calculated by using (7).

(7)

J.

Estimation of the air gap power

With the very limited test and measurements, an assumption of using the same value of mechanical
obtained in section 0, under no-load test in full-load losses calculations would be
rotational losses
acceptable [4]. Air gap power
can be calculated by using (8).
(8)
K.

Estimation of Synchronous Speed

Synchronous speed

can be estimated based on (9).

(9)

where,
is the rated frequency in Hz.
is the number of poles obtained from the nameplate.
L.

Estimation of Full-Load Slip

Full-Load slip

can be estimated based on (10).

(10)
M.

Estimation of Rotor Copper Losses

Full-load Rotor copper losses

can be estimated by using (11).

(11)

N.

Estimation of mechanical power

Calculated mechanical power

can be estimated by using (12).

(12)
The mechanical power represents the value of the estimated output power at full-load as shown in
(13).
(13)
O.

Estimation of Efficiency

Estimated efficiency

can be obtained by using (14).

(14)

2. EXPERIMENTAL RESULTS AND ANALYSIS

Method A is applied on a group of different induction motors ranged from 3 to 150 hp. The results of
the estimated efficiencies are tabulated in Table III.
The errors shown in Table III reflect a large degree of inaccuracy. Although this inaccuracy can be
compromised by the limited input data that feed the algorithm, such errors make the technique
unaccepted to be relied on when it is used to estimate efficiency in motor service centers.
Table III. Estimated versus measured efficiencies
Motor Size Measured Efficiency Estimated Efficiency
(hp)
(%)
(%)
Error
3
79.61
78.59
1.02
7.5
90.79
89.55
1.24
25
92.80
92.07
0.73
50
92.80
91.68
1.12
60
94.80
94.02
0.78
100
95.50
93.81
1.69
150
93.60
92.76
0.84
A thorough investigation into the source of errors showed that two factors have large impact on the
, and the second factor is
accuracy of the algorithm. The first one is the estimated stray load loss
the assumed full-load temperature
illustrated in Table I.
A.

Stray Load Loss

According to IEEE Std 112-2004, the stray load loss is that portion of the total loss in electrical
machine not accounted for by the sum of the friction and windage loss, the stator copper loss, the rotor
copper loss, and core loss. There are two ways to measure the stray load loss, indirect measurement
and direct measurement. In the indirect measurement, the stray load loss is determined by measuring
the total losses, and subtracting from these losses the sum of the friction and windage, core loss, stator
copper loss, and rotor copper loss. The remaining value is the stray load loss. In the direct
measurement of the stray load loss, the fundamental frequency and the high frequency components of
the stray load loss are determined and the sum of these two components is the total stray load loss. The
other procedure to determine the stray load loss according to IEEE Std 112-2004 is to assume it. If
the stray load loss is not measured, its value at rated load may be assumed to be the value as shown in

Table II. And according to International Standard IEC 60034-2-1, the stray load loss can be estimated
using (6).
A comparison between the estimated
according to both standards and the measured values for
five different induction motors was made. it is found that there is a wide difference between the
assumed values of stray load loss and the measured values is very clear, where the measured values
are much lower than the assumed, especially with the high power rating motors. It was decided that
using the assumed values will significantly affect the values of the estimated efficiency.
B.

Full-Load Temperature

It is also noticed the large difference between the assumed full-load temperature and the measured
values, and by using only the assumed full-load temperature
will contribute largely to the error of
the estimated efficiency.
C.

Using the Measured Stray Load Loss, and the Measured Full-Load Temperature

It can be clearly seen now that having the measured values of both stray load loss and full-load
temperature will dramatically reduce the errors encountered in Table III. Results of estimated
efficiencies of the same seven motors are tabulated in Table IV after integrating the Hydro-Qubec
data within the algorithm.

and
Table IV. Estimated versus measured efficiencies by using measured
Motor Size Measured Efficiency Estimated Efficiency
(hp)
(%)
(%)
Error
3
79.61
80.09
-0.48
7.5
90.79
90.73
0.06
25
92.80
93.30
-0.50
50
92.80
92.93
-0.13
60
94.80
94.74
0.06
100
95.50
95.01
0.49
150
93.60
93.42
0.18
Comparing the errors of Table III and those of Table IV, a very significant improvement occurred
when the measured values of both stray load loss and full-load temperature were integrated within the
algorithm of Method A. Although method A is expected to give less accurate value of full-load
efficiency depending on its limited data, but with the aid of the valuable data of Hydro-Qubec, this
method could give an accepted value of the estimated efficiency, though it can be considered as robust
technique to estimate the full-load efficiency from only no-load operating point with minimal
requirement of instrumentations.

3. METHOD A VALIDATION (192 MOTORS TESTED)

Method A requires the following data to be fed to the software: Line-to-line stator resistance, winding
temperature, nameplate data, or no-load line-to-line voltage (rated voltage, or any voltage level that is
close to the rated voltage in case of having fixed level of voltages out of transformer taps), line
current, and total input power. By having all of those required data, Method A is validated by
providing the estimated efficiencies of 192 induction motors. The following Table V shows the results
of only 10 chosen induction motors out of 192 motors tested using the proposed algorithm.

Table V. TESTING RESULTS OF TEN MOTORS OUT OF 192 INDUCTION MOTORS TESTED WITH METHOD
AS ALGORITHM
Motor Size Measured Efficiency Estimated Efficiency Error
(hp)
(%)
(%)
(%)
No.
1
1
84.43
84.14
0.292
2
7.5
90.79
90.73
0.06
3
10
89.70
89.10
0.598
4
15
88.67
89.28
-0.606
5
20
90.31
91.43
-1.118
6
30
93.89
94.00
-0.111
7
50
92.52
92.52
0.002
8
150
95.24
94.88
0.365
9
200
96.66
95.91
0.752
10
500
96.63
96.56
0.071

4. CONCLUSION
Method A is a simple technique designed to run with very limited data and measurements that usually
available in electric motor service centers in North America. Technical visits were achieved by the
research team to adjust the algorithm to match the technical environments of those motor repair shops.
A software based on spreadsheets and Visual Basic programming is designed to handle the
algorithm and the valuable supporting data received from Hydro-Qubec and BC Hydro which are
integrated in the algorithm. Having these data, has extremely helped improving the performance and
the output of the algorithm and could offset the relatively large errors in the estimated efficiency. A
total of 192 induction motors of size range from 1-to-500 hp were tested using the designed software.
The results of ten tested motors were presented.

ACKNOWLEDGEMENT
The authors acknowledge the support of the Natural Sciences & Engineering Research Council of
Canada and CEATI International Inc. The authors also acknowledge the big support of Hydro-Qubec
and BC Hydro by providing an extremely valuable data that significantly helped improving the
outcome and the feasibility of the research. Valuable feedback from senior engineers of HydroQubec, BC Hydro, SaskPower, and Manitoba Hydro are much acknowledged and appreciated.

BIBLIOGRAPHY

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