SAVING ENERGY USING ENERGY EFFICIENT MOTORS:A CASE STUDY

Khushdeep Singh Salana * Tejinder Singh# Navjeevanjot Singh+ *Guru Nanak Dev Engineering College,Ludhiana, Punjab, India, khushdeep.singh2000@yahoo.co.in
# Guru Nanak Dev Engineering College, Ludhiana, Punjab, India + Guru Nanak Dev Engineering College,Ludhiana, Punjab, India, nav.salana@yahoo.com

KEY

WORDS: Energy efficient motors,

factor, kilowatt, allowable

efficiency, power temperature rise

ABSTRACT: India is among the top growing countries in casting and forging units. These units consume a large portion of electrical energy produced in our country. The work presented in the paper explore the possibility to minimize the wastage of energy in casting and forging units. A careful study of working of Hammers & Instantaneous load analysis of motors has been carried out to compare with different make equal rating motors. The plant under study had 138 motors of various ratings. The already installed motors have poor efficiency and also operate at poor power factor. There were no efficiency standards for polyphase induction motors. So standard motors were designed with efficiencies high enough to achieve the allowable rise in temperature for the ratings. There is a variation in the efficiency for a given h.p rating from around 74% to 94 %. There is an increasing number of manufacturers who have started making energy efficient motors. We have procured data sheets for these motors and then replaced the existing plant motors with energy efficient motors. Then comparison of standard motors with energy efficient motors based on number of parameters viz. voltage, current, power, power factor has been made.. The costing and payback period for use of energy efficient motors has also been calculated. We have taken various motors already installed in the units and taken readings of rating, Voltage, Current, Power and Power Factor. Then replaced these motors with energy efficient motors and again took the above readings. After this the total tariff was calculated and

the payback period was found out. The study reveals that replacing standard motors with energy efficient motors , the total motor load of the plant comes to 804.59kW as compared to 870 kW of the previous arrangement. Besides leading to cost saving, this has also increased the efficiency of the plant.

INTRODUCTION: In the period from 1960s

to mid 70s, the conventional motor design philosophy was based more with the initial cost of the motor rather than the energy it consumes especially the motors in the range of 1-250hp were designed on the basis of their minimum cost. The materials such as steel laminations, copper or aluminum wires were selected at the minimum level required to meet the performance requirements of the motor. Efficiency was maintained in order to fulfill the temperature rise requirement of the motor under consideration. The increase in the cost of electrical energy from the mid 70s made it expensive to use inefficient electric motors. This had stimulated the consumers to search for motors with less consumption and with lower losses. The manufacturers therefore looked forward for different methods to enhance the efficiency of motors. The improvement in efficiencies or in other words loss reduction were achieved by increasing the amount of active materials, use of low loss magnetic steel material. There was no single definition of energy efficient motors. There were no efficiency standards for standard polyphase induction motors. The standard motors were designed with efficiencies high enough to achieve the allowable rise in temperature for the ratings. For example: for a given horse power rating, there is variation in efficiency. With the development of energy efficient motors many manufacturers started manufacturing these

motors. All the published data of various manufacturers was collected which depicted the nominal average efficiency as well as range of efficiencies. This data when compared with the standard motor efficiency data depicted the range in efficiency for a given hp as significantly lower. It shows that energy efficient motor tend to be more uniform as compared to the standard conventional motors.

60HP 4pole Voltage (V) 400 402 407 405 Current (A) 65 66 64 65 Power (kW) 38.72 39.5 38.34 30.16 P. F.

0.86 0.86 0.85 0.82

CASE STUDY:
In the present case study, we collected data for 138 nos. existing motors. The data included energy consumption by existing motors for one month. Total power and money saving by replacing the in efficient motors with efficient motors has been calculated. Analysis of some motors is presented below: 30HP 4pole Voltage (V) 400 398 410 404 Current (A) 43 45 44 43 Power (kW) 23.84 24.19 25.30 24.70 P. F.

Average Load 39.20kW 25 HP 4 Pole Voltage (V) 405 405 405 Current (A) 34 35 34 33.5 Power (kW) 20.27 20.62 20.3 19.79 P. F.

0.85 0.84 0.84 0.84

0.8 0.78 0.81 0.80

406

Average Load 20.18kW 20HP 4 pole Voltage (V) 404 405 Current (A) 28 29 28 29 Power (kW) 16.46 17.29 16.65 17.12 P. F.

Average Load =24.35 kW 50HP 4 pole Voltage (V) 400 402 407 406 Current (A) 56 56 56 57 Power (kW) 33.36 33.15 34.6 33.38 P. F.

0.84 0.85 0.85 0.84

404 406

0.85 0.86 0.84 0.85

Average load 16.88 kW

Average Load 33.36kW

On the basis of the technical data, the energy consumption by these motors on the basis that the motors were working for 21 hours daily was collected. If all the existing motors which run inefficiently because of being very old are replaced by energy efficient motors total money and power

saving has been calculated. The total load of the existing motors is 870kW. When we replace these motors with energy efficient motors, the energy bill comes down and also we get increased efficiency from machines. The results are presented below: Motor Rating 30Hp 4pole Existing 90.3% 24.35 7560 30hp 4pole Efficient 92.8%

The old motor can be sold in the market @ Rs400500/ hp and the proceeds add upto the profit. The price of new motor( energy efficient) is Rs.59200/Payback period = approx.8 months One of the 60hp motors was being used underrated and has been replaced by 50hp Motor Rating 50Hp 4pole Existing 93% 39.78 7560 50hp 4pole Efficient 93.6% 39.50 7560

Efficiency kW Running hours p.a. kWh p.a. Input cost @ Rs.4.2/kWh Net saving

Efficiency 23.70 kW 7560 Running hours p.a. 184086 773161 179172 kWh p.a. 752522 Input cost @ Rs.4.2/kWh Rs. 20639 Net saving

300737 12603096

298620 1254204

Rs. 8892

The old motor can be sold in the market @ Rs400500/ hp and the proceeds add upto the profit. The price of new motor( energy efficient) is Rs.37574/Difference paid: Rs.37570-15000= 22574

The old motor can be sold in the market @ Rs400500/ hp and the proceeds add upto the profit. The price of new motor( energy efficient) is Rs.59200/Payback period = approx.8 months

Payback period = approx.14 months. 25hp 4pole Motor Rating 50Hp 4pole Existing 93% 39.78 7560 50hp 4pole Efficient 93.6% Efficiency kW Running hours p.a. kWh p.a. Input cost @ Rs.4.2/kWh Net saving 39.50 kW 7560 Running hours p.a. 300737 12603096 298620 kWh p.a. 1254204 Input cost @ Rs.4.2/kWh Rs. 8892 Net saving Rs.27308 667111 639803 158836 152334 7560 7560 21.01 20.15 88% 91.8% Motor Rating 25Hp 4pole Existing 25hp 4pole Efficient

Efficiency

The old motor can be sold in the market @ Rs400500/ hp and the proceeds add upto the profit. The price of new motor( energy efficient) is Rs.33383/Payback period = approx.10 months

cost. A small difference ion efficiency can make significant difference in the running cost. REFERENCES: 1. Advisory Board on Energy (1986), The Energy Scene, Govt. of India, New Delhi Agarwal RK, Energy Efficient Motors, Proceedings of EDCOTS97, Jan1997, Vidisha, pp 157-160 Koelsch R.James, How motors and drives save energy and money? Automation World, 2005. Singh, Tejinder, Conservation of Electical Energy by using energy efficient motors: A case study, 2006.

20hp 4pole Motor Rating 20Hp 4pole Existing 87.8% 17.07 7560 20hp 4pole Efficient 92.2% 3. kW Running hours p.a. kWh p.a. Input cost @ Rs.4.2/kWh Net saving 16.26 7560 4. 129049 542006 122925 516285 2.

Efficiency

Rs.25721

The old motor can be sold in the market @ Rs400500/ hp and the proceeds add upto the profit. The price of new motor( energy efficient) is Rs.24999/Payback period = approx.7 months

CONCLUSION: From the results and observations we come to know that energy efficient motors bring a world of benefit to the organization. A substantial rise in productivity at a cost that is substantially lower can result in more profits. Running cost is the overriding factor then the initial