Energy Efficient Motors

2010 – 11
Why have high efficiency motors

 Save energy – this is a national priority

 Reduce operating cost

 Reduce harmful greenhouse gas emissions

Energy Efficient Motors A National Priority

 70 % of all electrical energy consumed in India is used for driving electric motors

 55 % of which is consumed by industrial motors

Consumption of Electricity by Sector

OTHERS, 30%
INDUSTRY, 39%

AGRICULTURE,
31%

A saving of 1 or 2 % by industry can save 500 MW

Initial Cost of an 11 kW motor is only 3.9% in the first
year of operation
Purchase Cost (Rs), 19,261/-, 3.9%

Annual Energy Cost (Rs) 4,94,382/-, 96.1%

Assumptions: Efficiency Eff2 : 89.0% (BBL)

Energy cost: Rs 5 per kWH
Working: 8000 hrs pa
Life Cycle Cost of a Motor

 In one year, a motor consumes energy equivalent to 10 to 25 times its purchase price

 Many consumers in India especially OEMs purchase cheap motors having low
efficiency values
National Standard for Energy Efficient Motors

 IS 12615: 2004 (First Revision)

Energy Efficient Induction Motors — Three Phase Squirrel Cage

 IS 12615 covers Energy Efficient motors from 0.37kW to 160kW (up to Fr. 315L)

 IS 12615 specifies two efficiency levels :

- eff2 and eff1
IS 12615: 2004 (First revision) - superior to existing Std.
IS 8789
 To be considered as energy efficient, a motor must conform to one of the following

efficiency levels specified in IS 12615:

 Improved Efficiency (eff2)

 High Efficiency (eff1)

 eff1 efficiency levels are higher than those of eff2

 Both eff1 & eff2 are higher than the nominal values specified in IS 8789: 1996
Why does IS 12615 specify two efficiency levels?

 User has the option to go for eff1 motor and save energy but at higher initial cost. It is

strongly recommended to go for eff1 motor when utilization is high

 The standard is hence user friendly since it has provided two levels of efficiency. This

in line with other international standards like CEMEP

New IEC 60034-30 “Efficiency classes of single speed 3
phase cage induction motors”

Released in Sept.2008

New classes defined: IE1, IE2, IE3 and IE4

Testing as per IEC 60034-2-1

IE1 and IE2 : Slightly lower than eff2 and eff1 (to compensate for new
testing method in which stray losses are higher)
Implications of new IEC 60034-2-1

• Main difference are;

– In evaluation of Stray losses

Earlier 0.5% of input power

Assigned From 2.5% below 1 kW to

or 0.5% above 10MW of input kW

Determined by actual testing using suitable equipment

Comparison of eff & IE classes

Output eff2 IE1 eff1 IE2 IE3 IE4

5.5kW
85.7 84.7 89.2 88.2 89.9 91.3
4P

11kW 88.4 87.6 91.0 90.2 91.7 92.9

4P

Dec 2008 Bharat Bijlee Ltd 12

Comparison of efficiencies of Standard & Energy
Efficient Motors
eff2 as per eff1 as per
Output 4 Pole IS 8789
IS 12615 IS 12615
0.75 kW 71.0% 73.0% 82.5%
1.5 kW 76.0% 78.5% 85.0%
3.7 kW 83.0% 84.0% 88.3%
11 kW 85.5% 88.4% 91.0%
18.5kW 87.0% 90.0% 92.2%
37 kW 88.5% 92.0% 93.6%
75 kW Not specified 93.6% 94.7%
110 kW Not specified 94.4% 95.2%
160 kW Not specified 95.0% 95.8%

Efficiency values are subject to tolerance as per IS325

Bharat Bijlee stock motors are superior to eff2 and eff1
levels as per IS 12615
Output kW at eff2 eff2 eff1 eff1
4 Pole As per IS 12615 BBL std. As per IS 12615 BBL std.
0.75 73.0 77.0 82.5 82.5
1.5 78.5 80.0 85.0 85.0
3.7 84.0 85.0 88.3 88.3
11 88.4 89.0 91.0 91.5
15 89.4 90.2 91.8 92.2
18.5 90.0 91.2 92.2 92.4
37 92.0 93.0 93.6 93.6
75 93.6 94.0 94.7 94.7
110 94.4 - 95.2 95.2
160 95.0 - 95.8 95.8

Efficiency values are subject to tolerance as per IS325

Bharat Bijlee Range of eff1 & eff2 motors.

 eff2 and eff1 motors are offered by Bharat Bijlee ex-stock

 Bharat Bijlee also offers a complete range of eff1 customised motors orders with a

lead time of 8 weeks

 Bharat Bijlee does not manufacture motors of efficiency class less than eff2
Energy Efficient Motors for Hazardous Areas

BBL has come out with energy efficient series motors used in hazardous areas

 Type MD – Flameproof Ex(d) eff2

 Type MJ – Flameproof Ex(d) eff1
 Type ME – Increased Safety Ex(e) eff2
 Type MI – Increased Safety Ex(e) eff1
 Type MN – Non Sparking Ex(n) eff2
 Type MS – Non Sparking Ex(n) eff1
Energy Efficient Motors- Flameproof, Increased Safety &
Non sparking motors

 eff1 motors can also be offered against customer requirement with a lead time of
8 to 10 weeks

 In a few eff1 outputs, next higher frame size is required

Why is the Energy Efficient motor more expensive?

 eff1 motors are generally priced 5 - 15 % higher than eff2 motors

 More laminations - longer core length and/or

 High Grade (low loss) laminations

 More Copper

Rs
How is efficiency improved?

Reduce Iron Loss Reduce Copper Loss

Reduce Reduce
Stator Cu Loss Rotor Cu Loss

Increase
Reduce Copper Section Increase
Flux Density Stator slot area Rotor bar section

Low Loss Magnetic Increase Reduce Increased

matl. Stator Yoke Rotor Dia Starting current Speed

Reduced Starting Torque

Core length has to be increased to maintain starting torque

Efficiency improvement to eff1 by use of Low Loss
Stamping & increased Fe and Cu
eff 1
11 kW 1500rpm eff 2
Low Loss Stamping + Increased Cu & Fe

Iron Losses 400W 330W 250W

Friction & Windage 120W 120W 120W

Constant Losses 520W 450W 370W

Load related Losses 840W 750W 650W

Total Losses 1360W 1200W 1020W

Efficiency 89% 90.2% 91.5%

Energy Efficient Motors have a Flat Efficiency Vs Load
Characteristic
 Motor rating is selected for max. load 95
conditions and next preferred rating 89 89
90
86
 Most motors operate on an average 85
85.5
around 75% load 84

Efficiency
80 80

75
70
70

65

60 60
25% 50% 75% 100%
Efficiency is almost same from Load
60% to 100% load in a well
designed EE motor Motor As per IS 8789 eff2 Motor
eff2 motor gives savings over an IS 8789 motor

IS 8789 eff2

Purchase Price of 11kW/4P motor Rs 17510 19261

Efficiency 85.5% 89.0%

Energy consumption p.a. for 8000 Hrs @ Rs 5

5,14,620 4,94,382
per kWh

Energy Saving p.a. Rs 20,238

Additional purchase price Rs 1751

Pay Back Period of eff2 motor is 1.0 month for a 10% price increase over an IS 8789 motor
eff1 motor gives further savings over an eff2 motor

eff2 eff1

Purchase Price of 11kW/4P motor Rs 19261 22149

Efficiency 89.0% 91.5%

Energy consumption p.a. for 8000 Hrs @ Rs 4,94,382 4,80,874

5 per kWh
Energy Saving Rs 13,507

Additional purchase price Rs 2888

Pay Back Period of eff1 motor is 2.6 months for a 15% price increase over eff2 motor
Energy savings at partial loads

11kW-4 Pole BBL eff2 motor Vs eff1 motor.

Load 100% 75% 50%

Working Hrs. p.a. 3000 3000 2000
Eff of eff1 (BBL stock motor) 91.5% 91.5% 89.5%
Eff of eff2 (BBL stock motor) 89% 89% 86%
Difference in input power (kW) 0.338 0.338 0.50
Energy saving p a @ Rs 5.0 per kWh Rs. 5065 Rs. 3799 Rs. 2501

Total Energy saving per annum : Rs 11365

Additional Price of eff1 motor over eff2 motor : Rs 2888

Payback Period is 3.0 Months

Energy Efficient Motors- Speed and Starting current

 Due to reduced rotor losses, speed is higher.(5-15rpm)

 The driven equipment ( fan / pump ) should be designed accordingly

 Due to reduced rotor and stator resistance, starting current is higher. This
can go to 700 % in eff1 motors.

 When used with a VVVF drive, this does not matter as the drive takes care.
 In other cases, this should be taken care during system design.
Nameplates - marking of Efficiency

BB High Efficiency Motor

Bharat Bijlee EE motors are clearly labeled “Eff 1 or Eff2”
Energy Savings Ready Reckoner

Eff1 ready reckoner as per LP 30.xls

Energy Savings Ready Reckoner

Energy Savings Ready Reckoner for eff1 Motors

You must enter yellow cells
Motor Rating / Polarity 45 kW / 4P 225M eff2

Energy Cost: Rs / kWH 5 225M eff1

50% 75% 100% Purchase Price of

% of load 0% load Total
load load load Motor in Rs
Working Hrs pa. 2000 3000 3000 8000
Efficiency of eff1 91.9 93.9 93.9 83149

Efficiency of eff2 91 93.2 93.2 75592

eff2 motor: kWH pa. 0 49451 108637 144850 302938
eff1 motor: kWH pa. 0 48966 107827 143770 300564
Energy Saving: Rs.
0 2421 4049 5399 11870 7557
pa.

Pay Back Period 7.6 months

When Should I Consider an eff1 motor

 More than 4000 hours of operation per annum

 New installations, typically HVAC systems and process industries

 Replace with eff1 instead of rewinding old motors

- rewinding increases iron and stray losses

 As part of a preventive maintenance or energy conservation plan

Intermittent duty applications….?

 Intermittent duty motors are typically used in crane, hoist, valve actuators and other
applications with frequent starts

 In these applications, motors are designed for low starting losses rather than low
running losses

For intermittent duty applications EE motors are not the best choice
Problems in field testing

 Efficiency measurement at site is unreliable.

 One needs to decouple the load in order to measure no load losses
 Variable voltage supply required in order to maintain rated voltage
 We recommend measurement of kWh using a energy meter and compare two motors
 Measurement of current is not a reliable indicator. Current is not directly proportional
to input power because power factor varies with load and voltage
Finance help

Are there any financing or leasing schemes for EE Motors?

Yes, IREDA and other financial companies such as ICICI, IDBI,SBI etc. have schemes

that can help you to acquire EE motors. (courtesy – web site of – International Copper

Promotion Council India)

Selective list of our eff1 Customers
TEFC Motors:
 Abhishek Industries
 A.P.Solvex Ltd
 B.A.R.C.
 DSM Anti-Infective (I) Ltd.
 Finolex Industries
 Garden Silk Mills
 Grasim Industries
 G.V.D. Textiles
 Hindustan Zinc
 Hightemp Furnace Ltd.
 Indian Steel Co Ltd.
 JCB (I) Ltd
 Koramandala Fertilizers
 KSB Pumps
 VVF  Purvi Pumps
 Rathi Group  Aditya BIirla Nuvo Ltd.
 Sandoz  Savita Chemicals Ltd.
 Ultratech Cement Ltd.  Kilburn Engg. Ltd.
 Power Build Ltd.  Sutlej Textiles
 IFFCO  Metso Minerals (India)
 Century Rayon  Yuken India Ltd.
 Thermax Ltd.  ELGI Equipments Ltd.
 Mather and Platt  Divi’s Laboratories Ltd
 Kanoria Chemicals  New Allenbury Works
 Essar Steel  Varat Pumps & M/cs
 Gujarat Narmada Valley  Shanti Gears Ltd.
 GSFC  Rank Cranes
 Nirma Ltd.  Pashupati Spinning
 Taj Group of Hotels  Kirloskar Ebara
Selective list of our eff1 Customers

Flameproof Motors:

 Kilburn Engg. Ltd.

 DCW Ltd.
 Themax Ltd.
 Divis Lab.
 VVF Ltd
 DSM Anti-Infective (I) Ltd.
 Sandoz Pvt.Ltd.
 Ingersoll Rand (I) Ltd.
 Kanoria Chemicals & Industries
 Ranbaxy Industries.
 Dresser-Rand India Pvt Ltd.
 Aarti Industries
 Gujarat Narmada Valley
 Hikal Ltd
 KSB Pumps
 GMM Pfaudler Ltd.
 Milton Roy India
Testimonial from Grasim Industries – Chemical Division

TO WHOMSOEVER IT MAY CONCERN

We are using Bharat Bijlee make energy efficient motors ranging from 5HP
to 100 HP since last 2 years and their performance is satisfactory. We have
achieved substantial savings by way of energy conservation.

For GRASIM CHEMICAL DIVISION

KBV PRASANNARAO

GENERAL MANAGER (ELECT. & INST)

 Bharat Bijlee manufactures the complete range of Energy Efficient motors conforming

to eff1 or eff2 of IS 12615

 Bharat Bijlee’s standard ex-stock motors up to 280M frame conform to eff2 of IS 12615.

 315 frame and above are eff1 as standard

 BB also maintains stocks of popular ratings of eff1 motors

 Inferior motors conforming to IS 8789 are not manufactured by BB

Summary and Conclusions

 There exists a national standard IS 12615: 2004 (Revision 1) for energy efficient

three phase induction motors from 0.37kW to 160 kW

 Energy savings are more at partial loads because Energy Efficient motors have a

Flat Efficiency Vs. Load Characteristic

 Payback period of eff2 motor over IS-8789 motor is approx 1500 working hrs.

 Payback period of eff1 motor over eff2 motor is approx 2500 working hrs.