tma ee motors presentation-june 2005
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BHARAT BIJLEE LIMITED
Energy Efficient Motors11 June 2005
T M ANKLESARIA
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Energy Efficient Motors
A National Priority
70 % of all electrical energy
consumed in India is used fordriving electric motors
55 % of which is consumed byindustrial motors
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Consumption of electricity by Sector
INDUSTRY, 39%OTHERS, 30%
AGRICULTURE,
31%
A saving of 1 or 2 % by industry can save 500 MW
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Life Cycle Cost of a Motor
In one year, a motor consumes energyequivalent to 10 to 20 times its purchaseprice
Many consumers in India especiallyOEMs purchase cheap motors having lowefficiency values.
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Initial Cost of an 11 kW motor is only5% in the first year of operation
Purchase
Cost (Rs),
13600, 5%
Annual
Energy
Cost (Rs),
256000,
95%
Assumptions: Efficiency: 85.5% (IS 8789)
Energy cost: Rs 4 per kWH
Working: 5000 hrs pa
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National Standard forEnergy Efficient Motors
IS 12615: 2004 (First Revision)
Energy Efficient Induction MotorsThree PhaseSquirrel Cage.
IS 12615 covers Energy Efficient motors from0.37kW to 160kW (up to Fr. 315L)
IS 12615 specifies two efficiency levels eff-2and eff-1.
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IS 12615: 2004 (First revision)- superior to existing Std. IS 8789
To be considered as energy efficient, a motormust conform to one of the following efficiencylevels specified in IS 12615: Improved Efficiency (eff 2)
High Efficiency (eff 1)
eff1 efficiency levels are higher than those of eff2.
Both eff1 & eff2 are higher than the nominalvalues specified in IS 8789: 1996.
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Comparison of efficiencies ofStandard & Energy Efficient Motors
Output4 Pole
IS 8789 eff 2 as per IS12615
eff 1 as per IS12615
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
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Why does IS 12615 specifytwo efficiency levels?
User has the option to go for eff1 motorand 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 sinceit has provided two levels of efficiency.This in line with other internationalstandards like CEMEP.
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Bharat Bijlee Range ofeff1 & eff2 motors.
Eff 2 motors are offered by Bharat Bijlee ex-stock.
Bharat Bijlee also offers a complete range of eff 1
motors against specific orders with a lead time of8 to 10 weeks.
BHARAT BIJLEE DOES NOT MANUFACTUREMOTORS OF EFFICIENCY CLASS LESS THAN EFF2
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Bharat Bijlee stock motors aresuperior to eff 2 as per IS 12615
Output in kW (4 Pole) Efficiency of BBLStock Motor
Eff 2 as per IS12615
0.75 77.0 73.0
1.5 80.0 78.5
3.7 84.0 84.0
11 89.0 88.4
18.5 91.2 90.0
37 93.0 92.0
75 94.0 93.6
110 95.2 94.4
160 95.8 95.0
Efficiency values are subject to tolerance as per IS325
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Why is the Energy Efficientmotor more expensive?
eff 1 motors are generally priced 20-25 %higher than eff 2 motors.
More laminations - longer core lengthand/or
High Grade (low loss) laminations
More Copper
Rs
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How is efficiency improved?
Core length has to be increased tomaintainstarting torque
ReduceStator Cu Loss
ReduceRotor Cu Loss
ReduceIron Loss ReduceCopper Loss
Low Loss
Magnetic matl.
ReduceFlux Density
IncreasedStarting current
IncreaseCopper Section
Stator slot area
IncreaseRotor bar section
Reduced S t a r t i n g T o r q u e
Increase ReduceStator Yoke Rotor Diam
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Energy Efficient Motors- Increased Safety & Flame Proof
Bharat Bijlee offers Flame Proof andIncreased Safety motors conforming to eff2 asstandard
Eff 1 motors can also be offered againstcustomer requirement with a lead time of 8 to10 weeks.
In a few eff1 outputs next higher frame size isrequired.
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Efficiency improvement to eff1 by use ofLow Loss Stamping & increased Fe and Cu
eff 2 eff111 kW 1500 rpm
Low LossStamping
+ increasedCu & Fe
Iron losses 400 W 330 W 250 W
Friction & Windage 120 W 120 W 120 W
Constant Losses 520 W 450 W 370 W
Load related Losses 840 W 750 W 650 W
Total Losses 1360 W 1200 W 1020 W
Efficiency 89% 90.2% 91.5%
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Energy Efficient Motors have a
Flat Efficiency Vs Load Characteristic
Motor rating isselected for max.load conditions and
next preferred ratingMost motors operate
on an averagearound 75% load. 60
80
84 85.5
70
8689 89
60
65
70
75
80
85
90
95
25% 50% 75% 100%Load
Efficie
ncy
Motor As per IS 8789
eff-2 Motor
Efficiency is almost samefrom 60% to 100% load in awell designed EE motor
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The more expensive eff2 motoris in fact cheaper
IS 8789 IS 12615 eff2
Purchase Price
11 kW motor
Rs 13,600
( - 15 %)
Rs 16,000
Efficiency 85.5 % 88.4 %Energy consumption p.a.
For 5000 hrs @ Rs 4 per kWH
Rs 2,57,310 Rs 2,48,868
Energy Saving Rs 8442 p.a.
Addl. Purchase Price Rs 2400
Pay Back Period of eff 2 motor is 3.4 months
for a 15% price difference over IS 8789 motor.
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Eff1 motor gives further savingsover an eff2 motor
eff2 eff1
Purchase Price Rs 16000 Rs 19200 +20%
of 11kWmotor
Efficiency 88.4% 91.0%Energy consumption p.a. Rs 2,48,868 Rs 2,41,758
(For 5000Hrs@ Rs 4.0/ kWH)
Energy Saving Rs 7110 p.a.
Additional Purchase Price Rs 3200
Pay Back Period of eff1 motor is 5.4 months fora 20% price increase over eff2 motor
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Energy savings increase at partial loadsdue to flat efficiency vs load Characteristic
11kW-4 Pole BBL eff 2 motor Vs motor as per IS 8789.
Load 100% 75% 50%
Working Hrs. p.a. 1000 3000 1000
Eff of IS-8789 motor 85.5% 84% 80%
Eff of eff 2 (BBL stock motor) 89 89% 86%
Difference in input power (kW) 0.506 0.551 0.48
Energy saving p a @ Rs 4.0 per kwH Rs 2024 Rs 6612 Rs 1920
Total Energy saving per annum : Rs 10556
Additional Price of eff-2 motor over motor as per IS8789 : Rs 2400
Payback Period is 2.7 Months
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Replacement Vs Rewinding11 kW 4 pole motor
Eff of Old Motor to be rewound or replaced IS 8789 eff2
New motor Efficiency eff2 eff1
Purchase Price of new motor Rs 16000 19200
Rewinding Cost Rs 4000 4600
Additional Cost Rs 12000 14600Efficiency of old motor 85.5% 88.4%
Efficiency after rewinding ( less 1.5%) 83.0% 86.9%
Efficiency of new motor 88.4% 91.0%
Saving by replacement with new eff2 motor 0.809 kW 0.570 kW
For 5000 Hrs @ Rs 4.0 per kWH (Rs) 16180 11406
Pay back period : 8.9 Months 15.4 Months
Replace old eff 2 motor with eff1 motor & get Payback in 15 months
Replace old IS8789 motor with eff2 motor & get payback in 9 months
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Problems in field testing
Efficiency measurement at site is unreliable.
One needs to decouple the load in order to measureno load losses.
Variable voltage supply required in order to maintain
rated voltage.
We recommend measurement of kWh using a energymeter and compare two motors.
Measurement of current is not a reliable indicator.Current is not directly proportional to input powerbecause power factor varies with load and voltage.
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Nameplates -marking of Efficiency
Type MH16M4734 Fr 160M
Bharat Bijlee Limited
Hz 50 Fr 160M Hz 50 Insl. Cl FInsl Cl F Type MA16M433
M/c. No.M/c. No. Duty S1 Duty S1Volts 415Volts 415kW/HP 11/15kW/HP 11/15 rpm 1450rpm 1460 P f 0.85 P f 0.84
A 19.7 A 20.5Eff % 91.5 Eff % 89.0
Bharat Bijlee Limited3 ph. Induction motor MADE IN INDIA 3 ph. Induction motor MADE IN INDIA
BB High Efficiency Motor BB Standard Motor(Improved Efficiency)
EFF-2EFF-1
Bharat Bijlee EE motors are clearly labeled
EFF-1 or EFF-2
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Intermittent dutyapplications.?
Intermittent duty motors are typically used incrane, hoist, valve actuators and otherapplications with frequent starts.
In these applications, motors are designed forlow starting losses rather than low runninglosses.
For intermittent duty applications EEmotors are not the best choice
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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. Pashupati Spinning.
Flameproof Motors: DCW Ltd. Divis Lab. DSM Anti-Infective (I) Ltd. Ingersoll Rand (I) Ltd.
Ranbaxy Industries.
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Testimonial from
Grasim IndustriesChemical Division
TO WHOMSOEVER IT MAY CONCERN
We are using Bharat Bijlee makeenergy efficientmotors ranging from 5HP to 100 HP since last 2
years and their performance is satisfactory. Wehave achieved substantial savings by way ofenergy conservation.
For GRASIM CHEMICAL DIVISION
KBV PRASANNARAO
GENERAL MANAGER (ELECT. & INST)
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Summary and Conclusions
There exists a national standardIS 12615: 2004(Revision 1) for energy efficient three phase inductionmotors from 0.37kW to 160 kW
Energy savings are more at partial loadsbecause Energy
Efficient motors have a Flat Efficiency Vs. LoadCharacteristic
Payback periodof eff2 motor over IS-8789 motor is approx
1500 working hrs.
Payback periodof eff1 motor over eff2 motor is approx2500 working hrs.
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Bharat Bijlee manufactures
Energy Efficient motors conforming toeff1 or eff2 of IS 12615
Bharat Bijlees Standard Ex stock Motorsconform to eff2 of IS 12615
Inferior motors conforming to IS 8789are not manufactured by BB
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