Energy Efficient Motors

2010 11
 70 % of all electrical energy consumed in India is used for driving electric motors

55 % of which is consumed by industrial motors

 OTHERS, 30%
INDUSTRY, 39%

AGRICULTURE,
31%

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

 Purchase Cost (Rs), 19,261/-, 3.9%

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

Assumptions: Efficiency Eff2 : 89.0% ()

Energy cost: Rs 5 per kWH
Working: 8000 hrs pa
 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
 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
 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
 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

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)
 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

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 Ltd 11

 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

 Output kW at eff2 eff2 eff1 eff1
4 Pole As per IS 12615 std. As per IS 12615 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

 eff2 and eff1 motors are offered by ex-stock

also offers a complete range of eff1 customised motors orders with a

lead time of 8 weeks

does not manufacture motors of efficiency class less than eff2

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
 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

 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
 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

 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%

 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
 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
 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
11kW-4 Pole eff2 motor Vs eff1 motor.

Load 100% 75% 50%

Working Hrs. p.a. 3000 3000 2000
Eff of eff1 ( stock motor) 91.5% 91.5% 89.5%
Eff of eff2 ( 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

 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.
BB High Efficiency Motor
EE motors are clearly labeled Eff 1 or Eff2
Eff1 ready reckoner as per LP 30.xls
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

 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 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
 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
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)

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

We are using 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)

 manufactures the complete range of Energy Efficient motors conforming

to eff1 or eff2 of IS 12615

Bharat Bijlees 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

 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.