energy efficient motors bu lv motors ap-m

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BU LV Motors AP-M

Energy Efficient Motors

International Conclave

On

Key Inputs for Accelerated Development

Of

Indian Power Sector for 11th Plan & Beyond

5th July 2007 New Delhi

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Low Voltage Motors Factories

Production

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Manufacturing Facility: Faridabad

FARIDABAD

LV Motors

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ABB - Motors India

One Factory located at Faridabad (North India )about 40 km from Delhi.

Another Factory at Bangalore , (Southern India).

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Milestones – ABB Motor India

ABB is pioneer to introduce high efficiency (EFF2) motors in India – in year 1991

ABB was again pioneer to introduce EFF1 motors for frame 315 & 355 in 1998 - more than 10000 successful Installations

Only motor factory in India to be accredited for IMS ( Integrated Management System), combination of ISO 9001 - 2000, ISO 14001- 1996 & OHSAS 180001- 1999 Center of Excellence for ABB Roller table motors up to 180 frame

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63 71 80 90 100 112 132 160 180 200 225 250 280 315 355 40056

Total offer – LV motors

Cast iron motors

Open drip proof motors

Brake motors

Flameproof motors

Increased safety motors (cast iron 90 – 355)

Non-sparking motors (cast iron 90 – 355)

Haz

ardo

us a

reas

Gen

eral

Pu

rpos

e

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• Standard three-phase TEFC (HX/+,M2BA)motors, IS:325 • Standard three-phase SPDP motors, IS:325• Crane duty motors• Brake motors (externally mounted)• Wind mill generators• Motors for frequency converter drive • Non-sparking motors type ‘n’, IS:9628• Increased safety motors type ‘e’, IS:6381• Flame Proof motors type ‘d’, IS:2148• Roller table motors

LV Motors - Product Range

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• Type Three phase squirrel-cage induction motors

• Output 0.18 ... 560 kw; 0.25 ... 750 hp

• Voltage 415 V; 220 ... 690 V

• Frequency 50 Hz; 25 ... 60 Hz

• Duty S1 ... S8 acc. to IS:12824

• Ambient 45oC / 50oC ; -20 ... 70oC

• Altitude Up to 1000 Meters

• Insulation Class ‘F’/Class ‘H’ (VPI on request)

LV Motors - Manufacturing Range

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• High Efficiency - ABB motors are engineered for high efficiency for minimum life cycle costs.

• Low noise level - The motors are designed to ensure low noise level.

• Accessories - Space heaters, thermistors, RTD and BTD’s on request.

• Terminal Box - Terminal box suitable for both Copper and Aluminium cables.Terminal box size sufficient for easy termination and maintenance of cable.

Special FeaturesSpecial Features

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• IP55 protection - IP55 protection (for TEFC) is an integral part of all motors.

• Voltage and frequency variation - The standard motors are suitable for 415Volts±10%, 50Hz ±5% and combined voltage and frequency variation of ±10% as standard : engineered for rigorous environment.

• Bearings - All motors are provided with deep-groove ball bearings with C3 clearance for high load capacity

Double sealed bearings up to frame 20063 series of bearings 100 frame onward Special care taken at the time of order for considering right bearing at the timeof order (eg. Roller Bearings for belt Application or Insulated bearingfor VFD Application)

Special FeaturesSpecial Features

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AC Induction Motors for Various Application

Food and beverage Variable speed drives Mining

Water and wastewater Pulp&paper

HVAC Multipurpose industrial use

Pharmaceutical

Cement industry

Petrochemical, oil and gas Wind power generation

Roller tables

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Manufacturing

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Machined Housing

Stack pressing

Coil mounting

Impregnation

Assembly

Testing

Rotor

Dynamic balancing

Shaft insertion

Die-cast rotor

Motors - Manufacturing Stages

Painting&

Packing

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Winding in ABB´s motorsRotor winding in ABB´s motors

1) Cast aluminium cage

2) Soldered copper bar cageBig motors (some 355, 400) Some VSD applications

3) Random wound windingSome big generator (400)

Stator winding in ABB´s motors

1) Random wound winding

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Manual winding Machine winding

Winding

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Insulation

Insulation System Combination of different insulationmaterials and impregnation material

AND

Conducting parts (active) & neutral parts (passive)

All electrical equipment/devices consist of insulating and conducting parts

THE INSULATION SYSTEMS

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Insulation

Requirements for insulation system in electrical motors

Electrical strength(voltage)

Thermal strength

Mechanical strength

Chemical strength

Strength against humidity/water

Suitability for winding work

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Insulation

In a LVAC electrical motor there areWire insulationSlot insulationSlot cover or slot wedgePhase insulationCoil insulationTying or lacing bandImpregnationSleevings on connections and phase leadsTerminal board or blockAccessories; PTCs, Pt100, heating resistors etc.

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Single layer winding in slot

Copper wire

Slot wedge

Enamel insulation:amide-imideovercoated polyester

Slot insulation

Enamel insulated copper wires

Random wound winding

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Single layer winding in winding end

Phase insulation

Coil

Slot insulation and slot wedge

Stator core

Random wound winding

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Slot wedge

Slot insulation

Enamel insulated copper wires

Layer insulation

Double layer winding in slot

Random wound winding

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Double layer winding in end winding

Random wound winding

Slot insulation and slot wedge

Phase insulation

Coil

Stator core

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0

20

40

60

80

100

120

140

160

180

B F H

Insulation class

Deg

. C Hotspot temperature marginMax. temperature riseMax. ambient temperature

40 40 40

8010

10105

125

15

130

155

180

Insulation classes acc. to IEC 85

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Impregnation

Methods and resins

Dip and roll impregnation, polyester and epoxy resins

Trickle impregnation, polyester and epoxy resins

Vacuum impregnation, polyester resin

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Impregnation

Dip and roll impregnationHeating during rolling:20°C/min, temperature in the end of rolling 130 - 140°CStoving:Temperature of the stove 140oC, stovingtime 1- 2 h

1-comp. polyester-imide or 1-comp. epoxy resinSEMOT: 2-comp. polyesterDipping time 5 min

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ImpregnationTrickle impregnation

Stoving:Temperature of the stove 150oC, stoving time 50 min

Silica filled 2-comp. polyester or 4-comp. epoxy resinSEMOT: 1-comp. polyesterHeating during rolling: 20°C/min, temperature in the end of the rolling 130 - 140°C (epoxy 160°C)

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Impregnation

Vacuum impregnation1-comp. polyester-imide resinVacuum sucks the resin into windingImpregnation time 45 minNo heating during impregnation

Stoving:Temperature of the stove 140oC, stovingtime 4 h

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Standard motors

Terminal box

End shield

Shaft

Outer bearing cover

Fan cover Fan

Frame

Bearing

Outer bearing cover

End shield

Inner bearing cover

Bearing

Inner bearing cover

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Energy Efficient MotorsEnergy Efficient Motors

Energy Efficient Motors

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Energy Efficient MotorsEnergy Efficient Motors

• Why improve motor efficiency?

• What is an Energy Efficient motor?

• What makes an motor “Energy Efficient “ ?

• Is Energy Efficient motor cost effective?

• Repair or replace?

• What is motor efficiency?

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What is motor efficiency ?

Motor efficiency is a measure of the effectiveness with which electrical energy is converted to mechanical energy, and is expressed as the ratio of power output to power input:

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The efficiency of a motor is primarily a function of load, horsepower rating, and speed, as indicated below:

a) Efficiency is a function of load

b) Efficiency of motors increases as the motor horsepower rating increases

c) Higher speeds, have a higher efficiency

Facts about motor efficiency

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Why improve motor efficiency?

• The shortage and large cost increases of vital national energy resources has demonstrated the need to conserve such resources.

• 65% of global industrial electricity is consumed by electric motors

• Electric cost is typically the largest individual cost component of lifecycle cost of a industrial electric motor

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Operation cost( > 95 % of the LCC)• Efficiency• Performance• Unavailability, Spare parts• Maintenance, After Sales Service• Disposal, upgrading

Investment Cost ( < 5% of the LCC)• Technology (Semiconductors, Motor Control,

Cooling, etc.)• System purchasing and Projecting• Civil works; Space, Layout, Cables • Installation, Commissioning, Training

Life cycle cost

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Environmental impactEnvironmental aspects Motor A: 12 kW Motor B: 12 kWover full lifecycle 91.1% efficiency 89% efficiencyUse of resourcesCoal (kg) 16,370 20,690Gas (kg) 2,070 2,620Oil (kg) 3,240 4,090Steel (kg) 27 24Copper (kg) 0.9 0.8Aluminium (kg) 4 4Silicon (kg) 1.1 1.0Other (kg) 0.09 0.09

EmissionsCarbon dioxide (kg) 62,940 79,560Sulfur dioxide (kg) 495 626Nitrogen dioxide (kg) 136 172Hydrochloric acid 8.8 11.1Metals (g) 538 538Heavy metals (g) 1.1 1.1Solid waste (kg) 117 106Particles (kg) 30.4 38.4Other (kg) 12 15

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An energy efficient motor produces the same output but uses less electrical power ( KW ) than a standard motor.

What is an Energy Efficient Motor ?

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Efficiency graphs, 4-pole

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Iron Loss in Core

Rotor Loss

Stator Copper LossStray Loss

Bearing, Windage &Friction Loss

What makes motors energy efficient ?

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Losses Design ChangesStator copper loss More copper,larger slot,higher slot

fill,reduced over hangIron loss Low loss steel,thinner lamination,

Improved core insulation,stress relieving

Rotor loss Larger rotor bars & end rings,higher conductivity bars & rings

Friction & windage losses Optimized fan design,optimum bearing selection,improved ventilation circuit

Stray load losses Larger airgap,low skewing,slot shape etc

What makes motors energy efficient ?

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Improved Quality ofDesignMaterialProcess

Reliability

+

Efficiency

What makes motors energy efficient ?

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Annual energy savings

Saving= KWxLxHr.xCx{1/(standard η)-1/(EE η)}Where,

L = Load factor (percentage of full load/100)Hr. = Annual operating hoursC = Average energy cost

Energy Efficient Motors

Simple Payback = Price Premium

(years) Annual savings

CostsBenefits

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22KW / 30 HP 4P motorStandard Motor Eff. at 90% loading = 91.5%ABB EFF1 motor At 90% loading = 92.6%Energy cost = Rs. 3.00 / KWHAssuming 22Hrs. Continuous run for 300 days

Savings for the year = Rs. 5090 /-

Energy Efficient MotorsEnergy Efficient Motors

Simple Payback = 7000 = 1.4 Years(years) 5090

Life Cycle Cost Saving =Rs 71,255.00Considering life of 15 Years

Are You buying a new motor ?

CostsBenefits

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Energy Efficient MotorsEnergy Efficient Motors

Simple Payback = 35000 = 1.7 Years(years) 19927

CostsBenefits

22KW / 30 HP 4P motorOLD Motor Eff 3 at 90% loading = 89%ABB EFF1 motor At 90% loading = 92.6%Energy cost = Rs. 3.00 / KWHAssuming 24 Hrs. Continuous run for 320 days

Savings for the year = Rs. 19927/-

Life Cycle Cost Saving =Rs 2,78,982.00Considering life of 15 Years

Replacing a Old Motor ?

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Reduced energy bill

Overall benefits of Energy Efficient Motor

Reduced downtime cost

Better tolerance to thermal stresses from frequent starts

Low noise

Better resistance to abnormal operating conditions

Eco - friendly operation

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Ontario Hydro Experiment

Repair or replace?

REPAIR

Replace

Ten new 15KW motors were independently tested and purposely damaged and sent to nine different repair companies

Efficiency loss varied from 0.3 to 3.4%

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Core losses are higher because of high temperature and lamination damage

Higher copper losses for low copper fill

Higher frictional losses for universal fans

Repaired motor has loss of efficiency

REPAIR

Replace

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