new ie3 requirements’ · 2019. 9. 20. · industrial controls, thanks to years of analysis and...
TRANSCRIPT
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New IE3 Requirements’
Impact on Industrial
Motors and Controls
Are You Ready?
siemens.com/ie3ready
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Restricted © Siemens AG 2016
• According to the
International
Energy agency,
electric motors
account for
approximately
45% of all
electricity usage.
Global energy consumption
by electric motors
45%
Energy consumption by electric motors
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75%
Industrial energy
consumption by electric
motors
• According to the
International
Energy agency,
electric motors
account for
approximately 75%
of all industrial
electricity usage.
Energy consumption by electric motors
http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwilu7fAi7fWAhWMZpoKHRSeAk8QjRwIBw&url=http://clipartbarn.com/factory-clipart_18241/&psig=AFQjCNEJLN3a8DUPiccfZzr2Hh5pnUTtVQ&ust=1506111173405862
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NEMA or IEC -The new requirements are similar
History:
• In 1989, NEMA developed a standard definition for energy efficient motors.
• EPAct 1992 required that most 230V and 460V electric motors from 1 to
200HP manufactured for sale in the United States after October 24, 1997
meet minimum efficiency standards, as defined by NEMA.
• European Union (EU) Regulation 640/2009 implemented Directive
2005/EC/2005 requiring that motors, 1,000V or less, meet minimum energy
performance standards (MEPS) level IE2 by June 19, 2011
• The Energy Independence and Security Act (EISA) of 2007 requires that 230V
and 460V motors from 1 to 500HP sold in the United States after Dec. 19,
2010 meet NEMA Premium Efficiency standards
• EU Regulation 640/2009 requires motors, 1,000 or less, from 7.5kW to 375kW
meet IE3 MEPS beginning Jan. 1, 2015. Beginning January 1, 2017 the IE3
requirement is extended down to 0.75kW motors.
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NEMA or IEC -The new requirements are similar
1997 2010 2011 2015 2017
NEMA Standard
Efficiency
IEC IE1
EPAct 1992
NEMA Energy
Efficient Motors
European Union
(EU) Regulation
640/2009 IE2
Motors
EISA 2007
NEMA Premium
Efficiency Motors
European Union
(EU) Regulation
640/2009 IE3
Motors 7.5 –
375kW European Union
(EU) Regulation
640/2009 IE3
Motors 0.75 –
375kW
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Potential energy savings
• Premium efficiency and IE3 compliant motors should be specified
in the following instances:
• New installations
• When making major modifications to existing facilities or processes
• For all new purchases of OEM products
• Purchasing spares
• In lieu of rewinding standard or high efficiency motors
• To replace oversized motors (when motor is operating at less than
40% of its rated load
• When replacing existing standard or high efficiency motors
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0
20
40
60
80
100
120
Life Cycle cost of anElectric Motor
Motor Purchase cost 3%
Energy Consumed 97%
Potential savings
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• 85% of electric motors are
15kW (20HP) or smaller.
(More than 50% are 3.75kW
(5HP) and smaller).
• Based on normal operating
hours, 15kW (20HP) and
smaller motors constitute 15%
of electric motor energy
consumption.
• Therefore, the greatest
potential energy savings is on
the larger motors.
Potential energy savings
• Smaller motors are typically less efficient than larger motors
• The smaller the motor, the greater percent efficiency
improvement. As the motor size (kW or HP) increases, the
efficiency gain (in percent) diminishes.
15kW (20HP)
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IEC Motor Efficiency
NEMA Motor Efficiency
7.5kW
150kW
10HP
200HP
Potential energy savings
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Potential energy savings
(7.5kW)
(18.75kW)
(37.5kW)
(56.25kW)
(75kW)
(122.5kW)
(150kW)
Typical Annual Value of a 1% Gain in Motor Efficiency ($0.08 per KWH)
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NEMA or IEC -The new requirements are similar
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What makes a motor premium efficient
or IE3 compliant?
Electric motor components that can be
modified to increase motor efficiency
Bearings
Rotor
Stator Windings
Air Gap
Stator Laminations
End Rings
Fan
Changes to the Stator Windings
and Laminations, and the Rotor
necessitate making the motor
longer. Due to motor standard
designs, the relationship
between mounting and output
shaft are kept the same.
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What makes a motor premium efficient
or IE3 compliant?
Standard Efficiency
Energy Efficient Premium Efficiency
All 3 motors have the same HP ratings
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NEMA or IEC -The new requirements are similar
The official
adoption date
of the new law
for IE3 motors
began in 2015!
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NEMA or IEC -The new requirements are similar
2017
0.75
The official
adoption date
of the new law
for IE3 motors
began in
2015!
In 2017, it
expanded to
include
smaller
motors.
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EU Regulations 640/2009 and 04/2014
define the scope
10.2016 Page 17
Exception:
IE2 + frequency converter remain valid at first,
although a motorstarter is the better alternative at
full speed
Regulation (EG) 640/2009 - 04/2014:
For AC squirrel cage motor 50 Hz or 50/60
Hz:
• rated voltage: up to 1000 V
• power rating: 0,75 – 375 kW
• number of poles: 2,4 or 6
• continuously rated
Valid until 26th of Juli 2014 (640/2009) Valid after 27th of Juli 2014 (04/2014)
> 1000 m above sea level > 4000 m above sea level
Ambient temperature > 40 °C Ambient temperature > 60°C
Ambient temperature < -15°C or < 0°C water-cooled Ambient temperature < -30°C or < 0°C water-cooled
Coolant temperature < 5°C or > 25 °C Coolant temperature < 0°C or > 32 °C
exception:
• Motors in operation fully covered in liquid
• Fully integrated motors in machines (e.g. fan)
• Brake motors
• Other types of motors that are constructed especially for operating under
the following parameters (table below)
Scope EU Regulation
Introduction of the EU Regulation
• in 2011 IE2 motors were set as standard
• after 01.01.2015
IE3 motors from 7,5 kW to 375 kW
• after 01.01.2017
IE3 motors from 0,75 kW to 375 kW
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10.2016 Page 18
IE3 and Premium efficiency motors behave differently
What does this mean for control and
protective devices?
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IE3 motors are different, compared to IE2 motors
– the results of 4 years of motor analysis
10.2016 Page 19
Challenges
► Decreasing nominal current at same power
► Ratio Ia/In is increasing
► Inrush current is increasing
What is changing from IE1/IE2 to IE3?
Impact of IE3 motors
►Inrush current is not published by the motor
manufacturers, and it is unknown to them
►The ratio Ia/In and the inrush current differ for
every motor
the data varies greatly
Starting behavior of an IE3 motor
Within the last 4 years, Siemens analyzed more
than five thousand motors, based on data
Based on own measurement of IE3 motors of
different manufacturer the validation of the
Inrush-current was possible
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The critical factors are partially reduced
by the application
10.2016 Page 20
Measurement of IE3 motors in worst case conditions – electrical network with high short circuit
power, minimum conductor length, adverse activation angle
Electrical network with low
short circuit power
Conductor length
Activation angle
Cave in of the voltage
Line impedance (inductance)
increases
Activation close to the zero
means less voltage
Impact of the application Attenuation of the current
Attenuation of the current by the application
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The increasing inrush current is the biggest
challenge for Industrial Controls
10.2016 Page 21
Lower nominal current
Increasing starting current
Increasing inrush current
Impact on devices with overload and short
circuit protection
Impact on devices with limitations of
maximum current during start-up
(e.g. solid state devices)
Impact on switching capacity and breaking
capacity of the devices
Changes with IE3 Impact on industrial controls
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10.2016 Page 22
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We are IE3ready!
10.2016 Page 23
An
aly
sis
We know all the requirements of the new IE3-motors for our
industrial controls, thanks to years of analysis and
measurements of the new motor generation IE3 – premium
efficiency
Op
tim
izati
on
We have optimized our SIRIUS industrial controls for those new
requirements, e.g. our new MSP 3RV2 size S2 with adapted
tripping behavior, extended setting ranges and increased
switching capacity
IE3 r
ea
dy!
We are IE3 ready!
Reliable switching and protection of motors at any time – for
IE1, IE2 and IE3
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Circuit breaker, contactor, motorstarter
– our devices are IE3ready
10.2016 Page 24 Stein, Gregor / DF CP S&MK MP 1
Jeffrey Woolfolk
E-Mail:
siemens.com/ie3ready
mailto:[email protected]