tma ee motors presentation-june 2005

8/3/2019 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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11 June 2005 Bharat Bijlee Ltd 2

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

tma ee motors presentation-june 2005

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