BHARAT BIJLEE LIMITED

Energy Efficient Motors

11 June 2005

T M ANKLESARIA

Energy Efficient Motors A National Priority

70 % of all electrical energy consumed in India is used for driving electric motors
55 % of which is consumed by industrial motors
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Consumption of electricity by Sector

OTHERS, 30% INDUSTRY, 39%

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 energy equivalent to 10 to 20 times its purchase price Many consumers in India especially OEMs purchase cheap motors having low efficiency values.

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Bharat Bijlee Ltd

Initial Cost of an 11 kW motor is only 5% 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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Bharat Bijlee Ltd

National Standard for Energy Efficient Motors

IS 12615: 2004 (First Revision) Energy Efficient Induction MotorsThree Phase Squirrel Cage.

IS 12615 covers Energy Efficient motors from 0.37kW to 160kW (up to Fr. 315L) IS 12615 specifies two efficiency levels eff-2 and eff-1.
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IS 12615: 2004 (First revision) - superior to existing Std. IS 8789

To be considered as energy efficient, a motor must conform to one of the following efficiency levels 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 nominal values specified in IS 8789: 1996.
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Comparison of efficiencies of Standard & Energy Efficient Motors

Output 4 Pole
0.75 kW 1.5 kW 3.7 kW 11 kW 18.5kW 37 kW 75 kW 110 kW

IS 8789
71.0% 76.0% 83.0% 85.5% 87.0% 88.5% Not specified Not specified

eff 2 as per IS 12615

73.0% 78.5% 84.0% 88.4% 90.0% 92.0% 93.6% 94.4%

eff 1 as per IS 12615

82.5% 85.0% 88.3% 91.0% 92.2% 93.6% 94.7% 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 specify two efficiency levels?

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.
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Bharat Bijlee Range of eff1 & 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 of 8 to 10 weeks.
BHARAT BIJLEE DOES NOT MANUFACTURE MOTORS OF EFFICIENCY CLASS LESS THAN EFF2

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Bharat Bijlee Ltd

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Bharat Bijlee stock motors are superior to eff 2 as per IS 12615

Output in kW (4 Pole) 0.75 1.5 3.7 Efficiency of BBL Stock Motor 77.0 80.0 84.0 Eff 2 as per IS12615 73.0 78.5 84.0

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18.5 37 75 110 160
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89.0
91.2 93.0 94.0 95.2 95.8
Bharat Bijlee Ltd

88.4
90.0 92.0 93.6 94.4 95.0
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Efficiency values are subject to tolerance as per IS325

Why is the Energy Efficient motor more expensive?

eff 1 motors are generally priced 20-25 % higher than eff 2 motors. More laminations - longer core length and/or High Grade (low loss) laminations

Rs

More Copper

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Bharat Bijlee Ltd

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How is efficiency improved?

Reduce Iron Loss Reduce Copper Loss
Reduce Stator Cu Loss Reduce Rotor Cu Loss

Reduce Flux Density

Increase Copper Section

Stator slot area Reduce Rotor Diam

Increase Rotor bar section Increased Starting current Torque

Low Loss Magnetic matl.

Increase Stator Yoke

Reduced S t a r t i n g

Core length has to be increased to maintain starting torque

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Energy Efficient Motors - Increased Safety & Flame Proof

Bharat Bijlee offers Flame Proof and Increased Safety motors conforming to eff2 as standard Eff 1 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.

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Efficiency improvement to eff1 by use of Low Loss Stamping & increased Fe and Cu
11 kW 1500 rpm eff 2 eff1 Low Loss + increased Stamping Cu & Fe
Iron losses Friction & Windage 400 W 120 W 330 W 120 W 250 W 120 W

Constant Losses Load related Losses Total Losses Efficiency

520 W 840 W 1360 W 89%

450 W 750 W 1200 W 90.2%

370 W 650 W 1020 W 91.5%

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Bharat Bijlee Ltd

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Energy Efficient Motors have a Flat Efficiency Vs Load Characteristic

Motor rating is selected for max. load conditions and next preferred rating Most motors operate on an average around 75% load.
Efficiency is almost same from 60% to 100% load in a well designed EE motor
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95 90 85 80 75 70 70 65 60 60 25% 50%

86 80

89 84

89 85.5

Efficiency

75%

100%

Load Motor As per IS 8789 eff-2 Motor

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The more expensive eff2 motor is in fact cheaper

IS 8789
Purchase Price 11 kW motor Efficiency Energy consumption p.a. For 5000 hrs @ Rs 4 per kWH Energy Saving Rs 13,600 ( - 15 %) 85.5 % Rs 2,57,310

IS 12615 eff2
Rs 16,000 88.4 % Rs 2,48,868 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 savings over an eff2 motor

Purchase Price of 11kWmotor Efficiency 88.4% Energy consumption p.a. Rs 2,48,868
(For 5000Hrs@ Rs 4.0/ kWH)

eff2 Rs 16000

eff1 Rs 19200 +20% 91.0% Rs 2,41,758

Energy Saving Additional Purchase Price

Rs 7110 p.a. Rs 3200

Pay Back Period of eff1 motor is 5.4 months for a 20% price increase over eff2 motor
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Energy savings increase at partial loads due to flat efficiency vs load Characteristic
11kW-4 Pole BBL eff 2 motor Vs motor as per IS 8789.
Load Working Hrs. p.a. Eff of IS-8789 motor Eff of eff 2 (BBL stock motor) Difference in input power (kW) 100% 1000 85.5% 89 0.506 75% 3000 84% 89% 0.551 50% 1000 80% 86% 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 Rewinding 11 kW 4 pole motor

Eff of Old Motor to be rewound or replaced New motor Efficiency Purchase Price of new motor Rs Rewinding Cost Rs IS 8789 eff2 16000 4000 eff2 eff1 19200 4600

Additional Cost Rs
Efficiency of old motor Efficiency after rewinding ( less 1.5%) Efficiency of new motor Saving by replacement with new eff2 motor For 5000 Hrs @ Rs 4.0 per kWH (Rs) Pay back period :

12000
85.5% 83.0% 88.4% 0.809 kW 16180 8.9 Months

14600
88.4% 86.9% 91.0% 0.570 kW 11406 15.4 Months

Replace old eff 2 motor with eff1 motor & get Payback in 15 months
11 June 2005 Replace Bharat Bijlee Ltd old IS8789 motor with eff2 motor & get payback in 9 months 20

Problems in field testing

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.
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Nameplates marking of Efficiency

Bharat Bijlee Limited
3 ph. Induction motor
Type MH16M4734 Fr 160M

Bharat Bijlee Limited

3 ph. Induction motor
Type MA16M433 M/c. No
Fr 160M

MADE IN INDIA
Hz 50

MADE IN INDIA
Hz 50

Insl Cl F

Insl. Cl F Duty S1

M/c. No

.
A 19.7 rpm 1460 EFF-1

Duty S1 Eff % 91.5 P f 0.85

A 20.5 rpm 1450 EFF-2

Volts 415 kW/HP 11/15

Volts 415

Eff % 89.0 P f 0.84

kW/HP 11/15

BB High Efficiency Motor

BB Standard Motor (Improved Efficiency)

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Bharat Bijlee EE motors are clearly labeled 11 June 2005 Bharat Bijlee Ltd EFF-1 or EFF-2

Intermittent duty applications.?

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
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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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Bharat Bijlee Ltd

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Testimonial from Grasim Industries Chemical Division

TO WHOMSOEVER IT MAY CONCERN We are using Bharat Bijlee 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)
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Summary and Conclusions

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.

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Bharat Bijlee manufactures Energy Efficient motors conforming to eff1 or eff2 of IS 12615
Bharat Bijlees Standard Ex stock Motors conform to eff2 of IS 12615 Inferior motors conforming to IS 8789 are not manufactured by BB
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