Energy Audit,

Management and
Conservation
 Chapter 4:
Motors

Second Semester 2024/2025

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 Electric motors convert Electrical Energy to Mechanical Energy
 About 90% of motors used in the industry are of Squirrel Cage Induction type motors.
synchronous motors , slip –ring motors and d.c motors account for the remaining 10%.
 Motors are classified by type of Supply (AC or DC) , Size(usually measures by power output )
and Speed (rpm).

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Eng. Asma’ shara’b PTUK
All motors operate on the principle of electromagnetic induction. The principle means that the
magnetic induction produces an electromotive force which causes the motor shaft to rotate, thus
rotation is the mean by which motors perform their designed task.

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 Motors Audit
Motor account for a significant portion of energy usage and demand in commercial and industrial
application. it is suggested that information be collected on motor 5HP and larger. Nameplate
information should be gathered as well as the condition, operating hours and operation
environment of the motor. Motor loading can be measured or assumes , depending on each
situation. In some cases, data loggers can be used to collect data over specified time period.

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 How To Read a Motor Nameplate

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Number of Phases This shows the type of power supply for which the motor is designed. There are In this example, the
single phase and three phase motors. number is „3‟ as the
motor is a three phase
motor.

Rated Operating Voltage This shows at which voltage is the motor is designed to operate most
(Volts) efficiently. Motors are designed to operate at +/-10% tolerance of this value.
Other parameters shown on the nameplate including: power factor, efficiency,
torque and current are at rated voltage and frequency. Using the motor at
voltage outside this tolerance will most probably lead to different performance.

Service Duty The parameter Duty/Time rating represents the period of time during which the In this case, S1 shows
motor can run at its nameplate rating/rated load safely and indicates whether the that this is a continuous
motor is rated for continuous duty. duty motor that works at
This is shown as “CONT” for continuous duty 24/7 but they can also have a a constant load for
short-time rating from 5 to 60 minutes, most motors are rated for continuous enough time to reach
duty. temperature Equilibrium.
The rating of the motor is the ambient temperature vs. the time it can operate at
that temperature, the EIC break this down into ten ratings.

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Efficiency This shows the percentage of the input power that is actually converted to work output from In our example, we are
Code the motor shaft. shown an IE Code of
The motor will have a “nominal” efficiency shown on the plate, this is the average efficiency. The IE3 which indicating
closer this value is to 100%, the lower the electricity consumption cost is going to be. premium efficiency.
The four levels of motor efficiency are
IE1 – Standard Efficiency
IE 2 – High Efficiency
IE 3 – Premium Efficiency
IE 4 – Super Premium Efficiency

Frame This shows the frame size. The frame size determines the mounting dimensions such as the
foot openings pattern and the shaft height.
Size The dimension of the electric motor based on the NEMA system for fractional hp motors (micro
motors) have two digits and represent the shaft height from the base‟s bottom in sixteenths of one
inch.
For large motors the frame size has three digits, the first two digits stand for the shaft height in
one quarter of an inch. The third digit is the bolt mounting holes dimension, the longer the motor
body, the longer the distance between mounting bolt holes in the base. Finally, the letter is the
type of frame.
The same concept applies for IEC type motors (metric motors) but the height is measured in
millimeters instead of inches.

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Degree of The IEC uses a two-digit ingress protection (IP) rating to measure how well the motor is In the example below
Protection protected from the environment. NEMA uses an enclosure description that is of a similar an IP of 55 tells us that
standard. the motor is „protected
against dust‟ and
„protected against jets
of water from all
directions.

Temperature Each class of insulation has a maximum motor winding temperature rise and a maximum
Rise temperature rating. In addition, a hot spot temperature rise is specified which pertains to motor
windings that are surrounded by other windings.

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Insulation The highest temperature in the motor‟s hottest spot has a serious impact on the life of the electric
Class motor. The temperature that occurs at that spot is a combination of motor design temperature and
the ambient temperature. The insulation class shows the motor‟s ability to withstand temperatures
over time.
The motors have different insulation capabilities. The insulation codes show their thermal tolerance
or ability to survive at a specified temperature for a period of time. The higher the designated code
letter, the greater the heat capability.
It is based on the highest temperature the material can withstand continuously without degrading
or reducing motor life. IES specify 5 different types of insulation classes:
Class A – 105c
Class E -120c
Class B – 130c
Class F – 155c
Class H – 180c
Frequency This shows the input electricity frequency that the motor is designed to operate at.
(Hz) Usually for motors, the input frequency is 50 or 60 Hz. If more than one frequency is marked on the
nameplate (like our example), then other parameters that will differ at different input frequencies
have to be indicated on the nameplate as well.
Rated This corresponds to the rated power output together with voltage and frequency. The current may
Operating deviate from the nameplate amperes if the phases are unbalanced or if the voltage turns out to be
Current lower than indicated.

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Motor Rated kW is an expression of the motor‟s mechanical output rating – its ability to deliver the torque
Power needed for the load at rated speed.

Full Load Full-load speed is the speed at which rated full-load torque is delivered at rated power output, In the example nameplate,
Speed (RPM) this speed is sometimes called slip-speed or actual rotor speed. this is declared as min‾¹,
but generally it is declared
in RPM; both these
measurements are the
same.

Power Factor Power factor is indicated on the nameplate as either “PF” or “P .F” or cos φ . Power factor is an
expression of the ratio of active power (W) to apparent power (VA) expressed as a percentage.

Ambient The maximum ambient temperature (AMB) lists the temperature at which the motor can In this example, the ambient
Temperature operate and still be within the tolerance of the insulation class at the maximum temperature temperature of the motor is
rise. 40c.

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Service This Indicates the amount of overload a motor can handle. Electrical motors are often
Factor designed to handle a temporary increase in demand, the ability of the motor to handle these
demands are represented by the service factor.
For example, a motor with 1.0 service factor cannot be expected to handle more than its
nameplate kW. A motor with service factor 1.15 can be expected to safely handle infrequent
loads to 15% past it‟s rated kW.

Altitude This indication shows the maximum height above sea level at which the motor will remain
within its design temperature rise, meeting all other nameplate data.
Below this altitude, the motor may run cooler. Above this temperature, the motor may run
hotter.
Motor Weight This shows the weight of the motor 78kg in our example.

Serial This shows the serial number of the motor. As it is unique to the motor, knowing this number
Number can help when liaising with manufacturers or M&E companies about the type of motor you
have.

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It is necessary to have the motors classified on the following basis :
1- Capacity/Rating.
2-Number of Hours running/ year.
3- Loading conditions
- Lightly loaded for long duration
- Lightly loaded for small duration
- Optimal loading condition
4- Speed
5-Task Oriented.
6-Voltage Classification.

The above classification will help to identify the motors which can be considered for implementation
of energy conservation measures.

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 Motor Basics
The primary motor used in commercial and industrial applications is the AC three –phase induction
motor. Three phase induction motors comprise 85 to 90 % of motors in use due to the following
characteristics:
 Simple in design
 Efficient
 Rugged
 Low cost
 Reliable
 Adaptable to VFDS

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 Motor Speed
The speed of a three-phase induction motor depends on the number of poles in the motor, and
the frequency of the alternating current.
The speed of the rotating magnetic field is called the synchronous speed and the equation
is as follows:

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The majority of motors today are two , four or six poles, 3600 rpm ,1800 rpm or 1200 rpm motor
respectively. By Using belts,puleys,gears,VFDS, etc., any load speed can be obtained. Note that
the motor shaft rotates a little slower than the rotating magnetic field due to slip. The full load rpm
on the nameplate reflects the actual shaft speed , and is a little lower than the synchronous
speed. For example, the motor nameplate full load speed may say 3550 rpm, which means it is a
3600 rpm two pole motor

Number of Poles Synchronous Speed (rpm)

2 3600
4 1800
6 1200
8 900
Synchronous speed and number of poles

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 Electrical Motor Efficiency

Efficiency is a measure of the ability of a motor to convert electrical into mechanical

energy.
In order to do an economic analysis of a motor replacement , the efficiency of the existing
motor must be determined . The efficiency rating on motors:
• Represents full load efficiency
• The efficiency drops off as the motor is more lightly loaded.
• Manufacturers only guarantee that the motor meets nominal efficiency rating which is defined
as "the average efficiency of large population of motor of the same design.”
• Motors built after 1982 will have the nominal efficiency expressed as a numerical value on the
nameplate.

Eng. Asma’ shara’b PTUK

 Energy Conservation in Electrical Motor
Energy-Efficient Motors (EEM) are the ones in which, design improvements are incorporated specifically to
increase operating efficiency over motors of standard design .Design improvements focus on
reducing intrinsic motor losses

Energy-efficient motors that are available now are typically

37-40% more efficient than standard motor
A) Improvements include the use of lower-loss steel, a longer core
(to increase active material ), thicker wires( to reduce
resistance), thinner laminations, smaller air gap between stator
and rotor , and smaller fan .

The efficiency of a motor is determined by intrinsic losses that

can be reduced only by changes in motor design. Intrinsic
losses are of two types: fixed losses - independent of motor load, Standard vs High Efficiency Motors
and variable losses - dependent on load

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 Motor losses
 Magnetic core losses (sometimes called iron losses) consist of
a) Eddy current losses, which occur because the magnetic core material it self consists of
material which conduct electricity as voltage are induced in this material by alternating
magnetic fields , current called Eddy current are produced.
b) Hysteresis losses ,which are voltage related and are constant for motor irrespective of
load.
 Copper losses known as (I² R) losses in the rotor and stator , which are proportional to
the square of the load current
 Friction and windage losses are caused by friction in the bearings of the motor and
aerodynamic losses associated with the ventilation fan and other rotating parts.
 Stray losses

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Comparison of losses between Energy Efficient and Standard Efficiency 5 HP ,1800 rpm motor at
full load

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 Motor Loading Determination
Motors rarely are operated at 100% of their full load rating. This means that motors are loaded or
have a load factor of less than 100%. Load factor is defined as:

Motor loading can be estimated in three ways:

1) Estimating motor load by current and voltage
Perhaps the most common method of estimating motor loading is to measure the current and
multiply it times the voltage times the square root of three (1.732). Current measurements can be
deceiving, however, as a low power factor can distort the results. In order to use this method,
estimate the power factor to be 0.8 - 0.9.

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2) Estimating motor load by slip Motor
load is closely proportional to slip, so loading can be estimated if you know the slip. The operating
speed of the motor is determined by using a tachometer. This number is then used in the following
equation to estimate motor loading. An average loading would consists of taking multiple operating
speed measurements throughout the day, month or year.

3) Assume motor loading

If measurements aren‟t made, it is suggested that you estimate the motor loading to be 60% to
70%. This is a typical motor loading in a fan or pump application. Note that some air compressors
may have a higher loading factor.

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B) Using Suitable Motor Loading
 Compare the motor name plate with real measurement . Measurement devices used to
determine the motor loading .
 The motor under Overload or under load will has less efficiency.

Eng. Asma’ shara’b PTUK

Eng. Asma’ shara’b PTUK
C) Using High Speed Motor
There could be 8-15% saving in energy consumption by using higher speed motors
depending on other factors ,however, higher speed motor costs more

Example: Size of motor 7.5 Kw,load 5 HP

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 Motor Economics
Why would a business owner replace a standard efficiency motor that is operating with an energy
efficient one? On a first cost basis the energy efficient motors can be as much as 25% more than
the cost of a standard motor, but the savings in operating cost can well exceed this additional
capital costs.

Demand and Energy Usage Calculations

In order to determine the power requirements of a motor, the following equations can be used:

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Example:
Determine the simple payback realized by replacing the following motor with an energy efficient
one.

Existing motor:
50 HP, 1800 RPM standard chilled water pump motor 4,500 hours per year operation Energy charge = $ .05/kWh
Demand Charge = $ 10.00/kW-Month Efficiency = 90.2% Cost = $1,080

New motor:
50 HP, 1800 RPM 4,500 hours per year operation Efficiency = 94.5% Cost = $1,340

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Solution:
First calculate the operating cost of the existing motor. Assume 70% motor loading and
twelve month operation.

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Calculate the operating cost of the energy efficient motor. Note that the only thing that
changes is the efficiency.

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Total operating costs savings = Existing motor operating cost – new motor operating cost

This payback assumes that the existing motor is operating. If the existing motor is burned
out, then the payback would reflect the difference in cost between the two motors, or

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 VARIABLE FREQUENCY DRIVES
The Synchronous Speed of an induction motor is shown by the following equation:

To change the motor speed, we need to change either the:

• Frequency
• Number of poles

Variable frequency drives change the frequency using solid state electronics.
• Controlling speed
• Starting and acceleration control
• Reducing operating costs

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Applications
VFDs will only save (energy) costs when used with a varying load. Typically weather related
equipment will have a varying load, and some industrial applications such as variably loaded
conveyors. If the load does not vary, the drive will not save any energy.
Basic applications include:
• Air handling units
• Conveyors
• Chilled water pumps
• Rolling mills
• Condenser pumps
• Hoists
• Cooling tower fans

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D) Induction motor controllers(Variable Speed Drivers):
Induction motors are constant speed motors , the speed being determines by the frequency of
the supply .They are more efficient at near full loads, and less at low loads. They have a high
starting torque

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E) Soft Starters:
Energy saving controllers basically try to reduce losses
during the period of light loads by reducing the voltage
applied to the motor . During the period of light
loads, voltage reduction leads to reduction in current ,
iron and copper losses and the power factor is also
improved. The voltage is reduced by control of
triggering of transistors or thyristors as required

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Eng. Asma’ shara’b PTUK
F) Power Factor Correction:
The impacts of power factor correction include reduced
KVA demand , reduced I²R losses in cables , reduced
voltage drop in the cables and an increase in the
overall efficiency of the plant electrical system

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G) Using one Large Motor in place of Two Small Ones :
The larger the motor, the more efficient it would be if there is an option or the facility to do so, it
advisable to use one large motor in place of two or more smaller motors

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 Factors Affecting Motor Performance
1-Quality of supply (voltage,frequency,unbalance)
2-Age of the motor.
3-Maintenance practices.
4-Rewinding burned out motors.
5-Checking load conditions to ensure that the motor is not over or under loaded.

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The Power Factor and kilovars without correction can determined by measuring the power factor,
line amperes and line voltage at the point of correction
For a three-phase system,

Or the line kilowatts, line amperes, and line voltage can be measured. Then,

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The Capacitive kilovars required to raise the system to the desired power factor can be calculated
as follows:
where PF is the desired power factor.

For example, consider a 1000-kW load with a 60% power factor, which one wishes to correct to
90 %

https://electrical-engineering-portal.com/why-raise-the-power-factor
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 Energy Saving Calculation
The electric power savings due to the motor replacement is first computed as follows :
Method 1: Simplified Method

This method has been and is still being used by most energy engineers to determine the energy
and cost savings incurred by motor replacement. Inherent to this method, two assumptions are
made:
(i) the motor is fully loaded and (ii) the change in motor speed is neglected.
The Electric Power Savings due to the motor replacement is first computed as follows:

where
Pm = the mechanical power output of the motor.
qt, = the design (i.e., full-load) efficiency of the existing motor (e.g., before retrofit).
q,. = the design (i.e., full-load) efficiency of the energy-efficient motor (e.g., after retrofit).

https://ebrary.net/195431/engineering/energy_savings_calculations
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 The Electric Energy Savings incurred from the motor replacement is thus:

where
Nh = the number of hours per year during which the motor is operating.
LFm = the load factor of the motor‟s operation in one year.

Method 2: Field Measurement Method

In this method, the motor electrical power demand is measured directly on site. Typically,
current IM, voltage VM, and power factor pfM readings are recorded for the existing motor to be
retrofitted. For three-phase motors (which are common in industrial facilities and in most HVAC
systems for commercial buildings), the electrical power used by the existing motor can be either
directly measured or calculated from current, voltage, and power factor readings as follows:

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The Load Factor of the existing motor can be estimated by taking the ratio of the measured current
over the nameplate full-load current IF, as expressed by Eq. (5.23):

It should be noted that Eq. (5.23) provides more accurate estimates of the motor load ratios than an
approach based on the ratio of the motor speeds (i.e., measured speed over nominally rated
speed) used by BPA (1990) and Lobodovsky (1994). It should be noted that Eq. (5.23) is
recommended for load ratios that are above 50 percent because for these load ratios, a typical
motor draws electrical current that is proportional to the imposed load.
The methodology for the calculation of the electrical power and energy savings is the same as
described for the mechanical power rating method using Eq. (5.18) through (5.23).

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 Example

Determine the cost-effectiveness of replacing a 10-hp motor with an efficiency of 85 percent with a
premium-efficiency motor with a rated full-load efficiency of 91.70 percent. Assume that:
The cost of electricity is $0.10/kWh.
• The differential cost of a premium versus standard motor is $300.
• The average load factor of the motor is 0.80.
• The average full-load operating hours of the motor are 5,000 hr/year

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SOLUTION
To determine the cost-effectiveness of installing a premium-efficiency motor instead of a standard-
efficiency motor, a simplified economic analysis is used to estimate the simple payback period.
The Savings in Energy use in kWh for the premium-efficiency motor can be calculated using
Eqs. (5.15) and (5.16):

where
N$ = the total number of hours (per year) during which the motor is operating at full load is 5,000 hr/year.
HP = the rated motor power output (10 hp).
LFm = the annual average load factor of the motor (LFM = 0.80). r|s)d and Г|с,у= the efficiencies of the standard
transformer and the efficient transformer (0.850 and 0.917), respectively.

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Thus, the Energy Saving in kWh is calculated as follows:

Therefore, the simple payback period SPB for investing in the premium-efficiency motor is:

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Eng. Asma’ shara’b PTUK