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Electric Motor Minimum Energy Performance
Improving the Efficiency of Motors and Motor Driven Systems
Frank CerraEngineering Manager, SEW-Eurodrive, AustraliaAI Group - Rotating Machines Forum (Chair)
Aust Eng Syd Mech Feb 2009
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Contents
Minimum Energy Performance Standards (MEPS) for Three Phase Cage Induction MotorsStandards and Legislative requirementsEffect of Efficiency Improvement on Motor Design and SelectionApplication Considerations and Total Drive System EfficiencyFuture Directions in Motor and Systems Efficiency
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MEPSMinimum Energy Performance Standards For Electric Motors
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Driving the worldSEW-EURODRIVE
Energy Information- World Energy consumption
Source: Technologie und Förderzentrum, Bayerisches Staatsministerium für Landwirtschaft und Forsten
Nuclear PowerWater, biomaterialGasCoalOil
World population
WorldPopulation(Billion) World
War 1
Great Depression
World War 2
Oil Crisis
Billion Tonne(Coal Equivalent)
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Source: OECD, 2008
Energy Information- World Electricity consumption
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Driving the worldSEW-EURODRIVE
Source: OECD, 2008
Energy Information- Australian Electricity consumption
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Driving the worldSEW-EURODRIVE
Source: OECD, 2008
Energy Information- Australian Energy Usage - Sectors
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Energy Information - Summary
World wide energy usage has been rising at a rapid rateElectricity production contributes to CO2 emissions Worldwide governments are looking at ways to reduce CO2 emissionsBulk of Australian electricity is generated from coalEnergy prices are expected to rise due to Carbon Trading (CPRS)Australian government is committed to improving the energy efficiency of electrical equipment and regulates energy efficiency of domestic, commercial and industrial products as a means of reducing energy usage and CO2 emissions
Department of Environment Water Heritage and The Arts (DEWHA) formerly Australian Greenhouse Office (AGO)e.g. Star ratings on domestic equipment (refrigerators, washers, ….) MEPS for three phase motors and distribution transformers, …
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Why 3 Phase Induction Motors ?
Easy to identify and regulate for efficiency2-5% improvement potential per motorSmall % increment, but many motorsMotor driven applications comprise 48% of total industrial energy use & 25% of total commercial energy use*
*Regulatory Impact Statement for Minimum Energy Performance Standards for Electric Motors. Prepared by Syneca Consulting. Published December 2003. http://www.energyrating.gov.au/library/pubs/200311-rismotors.pdf
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Australia has already implemented two MEPS stages for three phase cage induction motors …
Referred to as MEPS1 & MEPS2
MEPS regulated through State Government laws and regulations
MEPS excludes motors that fall below efficiency levels documented in the Australian Standard AS1359.5 from the market
Covers 2, 4, 6 and 8 pole cage induction motors in the power range 0.73 up to 185kW
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Abteilung / Name / Datum
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MEPS is mandatory for suppliers and motors must be registered – www.energyrating.gov.au/emmenu.html
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Abteilung / Name / Datum
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MEPS1
Came into effect October 2001MEPS 1 was a successful and straight forward programMotors were already available that met the minimum (EFF2) levels
• Australia is a net importer of motors
• As a result of CEMEP & US EPACT – suppliers already had motor designs available to the market
MEPS 1 removed approx 20% of motors from the market.
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MEPS1 à MEPS2 for Motors
The success of MEPS1 drove and sustained a rapid move to MEPS2 in 2006MEPS2 efficiency levels were equivalent to European Efficiency Level 1 and approx. matched USA EPAct motor efficiencies MEPS 1 will save 450 GWh pa (500 kt CO2-e pa GHG) by 2015 compared to BAUMEPS 2 will save additional 550 GWh pa (600 kt CO2-e pa GHG) by 2015 compare to BAUAt MEPS2 introduction 70% of motors on the market at that time would not meet the proposed MEPS2 levels and would be excluded from the market
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The changes introduced by MEPS2 into AS1359.5:2004A3 and B3 new High Efficiency levels were defined.
• based on 15% additional reduction of losses to A2 and B2 (EFF1) level.
A2 and B2 (EFF1) became MEPS from April 2006
A1 and B1 (EFF2) dropped, “grand-fathered” from April 2006
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MEPS 2 – Summary
• Motors supplied into Australia –after 1 April 2006 –must meet new Minimum Energy Performance Standards –to the levels set out in Australian Standard AS1359.5:2004
• Tables A2 & B2 (MEPS), A3 & B3 (“High” Efficiency)
• This affects –2, 4, 6 and 8 pole single speed three phase induction motors – in the power range 0.73 to 185kW
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Standards and Legislative requirements
And equivalent regulations in the States
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Regulations
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Standards
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Standards requirements
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Australian Standard AS/NZS1359.5:2004Applies to three phase cage induction motors in 2, 4, 6 and 8 pole designIn the power range 0.75 up to 185kWStipulates minimum motor efficiency levels to two internationally recognized test methodsIdentifies changeover datesCurrent MEPS = Tables A2 or B2“Premium” High Efficiency = Tables A3 or B3
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Why Two Efficiency Test Methods ?
• Both “were” internationally recognised and used• Test Method A (AS1359.102.3)
– involves direct measurement of stray load losses • Based on IEEE112B & IEC61972 – “US method”• is equivalent to the “new” IEC60034-2-1• is more accurate and is expected to be adopted as preferred
method in future
• Test Method B (AS1359.102.1)– assumes a fixed 0.5% for stray load losses
• Based on the old IEC34-2 – “Old European method” that is now superseded by IEC60034-2-1
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Effect of Efficiency Improvement on Motor Design and Selection
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What makes up efficiency losses?
Friction losses
Iron losses
Additional losses
I²R losses in rotor-cage
I²R losses in stator winding
BearingsFan
Pulsation losses in teeth and yokeSurface losses in stator an rotorLosses due to transverse currents between rotor-barsLosses in stator winding due to currents of non line frequencyLosses in stator winding due to eddy currentsLosses in end areas of winding...
Alternating magnetization of core sheetsEddy current losses
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Losses in induction motors
Relative Distribution of Losses in Asynchronous Motors
Note: small motors have higher I2R stator losses à loss reduction means more slot area à larger motors
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Efficiency improvement by Motor loss reduction Stator slot design, more copper in stator slots and winding geometry changes to reduce stator resistance losses
Increase in active material, slot design optimization, improved quality of lamination steels and thinner laminations to reduce iron losses
Improved fan design, sealing and low friction bearings to reduce friction losses
Increase in size of conductor bars, slot design and end rings, possible use of copper instead of aluminium to reduce rotor resistance losses
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What happened to the motor ?Efficiency éIncrease in active material = size increase
1.5 kWMEPS1
1.5 kWMEPS2
1.5 kWMEPS2 HE
+ η à + η à
Torque/speed characteristic curves become flatter and flatter from standard to premium, with less pronounced pull-up and pull-out torques.
M
n
MEPS1
M
n
MEPS2 HE
M
n
MEPS2• MN
• MN• MN
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What happened to the motor ?
Starting to Nominal Current ratio éPeak torques to nominal torque éSlip at rated power ê, Rated Speed éPower factor êThermal utilization êRotor Inertia éWeight éPrice é
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High and Premium Efficiency MotorsFrame
Size ModelRotor
Material DRE DRP50 Hz 50 Hz
eff1 Aus-Prem.[kW] [kW]
71 DR.71S4 Alu 0.37DR.71M4 Alu 0.55
80 DR.80S4 AluDR.80M4 Alu 0.75
90 DR.90M4 Alu 1.1 0.75DR.90L4 Alu 1.5 1.1
100 DR.100M4 Alu 2.2 1.5DR.100L4 Alu 2.2
DR.100LC4 Copper 3112/132 DR.112M4 Alu 3
DR.132S4 Alu 4 3DR.132M4 Alu 5.5 4
DR.132MC4 Copper 7.5 5.5160 DR.160S4 Alu 7.5 5.5
DR.160M4 Alu 9.2DR.160MC4 Copper 11 7.5
180 DR.180S4 Alu 11 7.5DR.180M4 Alu 15 11DR.180L4 Alu 18.5 15
DR.180LC4 Copper 22 18.5 / 22200/225 DR.200L4 Alu 22 18.5 / 22
DR.225S4 Alu 30 30DR.225M4 Alu 37 37
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Application Considerations and Total Drive System Efficiency
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Average Induction Motor Life (including repairs)
Power range Average life –years
1.0 – 7.5 kW 12
7.5 – 75 kW 15
75 – 250 kW 20
Source: EUP Lot 11 Motors Final Report February 2008 , ISR- University of Coimbra, Aníbal T. de Almeida et al
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Lifecycle cost of motorOver a motor lifecycle the costs of running the motor can far exceed the initial purchase costs especially in applications where the motor is running continuouslyWhen buying a motor consider
• Life Cycle costs• Application• Operating time and duty cycle• Efficiency• Motor size • Transmission losses• Rewind/Repair• Variable speed Operation
96%
1.50% 2.5
0%0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Typical motorlife cycle
costs
Energy Maintenance Purchase CostSource: EUP Lot 11 Motors, Report No. 3, Analysis of existing technical and market information, ISR- University of Coimbra, Aníbal T. de Almeida et al, April 2007
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Motor Application“Highest” efficiency motors are “most” suited where• Many hours of operation daily• Majority of operation at high load (75% +)• Few start/stop and braking operations• Combination with transmission elements that also
have a high degree of efficiency
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Motor Application
Applications where “Highest” efficiency motors are “less” suited due to their higher cost, rotor inertia, weight, or may not be the best technical or economic choice:• Low utilization applications where the number of
operating hours is small• Start - stop (S3 duty) applications• Applications with weight and/or space restrictions
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Saving Potential in Electric Motor Driven Systems
Energy Saving Potential in %
Use of Higher Efficiency Motors 10%
Electronics Speed Control 30%
Mechanical System Optimization 60%
Source: ZVEI Saving Energy with Electric Drives, April 2006, www.zvei.org
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The drive train – effect on system efficiency
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Look at the drive system components !!!Worm Gear unit (75%)
Overall drive efficiency = 60.8%Power delivered to conveyor headdrum = 9.1kW
Power drawn from mains at motor rated load = 16.5kW
Energy used based on 16h/day, 250days/yr = 66000kWh
Cost of energy based on $0.10/kwh = $ 6600 per year
Overall drive efficiency = 88%Power delivered to conveyor headdrum = 9.1kW
Power drawn from mains = 10.3kW
Energy used based on 16h/day, 250days/yr = 41200kWh
Cost of energy based on $0.10/kwh = $ 4120 per year
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Efficiencies of Transmission Elements
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Look at the “system”
Sources: Motor Challenge - Energy Efficient Motor Driven Systems, European Copper Institute, April 2004& EUP Lot 11 Motors Final Report, Almeida et al., Feb 2008.
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Consider Total System Efficiency
Source: SEEEM Update,International harmonization of motor standards saves energy, Conrad Brunner, 2007 - www.seeem.org
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Pumps & VSDs
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Fans & VSDs
Relative power consumption of different air flow control methods
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Compressors & VSDs
Energy saved by using a VSD on a rotary screw air compressor
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Conveyors and VSDs
Energy savings in a conveyor using speed control
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Efficiency Gains / Energy Cost Reduction-
Take the whole system approach.
It can result in much higher
efficiency gains and
cost savings
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Future Directions in Motor Efficiency
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Future Directions – International StandardsIEC 60034-2-1 Ed.1: Rotating electrical machines - Part 2-1: Standard methods for determining losses and efficiency from tests
Published September 2007Harmonizes the motor efficiency test methods to one set of methods globally that deliver low uncertainty in measurement
IEC 60034-30 Ed.1: Rotating electrical machines - Part 30: Efficiency classes of single-speed three-phase cage induction motors
Published October 2008Harmonizes motor efficiency levels globally
for 2, 4 & 6 pole 3 phase induciton motors from 0.75kW to 370kW
IE1 Standard EfficiencyIE2 High EfficiencyIE3 PremiumEfficiencyIE4 Super-Premium Eff
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International Motor Efficiency
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http://www.motorsystems.org/files/otherfiles/0000/0028/MEPS_Guide_1st_Edition_February_2009.pdf
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Abteilung / Name / Datum
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The Global Move to Higher Efficiency Motors
Source: MEPSA Sydney 2009, 2009-motors-session3-brunner.pdf, C Brunner, SEEEM.org
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Summary
Motor and Drive Energy Efficiency:• Reduction of greenhouse emissions by improving the energy efficiency
of motors and motor driven systems• Mandated MEPS• Energy efficiency = reduced operating costs• Look past the motor – there are significant savings in drive train and
“system” optimization• Harmonized standards
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Thank you
Questions ?
Further information:• www.sew-energy-saving.com• www.energyrating.gov.au/emmenu.html• http://www.aigroup.com.au – Rotating Machines Forum• http://www.motorsystems.org/• frank.cerra@sew-eurodrive.com.au
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