Electric Motor Minimum Energy Performance Feb 2009.ppt · Aust Eng Syd Mech Feb 2009 Drive Technology \Drive Automation \System Integration \Services Driving the world Contents Minimum

$Page 1: Electric Motor Minimum Energy Performance Feb 2009.ppt · Aust Eng Syd Mech Feb 2009 Drive Technology \Drive Automation \System Integration \Services Driving the world Contents Minimum$
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Drive Technology \ Drive Automation \ System Integration \ Services

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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


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



Source: OECD, 2008

Energy Information- Australian Electricity consumption

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Source: OECD, 2008

Energy Information- Australian Energy Usage - Sectors



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

http://www.energyrating.gov.au/library/pubs/200311

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MEPS is mandatory for suppliers and motors must be registered – www.energyrating.gov.au/emmenu.html

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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.

http://www.energyrating.gov.au/emmenu.html

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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

http://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

http://www.seeem.org

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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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http://www.motorsystems.org/files/otherfiles/0000/0028/MEPS_Guide_1st_Edition_February_2009.pdf

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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/• [email protected]

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http://www.sew-energy-saving.com

http://www.energyrating.gov.au/emmenu.html

http://www.aigroup.com.au

http://www.motorsystems.org/

mailto:[email protected]

Documents

Electric Motor Minimum Energy Performance Feb 2009.ppt · Aust Eng Syd Mech Feb 2009 Drive Technology \Drive Automation \System Integration \Services Driving the world Contents Minimum