An Accurate Method To Determine Electric Motor Efficiency While The Motor Is in Operation

An Accurate Method to Determine
Electric Motor Efficiency While the

Motor is in Operation
Rich Schiferl
Rockwell Automation
In-field electric motor efficiency measurement
Outline
Background
New method for determining electric motor
efficiency
Implementation
Accuracy vs lab tests
Conclusions
Background
Energy cost is growing at a high rate
Plants can save a substantial amount of money by
replacing existing inefficient motors with new highly
efficient motors
An accurate method to determine electric motor efficiency
is needed to make these decisions
Without the need to disconnect the motor from the driven
equipment
Without the need to make connections at the motor terminal box
Include all motor losses
Provide both motor efficiency and output load information
Electric Motor Efficiency Wizard

Portable metering
Speed
Temperature
Resistance
Power
Voltage
Current
Frequency
Laptop computer for data

collection
Proprietary algorithm to
calculate motor efficiency
Measurements made at Two Motor

Load Points
Motor
Starter
Voltage,
Frequency,Resistance
Efficiency
Wizard Kit
Current
Three phase
induction motor
Temperature and Speed
Test Procedure
Disconnect motor power at the starter
Measure line to line resistances at the
starter.
Measure the motor and cable temperature
using the Infra Red meter
Record cable length (starter to motor) and
gage
Test Procedure...
Connect the Power Monitor and frequency
monitor leads at the starter box
current, voltage, frequency, input power
Start data download to the Laptop PC

Record motor fan diameter and nameplate data
Start the motor and bring it to normal load
condition.
Measure motor speed and surface temperature at a
normal running load and at a second load point.
Enter data into the Laptop PC
Motor Input Data Sheet

Motor Data
REL S.O.
xxxxxxxx
Volts
Frame
HP
Type
Hertz
75
Amps
AMB
C/INSUL.
Duty
91 CONT
460
Code Letter Enclosure
G
TENV
E/S
RPM
60
Rotor
S.F.
Test S.O. Date Test Date

2/27/02
2/27/02
Input Power
KW
N. of Poles Frequency V L12
V L13
1186.7
60.51
6
60.002
466.833
466.833
1193.2
32.976
6
59.995
469.1
469.1
Item
Test Point 1"High Load"
Test Point 2 "Low Load"
RPM
Item
Test Point 1"High Load"
Test Point 2 "Low Load"
V L23
I1
466.833
469.1
Stator Resistance &

Temperature**
Resistance
StatorTem
perature in
R12 total
R13 total
R23 total C
Cable Temp
0.16
0.16
0.17
51
24
** Measure the resistance of

the stator
and record the temperature at
the time
of measurement.
SLL % Factor at Rated Power
Performance Curves Rated
Voltage
Performance Curves Rated
Freq.
Design Factor
Hours Per Week
KW hour cost in dollars
Motor Appliction
XEX Motor Efficiency
1185
Nema
Design
B
I2
88.012
56.299
Motor HP
I3
88.012
56.299
Stator
Cable
Temperature Temp
88.012
60
56.299
56
F&W
watts
39
39
250
250
SLL % of
Output
1 - 125
126 - 500
1.8 501 - 2499
460
60
1.0325
168
0.05
#3 Boiler
Fan
95
Cable
Length in
Feet
Cable
Gauge
1
213.5
Cables /phase
1
Results Provided
Motor output torque and horsepower at the two load
points
Motor efficiency at the two load points
Includes I2R, core, friction and windage, and stray load loss
Motor equivalent circuit parameters

Performance curves for the motor
Power and torque vs speed
Efficiency, power factor and current vs load
Energy savings (in kilowatt hours and $) if this motor

is replaced with an energy efficient motor
Given energy cost, hours of operation per week
Output Data Sheet

Motor Data
REL S.O.
xxxxxxxx
Volts
Frame
HP
0
Amps
Duty
460
91 CONT
Code Letter Enclosure E/S
G
TENV
Type
Hertz
RPM
0
60
1185
AMB C/INSUL. S.F.
Nema Design
0
0B
Rotor
Test S.O. DatTest Date
0
0
37314
37314
75
Input
Output Torque
Item
Output HP
Current
Speed
ft.lb
Power factor Efficiency
Test Point 1"Hig
72.66
88.0
1186.7
321.6
0.85
90.6
Test Point 2 "Low
38.75
56.3
1193.2
170.5
0.72
88.4
Motor
Parameters
Phase
Stator
Core
Rotor
Rotor
Resistance Inductance Resistanc
Magnetizing
Inductance Resistance
R1&cable
L1
e Rc
Inductance Lm
L2
R2
0.057
0.00060
77.471
0.0189
0.00082
0.03767
Output Power
HP
Input Current
5.5
37.2
24.8
46.1
43.4
60.2
60.9
76.4
77.5
93.4
85.4
101.9
92.9
110.4
XEX Motor
Efficiency
$ Savings Per
Year
Annual KWH
Saving
Power
factor
Efficiency
0.242
57.5
0.595
84.8
0.756
89.2
0.825
90.4
0.857
90.6
0.866
90.6
0.872
90.4
Output
Speed RPM Torque ft.lb.
1199.0
24.2
1195.6
109.1
1192.3
191.0
1188.9
269.2
1185.5
343.3
1183.8
378.7
1182.1
412.9
95
1223
24468
10
Efficiency Calculation Accuracy

10 HP Motor
92
91
90
Efficiency
89
IEEE 112B lab test

Efficiency Wizard
Measured E fficiency
E stimated E fficiency
88
87
86
85
84
1 /4 L o ad
1 /2 L o ad
3 /4 L o ad
F ull L o ad
M o to r L o a d
11
Efficiency
600 HP Motor
IEEE 112B lab test

Efficiency Wizard
100
98
96
94
92
90
88
86
84
Measured
Efficiency
Estimated
Efficiency
1/4 Load 1/2 Load 3/4 Load Full Load

Motor Load
12
Efficiency
150 HP Motor
93
92
91
90
89
88
87
86
85
84
83
IEEE 112B
lab test
Measured
Efficiency
Estimated
Efficiency
Efficiency
Wizard
1/4
Load
1/2
Load
3/4
Load
Full
Load
Motor Load
13
Motor Efficiency Versus Output Power

Mitsubishi
2/27/02
REL
Efficiency
xxxxxxx
#3 Boiler Fan
75 HP
100.0
90.0
80.0
Efficiency (%)
70.0
60.0
50.0
40.0
30.0
20.0
10.0
0.0
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
Horespower
14
Input Current Versus Output Power

Mitsubishi
2/27/02
#3 Boiler Fan
Input Current
REL S.O. xxxxxxxx
75 HP
120.0
Input Current (Amps)
100.0
80.0
60.0
40.0
20.0
0.0
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
Horse Power
15
Power Factor vs Output Power

Mitsubishi
2/27/02
#3 Boiler Fan
Power factor
REL S.O. xxxxxxxx
75
HP
0.90
0.85
0.80
Power Factor
0.75
0.70
0.65
0.60
0.55
0.50
0.45
0.40
0
10
20
30
40
50
60
70
80
90
100
Horsepower
16
Speed vs Output Power

2/27/02
Mitsubishi
Speed RPM
REL S.O. xxxxxxxx
75
#3 Boiler Fan
HP
1200
1198
1196
1194
RPM
1192
1190
1188
1186
1184
1182
1180
0
10
20
30
40
50
60
70
80
90
100
Horsepower
17
Motor Torque vs Speed

2/27/02
Mitsubishi
REL S.O.
Output Torque ft.lb.
xxxxxxxx
75
#3 Boiler Fan
HP
450
400
350
Torque ft.Ib
300
250
200
150
100
50
0
1180
1182
1184
1186
1188
1190
1192
1194
1196
1198
1200
RPM
18
How Does it Work

Input data at the two load points is used to
calculate the induction motor equivalent circuit
parameters
Core loss, stator I2R loss and rotor I2R loss are obtained
by solving for equivalent circuit losses
Stray load loss is estimated from IEEE standard

formula
Friction and windage loss is determined from an
electric motor database
fan diameter and speed as inputs
19
Induction Motor Equivalent Circuit

R1
Va
L1
I1
V1
I2
I3
Rc
L2
Lm
R
2
s
20
How Does it Work

Performance curves are calculated
using the equivalent circuit model
efficiency, power, torque, power factor
and current vs speed and/or load
21
Features of the Efficiency Wizard

All electrical measurements can be made at
the motor starter
Lead length compensation is included in the
software calculations
No need to mechanically disconnect the

motor from the load
Two separate load points are required
Definite purpose portable field kit with high

accuracy metering
22
Features of the Efficiency Wizard
All motor losses are determined

Can be used on all induction motors
High accuracy test results
Motor performance curves provided
Automatic calculation of potential
energy and $ savings
23
Potential Uses
Provide information for:
Decisions to immediately replace a motor with
a more efficient one
Data base of in-service motor performance
Can be used for future motor replacement decisions
Can detect under loading or over loading
Prioritize present or future motor replacements
Provides data for fact based decisions on

motor replacement
Energy savings drop to the bottom line
24
Example Results
250 HP motor
Existing motor efficiency = 92.4 %
Energy efficient motor efficiency = 96.2%
Annual energy cost savings with motor
replacement = $1417
The present value of the savings over 20

years will be $15,256.
25
Conclusions
An accurate field tool for determining
induction motor efficiency has been
developed
Portable hardware kit
Proprietary software
The new tool can be used on-site without

the need to disconnect the motor from the
driven equipment
Two load points
Electrical connections at the motor starter
26
Conclusions
Accuracy is to within 1% of laboratory
test comparisons
10 hp thru 600 hp
Motor performance, energy and $ cost

savings are calculated from in-field test
data
Energy saving opportunities can now
be readily identified
27
Thank You
28

An Accurate Method To Determine Electric Motor Efficiency While The Motor Is in Operation

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An Accurate Method to Determine

Electric Motor Efficiency While the

In-field electric motor efficiency measurement

In-field electric motor efficiency measurement

In-field electric motor efficiency measurement

Electric Motor Efficiency Wizard

Laptop computer for data

Measurements made at Two Motor

Temperature and Speed

In-field electric motor efficiency measurement

In-field electric motor efficiency measurement

Start data download to the Laptop PC

Motor Input Data Sheet

Test S.O. Date Test Date

Stator Resistance &

** Measure the resistance of

In-field electric motor efficiency measurement

Motor equivalent circuit parameters

Energy savings (in kilowatt hours and $) if this motor

Output Data Sheet

In-field electric motor efficiency measurement

Efficiency Calculation Accuracy

IEEE 112B lab test

In-field electric motor efficiency measurement

Efficiency Calculation Accuracy

IEEE 112B lab test

1/4 Load 1/2 Load 3/4 Load Full Load

In-field electric motor efficiency measurement

Efficiency Calculation Accuracy

In-field electric motor efficiency measurement

Motor Efficiency Versus Output Power

In-field electric motor efficiency measurement

Input Current Versus Output Power

REL S.O. xxxxxxxx

Input Current (Amps)

In-field electric motor efficiency measurement

Power Factor vs Output Power

REL S.O. xxxxxxxx

In-field electric motor efficiency measurement

Speed vs Output Power

REL S.O. xxxxxxxx

In-field electric motor efficiency measurement

Motor Torque vs Speed

Output Torque ft.lb.

How Does it Work

Stray load loss is estimated from IEEE standard

In-field electric motor efficiency measurement

Induction Motor Equivalent Circuit

In-field electric motor efficiency measurement

How Does it Work

In-field electric motor efficiency measurement

Features of the Efficiency Wizard

No need to mechanically disconnect the

Definite purpose portable field kit with high

Features of the Efficiency Wizard

All motor losses are determined

In-field electric motor efficiency measurement

Provides data for fact based decisions on

The present value of the savings over 20