A

Micro Project Report

on
“Energy saving using Energy Efficient Motor”

Submitted by
Gowardhane Pawan Dhulaji: 1911670424
Gadakh Aditya Laxmikant: 1911670425
Dhake Lokesh Anil: 1911670426

Under the Guidance of

Prof. P.G.Patil
In the partial fulfilment of Fifth Semester of
Diploma in Electrical Engineering

Department of Electrical Engineering

Sandip Polytechnic
Mahiravani, Nashik - 422213
Affiliated to
Maharashtra State
Board of Technical Education, Mumbai
Academic Year 2021-22

Maharashtra State
Board of Technical Education

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 Certificate

This is to certify that Gowardhane Pawan Dhulaji (10),Gadakh Aditya

Laxmikant (11), Dhake Lokesh Anil (12) of Fifth Semester of Diploma in
Electrical Engineering of Institute Sandip Polytechnic, Nashik (1167) have
completed the Micro Project satisfactorily in the subject “Energy
Conservation and Audit ”(22525)for the academic year 2021-22 as prescribed
in the curriculum.

Enrollment No Student 1: 1911670424 Exam Seat No 1:

Enrollment No Student 2: 1911670425 Exam Seat No 2:
Enrollment No Student 3: 1911670426 Exam Seat No 3:

Place: Nashik Date: 31/12/2021

Subject Teacher Head of the Department Principal

Seal

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 ACKNOWLEDGEMENT

We express our deep sense of gratitude to our subject teacher Prof. P.G.Patil
for their valuable guidance, support and encouragement in completing our micro
project.

We would like to extend our gratitude to the head of the department of

Electrical Engineering Prof. S.A.Shastri for permitting us to utilize all the necessary
facilities of the department.

We are also thankful to all the faculties and staff members of our department
for their kind co-operation and help.

Lastly we would like to express our deep appreciation towards our classmates
and our indebtedness to our parents for providing us the moral support and
encouragement.

Gowardhane Pawan Dhulaji (10) Enrollment No 1: 1911670424

Gadakh Aditya Laxmikant (11) Enrollment No 2: 1911670425
Dhake Lokesh Anil (12) Enrollment No 3: 1911670426

Place: Nashik Date: 31/12/2021

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 Evaluation Sheet for the Micro Project
Academic Year: 2021-22

Course: Electrical Engineering Course Code: EE5I

Subject: Energy Conservation and Audit Subject Code: 22525

Name of the Faculty: Prof. P.G.Patil

Title of Micro Project: Energy Saving Using Energy Efficient Motor

COs addressed by Micro Project:

B) Implement energy conservation techniques in electrical machines.

Major Learning Outcomes achieved by students by doing the project:
a. Practical Outcomes-:Determine the reduction in power consumption in star mode
operation of induction compared to delta mode.
b. Unit Outcomes in Cognitive Domain: Describe the techniques to improve the
performance efficiency of the given type of electrical machines.
c. Outcomes in Affective Domain :Practice energy conservation

Marks out of Marks out of

Total
06 for 04 for
Roll Enrolment Marks
Name of Student performance performance
No. No out of
in group in oral/
10
activity presentation
Gowardhane Pawan
10 1911670424
Dhulaji
Gadakh Aditya
11 1911670425
Laxmikant
12 Dhake Lokesh Anil 1911670426

(Name Signature of Faculty)

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INTRODUCTION

Electric motors are industry's basic need. Industries consume about 50% of the power
generated in the country and electrical motors consume around 72% of the total electricity
used in the industrial sectors. Three phase induction motors are the prime source of energy
consumption in industry India is facing a problem of heavy energy crunch and gap between
demand and supply is increasing day by day. Now this is the time to pay utmost attention to
more efficient designs. It is always better to use more efficient equipment, motors etc. with
the available supply facilities rather than increasing supply facilities to feed the inefficient or
less efficient loads The energy efficient motors (EEM) were introduced by the middle of
1970s Large motor manufacturers started offering EEMs in addition to their standard
efficiency motors(STMs). Efficiency of a standard motor is less as compared to EEM for any
rating EEMS are more efficient due to their designs, material used, perfect sizing etc.

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IMPORTANCE OF ENERGY EFFICIENCY IN THE INDUSTRY

As industries keep growing globally, there will be corresponding increase in energy use
which will result in more emission of greenhouse gas, such as carbon dioxide (CO2), sulphur
dioxide (SO2), nitrogen Oxide (NOx) and carbon monoxide (CO). These dangerous gases
affect the climate adversely by raising the temperature, flood, drought as well as economic
chaos. If the current practices in most industries in the world continue, greenhouse emission
will increase. Energy efficient technology offers great opportunity in trimming down energy
budget by utilizing high efficiency with corresponding growth in the economy, as well as
environmental protection. Three approaches have been suggested as means of improving
energy efficiency: energy saving by management, energy saving by technology and energy
saving by regulation.

A. Energy Saving By Management Energy management has been an integral component of

industrial management tree since 1970s due to fear of impending exhaustion of world energy
deposit and increasing price of fossil fuels. Management main objective is to devise means of
optimizing energy using systems and procedures that will minimize cost without affecting
production and quality and at the same time preserving the environment. This strategy has the
potential of meeting energy needs of the nation at any point in time.

B. Energy Saving By Technology Implementation of technologies may hold a great potential

of saving energy by reducing consumption. One of such technologies is the use of high
efficient motor. The bulk of energy consumed in the industry is by electric motor as majority
of the activities depend so much on it. Although standard electric motor has high efficiency,
replacing it with energy efficient motor will further increase the efficiency by about 3%
which will lead to lower cost of running the machine, with corresponding energy saving.

C. Energy Saving By Regulation Efficiency of electric motors can be improved if there are
regulations guiding the equipment. Regulation can specify regular energy audit and mandate
that energy manager be employed or energy management system be adopted. Fiscal policy is
also a way of improving energy efficiency by taxation, imposition of taxes, investment tax
credit and establishing investment tax lending. This bank lending can place priority on
projects that would improve energy efficiency. This will in turn save energy by reducing
consumption rate.

D. The Need To Increase Efficiency Of Induction Motor In order to increase the importance
of improving on the efficiency of electric, there are important considerations that should be

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made. Electric motors currently consumed between 40% and 50% of energy generated
globally. Electrical motors consume energy equivalent to 120% of its purchase price. Though
the efficiency of standard electric motor ranges between 65% and 95%, increasing efficiency
by 0.5% will lead to saving a huge amount of energy. It is also expected that in 30 years’
time, demand for energy would have doubled. With the aforementioned facts, it is reasonable
that implementing energy efficient motors would save a lot of energy to meet the growing
energy

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OVERSIZING OF STANDARD MOTORS

An overrated motor for smaller load is less efficient. While employing an electric motor for
particular application, safety margins are provided at every step by a designer, an engineer, a
manufacturer and user which adversely affects efficiency and power factor (p. f) For the same
load the oversized motor will take more current as compared to proper sized motor:
Oversized motor is not loaded fully. Most of the standard motors in industry run it a load
which is less than full load Exact rating of EEM may be selected due to very high reliability
and also service factor which EEM is offering is 1.15 Service factor specifies the capacity of
motor to withstand prolonged overload conditions

REWINDING OF A STANDARD

When the motor winding burns due to overheating, old winding is stripped out and replaced
with a new one. This rewinding is very common which often leads to poor performance and
deterioration of efficiency in case of a standard motor. For this there are number of reasons
which are as follows

1) Even slight damage of core or insulation between the stampings may result into
increased losses.
2) Overheating prior to rewinding might change the characteristics of stator core which
may result in increase in iron losses
3) During rewinding if smaller diameter wire issued, that results into increase in copper
losses.

In addition if better insulation is not provided, or if proper procedures are not followed,
degradation takes place which is often overlooked so as to minimize the cost. But that results
into high running charges User should carry out the w economics of EEM vs rewinding as
most of the times energy saving from installing a new EEM instead rewinding the existing
STM may be large.

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DESIGN OF EEM TO REDUCE THE LOSSES

Design criteria for EEM involves addition of more active magnetic and conducting material,
optimum design of slots, air gaps and windings so as to achieve the maximum efficiency.
Points considered while designing the EEM are.

Core Losses

Core losses can be reduced by using high grade silicon steel. The silicon content is up to 4%.
The magnetic loss in watts per kg is very low. Silicon content decreases hysteresis and eddy
current loss Eddy current loss is further reduced by using very thin laminations for the core
Many standard motors use 24 gauge laminations. In EEM, thinner laminations like 26 gauge
or 29 gauge are used to reduce the core loss. By employing thinner laminations, core loss
reduction obtained is up to 10 to 25 % There is a limit to this because, with the redaction in
the flux density, permeability reduces which increases the magnetizing current and reduces
the p.f.

Copper Losses

Stator winding is designed such that a resistance is minimised. Stator copper losses are
reduced by increasing the copper section of wire which is to be wound on the core. This
reduces resistance and reduces I²R losses. Maximum. utilization of slots is done Rotor copper
losses are reduced by increasing section of rotor bars and end rings. This results into motor
operation at lower temperatures

Friction And Windage Losses

Friction in the bearing causes the friction loss. While ventilating fan and other rotating
elements in the motor cause windage loss In EEM, improved bearings are used to reduce the
friction loss and optimum design of fan reduces the windage loss. In EEM, less heat is
generated therefore fan size can be reduced to lower the windage loss

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Stray Losses

Stray loss is a function of many design elements and processing of the motor These losses are
minimises by careful manufacturing process control ic careful selection of slot numbers,
tooth/slot geometry, air gap length etc.

Other design aspects

Air gap between stator and rotor is optimized to reduce the magnetizing current and
associated losses. This results into improved p.f.

Class For H type insulation is provided which can withstand very high temperatures. This
results into cooler motor operation and requires less maintenance.

EEM may be provided in drip proof totally enclosed, fan cooled, explosion proof type
enclosures. Generally, 30% increase in copper and 20% increase in iron provides high
efficiency in a motor.

FEATURES OF ENERGY EFFICIENT MOTOR

Performance of EEM is better than STM under fall, partial and no load conditions Due to
higher efficiency, EEMs not only save energy in their own and contribute to reduced demand
but also energy in the cables and transformer that supply the motor EEM nun cooler. As
thermal stresses are low, cooling requirements are low. EEM's bearings run about 10° c
cooler than STM bearing This doubles the insulation life. EEM's windings run 20'c cooler
which increases insulation life by four times.

• As EEMs have lower losses, their slip is smaller than the standard motor. This small
slip causes them to have lower starting torque than the standard motor. Therefore
EEM are not suitable for those applications where higher starting torque is required.

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 • When slip is small, speed of the motor is high This higher speed causes more power
drawn by the motor as power increases with cube of the speed in some loads Due to
this, saving obtained due to use of EEM may be lost. Some methods to reduce this
property may be employed for EEM .

• Generally EEM operates at higher p.f than the standard motor. This results into low
losses Also amount to be spent in the p.f correction is saved Rarely EEM may have
lower p.f. than STM. . Starting current is more in case of an EEM than STM. Because
of this, sometimes short circuit protection may trip.

EEM STANDARDS

Number of efficiency standards for motors have been adopted and proposed over the years
These standards recommend motors to exceed their efficiency to some specific value which
varies with the motor size, motor speed, enclosure type etc

National Electrical Manufacturer's Association (NEMA) in 1989, published a standard that

lists the nominal and minimum efficiency for a motor. Motor efficiency must exceed the
minimum efficiency mentioned in the standards in order to be designated as an energy
efficient motor.

NEMA suggested standards for some of the motor sizes for four pole three phase EEM are
given in .The Bureau Of Indian Standards (B.L.S.) has adopted IS 12615, 1989 for Energy
efficient three phase Squirrel Cage Induction Motor, 15 12615 specifics efficiencies at 75%
and 100% of the rated output and the range is from 0,75 kW to 37 kW. This standard
specifies that efficiency of an EEM at 75% and 100% of the rated output shall not be less
than that specified in the standard IS 8789 gives efficiencies of Standard three phase
Induction Motor.

COST BENEFIT ANALYSIS

When a motor is designed to achieve high efficiency and high pf, by using more and better
material, cost of the motor increases by 15 to 20% that of the standard motor. This increase in
the cost is due to more copper used, higher grade laminations, longer core length, better

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insulating material etc. Though cost of EEM is higher than the STM EEM is preferred
because running cost of EEM is much less as compared to the standard motor for any given
load In general in industry, annual motor consumption of electricity is equivalent to 4 to 5
times it's purchase price. In fact no energy using appliance should be bought purely on the
basis of capital cost when there is a rise in the cost of the energy almost every year

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