KJ'S EDUCATIONAL INSTITUTES

Trinity Polytechnic, Pune

ELECTRICAL DEPARTMENT

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UNIT: 02 Energy Conservation Techniques in Electrical Machines

Course: - Energy Conservation and Audit Course Code: 22525 Class:TYEE

Relevan
Que. Bloom’
Questions ce to
No. s Level
CO
1 2 Explain the necessity of energy conservation in Electrical motors.
Marking Any four points 1 mark each
Scheme
Need of energy conservation in Electrical motors:
1. Induction motors are used as electrical drives in industrial, commercial and
residential sectors.
2. Considering all industrial applications, 70% of total electrical energy is consumed by
only electric motor-driven equipment.
3. Half of total energy consumed by any equipment in any application is used by
Answer motors.
COI504.2
4. Induction Motor’s efficiency is maximum at full load only and on an average of 80 %
to 85%. For load less than 30%, efficiency is very poor.
5. Induction motor works with poor power factor (less than 0.85) at full load and less
than 0.35 at low load condition.
6. Induction Motor draws high starting current and hence creates voltage drop in supply
line, which affects performance of other apparatus connected tom the same system.
7. Induction motor also needs lagging reactive power which is required for its working;
hence it also acts as reactive power load on supply system.
8. To adopt advanced technology in design and to use better quality materials.
2 2 State the need of energy conservation in transformer and material used
to improve the design & performance of transformer.
Marking Any four points 1 Mark each.
Scheme
Need of energy conservation in transformer:
 In electrical power system, transformers are used to change the voltage levels of
different sections as per the need of economic and efficient operation of the
system. Since the transformers are integral part of power system and large in
numbers, whether they are on load or no load, they always remain on line.
 The power losses in windings (no load primary copper losses due to no load
Answer
current) and in magnetic core (due to rated voltage across primary) results in
energy wastage.
 As rated voltage and no load current are there around the clock, reduction in
these losses in transformer leads to large amount of energy savings over the COI504.2
period, which can be used for some other good reason. Therefore, there is need
of energy conservation in transformer.
 Material used to improve the design & performance of transformer:
(i) Amorphous metal or amorphous steel
(ii) Epoxy Resin
(iii) Polyester sealent
(iv) Cast Resin
(v) Metglass
Describe the following energy conservation methods of electrical
motors :(I) Matching motor (II) By operating in star mode (III) By
3 3 motor survey
(IV) Minimizing idle and redundant running of motor.
(V) Rewinding of motor (VI) by improving power quality.
Marking
Any four 1 mark each
Scheme
(1) Matching motor:
i) Industrial motors frequently operate under varying load conditions due to process
requirements. A common practice in cases where such variable loads are found is to
select a motor based on the highest anticipated load.
ii) In many instances, an alternative approach is typically less costly, more efficient, and
provides equally satisfactory operation. With this approach, the optimum rating for the
motor is selected on the basis of the load duration curve for the particular application.
Thus, rather than selecting a\ motor of high rating that would operate at full capacity for
only a short period, a motor would be selected with a rating slightly lower than the peak
anticipated load and would operate at overload for a short period of time.
iii) The operation within the thermal capacity of the motor insulation is of greatest
concern in a motor operating at higher than its rated load, the motor rating is selected as
that which would result in the same temperature rise under continuous full-load COI504.2
operation as the weighted average temperature rise over the actual operating cycle.
Under extreme load changes, e.g. frequent starts / stops, or high inertial loads, this
method of calculating the motor rating is unsuitable since it would underestimate the
heating that would occur.
iv) Where loads vary substantially with time, in addition to proper motor sizing, the
control strategy employed can have a significant impact on motor electricity use.
Traditionally, mechanical means (e.g. throttle valves in piping systems) have been used
when lower output is required. More efficient speed control mechanisms include multi-
speed motors, eddy-current couplings, fluid couplings, and solid-state electronic
variable speed drives.
Answer
(2) Operating in star mode:
i) Lesser than 30% load means torque required by load is less than 30%. Hence current
requirement is reduced.
ii) When connected in star, the phase voltage reduces to (1/3) times that in delta mode.
As the torque generated by motor is directly proportional to the (applied voltage per
phase)2 the torque produced falls to 1/3 compared to delta mode.
iii) Due to decreased phase voltage, the iron losses decrease to nearly 1/3, as total iron
losses are proportional to (applied voltage per phase)2 before saturation.
iv) Due to reduction in phase voltage the current drawn in the lines also reduces leading
to lower copper losses in motor and decrease line losses.

3) By Motor Survey:
Large industries have a massive population of LT motors. Load survey of LT motors
can be taken-up methodically to identify improvement options.
i) Sampling Criteria:
Towards the objective of selecting representative LT motor drives among the motor
population, for analysis, the criteria considered are:
− Utilization factor i.e., hours of operation with preference given to continuously
operated drive motors.
− Sample representative basis, where one drive motor analysis can be reasoned as
representative for the population. e.g. Cooling Tower Fans, Air Washer Units, etc.
− Conservation potential basis, where drive motors with inefficient capacity controls on
the machine side, fluctuating load drive systems, etc., are looked into.
ii) Measurements:
Studies on selected LT motors involve measurement of electrical load parameters
namely volts, amperes, power factor, kW drawn. Observations on machine side
parameters such as speed, load, pressure, temperature, etc., (as relevant) are also taken.
Availability of online instruments for routine measurements, availability of tail-end
capacitors for PF correction, energy meters for monitoring is also looked into for each
case.
iii) Analysis
Analysis of observations on representative LT motors and connected drives is
carried out towards following outputs:
− Motor load on kW basis and estimated energy consumption.
− Scope for improving monitoring systems to enable sustenance of a regular inhouse
Energy Audit function.
− Scope areas for energy conservation with related cost benefits and source
information.

4) By matching loads with motor rating

 Industrial motors frequently operate under varying load conditions due to
process requirements.
 A common practice in cases where such variable-loads are found is to select a
motor based on the highest anticipated load. In many instances, an alternative
approach is typically less costly, more efficient, and provides equally
satisfactory operation.
 With this approach, the optimum rating for the motor is selected on the basis of
the load duration curve for the particular application. Thus, rather than selecting
a motor of high rating that would operate at full capacity for only a short period,
a motor would be selected with a rating slightly lower than the peak anticipated
load and would operate at overload for a short period of time.
 Since operating within the thermal capacity of the motor insulation is of greatest
concern in a motor operating at higher than its rated load, the motor rating is
selected as that which would result in the same temperature rise under
continuous full-load operation as the weighted average temperature rise over the
actual operating cycle.

(5)Improving Power Quality:

 Voltage: Maintaining the voltage at the rated value for motors results in the
properly expected torque speed characteristics available to drive the load. Lower
voltage leads to excessive current drawn due to which the line losses increase,
machine copper losses increase and line voltage drops increase. Even if voltage
is above required value higher flux density results in motors that leads to higher
iron losses. These lead to decrease inefficiency. Hence proper voltage has to be
maintained.
 Frequency: It governs the speed related losses and iron losses. If its value is
 more than rated these losses increase as speed is directly proportional to the
frequency the speed dependent friction &windage losses increase that will
decrease the efficiency. Lower value of frequency leads to lower speed that
affects the output power. Hence frequency has to be maintained at rated value.
 When the supply waveform is purely sinusoidal then harmonics are absent
which means no iron & copper losses due to harmonic voltage & currents. The
harmonics causes production of unwanted harmonic torques in motors which is
waste of energy. Hence the supply voltage must be asnear as possible to sine
wave in case of AC motors.

Rewinding of Motor:
i) During rewinding by preserving the original winding characteristics
(material quality, design and structure). It is possible to maintain the
original operating characteristics.
ii) Using larger cross section area of conductors and better insulation the
copper losses can be minimized.
iii) Rewinding for the required torque and power or speed results in
lowering of the losses(better efficiency and hence energy savings)
iv) Extension of coils beyond the slot insulation must be minimized to
reduce the amount of copper used that leads to lowering of the copper
losses.
State any four periodical maintenance which is necessary in transformer to
4 3
achieve energy conservation.
Marking Any four points 1 Mark each.
Scheme
Periodical maintenance necessary in transformer to achieve energy conservation:
Proper periodical maintenance leads in Energy conservation
1) Check Voltage, current, temperature and other parameters. COI504.2
2) Check for winding resistance.
3) Check oil level and dielectric strength of oil.
4) Check breather and silica gel.
5) Check cooling arrangement.
6) Check Insulation resistance.
Answer
5 2 Explain VFD and State the use of variable frequency drive.
Marking use 2 marks and benefits 2 marks
Scheme
Answer variable frequency drive(VFD):-

COI504.2
 Explanation:-
VFD is power electronics based device which converts a basic fixed frequency, fixed
voltage sine wave power (line power) to a variable frequency, variable output voltage
used to control speed of induction motor(s).
It regulates the speed of a three phase induction motor by controlling the frequency and
voltage of the power supplied to the motor.

Since the number of pole is constant the speed Ns can be varied by continuously
changing frequency.
Use of Variable Frequency Drive:
1. For conveyers, machine tools and other production line equipment machine starting
and controlling
2. Tunnel boring, mining and oil drilling platform machines staring and controlling
3. For controlling motor driven centrifugal pumps, fans and blowers.
Describe the working of soft starter and state its advantages over
6 2
conventional starter.
Marking Working 2 marks advantages 2 marks
Scheme
Working of soft starter:
Soft starter delivers a controlled power to the motor to provide smooth, step less
acceleration and deceleration. It consists of thyristor in main circuit and the motor
voltage is regulated with a printed circuit board. So as the voltage is low at the time of
starting, current & torque developed will be also low. During starting period the soft
starter provides low voltage to motor which enables to adjust the play between the gear
wheels or stretching driving belts or chains etc. In other words it eliminates unnecessary
jerks during the start. Gradually the voltage and the torque increase so that the
machinery starts to accelerate. The line voltage drops & losses at start are thus very
low. It provides a reliable and economical solution to overcome problem related with COI504.2
Answer starting.
Advantages over conventional starter:
1) Motor starts (without jerk) smoothly.
2) Severe spikes of starting currents are eliminated.
3) Loss of energy during starting is minimized to about 40 to 50%.
4) Severe wear and tear of mechanical parts such as bearing etc. during starting
is eliminated leading to longer life of bearings and other related components.
5) Very low mechanical stress.
 6) As starting currents are highly inductively limiting their magnitudes results in
improved power factor.
7) As current peaks are controlled the MD is reduced which may lead to lower
MD billing.
8) Less mechanical maintenance.
9) Saving in operating costs.
Explain amorphous core transformer and epoxy resin cast (dry type
7 2
transformer) w.r.t. energy conservation.
Marking Working 2 marks each
Scheme
Amorphous core transformer w.r.t. energy conservation:
i) Amorphous core transformer is energy efficient transformer. The magnetic core is
made up of amorphous metal. This core can be easily magnetized and demagnetized.
ii) The amorphous alloy is made up of iron, boron, silicon alloy, molten metal mixture
when cooled to solid state at a very high speed rate, retain a random atomic structure
that is not crystalline. This amorphous resembles to glass so referred as glass metal.
iii) In case of amorphous core material, size of core, conductor, tank and insulating oil
is increased.
iv) The amorphous material is 9 times harder than CRGO steel. Hardness, along with
small thickness makes slitting and shearing process more difficult. COI504.2
v) The amorphous material consists of high electrical resistivity and low field
magnetization. Due to low field magnetization, hysteresis loss is low. Due to high
electrical resistivity, eddy current loss is suppressed.
vi) Hence amorphous core transformer is approximately 20 to 30 % costlier than
conventional core transformer.

Answer Epoxy resin type or dry type transformer w.r.t energy conservation:
1. Epoxy resin impregnated:
In this transformer, the polyester silent is applied on transformer winding & the coils
are poured in some chemical liquids & after it, it is dried in the oven. Due to this the
winding resistance for corona increases and corona effect decreases. The high voltage
sustained capacity increases. There will be more resistance to the moisture & due to
epoxy resin impregnation there will be high temperature resistance. Due to all this, the
losses in the transformer are less & efficiency of the transformer increases.
2. Cast resin impregnated:
Basically the dielectric strength of the cast resin insulation is more than epoxy resin
impregatition. It is equal to insulation level of transformer oil. The overload capacity of
these transformers is more. The lighting surges
caused due to any reasons affect minimum to these cast resin transformers

8 3 Compare soft starter with conventional starter (any four point).

Marking Any four points 1 Mark each.
Scheme
 COI504.2

Answer

Explain following method for energy Conservation in transformer:

9 2
(1) Parallel Operation (2)Isolation Transformer
Marking Working 2 marks
Scheme
(1)Parallel operation of transformer in context of energy conservation:
The transformers operate near their maximum efficiency around 70 % to 100 % of their
rated loads. For huge establishments drawing highly varying powers at different times
supplying from single transformer will be uneconomical and inefficient as the
efficiency varies. Because at light loads, a higher rated transformer has higher constant
losses compared to a lower rated one. Also the allied systems for the transformers draw
power thus reducing the overall efficiency. Hence to operate the system at highest
efficiencies as much as possible, parallel
Connected transformers are utilized such that at lower power requirements one of those
with lower capacity (and hence lower power losses) in parallel will supply at around its
maximum efficiency while the other is switched off thus saving its low load losses. This COI504.2
is done as per the requirements of the loads.

(2)Isolation Transformer:- Transformers are electromagnetic devices which transform

Answer alternating current (AC) electrical energy from primary to secondary side. The energy is
transformed with equal frequency and approximately equal power by means of the
transformer core magnetic field. Thus they provide galvanic isolation in the electrical
system.
The isolation transformers operate in the same way as other transformer types. But the
main task is to provide the galvanic isolation in the electrical system. They can work as
step-up transformer or step-down transformers but often operate with turns ratio

The isolation transformers are used in many electrical devices as computers,

measurement devices or specific industry power electronic devices.
 Applications:-
1. For preventing data corruption and failure in computers using hard disc,
2. For the protection of telecommunication and data communication equipment
3. For the patient’s safety while using machines like ECG, EEG or EMG pacemakers
or any electrosurgical aid.
4. For clear recording in audio and video recording equipment.
5. For error free data in process control instruments.
6. For elimination of earthing problem in electrical installations.
7. For protection of CNC/ PLC equipment from surges / spikes.
10 2 State two benefits and applications of variable frequency drives.
Marking Any 2 benefits and applications 1 Mark each.
Scheme
Benefits and applications of variable frequency drives:
The variable frequency drive helps to conserve electrical energy and gives the following
benefits:
1) Energy saving due to optimum use for applications.
2) Smooth starting. Can start the motor under load smoothly hence losses avoided.
3) Smooth speed control: losses and shocks during speed control & speed changing
operations are avoided as smooth increase (up to 300%) or decrease (to 11%) of the
rated speed is possible.
COI504.2
4) Better process control, (with Micro controller and IGBT -Insulated Gate Bi-polar
Transistor) optimization of input variables to get required outputs.
5) Less maintenance cost due to optimum working.
Answer 6) Higher life span with very low losses for bearing & motors due to which we have
improved optimal output power quality.
Applications:
1) Pumps used for fluids
2) Conveyers and transmission belts.
3) Machine tools operations.
4) Process control drives.
5) Textile industry machines.
6) Paper industry machines.
3 Compare energy efficient motor with standard motor on the basis of
11 (a) Starting torque (b) Construction
(c) Energy conservation (d) Efficiency COI504.2
Marking Any four points 1 Mark each.
Scheme
Answer

3 Explain following Energy conservation Equipment’s

12
(1) APFC (2) IPFC (3) AHF
Marking Diagram 2 marks working 2 marks
Scheme
(1) Automatic Power Factor Controller (APFC):

Answer

 The pf controller is used to maintain the pf at unity using capacitor bank across
the line. It is controlled through microcontroller and contactor arrangement.
 Power factor of load is sensed and capacitors are connected / disconnected on COI504.2
the basis of KVAR demand.
  Maintaining the pf at unity leads to reduction in the current through the lines as
Real power = apparent power x pf.
 The apparent power decides the MD for which the consumer is billed. The block
diagram of the APFC is shown above.
 The Supply main terminals are connected to input of APFC Panel. Power factor
is sensed by the CT & PT placed in line side. As per the requirement the
capacitor banks are operated to achieve calculated power factor by
microprocessor based APFC relay.
 The appropriate capacitor bank will operate with respect to kVAR required to
achieve target PF by APFC panel. After it CT & PT will check the feedback
from the switching capacitors. Finally the required set power factor is achieved.
(2) Intelligent Power factor Controller(IPFC):-
It is a microprocessor based power factor controller with built in intelligence The built
in on board memory provides for intelligent Power Factor Controlling based on the
capacitor bank switching history (ON/OFF Switches and total ON Hours), thereby
increasing the life of each capacitor.
Advantages:-
 Three phase sensing gives accurate measurement of PF
 Fault Detection (Over compensation, Under compensation, Over voltage, Over
current, Under voltage, Over harmonics for voltage and current)
 Automatic or Manual Control(manual control with power backup option)
 Intelligent operation
Applications:-
 In all Incomers
 Fixed power factor corrections individual (e.g. motor, transformers, lighting,
etc.)
 Group fixed power factor correction (several equipment’s connected in a group)
 Capacitor banks of tuned and detuned
 Harmonic trap applications (e.g. UPS, Frequency Drives and Converters, etc.)

Active Harmonic Filter(AHF):-

Shunt Active Filters:-
It is used to compensate the load current harmonics and reactive power as well.
It is connected in parallel to the distribution supply at PCC and it injects harmonic
current that is equal in magnitude to the load harmonic current but having 180 degree
phase shift to cancel out the load current harmonics and the source current becomes
sinusoidal

Series Active Filter:-

The Series Active Power Filter is connected in series with the utility by a matching
transformer. Normally, it is suitable for harmonic compensation of a voltage harmonic
source such as diode rectifier with a DC link capacitor