NOVEL METHOD OF ELECTRICAL

ENERGY CONSERVATION IN
INDUCTION DRIVE

Presented by:-

A.PARTHASARATHI, II B.E. EEE

parthasarathia@yahoo.co.in
Contact no: 9486118899
P.T.SASIKKANNAN, II B.E. EEE
Sasi_pts@yahoo.co.in
Contact no: 9842805073
ERODE SENGUNTHAR ENGINEERING COLLEGE
THUDUPATHI, ERODE-638 057.
 NOVEL METHOD OF ELECTRICAL ENERGY
CONSERVATION IN INDUCTION DRIVE
A.PARTHASARATHI, II B.E. EEE
P.T.SASIKKANNAN, II B.E. EEE
ERODE SENGUNTHAR ENGINEERING COLLEGE
THUDUPATHI, ERODE-638 057.

ABSTRACT:

The Indian power sector more than tripled its installed capacity; however the

country is still plagued by severe peaking and energy shortages. These energy shortages

are exacerbated by in efficiencies in power generation, distribution and end use system.

The efficiencies in the end use system are due to irrational tariffs, technological

obsolescence of industrial equipment, lack of awareness, a nascent energy services

industry and inadequate policy drivers. This paper presents an analysis of induction

motor with energy efficiency. Attributes under investigations include,

1) Effect of using oversize induction motor

2) Power Electronics in induction motor drives

3) Energy efficient motors

4) Life cycle costing analysis

5) Case study on spinning frame(55KW motor)

Keywords: - Energy efficiency, Induction motor, Power Electronics.

 1. INTRODUCTION
With ever increasing energy prices,
every rupee saved because a wise investment for
the future, and if the saving is in the form of
electrical energy, it makes even more practical
sense for all types of industries. In industries,
induction motor consumes around 70% of the
electricity used. Collectively their energy
consumption is very high. Even a small
increment in the efficiency of this motor can
result in substantial savings in the long run. On
an average standard motors consumes electricity
equivalent to 60-100 times its purchasing price
during its working life. A motor consumes
electricity equivalent to its capital cost in just
three weeks of continuous use. This result in
steep electricity bills and huge maintenance cost
while using. It is estimated that about 1.2 million
small size motors are added per year in various
types small sized industries in India like power
looms, flour mills, ice factories, ware housing
etc., with estimated energy consumption of
135 GWh. Induction motor has poor efficiency
and low power factor slightly load fed condition
even when it has an energy efficient design. In
some industrial applications motors operate
below 50% load for an inefficiently long duration
where as replacement by a lower capacity motors
may not be viable, as the motors need to take a
full load occasionally. Reduced voltage operation
in such a cases helps improvement both in
efficiency and power factor. Voltage controllers
for induction motor where developed in the past,
which worked on the principle of current or
speed, feed back. Yet many are not aware of this
technique. Energy efficient motors are designed
to minimize losses both in the core and windings
thus improving overall efficiency. They have
better efficiencies even at partial load (up to 50%
load) compared to the standard motor. Yet
efficiency low at lightly loaded condition in case
of constant voltage operation, as the core loss
remains constant.
2. EFFECT OF USING OVERSIZE
INDUCTION MOTOR
The power factor of an induction motor
depends upon its type, size, RPM and load. Slip
ring induction motor have lower power factor
than squirrel cage motors of the same size. The
power factor of induction motor for different size
and at different load is shown in table1, a motor
running near to full load has good power factor
compare to part load. Power factor deteriated
very much, when load below 75% of rated load.
Efficiency: The efficiency of three phase
induction motor varies with type, size and load.
It ranges from 85% to 93% in case of squirrel
cage motor above 5HP. It is about 75% in case of
smaller motor. The efficiency is less in case of
slip ring motors, slow speed motors and motors
running at part loads.
Motor losses can be classified in three
categories:
1. Iron loss
2. Rotational losses
(Friction and windage losses)
3. Ohmic losses
Among first two are constant losses, which
is not affected by motor shaft load is known as
constant losses, which varies with motor shaft
load and proportional to square of fraction of
rated load.
The efficiency of motor is decreases faster
when load is below the 75% of rated load.
Maximum demand: In industries maximum
demand is very important factor. The maximum
demand depends upon the type of load, ie.
Whether resistive or inductive load. In industries
maximum electricity load is contributed by
induction motor and it is highly inductive load,
that’s why the maximum demand varies much
motor depends on shaft load of motor and
efficiency because its shaft load is lower than full
load of motor. The power factor and efficiency of
motor decreases and maximum demand is
increases. So that proper size of the motor
selection will reduce the maximum demand and
cut the electric bill.
Energy saving: If motor is loaded above 75% of
full load, motor has high efficiency reduces and
increases the losses, this can be observed from
table 1 that proper size of motor, this will save
energy and the pay back period of replaced motor
is about 1.5to2.5 years in most of the case.
No Load Current: No load current of induction
motor varies from 25% to 60% of full load current.
Usually no load power factor of induction motor is
around 0.15 lagging or even less. No load current
of some typical induction motor shown in table 2
for 2 pole 4 pole and 6 pole. Generally as the
number of pole increases in induction motor the no
load current of motor also increases, and at the
same time full load current of motor also increases
simultaneously. This can visualize from table 2
that motor no load current varies from 25% to 40%
of full load current for 2 poles motors, 30% to 50%
for 4 pole motors, and 35% to 60% for 6 poles
motors expect some small capacity motors
generally has higher values.
Load current: To estimate the load current at
different loads, we can use the information given
in the manufacturer catalogues
1) Efficiency of motor at 100%, 75%, 50% of
full load.
2) PF of motor at 100%, 75%, 50% of full load.
3) Motor full load current.
To determine the load current at 100%, 75%, 50%
of full load, following formula is used
I 175 =
0.75 X Rated output power
3 X V L X η75 X PF 75
No load current may be determined by either no
load test of motor or from motor test certificate.
This graph can be utilize for determine the shaft
load for given value of motor current.
3. POWER ELECTRONICS IN INDUCTION
MOTORS
In recent years, the field of power electronics has
experienced a large growth due to confluence of
general factors. Revolutionary advances in
semiconductor fabrication technology have made it
possible significantly improve the voltage and
current handling capability and the switching speed
of power semiconductor devices, industrial and
power system applications. At one time, the
growth was pushed by energy conservation goals.
Variable speed Drives: Several drives are driven at
constant speeds by induction motors, although
operation at variable speed could lead to saving of
substantial of energy. Such practice was adapted in
the past because of non-availability of efficient
methods of speed control of induction motors. One
prominent example of such a case in pump drives
where fluid flow control is required. These pump
drives have applications in several industries such
as chemical plants, photochemical plants,
refineries, boilers and so on. The drives ratings
range up to several megawatts. Earlier the pumps
were run at a constant speed by induction motor
and control the fluid flow was obtained by
adjusting of opening values (by throttling) or by
passing excess output. Such an arrangement is
highly inefficient. The shows pump and load
characteristics, which represent the opposition
offered to the flow of fluid through pipes. Load
curve has two components: one to lift the fluid to
required height and other to overcome friction. The
steady state operating point is obtained where the
two curves are intersected. The operating point P
corresponds to maximum opening of the valves are
reduced, friction component is increased and load
curve is increased and load curve modifies to that
shown by dotted line. Pump and load curve now
meet at Q, which is the new operating point. Note
that the flow has reduced but pump head has
somewhat increased.

When variable speed drive is employed, valve
opening is kept at the maximum. As , the operating
point P is obtained at full speed; which is same in ,
when the drive speed is reduced, pump
characteristics is shifted down(shown by chain
dotted line) but load characteristics is not altered
because the valve has not changed. The new
operating point is ‘Q’, which gives the same fluid
flow as point Q but at substantially reduced head.
In a pump, the output power is product of head and
fluid flow. Since head is substantially lower. Thus,
use of variable speed drive can lead to large saving
of energy. Studies have shown that the energy
saving range is from 20-40% and extra cost
incurred in providing speed control can be
recovered in a period of 2-5 years. Considering
that a number of these drives have ratings in
megawatt range, large amount of energy can be
saved by the use of variable speed drives.
Energy efficient operation of drives: In many
applications constant speed operation, induction
motors operate under no load or light load for
prolonged periods, such as in pressing machine,
conveyors, rock crushers, centrifuges, drill presses,
wood saw and, some machine tools in such
applications, saving in energy can be achieved by
operating the motors at low voltages while running
at no load and light loads. When a motor operates
at full voltages at no load, core loss has a large
value. Reduction in voltage increases the copper
loss, but reduces the core loss by larger amount.
Therefore, net loss is reduced. At some voltage
when core loss is equal to copper loss; the loss is
minimum value and efficiency in maximum. Any
increase or decrease of voltage from this value
increases the loss. Therefore, for each loading,
there is an optimum value of voltage for which the
loss is minimum. Energy saving is achieved by
operating the induction motor at optimum voltage
values.
The energy saving depends on following factors:
Duty cycle of motor: Energy saving occurs mainly
no load and light load operation. Therefore, energy
saving is larger in drives which operate at low duty
cycles.
Operation with over voltages: When motor is
located in the area where over voltages are
common, larger amount of energy can be saved.
At over voltages, because of saturation of magnetic
circuit of motor, the core loss becomes larger than
its full voltage value. Operation at the optimum
voltages gives rise to larger reduction in loss and
greater saving in energy.
Quality of motor design: Badly designed motors
use inferior core material and operate with
saturation even at full voltage and over voltage
than the motor with good design. Operation of
badly designed motors at the optimum voltages
reduces the loss by a larger amount than in a motor
with good condition.
As explained above, for each loading there is an
optimum voltage. The loss minimization requires
that the motor voltage be continuously vary with
load. Therefore, an AC voltage controller must be
incorporated between motor and the source. The
economic benefits of the net energy saved should
be compared with the increase in cost due to the
addition of an AC voltage controller to arrive at a
decision about the desirability of using this energy
saving scheme. In several applications requiring
soft start, AC voltage controller is always there,
and therefore, no additional cost is incurred in
implementation of energy saving scheme. Energy
saving scheme is particularly beneficial in single
phase motors.
4. ENERGY EFFICIENT MOTOR:
Most of plant people get confused with the
terminology like energy efficient motor, high
efficiency motor, super sufficient motor etc.
Different motor manufactures use different names
and claim their motor efficiency is more over the
others to confuse the users. But all these terms
sense the sane meaning that these motors are
having higher than the standard motors.
Efficiency of the motor is varying important
parameter while selecting any new motor for any
application. When a motor is required to produce a
relatively constant and continuously torque, the
main selection is its rated efficiency. The running
costs will be lower with high efficiency motor if
the duty cycle is high. Technological
improvements in the design of an induction motor
helped to improve its efficiency by 3-4%. In the
recent past, many design changes have been made
to improve the efficiency of an induction motor.
As we know the losses in the motor.
5. LIFE CYCLE COSTING:
The cost of any energy efficient motor is
about 20-30% more than the standard motor.
Unless the duty cycle of the motor is high, the pay
back period is go up to 4 years or more and hence
life cycle costing method is vary much to find out
the cash flow beyond its payback period and the
feasibility of the application of energy efficient
motor.
The benefits of investing in more efficient motor
and derives are electrical cost savings, reduced
maintenance cost and improved production process
resulting from better control. When purchasing any
new energy efficient motors financial
consideration like planning cost, cost of spares,
cost of modification to existing equipment, cost of
production downtime during installation and cost
of old motor should be taken into consideration.
A project’s cost effectiveness can be estimated
by calculating either payback period or the return
on the investment. The basic information required
for this is collection of data like capital and
installation cost of equipment, any extra annual
operating cost, annual energy savings, per unit cost
and the life of equipment. Simple payback period
can be obtained by dividing the capital and
installation cost of the equipment with annual
savings minus annual operating cost. The main
disadvantage of this method is does not consider
the cash flow beyond the payback period. Also it
will not help to compare projects, which have
identical payback periods but different annual
returns. And one more important thing is this
method does not take into the account the payment
of interest on borrowed capital. These methods
might be useful in situations like:
Where rapid payback period may be the prime
criterion when the investors has funds available for
only a short time.
When speculator is interested in quick return.
When expected life of assets is difficult to predict.
Life cycle offers a much more details approach
to investment appraisal and is very much useful for
energy efficient projects. However this method is
little complicated because of involvement of so
many variables and definitions.
S. No. Duration Motor input
1. 30 Minutes 13.90 kW
2. 30 Minutes 17.67 kW
3. 30 Minutes 25.08 kW
4. 30 Minutes 27.30 kW
5. 30 Minutes 30.72 kW
6. 30 Minutes 33.52 kW
7. 30 Minutes 34.54 kW
Life cycle costing analysis is an economic
decision making tool for choosing between
alternative motors are motor systems that are
intended to serve the same purpose. A life cycle
costing analysis adjusts for the time value of
money and sums, over a designated study period,
all costs related to the owing and operating of a
motor driven system.
The important parameters in life cycle of any
motor include the operating life of motor,
operating life of the driven equipment and the
operating life of the process. The operating life of
any motor varies from 10 to 25 years depending on
the design and the operating condition.
In case when ever the operating life is 5 to 10
years, this can be used for any life cycle
calculation. Where projected life is greater than 10
years, motor life may have to be taken into
account, either figure extrapolated from the
average motor lives, or based on the data from the
equipment supplier. A life cycle coasting analysis
takes into account the time value of money and
energy cost inflation.
applications of the energy efficient motor. Life
cycle costing analysis helps find out the cash flows
beyond payback period and also helps to find out
the affect of inflation, interest rate, taxes, and
equipment life on the investment. In order to avoid
harmonic current amplification due to power
electronics load detuned filter circuits must be
used.
REFERENCE:
(1) C. Thangaraj, S.C.Ramesh,”Role of power
electronics in electrical energy conservation”, IEE
(UK) Calcutta branch, International Conference
Proceedings on power, Energy and IT in power
sector, page 242-245

(2) Mohan, Undeland, Robbins, “Power

6. CASE STUDY: Electronics-converters, Applications, and design”,
John Wileyand sons Publications-Third Edition.
Table 3 load factor for one complete cycle.

Voltage control of lightly loaded induction

motors should be judiciously planned based on the
actual duty cycle. Case study where the energy
conservation is applied in partial loaded induction
motor in the organization has been presented.

While carrying out the preliminary energy audit

in 55KW motor in spinning frame this motor, its
load factor for one complete cycle is shown in
table 3.

Replacement of existing motor’s starter by energy

efficient drive (power electronics based voltage
control) was recommended so as to improve the
efficiency and power factor in the considerable
amount.

7. CONCLUSION:

Energy efficient motors offer considerable

energy savings when the existing motors are very
old, rewound several times, oversized with high
duty cycle. Replacement of existing standard
motor with energy efficient motor is best
 Table 1: Efficiency and power factor of different capacity motors at different loading

Hp KW Pole Efficiency Power factor

100% 75% 50% 100% 75% 50%
2 83.1 81.2 77.3 0.84 0.80 0.70
5.0 3.7 4 82.0 82.0 80.0 0.88 0.84 0.75
6 85.0 84.3 81.3 0.78 0.69 0.53
2 84.3 83.2 79.4 0.91 0.88 0.80
10.0 7.5 4 85.5 84.6 81.3 0.85 0.77 0.64
6 87.0 85.5 82.5 0.76 0.68 0.53
2 88.5 87.7 85.0 0.95 0.93 0.86
25.0 18.5 4 89.5 89.4 87.9 0.89 0.85 0.75
6 89.8 90.0 89.0 0.82 0.78 0.67
2 38.5 87.5 85.0 0.92 0.90 0.86
50.0 37.0 4 91.3 91.0 89.5 0.84 0.81 0.73
6 91.3 91.2 90.2 0.86 0.83 0.77
2 - - - - - -
75.0 55.0 4 92.7 92.5 91.0 0.85 0.81 0.69
6 93.7 93.9 93.4 0.80 0.74 0.67
2 - - - - - -
100 75.0 4 92.9 92.6 91.2 0.91 0.89 0.36
6 92.7 92.6 91.4 0.80 0.75 0.64

Table 2: No load current of different sized induction motor

HP K Full load current No load current % of full load

W current
2P 4P 6P 2P 4P 6P 2P 4P 6P
5 3.7 7.37 7.13 7.76 4.5 3.8 4.5 61.0 53.3 57.99
6 0
10 7.5 13.3 14.3 15.7 5.0 8.0 10. 37.3 55.7 63.37
6 6 8 8 0 5 1
25 18. 30.6 32.3 34.9 8.1 13. 16. 26.6 41.4 46.92
5 1 1 5 6 4 4 6 7
50 37 63.2 67.1 65.5 17. 27. 20. 27.6 40.5 31.73
2 2 6 5 2 8 8 2
75 55 - 97.6 102. - 41. 47. - 42.5 46.83
8 1 6 8 9
100 75 - 123. 140. - 32. 60. - 26.5 42.62
4 7 8 0 8