Date and Place of Presentation in Arial Italic 11 pt

Energy Efficiency Avenues In Indian Industries

Presented by – R.K. Paul

Senior General Manager- Marketing (Motor)

M:+91 9810 622 768

Email: ravinder.paul@bharatbijlee.com

Consumption of electricity by Sector

Why Energy Conservation

High Cost of generation per MW compared to saving of energy.

Government of India taking initiative towards energy conservation.

Win-Win situation for both the user and supplier of energy efficient equipments.

Since 2003, there has been a rise of 12.5% in the amount of electricity consumption in commercial sector.

Energy is like “raw material” for many energy intensive industries like Steel,Paper,Textile and so on.

Initiatives taken By Govt. of India

“Energy Conservation Act” already in place since 2001.

“Energy Conservation Building Code- 2007(ECBC)” also in place. This code mentions about HVAC System and motors.

Energy Audit companies being shortlisted & set up by BEE to conduct Energy Audits and consultation on profit sharing basis.

Sectors Covered By Energy Conservation Act

Aluminium Ferilizers Iron & Steel Cement Pulp & Paper Chlor Alkali Sugar Textile Chemicals Railways Port Trust Transport Petrochemicals Power Stations Commercial buildings

Note : Number of sectors already purchasing high efficiency motor and reaping the fruits of low electricity bills and also conserving energy

Regulatory Interventions

The Government of India has identified the importance of energy conservation in light of the huge gap between the demand & supply of power.

The Government of India had constituted the Bureau of Energy Efficiency (BEE) as the authority responsible for the implementation of the Act.

The EC Act identifies energy intensive industries and establishments as Designated Consumers (DCs) who are required to-

• Appoint or designate an Energy Manager (EM) in their plant.

• Get energy audit conducted by an accredited Energy Auditor (EA)

• Implement techno-economically viable recommendations for energy conservation

• Comply with fixed norms of specific energy consumption

• Submit reports on the measures taken in a specified format. BEE is implementing a labeling program, in preparation to introduction of

Minimum Energy Performance Standards (MEPS) for appliances and equipment.

Energy Efficient Motors- A National Priority

70% of all electrical energy consumed in India is used for driving electric motors.

55% of which is consumed by industrial motors

8

National Standard for Energy Efficient Motors

IS 12615: 2004 (First revision) -Superior to existing Std. IS 8789

To be considered as energy efficient, a motor must conform to one of the following efficiency levels specified in IS 12615:

Improved Efficiency (eff 2) High Efficiency (eff 1)

eff1 efficiency levels are higher than those of eff2.

Both eff1 & eff2 are higher than the nominal values specified in IS 8789: 1996.

Range of Energy Efficient Motors

Eff 2 motors are offered ex-stock by few manufacturers.

Most of manufacturers offer a complete range of eff 1 motors against specific orders with a lead time of 8 to 10 weeks. Fast moving ratings are available of the shelf in case of Bharat Bijlee.

Comparison of efficiencies of Standard & Energy Efficient Motors

Output 4 Pole

IS 8789 eff 2 as per IS 12615

eff 1 as per IS 12615

0.75 kW 71.0% 73.0% 82.5%

1.5 kW 76.0% 78.5% 85.0%

3.7 kW 83.0% 84.0% 88.3%

11 kW 85.5% 88.4% 91.0%

18.5kW 87.0% 90.0% 92.2%

37 kW 88.5% 92.0% 93.6%

75 kW Not specified 93.6% 94.7%

110 kW Not specified 94.4% 95.2%

160 kW Not specified 95.0% 95.8%

Salient Features of Eff1 Motors

Why does IS 12615 specify two efficiency levels?

User has the option to go for eff1 motor and save energy but at higher initial cost. It is strongly recommended to go for eff1 motor when utilization is high.

The standard is hence user friendly since it has provided two levels of efficiency. This is in line with other international standards like CEMEP.

How is motor Efficiency Improved

Reduce Stator Cu Loss

Reduce Rotor Cu Loss

Reduce (1)Iron Loss Reduce (2)Copper Loss

Low Loss

Magnetic matl.

ReduceFlux Density

Increased Starting current

IncreaseCopper Section

Stator slot areaIncreaseRotor bar section

Reduced S t a r t i n g T o r q u e

Increase ReduceStator Yoke Rotor Diam

Efficiency improvement to eff1 by use of Low Loss Stamping & increased Fe and Cu

11 kW 1500 rpm eff 2 eff1

Low Loss Stamping

+ increased Cu & Fe

Iron losses 400 W 330 W 250 W

Friction & Windage 120 W 120 W 120 W

Constant Losses 520 W 450 W 370 W

Load related Losses 840 W 750 W 650 W

Total Losses 1360 W 1200 W 1020 W

Efficiency 89% 90.2% 91.5%

Why is the Energy Efficient motor more expensive?

eff 1 motors are generally priced 5 - 15 % higher than eff 2 motors.

More laminations - longer core length and/or

High Grade (low loss) laminations

More Copper

Rs.

Life Cycle Cost of Motor

In one year, a motor consumes energy equivalent to 10 to 20 times its purchase price.

Many consumers in India especially OEMs purchase cheap motors having low efficiency values.

Initial Cost of an 11 kW 4Pole motor is only 4% in the first year of operation

Assumptions: Efficiency Eff2 : 89.0%

Energy cost: Rs 5 per kWh

Working: 8000 hrs pa

Energy Efficient Motors have a Flat Efficiency Vs Load Characteristic

Motor rating is selected for max. load conditions and next preferred rating

Most motors operate on an average around 75% load.

Efficiency is almost same from 60% to 100% load in a well designed EE motor

Energy savings increase at partial loads due to Flat efficiency vs Load Characteristic

11kW-4 Pole eff 2 motor Vs eff1 motor.

Total Energy saving per annum : Rs. 12112

Additional Price of eff-1 motor over eff2 motor : Rs. 2627

Payback Period is 2.6 Months

Eff1 motor gives further savings over an eff2 motor

  Eff2 Eff1

Purchase Price of 11kW/4P motor Rs 17509 20135

Efficiency 89.0% 91.5%

Energy consumption p.a. for 8000 Hrs @ Rs 4 per kWH 3,95,504 3,84,700

Energy Saving Rs 10804

Additional purchase price Rs 2626

Pay Back Period of eff1 motor is 2.9 months for a 15% price increase over eff2 motor

Energy Efficient-Increased Safety & Flame Proof Motors

Bharat Bijlee offers Flame Proof and Increased Safety motors conforming to eff2 as standard

Eff 1 motors can also be offered against customer requirement with a lead time of 8 to 10 weeks.

In a few eff1 outputs next higher frame size is required.

Need for High Efficiency Motors

Use of High efficiency motors in sectors like Fertilizers / Sugar / Central Air-conditioning units and AHUs/etc, will allow considerable energy saving at locations with high usage.

The use of high efficiency motors helps to reduce the power consumption.

(Example in next slide)

The following table will provide insights on energy savings on usage of energy efficient (eff-1) motors against (eff-2), or any other standard motor.

The ratings in the table correspond to the requirement of a modern building project, whose enquiry has come up with Bharat Bijlee

Rating Efficiency Qty ofAnnual Savings

Purchase Price (Approx) Rs. Price

PayBack Period

HP Pole KW eff2 eff1 Motors Rs. Eff-2 Eff-1Difference (Rs.) Months

1.5 4 1.1 78 83.8 1 1969.9 3755 4319 565 3.44

2 4 1.5 80 85 1 2205.9 4108 4721 613 3.34

3 4 2.2 82 86.4 1 2732.6 5427 6243 816 3.58

5 4 3.7 85 88.3 1 3253.6 6944 7990 1046 3.86

7.5 4 5.5 86 89.5 1 5001.9 9570 11008 1438 3.45

10 4 7.5 87 90.3 1 6300.8 11176 12857 1681 3.20

12.5 4 9.3 88 90.5 1 5838.8 17317 20048 2731 5.61

15 4 11 89 91.5 1 6753.9 17891 20573 2682 4.77

20 4 15 90.2 92.2 1 7214.6 22232 25568 3335 5.55

30 4 22 91.8 92.8 1 5164.9 33416 36756 3340 7.76

40 4 30 92 93.2 1 8397.1 45077 49586 4509 6.44

100 4 75 94 94.7 1 11795.4 123421 129594 6172 6.28

Replacement Vs Rewinding -11 kW 4 pole motor

Eff of Old Motor to be rewound or replaced

IS 8789 eff2

New motor Efficiency eff2 eff1

Purchase Price of new motor Rs 16000 19200

Rewinding Cost Rs 4000 4600

Additional Cost Rs 12000 14600

Efficiency of old motor 85.5% 88.4%

Efficiency after rewinding ( less 1.5%) 83.0% 86.9%

Efficiency of new motor 88.4% 91.0%

Saving by replacement with new eff2 motor

0.809 kW 0.570 kW

For 5000 Hrs @ Rs 4.0 per kWH (Rs) 16180 11406

Pay back period : 8.9 Months 15.4 MonthsReplace old eff 2 motor with eff1 motor & get Payback in 15 months

Replace old IS8789 motor with eff2 motor & get payback in 9 months

Nameplates - Marking of Efficiency

Type MH16M4734 Fr 160M Hz 50 Fr 160M Hz 50 Insl. Cl FInsl Cl F Type MA16M433

M/c. No.M/c. No. Duty S1 Duty S1

Volts 415 Volts 415 kW/HP 11/15kW/HP 11/15 rpm 1450rpm 1460 P f 0.85 P f 0.84

A 19.7 A 20.5Eff % 91.5 Eff % 89.0

3 ph. Induction motor MADE IN INDIA 3 ph. Induction motor MADE IN INDIA

A High Efficiency Motor A Standard Motor(Improved Efficiency)

EFF-2 EFF-1

The EE motors are clearly labeled “EFF-1 or EFF-2”

Manufacturer NameManufacturer Name

Inrush current

Energy-efficient motors feature low electrical resistance and thus exhibit higher inrush currents than standard models. The inrush current duration is too short to trip thermal protection devices

Advantages- Apart from Higher Efficiency

• Less maintenance and longer life time due to lower temperature in windings and bearings

• Higher reliability due to lower losses.

• Better tolerance to thermal stresses resulting from stalls or frequent starting.

• Increased ability to handle overload conditions.

• Better resistance to abnormal operating conditions, such as under and over voltage or phase unbalance.

• Higher tolerance to poorer voltage and current wave shapes.

Design Factor to be considered..

• Motor Size. Size motors for efficiency. Motors should be sized to operate with a load factor between 65% and 100%.

• The common practice of oversizing results in less efficient motor operation. For example, a motor operating at a 35% load is less efficient than a smaller motor that is matched to the same load

• The Next figure explains the same.

To Add..

Energy savings are more at partial loads because Energy Efficient motors have a Flat Efficiency Vs. Load Characteristic

Payback period of eff2 motor over IS-8789 motor is approx 1500 working hrs.

Payback period of eff1 motor over eff2 motor is approx 2500 working hrs.

How to Determine Cost effectiveness?

The cost effectiveness of an energy-efficient motor in a specificsituation depends on several factors, such as

Motor price Efficiency rating Annual hours of use Percent full load Energy rates Cost of installation and downtime, The availability of utility rebates or other incentives.

Advantages of Using High Efficiency Motors

When Should I Consider an Energy-Efficient Motor?

Most motors should be replaced with an energy-efficient model if they operate

over 1500 hours per year. In general, energy-efficient motors should be

considered in the following circumstances:

New installations, both separate and as part of packages such as HVAC

systems

When major modifications are made to a facility or a process

Instead of rewinding old motors, use high-efficiency motors

Existing motors are under loaded or overloaded.

As part of a preventive maintenance or energy conservation plan

Intermittent duty applications….?

Intermittent duty motors are typically used in crane, hoist, valve actuators and other applications with frequent starts.

In these applications, motors are designed for low starting losses rather than low running losses.

For intermittent duty applications EE motors are not the best choice

Problems in field testing

Efficiency measurement at site is unreliable.

One needs to decouple the load in order to measure no load losses. Variable voltage supply required in order to maintain rated voltage.

We recommend measurement of kWh using a energy meter and compare two motors.

Measurement of current is not a reliable indicator. Current is not directly proportional to input power because power factor varies with load and voltage.

Who should Help in promoting Eff1 Motors?

Finance Help

Are there any financing or leasing schemes for EE Motors?

Yes, IREDA and other financial companies such as ICICI, IDBI etc. have schemes that can help you to acquire EE motors. (courtesy – web site of COPPER – international copper Promotion council India)

Energy Efficient Motors & Carbon Credits

Lower energy consumption means lesser burning of natural resources – Thus lower pollution.

Better efficiency means lower operating costs, hence improved bottom lines.

Opportunity to participate in World Carbon Credit Market, which stands for just 6% in India (against 71% in China) at an estimated value of US $ 64 billion as per World Bank Estimate for 2007.

(Source – Economic Times)

•Bharat Bijlee manufactures Energy Efficient motors conforming to eff1 or eff2 of IS 12615

•Bharat Bijlee’s Standard Ex stock Motors conform to eff2 of IS 12615

•Inferior motors conforming to IS 8789 are not manufactured by Bharat Bijlee

Summary & Conclusion

There exists a national standard IS 12615: 2004 (Revision 1) for energy efficient three phase induction motors from 0.37kW to 160 kW

Energy savings are more at partial loads because Energy Efficient motors have a Flat Efficiency Vs. Load Characteristic

Payback period of eff2 motor over IS-8789 motor is approx 1500 working hrs.

Payback period of eff1 motor over eff2 motor is approx 2500 working hrs.