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

In-field electric motor efficiency measurement

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

In-field electric motor efficiency measurement

Electric Motor Efficiency Wizard

Portable metering
Speed Temperature Resistance Power Voltage Current Frequency

Laptop computer for data collection Proprietary algorithm to calculate motor efficiency
In-field electric motor efficiency measurement

Measurements made at Two Motor Load Points

Motor Starter
Voltage, Frequency,Resistance

Efficiency Wizard Kit

Current

Three phase induction motor

Temperature and Speed

In-field electric motor efficiency measurement

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

In-field electric motor efficiency measurement

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
In-field electric motor efficiency measurement

Motor Input Data Sheet

Motor Data REL S.O. xxxxxxxx Volts 460 Code Letter Enclosure G TENV Frame HP 75 Amps Duty 91 CONT E/S AMB C/INSUL. S.F. Type Hertz 60 RPM 1185 Nema Design B Rotor 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 Stator Cable Temperature Temp 88.012 60 56.299 56 F&W watts 39 39 250 250

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

I2 88.012 56.299 88.012 56.299

I3

Stator Resistance & Temperature** Resistance ** 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

StatorTem perature in R12 total R13 total R23 total C Cable Temp 0.16 0.16 0.17 51 24 SLL % of Output

Motor HP 1 - 125 126 - 500 1.8 501 - 2499

460 60 1.0325 168 0.05 #3 Boiler Fan 95

Cable Gauge 1

Cable Length in Feet 213.5

Cables /phase 1

In-field electric motor efficiency measurement

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
In-field electric motor efficiency measurement

Output Data Sheet

Motor Data REL S.O. xxxxxxxx Volts Frame 0 HP 75 Amps Duty 460 91 CONT Code Letter Enclosure E/S G TENV Hertz RPM 0 60 1185 AMB C/INSUL. S.F. Nema Design 0 0B Rotor Test S.O. DatTest Date 0 0 37314 37314 Type

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 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 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

Motor Parameters

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

95 1223 24468

In-field electric motor efficiency measurement

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Efficiency Calculation Accuracy 10 HP Motor

92 91 90 89 Efficiency 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
Measured E fficiency E stimated E fficiency

IEEE 112B lab test Efficiency Wizard

In-field electric motor efficiency measurement

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Efficiency Calculation Accuracy

600 HP Motor

100 98 96 94 92 90 88 86 84
Motor Load

IEEE 112B lab test Efficiency Wizard

Measured Efficiency Estimated Efficiency

Efficiency

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

In-field electric motor efficiency measurement

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Efficiency Calculation Accuracy

150 HP Motor
93 92 91 90 89 88 87 86 85 84 83 1/4 Load 1/2 Load 3/4 Load Full Load

Efficiency

IEEE 112B lab test Measured Efficiency Estimated Efficiency Efficiency Wizard

Motor Load

In-field electric motor efficiency measurement

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Motor Efficiency Versus Output Power

2/27/02
Mitsubishi Efficiency

REL

xxxxxxx

#3 Boiler Fan 75 HP

100.0 90.0 80.0 70.0 Efficiency (%) 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

In-field electric motor efficiency measurement

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Input Current Versus Output Power

2/27/02
Mitsubishi Input Current

#3 Boiler Fan

REL S.O. xxxxxxxx

120.0

75 HP

100.0

Input Current (Amps)

80.0

60.0

40.0

20.0

0.0 0.0 10.0 20.0 30.0 40.0 50.0 Horse Power 60.0 70.0 80.0 90.0 100.0

In-field electric motor efficiency measurement

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Power Factor vs Output Power

2/27/02
Mitsubishi Power factor

#3 Boiler Fan 75 HP

REL S.O. xxxxxxxx

0.90 0.85 0.80 0.75 Power Factor 0.70 0.65 0.60 0.55 0.50 0.45 0.40 0 10 20 30 40 50 Horsepower 60 70 80 90 100

In-field electric motor efficiency measurement

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Speed vs Output Power

2/27/02
Mitsubishi Speed RPM

REL S.O. xxxxxxxx

75

HP

#3 Boiler Fan

1200 1198 1196 1194 1192 RPM 1190 1188 1186 1184 1182 1180 0 10 20 30 40 50 Horsepower 60 70 80 90 100

In-field electric motor efficiency measurement

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Motor Torque vs Speed

2/27/02
Mitsubishi Output Torque ft.lb.

REL S.O.

xxxxxxxx

#3 Boiler Fan

75

HP

450 400 350 300 Torque ft.Ib 250 200 150 100 50 0 1180

1182

1184

1186

1188

1190 RPM

1192

1194

1196

1198

1200

In-field electric motor efficiency measurement

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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
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In-field electric motor efficiency measurement

Induction Motor Equivalent Circuit

R1 L1

Va

L2

I1 V1 Rc

I3 Lm

I2

R 2 s

In-field electric motor efficiency measurement

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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

In-field electric motor efficiency measurement

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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

In-field electric motor efficiency measurement

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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
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In-field electric motor efficiency measurement

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
In-field electric motor efficiency measurement

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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.

In-field electric motor efficiency measurement

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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
In-field electric motor efficiency measurement

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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
In-field electric motor efficiency measurement

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Thank You

In-field electric motor efficiency measurement

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