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kVA = 0.00173 230 42 kVA = 16.7 4. Calculate the kW: kW = kVA PF 0.01 (where PF is the power factor in %) Unfortunately, a voltmeter and clip-on ammeter wont tell us what the PF is. Still, even if we dont have equipment to measure PF directly, we can estimate it: First, calculate % Max Amps actual motor current as a percentage of rated full load current. 100 measured motor amps % Max Amps = max. rated motor amps
Second, from the graph above, estimate the motor PF. Do this by choosing the motor power curve closest in value to the rating of your motor. Then, following along that curve, see what the PF is at the % Max Amps value you calculated above. In our example, following the 20 hp curve to a % Max Amps value of 86 gives a PF of approximately 76 per cent. Third, calculate the input power in kW. kW = kVA PF 0.01 (PF in %) And for our example: kW = 16.7 76 0.01 = 12.7 5. Calculate monthly kWh: kWh = kW hours of operation per month Lets assume that our motor operates 333 hours per month. kWh = 12.7 333 = 4230 6. Calculate the cost. First, figure out how much each kWh costs your firm by taking a recent electricity bill and dividing the total dollar amount (including taxes) by the total number of kWh consumed during the billing period. Second, multiply this number times the kWh value calculated in Step 5 above. This will give the approximate monthly cost of running the motor including that motors share of demand charges and taxes as well as its kWh consumption. In our example, if the average cost of a kWh is 11.2 cents, then the cost of running this 20 hp motor would be 4230 0.112, or $474 a month
Note: If you see a way to reduce the load on the motor or reduce its running time, you may want to know how much you will save. To perform an accurate cost calculation requires taking into account the multiple block structure of some electricity rates. For help with this, contact Mike Proud or Ron Estabrooks at 368-5010 (toll free). UNDERLOADED AND OVERLOADED MOTORS Another reason to make motor measurements is to ensure that the motors in your plant are properly sized for the tasks they perform. Motors that are built into commercial equipment tend to be properly sized, but other motors may not be. For one thing, motors are often specified to have more horsepower than is actually required. These underloaded motors cost more to run than properly loaded ones because they operate on a less efficient part of their load curve. At the other extreme, some motors are called upon to deliver more power than they are designed to deliver. They will do this for a while, but they overheat and eventually fail. A MORE ACCURATE ASSESSMENT In some applications the load on a motor is not constant, but varies greatly (and perhaps unpredictably) from moment to moment and hour to hour. Here, longer-term data gathering is needed, using a device known as a recording wattmeter. The Energy and Minerals Section has one of these units, and if you think it might shed light on your situation, call Mike Proud or Ron Estabrooks at 368-5010 (toll free).