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AbstractThe performance of the oversized three-phase induction motors can be improved, both in terms of efficiency and
power factor, with the proper change of the stator winding connection, which can be delta or star, as a function of their load.
A practical method is proposed to quickly and easily evaluate
which stator winding connection is more appropriate for the actual motor load profile, in order to increase the motor efficiency
and power factor. This new method is suitable for in-field evaluation, because it requires only the use of inexpensive equipment
and has enough accuracy to allow a proper decision to be made.
The automatic change of the stator winding connection, as a function of the motor line current, is also analyzed. When properly
applied, these methods can lead to the improvement of the efficiency and power factor of permanently oversized motors, motors
with a load variation between low load and near full load during
their duty cycle, and/or motors driving high-inertia, low duty cycle
loads. The proposed methods are particularly suitable to industrial plants where typically many electric motor systems are oversized and/or can have a wide load variation. In these conditions,
the active and reactive electrical energy bill can be significantly
reduced.
Fig. 1. Average load factor by power range for motors, in the industrial and
tertiary sectors, in the European Union, 2000 [2].
I. INTRODUCTION
N industry, more than 90% of the electrical motors are threephase squirrel-cage induction motors, hereafter denominated
only by motors [1], [2]. In the European Union, the average load
factor for motors, in both industrial and tertiary sectors, is 0.57
(Fig. 1). However, the average load factor per power range in
some sectors can be as low as 0.25 [2]. Individual motors in
those ranges have even lower load factors. Because the load
factor is an average of the motor load during a defined period,
the motor load can vary between values lower and higher than
the load factor.
Motor oversizing is mainly due to the poor motor system
design or due to the gross overestimation of the mechanical
power required by the load [2]. Additionally, motor oversizing
Manuscript received December 10, 2005; revised December 10, 2005. Paper
no. TEC-000130-2005.
F. J. T. E. Ferreira is with the Department of Electrical Engineering, Engineering Institute of Coimbra (ISEC), Coimbra 3030, Portugal, and also with
the Institute of Systems and Robotics, University of Coimbra, Coimbra 3030,
Portugal (e-mail: fernando@mail.isec.pt and jeepisr@isr.uc.pt).
A. T. de Almeida is with the Department of Electrical and Computer Engineering, University of Coimbra, Coimbra 3030, Portugal (e-mail:
adealmeida@isr.uc.pt).
Digital Object Identifier 10.1109/TEC.2006.874248
FERREIRA AND DE ALMEIDA: METHOD FOR IN-FIELD EVALUATION OF THE STATORWINDING CONNECTION
371
Fig. 3.
Pmech
T
=
.
Pelec
Pelec
(1)
In the absence of voltage unbalance and motor electromechanical asymmetries, the active power Pelec absorbed by the
motor is given by (2), where VLL is the line-to-line voltage (rms),
IL is the line current (rms), and is the power factor:
Pelec = 3 VLL IL .
(2)
The motor load is defined by (3), where PN is the motor
nominal power:
=
Pmech
.
PN
(3)
The motor slip s is given by (4), where sync is the synchronous speed:
s=
sync
.
sync
(4)
372
Fig. 4.
Simulated motor efficiency, as a function of the load, for motors with different power rating: (a) 3 kW, (b) 11 kW, and (c) 300 kW.
TABLE I
EXPERIMENTAL VALUES FOR THE INDICATORS IN THE POINT
IL(D
Y
)
=
.
(5)
IL(Y
D
)
To identify point , four indicators based on the motor in-field
measurements and motor nameplate values (nominal values) are
analyzed:
two line current-based indicators (KI 1 and KI 2 );
two slip-based indicators (Ks1 and Ks2 ).
The proposed indicators are based in values easily obtained in
the field, using common measurement devices (voltmeter, clamp
ammeter, and stroboscopic tachometer), namely, the rms lineto-line voltage, the rms line current, and the motor speed. The
measurement of the power factor is avoided because it requires
the use of a power factor measurement device, a wattmeter or a
power analyzer, which, to have sufficient accuracy, are expensive
devices.
The indicators KI 1 , KI 2 , Ks1 , and Ks2 are defined by (6)
(9), where IN is the motor nominal line current, VN the motor
nominal line-to-line voltage, Vmeas is the actual motor line-toline voltage, sN is the motor nominal slip, and smeas is the actual
motor slip:
KI 1 =
IL(D )
IN
IL(D )
IL(Y )
2
sync meas(D )
VN
=
sync N
Vmeas
KI 2 =
profile is similar to the load shape of Fig. 6(c), the stator winding connection should be automatically managed by a suitable
control device.
VI. PERMANENT CHANGE OF THE WINDING CONNECTION
When the stator winding connection
is changed from D to
Y , the winding voltage decreases 3 times. In point , the
Ks1
=
Ks2 =
(6)
(7)
Smeas(D ) VN2
2
SN Vmeas
(8)
Smeas(D )
.
Smeas(Y )
(9)
FERREIRA AND DE ALMEIDA: METHOD FOR IN-FIELD EVALUATION OF THE STATORWINDING CONNECTION
373
Fig. 5. Experimental results for the 3-kW four-pole motor (Brand A) and for the 5.5-kW four-pole motor (Brand B): (a) motor efficiency, (b) motor power factor,
(c) motor speed, and (d) motor line current, as a function of the load.
Fig. 6.
Motor load profiles for (a) permanent Y connection, (b) permanent D connection, and (c) automatic management of the connection.
The indicators KI 1 and Ks1 are obtained without disconnecting the motor and the indicators KI 2 and Ks2 require the motor
stator winding connection change.
In Table I, a summary of the indicator values, their average
values, standard deviation, and variation with load, in relation
to the point , for the tested motors is presented. In Table II,
a summary of the obtained indicator values, in relation to the
point , for the simulated motors is presented.
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TABLE II
SIMULATED VALUES FOR THE INDICATORS IN THE INDICATORS IN THE POINT
Table I, the average variation of the indicators in the neighborhood of point (10% variation) is presented.
The indicator Ks1 is easy to obtain (it requires a stroboscopic tachometer and a voltmeter) but has errors related to the
speed measurement device errors (typically 1 r/min) and to the
nameplate speed errors due to the numerical rounding process
(the speed is rounded to 5-r/min multiples) [7]. The indicator
Ks1 includes a voltage correction related to the fact that, for a
constant torque, the motor slip is approximately inversely proportional to the voltage square. Therefore, if there is a difference
between the motor actual voltage and its nominal voltage, it is
necessary to compensate the slip, considering the relation between both voltages. The variation between Ks1 for the tested
motors, in the point , is reduced ( = 0.06 for an average equal
to 0.30). It can be concluded that if a motor has a Ks1 0.25,
there is a fair possibility (93% of the tested motors and 100%
of the simulated motors verify that condition) of being operating in the zone where energy consumption reduction can be
obtained after the stator winding connection change from D
to Y . In the simulated data, it can be concluded that Ks1 can
slightly increase with the motor rated power.
The indicator Ks2 is also easy to obtain (it also requires a
stroboscopic tachometer and a voltmeter) and it is more reliable
than Ks1 , but requires the motor stator winding to be changed.
The variation between Ks2 for the tested motors, in the point
, is reduced ( = 0.03 for an average equal to 0.27). It can
be concluded that if a motor has a Ks2 0.30, there is a high
possibility (100% of the tested and simulated motors verify
that condition) of being operating in the zone where energy
consumption reduction can be obtained after the stator winding
connection change from D to Y .
The KI 1 is not a good indicator because, when the motor
load is moving away from point , for the tested motors, it has
a very low average variation (2%), tending to 0% for motors
with PN 1 kW.
The KI 2 average is 1.67 ( = 0.11), which is also equal to
the ratio between the Y and D power factors, in point , as it
was demonstrated in (5).
All indicators present low standard deviation, but those with
higher variation, when the motor load is moving away from
point , are more appropriate for the selection of the best connection mode. In general, the slip-based indicators are more
suitable to in-field purposes because they have both lower standard deviation and higher average variation as a function of the
motor load. Additionally, the measurement of the motor slip is
normally easier and faster than the measurement of the motor
line current.
Fig. 7.
Therefore, it can be concluded that the Ks1 is the most appropriate indicator for a preliminary evaluation of the motor
efficiency improvement possibility, before the stator winding
connection change. After changing the stator winding connection, Ks2 can be used to check with more accuracy the motorefficiency improvement.
On the basis of the previous conclusions, a simple in-field
method to evaluate which connection is more appropriated for
the motor stator winding, as a function of the motor slip, can
be defined based only on the Ks1 and Ks2 indicators (see
Fig. 7). In this evaluation, the higher loads of the motors during
their duty cycle should be considered. Firstly, the possibility
of motor efficiency improvement after the stator winding connection change from D to Y should be determined based on
the nameplate and actual motor speed and voltage, using Ks1 .
The D to Y change should only be made if Ks1 0.25, with
a fair possibility of efficiency improvement. After the D to Y
change, a slip based re-evaluation should be made using Ks2 . If
Ks2 0.30 the Y connection should be maintained, otherwise
the winding should be reconnected to D.
Note that, even if there are no significant efficiency improvements due to the proximity between the motor load and the point
, the power factor still significantly improves.
Although the proposed method was only experimentally validated for the 185 W7.5 kW motor power range, in principle,
it can be applied to all the motors, because Ks2 has a very low
dependency on the motor rated power and Ks1 can slightly increase with the motor rated power, as was demonstrated by the
simulated results (see Table II).
The permanent stator winding connection should be reevaluated periodically if the load characteristics change. The
proposed method is suitable for grossly oversized motors and/or
motors driving loads with low duty cycles and high inertia (e.g.,
FERREIRA AND DE ALMEIDA: METHOD FOR IN-FIELD EVALUATION OF THE STATORWINDING CONNECTION
375
Fig. 8. Basic topology of an electronic device for the automatic change of the
motor stator winding connection [8].
The motor speed and load variation after the stator winding
connection change also deserve to be analyzed. After the stator
winding connection change from D to Y , the motor line current
significantly decreases and the motor speed slightly decreases
(in the point , the motor slip increases 34 times). After the Y
to D change, the motor line current significantly increases and
the motor speed slightly increases. The decrease of the motor
speed after the D to Y change
is related to the stator winding
voltage decrease (decreases 3 times) and the consequent reshape of the motor torque-speed curve. 2 The slight increase or
decrease of the motor speed after the stator winding connection change generally leads to an increase or decrease of the
motor load, respectively. This fact can lead to significant power
reductions in constant, linear, or quadratic torque loads, particularly for the last ones (e.g., centrifugal pumps and fans). For a
speed variation of = (D Y )/D several outcomes are
possible depending on the type of load, namely
loads with constant horsepower, Y D ,
loads with constant torque, Y D (1 ),
loads with linear torque, Y D (1 )2 , and
loads with quadratic torque, Y D (1 )3 .
Care must be taken to ensure that the motor speed after stator winding change from D to Y is still appropriate to the
driven load operation. For example, in a centrifugal pump, it
is necessary to guaranty that the speed reduction does not lead
to insufficient fluid flow (the pump flow is proportional to the
speed) and lifting incapacity 3 (the pump head is proportional
the speed square).
However, the lower the motor load is, and the higher the motor
rated power is, the lower the motor speed variation will be, after
stator winding connection change. If the D to Y change is made
near the point , the motor slip never exceeds the motor nominal
slip.
B. Motor Start-Up Precautions
When the motor stator winding is connected in the Y mode,
the starting torque is reduced approximately to 1/3 of the nominal value (for D connection), which can lead to a significant
increase of the starting period or even to the lack of starting
capabilities. If the Y starting mode is adopted, the user should
evaluate the increase of the starting timeframe and the increase
of the temperature that can result from such situation, potentially leading to a decrease in the motor lifetime. Therefore, the
user has to evaluate if the motor torque is able to accelerate
the motor in a suitable timeframe, particularly for high-inertia
loads and/or loads with high demanding torque requirements
(e.g., constant horsepower or constant torque loads).
376
Fig. 9. Motor efficiency, power factor, current (p.u.), and speed (p.u.) as a function of the load, for the 3-kW four-pole motor (Brand A): (a) without automatic
change and (b) with automatic change.
Fig. 10. Motor efficiency, winding current (p.u.), and line current (p.u.) as a
function of the load for the 3-kW four-pole motor (Brand A).
Fig. 11. Simulated motor efficiency, winding current (p.u.), and line current
(p.u.) as a function of the load for a 300-kW six-pole motor.
FERREIRA AND DE ALMEIDA: METHOD FOR IN-FIELD EVALUATION OF THE STATORWINDING CONNECTION
Fig. 12.
377
(a) Motor stator winding and rotor currents and (b) motor per-phase losses, as a function of the load, for the 3-kW four-pole motor (Brand A).
S=
i
i
Pmech(D
)
i
D
i
Pmech(Y
)
Yi
h C
i
(11)
378
Fig. 13.
Elevating conveyor with different load levels. (a) Motor load = 25%. (b) Motor load = 95%.
Fig. 14. Mixer with different load levels. (a) Motor load = 25%. (b) Motor
load = 95%. (c) Motor load = 15%.
the energy savings can increase about 2.7 times, reducing the
payback time to less than ten months. The average daily power
factor of the 3-kW motor improves by 0.31 (increases from 0.47
to 0.78) and 0.31 (increases from 0.44 to 0.75) for the conveyor
and mixer, respectively. The motor power factor improvement
for 25% and 15% of full load is 0.41 (from 0.37 to 0.78) and
0.39 (from 0.28 to 0.67), respectively.
Considering the simulated 300-kW motor with automatic
change, the energy savings are 10887 kWh/year and 12099
kWh/year for the conveyor and mixer, respectively. This can
be translated into 544 /year and 605 /year, respectively. For
this case, the payback time for the automatic change device can
be 1 month. The daily average of the 300-kW motor power factor improves by 0.15 (from 0.76 to 0.91) and 0.19 (from 0.70 to
0.89) for the conveyor and mixer, respectively. The motor power
factor improvement for 25% and 15% of full load is 0.20 (from
0.71 to 0.91) and 0.33 (from 0.52 to 0.85), respectively.
X. CONCLUSION
Grossly oversized three-phase induction motors operate with
lower efficiency and power factor, which is by far the most
important cause of poor power factor in industrial installations.
In some situations, motor performance can be improved both
in terms of efficiency and power factor through stator winding
connection change from delta to star. However, for variable
load motors, permanent connection change is not an acceptable
solution.
FERREIRA AND DE ALMEIDA: METHOD FOR IN-FIELD EVALUATION OF THE STATORWINDING CONNECTION
379