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© B
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BU LV Motors AP-M
Energy Efficient Motors
International Conclave
On
Key Inputs for Accelerated Development
Of
Indian Power Sector for 11th Plan & Beyond
5th July 2007 New Delhi
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Low Voltage Motors Factories
Production
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Manufacturing Facility: Faridabad
FARIDABAD
LV Motors
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ABB - Motors India
One Factory located at Faridabad (North India )about 40 km from Delhi.
Another Factory at Bangalore , (Southern India).
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Milestones – ABB Motor India
ABB is pioneer to introduce high efficiency (EFF2) motors in India – in year 1991
ABB was again pioneer to introduce EFF1 motors for frame 315 & 355 in 1998 - more than 10000 successful Installations
Only motor factory in India to be accredited for IMS ( Integrated Management System), combination of ISO 9001 - 2000, ISO 14001- 1996 & OHSAS 180001- 1999 Center of Excellence for ABB Roller table motors up to 180 frame
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63 71 80 90 100 112 132 160 180 200 225 250 280 315 355 40056
Total offer – LV motors
Cast iron motors
Open drip proof motors
Brake motors
Flameproof motors
Increased safety motors (cast iron 90 – 355)
Non-sparking motors (cast iron 90 – 355)
Haz
ardo
us a
reas
Gen
eral
Pu
rpos
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• Standard three-phase TEFC (HX/+,M2BA)motors, IS:325 • Standard three-phase SPDP motors, IS:325• Crane duty motors• Brake motors (externally mounted)• Wind mill generators• Motors for frequency converter drive • Non-sparking motors type ‘n’, IS:9628• Increased safety motors type ‘e’, IS:6381• Flame Proof motors type ‘d’, IS:2148• Roller table motors
LV Motors - Product Range
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• Type Three phase squirrel-cage induction motors
• Output 0.18 ... 560 kw; 0.25 ... 750 hp
• Voltage 415 V; 220 ... 690 V
• Frequency 50 Hz; 25 ... 60 Hz
• Duty S1 ... S8 acc. to IS:12824
• Ambient 45oC / 50oC ; -20 ... 70oC
• Altitude Up to 1000 Meters
• Insulation Class ‘F’/Class ‘H’ (VPI on request)
LV Motors - Manufacturing Range
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• High Efficiency - ABB motors are engineered for high efficiency for minimum life cycle costs.
• Low noise level - The motors are designed to ensure low noise level.
• Accessories - Space heaters, thermistors, RTD and BTD’s on request.
• Terminal Box - Terminal box suitable for both Copper and Aluminium cables.Terminal box size sufficient for easy termination and maintenance of cable.
Special FeaturesSpecial Features
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• IP55 protection - IP55 protection (for TEFC) is an integral part of all motors.
• Voltage and frequency variation - The standard motors are suitable for 415Volts±10%, 50Hz ±5% and combined voltage and frequency variation of ±10% as standard : engineered for rigorous environment.
• Bearings - All motors are provided with deep-groove ball bearings with C3 clearance for high load capacity
Double sealed bearings up to frame 20063 series of bearings 100 frame onward Special care taken at the time of order for considering right bearing at the timeof order (eg. Roller Bearings for belt Application or Insulated bearingfor VFD Application)
Special FeaturesSpecial Features
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AC Induction Motors for Various Application
Food and beverage Variable speed drives Mining
Water and wastewater Pulp&paper
HVAC Multipurpose industrial use
Pharmaceutical
Cement industry
Petrochemical, oil and gas Wind power generation
Roller tables
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Manufacturing
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Machined Housing
Stack pressing
Coil mounting
Impregnation
Assembly
Testing
Rotor
Dynamic balancing
Shaft insertion
Die-cast rotor
Motors - Manufacturing Stages
Painting&
Packing
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Winding in ABB´s motorsRotor winding in ABB´s motors
1) Cast aluminium cage
2) Soldered copper bar cageBig motors (some 355, 400) Some VSD applications
3) Random wound windingSome big generator (400)
Stator winding in ABB´s motors
1) Random wound winding
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Manual winding Machine winding
Winding
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Insulation
Insulation System Combination of different insulationmaterials and impregnation material
AND
Conducting parts (active) & neutral parts (passive)
All electrical equipment/devices consist of insulating and conducting parts
THE INSULATION SYSTEMS
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Insulation
Requirements for insulation system in electrical motors
Electrical strength(voltage)
Thermal strength
Mechanical strength
Chemical strength
Strength against humidity/water
Suitability for winding work
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Insulation
In a LVAC electrical motor there areWire insulationSlot insulationSlot cover or slot wedgePhase insulationCoil insulationTying or lacing bandImpregnationSleevings on connections and phase leadsTerminal board or blockAccessories; PTCs, Pt100, heating resistors etc.
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Single layer winding in slot
Copper wire
Slot wedge
Enamel insulation:amide-imideovercoated polyester
Slot insulation
Enamel insulated copper wires
Random wound winding
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Single layer winding in winding end
Phase insulation
Coil
Slot insulation and slot wedge
Stator core
Random wound winding
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Slot wedge
Slot insulation
Enamel insulated copper wires
Layer insulation
Double layer winding in slot
Random wound winding
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Double layer winding in end winding
Random wound winding
Slot insulation and slot wedge
Phase insulation
Coil
Stator core
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0
20
40
60
80
100
120
140
160
180
B F H
Insulation class
Deg
. C Hotspot temperature marginMax. temperature riseMax. ambient temperature
40 40 40
8010
10105
125
15
130
155
180
Insulation classes acc. to IEC 85
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Impregnation
Methods and resins
Dip and roll impregnation, polyester and epoxy resins
Trickle impregnation, polyester and epoxy resins
Vacuum impregnation, polyester resin
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Impregnation
Dip and roll impregnationHeating during rolling:20°C/min, temperature in the end of rolling 130 - 140°CStoving:Temperature of the stove 140oC, stovingtime 1- 2 h
1-comp. polyester-imide or 1-comp. epoxy resinSEMOT: 2-comp. polyesterDipping time 5 min
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ImpregnationTrickle impregnation
Stoving:Temperature of the stove 150oC, stoving time 50 min
Silica filled 2-comp. polyester or 4-comp. epoxy resinSEMOT: 1-comp. polyesterHeating during rolling: 20°C/min, temperature in the end of the rolling 130 - 140°C (epoxy 160°C)
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Impregnation
Vacuum impregnation1-comp. polyester-imide resinVacuum sucks the resin into windingImpregnation time 45 minNo heating during impregnation
Stoving:Temperature of the stove 140oC, stovingtime 4 h
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Standard motors
Terminal box
End shield
Shaft
Outer bearing cover
Fan cover Fan
Frame
Bearing
Outer bearing cover
End shield
Inner bearing cover
Bearing
Inner bearing cover
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Energy Efficient MotorsEnergy Efficient Motors
Energy Efficient Motors
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Energy Efficient MotorsEnergy Efficient Motors
• Why improve motor efficiency?
• What is an Energy Efficient motor?
• What makes an motor “Energy Efficient “ ?
• Is Energy Efficient motor cost effective?
• Repair or replace?
• What is motor efficiency?
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What is motor efficiency ?
Motor efficiency is a measure of the effectiveness with which electrical energy is converted to mechanical energy, and is expressed as the ratio of power output to power input:
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The efficiency of a motor is primarily a function of load, horsepower rating, and speed, as indicated below:
a) Efficiency is a function of load
b) Efficiency of motors increases as the motor horsepower rating increases
c) Higher speeds, have a higher efficiency
Facts about motor efficiency
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Why improve motor efficiency?
• The shortage and large cost increases of vital national energy resources has demonstrated the need to conserve such resources.
• 65% of global industrial electricity is consumed by electric motors
• Electric cost is typically the largest individual cost component of lifecycle cost of a industrial electric motor
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Operation cost( > 95 % of the LCC)• Efficiency• Performance• Unavailability, Spare parts• Maintenance, After Sales Service• Disposal, upgrading
Investment Cost ( < 5% of the LCC)• Technology (Semiconductors, Motor Control,
Cooling, etc.)• System purchasing and Projecting• Civil works; Space, Layout, Cables • Installation, Commissioning, Training
Life cycle cost
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Environmental impactEnvironmental aspects Motor A: 12 kW Motor B: 12 kWover full lifecycle 91.1% efficiency 89% efficiencyUse of resourcesCoal (kg) 16,370 20,690Gas (kg) 2,070 2,620Oil (kg) 3,240 4,090Steel (kg) 27 24Copper (kg) 0.9 0.8Aluminium (kg) 4 4Silicon (kg) 1.1 1.0Other (kg) 0.09 0.09
EmissionsCarbon dioxide (kg) 62,940 79,560Sulfur dioxide (kg) 495 626Nitrogen dioxide (kg) 136 172Hydrochloric acid 8.8 11.1Metals (g) 538 538Heavy metals (g) 1.1 1.1Solid waste (kg) 117 106Particles (kg) 30.4 38.4Other (kg) 12 15
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An energy efficient motor produces the same output but uses less electrical power ( KW ) than a standard motor.
What is an Energy Efficient Motor ?
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Efficiency graphs, 4-pole
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Iron Loss in Core
Rotor Loss
Stator Copper LossStray Loss
Bearing, Windage &Friction Loss
What makes motors energy efficient ?
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Losses Design ChangesStator copper loss More copper,larger slot,higher slot
fill,reduced over hangIron loss Low loss steel,thinner lamination,
Improved core insulation,stress relieving
Rotor loss Larger rotor bars & end rings,higher conductivity bars & rings
Friction & windage losses Optimized fan design,optimum bearing selection,improved ventilation circuit
Stray load losses Larger airgap,low skewing,slot shape etc
What makes motors energy efficient ?
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Improved Quality ofDesignMaterialProcess
Reliability
+
Efficiency
What makes motors energy efficient ?
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Annual energy savings
Saving= KWxLxHr.xCx{1/(standard η)-1/(EE η)}Where,
L = Load factor (percentage of full load/100)Hr. = Annual operating hoursC = Average energy cost
Energy Efficient Motors
Simple Payback = Price Premium
(years) Annual savings
CostsBenefits
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22KW / 30 HP 4P motorStandard Motor Eff. at 90% loading = 91.5%ABB EFF1 motor At 90% loading = 92.6%Energy cost = Rs. 3.00 / KWHAssuming 22Hrs. Continuous run for 300 days
Savings for the year = Rs. 5090 /-
Energy Efficient MotorsEnergy Efficient Motors
Simple Payback = 7000 = 1.4 Years(years) 5090
Life Cycle Cost Saving =Rs 71,255.00Considering life of 15 Years
Are You buying a new motor ?
CostsBenefits
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Energy Efficient MotorsEnergy Efficient Motors
Simple Payback = 35000 = 1.7 Years(years) 19927
CostsBenefits
22KW / 30 HP 4P motorOLD Motor Eff 3 at 90% loading = 89%ABB EFF1 motor At 90% loading = 92.6%Energy cost = Rs. 3.00 / KWHAssuming 24 Hrs. Continuous run for 320 days
Savings for the year = Rs. 19927/-
Life Cycle Cost Saving =Rs 2,78,982.00Considering life of 15 Years
Replacing a Old Motor ?
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Reduced energy bill
Overall benefits of Energy Efficient Motor
Reduced downtime cost
Better tolerance to thermal stresses from frequent starts
Low noise
Better resistance to abnormal operating conditions
Eco - friendly operation
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Ontario Hydro Experiment
Repair or replace?
REPAIR
Replace
Ten new 15KW motors were independently tested and purposely damaged and sent to nine different repair companies
Efficiency loss varied from 0.3 to 3.4%
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Core losses are higher because of high temperature and lamination damage
Higher copper losses for low copper fill
Higher frictional losses for universal fans
Repaired motor has loss of efficiency
REPAIR
Replace
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