NEW EFFICIENCY STANDARD PRESENTATION BY Bhalchandra Bansod Regional Manager-Industrial [email protected] +919766342489
NEW EFFICIENCY STANDARD PRESENTATION BY Bhalchandra Bansod Regional Manager-Industrial [email protected] +919766342489.
Apr 01, 2015
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NEW EFFICIENCY STANDARD
PRESENTATION BY
Bhalchandra BansodRegional Manager-Industrial
+919766342489
INDIAN STANDARS SCENARIO
INDIAN STANDARS SCENARIO
IS8789(1978, REVISED 1998) IS SUPERCEDED BY IS12615(1996, REVISED 2004)
IS8789 MOTORS ARE NOT MANUFACTURED BY REPUTED MANUFACTURERS
IS12615 PRESENTLY USES IEC60034-2 EFFICIENCY MEASUREMENT METHOD.
IS12615 IS JUST REVISED EFFECTIVE JUNE 2011
REVISED STANDARD USES IEC60034-2-1 METHOD OF EFFICIENCY MEASUREMENT.
TOMMORROWS EFFICIENCIES TOMMORROWS EFFICIENCIES
IS12615 -2011 IS12615-2004
IE1 Eff2
IE2 Eff1
IE3 Premium Eff
IE4 Super Premium
75
80
85
90
95
100
1.1
2.2
5.5
11
18.5 30 45 75
110
187
250
340
Eff
icie
nc
y
Power kW
IEC / NEMA Comparison
EPAct
NEMA Premium
EFF2
EFF1
EFF3
Efficiency Comparison across the GlobeEfficiency Comparison across the Globe
EFFICIENCY MEASUREMENT IS APPROXIMATE
EFFICIENCY MEASUREMENT IS APPROXIMATE
EFFICIENCY MEASUREMENT METHODEFFICIENCY MEASUREMENT METHOD
Motor Loaded by Generator Input given equal to output by Name
plate efficiency Stator resistance is measured to calculate
Stator copper loss Slip is measured to calculate rotor copper
loss Friction and windage loss assumed as 1%
of output Stray Loss assumed as 0.5% of Output. Input-losses=Output and
Output/Input=Efficiency
Motor Power
kW IEC 60034-2 IEC 619720.75 0.50 3.001.1 0.50 2.991.5 0.50 2.992.2 0.50 2.983.7 0.50 2.975.5 0.50 2.967.5 0.50 2.9411 0.50 2.9215 0.50 2.89
18.5 0.50 2.8622 0.50 2.8430 0.50 2.7837 0.50 2.7245 0.50 2.6655 0.50 2.5875 0.50 2.4495 0.50 2.30110 0.50 2.16150 0.50 1.88
Assumed stray load losses (% of full-load power)
NEW STANDARD ASSUMES MUCH HIGHER STRAY LOSSES
NEW STANDARD ASSUMES MUCH HIGHER STRAY LOSSES
Stray load losses are due to Magnetic transfer loss in the air gap between the stator and rotor
IS12615 REVISIONIS12615 REVISION IN LINE WITH HARMONISED
GLOBAL STADARD IEC60030-30.
LARGE RANGE FROM 0.37KW TO 375KW.
INCLUSION OF 6 POLE MOTORS
REVISED PUBLICATION IN JUNE 2011
PROPOSED WITHDRAWL OF IE1- JAN 2012
PROPOSED WITHDRAWL OF IE2- JAN 2014
INTRODUCTION OF IE3- JAN 2014
INTRODUCTION OF IE4- TO BE DECIDED
Super E Gives Better Part Load Efficiencies.
Nema Super E compared with Eff2
Super E Gives Better Part Load Efficiencies.
Nema Super E compared with Eff2
50 HP, 4 POLE MOTOR
05
101520253035404550556065707580859095
100105110
0 25 50 75 100 125
% Load
% E
ffici
ency
NEMA PREMIUM
EFF2(IEC)
Upgrading even one, 1 kW motor to a Premium Efficient motor gives double benefit
of Energy Savings and Carbon credits..IN PAT..
Upgrading even one, 1 kW motor to a Premium Efficient motor gives double benefit
of Energy Savings and Carbon credits..IN PAT..
Every year will eliminate:
1 Drum of Oil from being burned
250 Kg of coal from being burned
Up to 800 gms. of carbon emissions from being released into the atmosphere
and....
or....
PREMIUM EFFICIENCY INSIDEPREMIUM EFFICIENCY INSIDE
High Quality Ball Bearing, reduce friction and vibration
Patented Lube-Lok retainer grease seal on both end
Locked bearing reduces endplay and minimizes energy loss in axial movement
How to improve motor Efficiency and provide longer life?
FRICTION LOSS REDUCTION
PREMIUM EFFICIENCY INSIDEPREMIUM EFFICIENCY INSIDE
Fan & Fan cover designed for optimum cooling and quieter operation
Smaller fan generate less losses
Smaller fan can be used due to cooler operation
How to improve motor Efficiency and provide longer life?
WINDAGE LOSS REDUCTION
PREMIUM EFFICIENCY INSIDEPREMIUM EFFICIENCY INSIDE
More Wire volume
Improved slot design
ISR (Inverter Spike Resistant) magnet wire is up to 100 times more resistant to voltage spikes
End turns laced both end
Low temp. raise (< 80°C)
Class F insulation systems
Each 10°C below max allowed temperature double insulation life
How to improve motor Efficiency and provide longer life?
STATOR COPPER LOSS REDUCTION
PREMIUM EFFICIENCY INSIDEPREMIUM EFFICIENCY INSIDE
Improved Rotor insulation
High-pressure die cast aluminum Rotor
Rotor dynamically balanced to IEEE 841 vibration limits as standard (0.08 in/sec). This reduces energy losses in vibrations.
How to improve motor Efficiency and provide longer life?
ROTOR LOSS REDUCTION
PREMIUM EFFICIENCY INSIDEPREMIUM EFFICIENCY INSIDE
Thinner lamination
Improved steel properties for lower losses and also allow same performance after rewind
Optimized air gap. (Hardened and thicker inside shaft)
More steel - Longer stack
How to improve motor Efficiency and provide longer life?
IRON AND STRAY LOSS REDUCTION
What Motors To ReplaceWhat Motors To Replace
Non Branded
Old motors having no efficiency written on name plate(IS8789)
New motors having lower efficiecy on name plate
Motors which are rewound more than once.
WHY BALDOR MOTORSWHY BALDOR MOTORS
Online Greasing facility even for 1 HP motor.
All motors are Inverter ready by Default.
Highest levels of efficiencies IN THE WORLD, Ex stock at Pune/Mumbai/Ahmedabad warehouse.
Customised Compact Motors
Motors and Drives Packages like Cooling Towers to replace the Gearbox with Direct Drives.
Motors with IEC Dimensions for exact replacement.
Distributor in Major Cities.
Service Centers in Major Cities.
High Mechanical Maintenance
More components to fail over time:– Gearbox failures– Oil leaks & contamination– Failed & misaligned drive shafts– Excessive vibration– Additional replacement time due
to large mounting frame
Conventional Cooling Tower Control– Lightly loaded majority
of the time– Peak load for short
durations– Started across the line
• High inrush currents• Mechanical stresses
Conventional Cooling Tower Drives
• IP56 Protection with Enpro Sealing+ Flinger• Permanent Magnet Laminated Yoke Sync
Motor• Encapsulated winding.• Online Greasing once in a year• Unity power factor• 13% Guaranteed Savings at Full Speed.• Upto 50% Energy savings at Low rpm• Installation at Ruchi Infra Kakinada.
New Direct Drive Technology
Affinity Laws for Centrifugal LoadsAffinity Laws for Centrifugal Loads
100%90%80%70%60%50%40%30%
100%73%51%34%22%13%
6%3%
Speed VolumeHorsepower
Required Pressure/
Head
100%81%64%49%36%25%16%
9%
100%90%80%70%60%50%40%30%
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