MotorEffic&PF CM5

ME 416/516
Motor Efficiency
and Power Factor
ME 416/516
Motivation
More than half of all electric energy generated
goes to power electric motors.
Electric motor converts electric power into shaft
power. In thermodynamics terms, this is simply
converting work from one form to another.
The Second Law allows electric motors to have
a theoretical efficiency of 100%.
In reality, several types of power loss occur from
where electricity leaves power plant to the point
where shaft power leaves the motor.
ME 416/516
Electric Power Losses
1. Transmission and transformer I
2
R and hysteresis
losses of real power component.
2. Transmission and transformer losses of
imaginary power component.
3. Losses in the motor resulting from winding
losses, frictional losses, etc.
Loss 1 can be reduced by transmitting power at
higher voltage: Power = VI and Loss = I
2
R.
Same power can be transmitted by increasing V
and reducing I: losses are reduced as 1/V
2
.
ME 416/516
Electric Power Losses (Contd)
Losses can also be reduced by decreasing R,
but this means larger conductors (heavier wire)
and copper is expensive.
Loss 2 can be reduced by lowering imaginary,
reactive part of current, which is accomplished
by power factor improvement, discussed next.
Loss 3 can be reduced by using more efficient
motors, where electric motor efficiency is
defined as:
= Shaft Power Out/Electric Power In
ME 416/516
Motor Ratings
An electric motors nameplate or rated power is
its output power, not its electric input power.
Electric power consumption is rated power
divided by motor efficiency.
Rated power depends on class of motor (which
considers intended duty). Industrial grade
motors usually are rated for continuous duty.
Motor efficiency requirements are set by 1992
Energy Policy Act (EPACT), primarily for larger
motors as used in industry and HVAC.
ME 416/516
1992 EPACT Selected Full-Load Motor
Efficiency Requirements
Open Motors Closed Motors
hp 2 pole 4 pole 6 pole 2 pole 4 pole 6 pole
1 --- 82.5 80.0 72.5 82.5 80.0
5 85.5 87.5 87.5 87.5 87.5 87.5
10 88.5 89.5 90.2 89.5 89.5 89.5
20 90.2 91.0 91.0 90.2 91.0 90.2
50 92.4 93.0 93.0 92.4 93.0 93.0
100 93.0 94.1 94.1 93.6 94.5 94.1
200 94.5 95.0 94.5 95.0 95.0 95.0
ME 416/516
Energy Savings through Electric
Motor Efficiency Improvement
EPACT was passed in 1992 but motor efficiency
provisions took effect in 1997.
Commercial, institutional and, particularly,
industrial operations use substantial amounts of
power for electric motors.
Although high or premium efficiencies may
have only a few percentage points better
efficiencies and may cost thousands of dollars
more, they often are good investments.
ME 416/516
Example- Elevator Motor
An elevator in an Orange Beach condominium lifts
an elevator weighing 5500 lbf at a rate of 5 ft/s. The
elevator operates 7 hr/day in APCo summer months
and 3 hr/day in winter months using an 85% efficient
motor installed when the condo was built. Consider
a replacement 95% efficient Baldor Super-E motor
costing $3500 + $500 installation. Assuming an
interest rate of 4%, electricity inflation rate of 4%,
overall inflation rate of 2.5%, 40% tax rate, 5-yr
depreciation, a 10% tax credit and no salvage value,
does it make sense to change motors? The condo
is a APCo Rate LPM customer.
ME 416/516
Example (Contd)
See Elevator Example Excel Spreadsheet
ME 416/516
Power Factor Correction
Electrical loss 2 between power plant and useful
work output of motor was the transmission and
transformer I
2
R and hysteresis losses resulting
from the imaginary component of the power.
This loss applies whenever an imaginary
component is present- not just for motors.
Power factor (PF) correction can reduce loss by
reducing imaginary component magnitude.
PF correction is relatively simple and economical,
and often yields large energy and cost savings.
ME 416/516
What Is Power Factor?
The total power in units of kVA is given by:
kVA = Volts * Amps * (N
ph
)
1/2
* 10
-3
where Volts and Amps are the measured rms
voltage and current and N
ph
is the number of
phases (1 or 3).
The relation between total power, reactive power
and real power is shown in the "power triangle".
For AC service, total power is the
vector sum of the real power and
reactive (imaginary) power.
ME 416/516
Power Factor Triangle
Real Power (kW)

T
o
t
a
l

P
o
w
e
r

(
k
V
A
)
R
e
a
c
t
i
v
e

P
o
w
e
r

(
k
V
A
R
)
(
k
V
A
R
)
ME 416/516
Notes on Power Triangle
Imaginary component of power is due to
imaginary impedance elements in the load.
Pure resistors have no imaginary component, so
current and voltage are "in phase" if impedance
consists only of resistance elements.
Capacitance causes voltage to lead the current,
i.e., V reaches maximum before current (leading).
Inductive impedance causes current to lead
voltage, i.e., the voltage reaches maximum
behind current (lagging).
ME 416/516
Power Triangle Notes (Contd)
The cycle angle by which voltage leads or lags
behind the current is called the phase angle, .
By simple trigonometry of the power triangle, the
real component of power (in units of kW) is:
kW = kVA * cos
Cosine is the power factor(PF): PF = cos
Similarly, reactive power (in units of kVAR) is:
kVAR = kVA*sin
Also by the Theorem of Pythagoras:
kVA
2
= kW
2
+ kVAR
2
ME 416/516
Why IS PF Less than 1?
Many common uses of electricity have inductive
components of impedance that produce a lagging power
factor:
induction motors (AC)
power thyristors for DC motor control
transformers and voltage regulators
electric welding equipment
electric arc and induction furnaces
neon and fluorescent lights (ballasts)
ME 416/516
Why Worry About
PF < 1?
Because V is fixed, then I is
proportional to total power
(kVA), and kVA = kW/PF.
The larger phase angle between V and I, the
smaller PF, the larger kVA and, thus, the larger
the current the utility must send over its lines.
Larger I causes larger I
2
R losses and requires
utility to install larger conductors & transformers.
Although customer uses same real power, the
lower PF costs the utility more to provide it.
ME 416/516
Results of Low PF
It costs the utility more to deliver the same real
power to a customer with low power factor, so
utilities charge a higher rate for low PF, either:
a direct penalty-higher charge for lower power
factors levels (e.g., PF > 95%, no extra charge; 90
< PF < 95%, 5% surcharge; 85 < PF < 90%, 10%
surcharge, etc.
or charge per kVA rather than per kW (APCo).
The customer also has to buy larger wiring,
switches, transformers, etc., because of higher
current and kVA.
ME 416/516
How Can Low PF Be Improved?
Recall that capacitance and inductive elements
have the opposite effect on the phase angle
between voltage and current.
Inductors have negative imaginary impedances,
but capacitors have positive imaginary
impedances.
Capacitors can be added to the power circuitry
to increase PF, as described in the power
triangle diagram following:
ME 416/516
Real Power (kW)
O
l
d

k
V
A
S
y
s
t
e
m

k
V
A
R
(
N
e
w

k
V
A
R
)
N
e
w

k
V
A
kW
C
a
p
.

k
V
A
R
Old
New
ME 416/516
Capacitor Sizing
First step is to measure present (old) kVA and
PF, or get them from the power bill.
Calculate kW: kW = PF
old
* kVA
old
Calculate system kVAR
sys
:
Identify a target PF
new
.
Calculate the new kVA using target PFnew:
kVA
new
= kW/PF
new
2 2
old sys
kW kVA kVAR =
ME 416/516
Capacitor Sizing (Contd)
Calculate kVAR
new
once target PF
new
is
achieved:
kVAR
new
is the difference between kVAR
sys
and
the added capacitor's kVAR:
kVAR
new
= kVAR
sys
- kVAR
cap
So kVAR of the capacitors to be installed is:
kVAR
cap
= kVAR
sys
- kVAR
new
2 2
new new
kW kVA kVAR =
ME 416/516
Who Is Affected by PF
Concerns?
Most utilities only assess a penalty for low PF
for relatively large power users.
For example, to get rate LPL, APCo customers
must have a 1200 kVA minimum capacity (this
corresponds to a $200,000 per year power bill).
Consequently, most customers to whom PF
correction is most important are industrial or
large institutional customers (like UA).
Both categories have large portion of load made
up by power supplied to large electric motors
and to fluorescent and HID lighting.
ME 416/516
Location of Capacitors
Effective PF correction begins by installing
capacitors at largest motors first and then
adding capacitors as required at distribution
load centers.
Capacitors typically are not supplied to motors
rated less than 20 hp unless these are the
largest motors in service.
Capacitors are normally installed on the load
side of the motor starter so that they are
effective only when the motor is operating.
ME 416/516
Location of Capacitors (Contd)
For motors that reverse, jog, etc., or where motor
may at times be driven by the load (elevators,
cranes), capacitors are connected on supply line
side of motor controls with a separate switch.
Adding excess capacitance can result in
dangerous or damaging capacitor discharge
through motor windings after motor is shut off.
Capacitance must be controlled to match loads to
avoid large discharge through motors and to lower
PF from too much leading impedance.
ME 416/516
Correcting PF of an Individual
Motor
One set of following information is needed:
Nameplate hp, efficiency, PF
Nameplate hp, efficiency, voltage, full load
amps (FLA)
Nameplate PF, voltage, FLA
Measured PF, voltage, FLA
ME 416/516
Correcting PF of an Individual
Motor (Contd)
Get motor kW and kVA using these equations :
kW = hp * 0.746/effic. = kVA * PF
kVA = FLA * Voltage * (Nph)
1/2
* 10
-3
where N
ph
is the number of phases (1 or 3).
Find the required kVAR capacitor as shown
before.
ME 416/516
Example
Given: PF = 0.82 and motor with nameplate info
of 100 hp and 94% efficiency.
Find: Capacitor kVAR needed for Pf
new
= 0.96.
Soln: Calculate present power requirement:
kW = 0.746 kW/hp*100 hp/0.94 = 79.4 kW
Calculate present kVA
kVA
old
= 79.4/0.82 = 96.8 kVA
Calculate present (system) kVAR:
kVAR
sys
= (96.8
2
- 79.4
2
)
1/2
= 55.4 kVAR
ME 416/516
Example (Contd)
Calculate new kVA if PF = 0.96 is reached:
kVA
new
= 79.4 kW/0.96 = 82.7 kVA
Calculate combined kVAR after capacitor
added:
kVAR
new
= (82.7
2
- 79.4
2
)
1/2
= 23.1 kVAR
Find kVAR of the capacitor to be installed:
kVAR
cap
= 55.4 - 23.1 = 32.3 kVAR
The nearest standard size would be installed,
probably 30 kVAR. A larger std. capacitor than
actually needed would be avoided if PF 1

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ME 416/516

Real Power (kW)

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