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Energy Efficiency Improvements in Electric Motors and Drives Springer Berlin Heidelberg New York Barcelona Hong Kong London Milan Paris Singapore Tokyo Paolo Bertoldi Anibal T. de Almeida Hugh Falkner (Editors) Energy Efficiency Improvements in Electronic Motors and Drives With 260 Figures and 87 Tables Springer Dr. Paolo Bertoldi European Commission DG XVII Rue de la Loi, 200 1049 Brussels Belgium E-mail: [email protected] Prof. Anibal T. de Almeida University of Coimbra ISR - Dep. Eng. Electrotecnica P6lo II 3030 Coimbra Portugal E-mail: [email protected] Dr. Hugh Falkner ETSU Harwell Didcot Oxfordshire OXIl ORA United Kingdom E-mail: [email protected] ISBN-13: 978-3-540-67489-4 e-ISBN-13: 978-3-642-59785-5 DOl: 10.1007/978-3-642-59785-5 Die Deutsche Bibliothek - CIP-Einheitsaufnahme Energy efficiency improvements in electronic motors and drives: with 87 tables I Paolo Bertoldi ... (ed.). - Berlin; Heidelberg; New York; Barcelona; Hong Kong; London; Milan; Paris; Singapore; Tokyo: Springer, 2000 ISBN-13: 978-3-540-67489-4 This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer-Verlag. Violations are liable for prosecution under the German Copyright Law. Springer-Verlag is a company in the BertelsmannSpringer publishing group. © Springer-Verlag Berlin . Heidelberg 2000 Reprint of the original edition 2000 The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Cover-Design: Erich Kirchner, Heidelberg SPIN 10724842 4212202-5 4 3 2 1 0 - Printed on acid-free paper Preface The 1997 Kyoto Conference defined CO emISSIOn targets for the developed 2 regions of the world. The EU target of decreasing the emissions 8% below the 1990 level, by 2010, will require a very substantial effort covering basically all activities if such a target is to be reached. Energy-efficient motor systems can provide one of the most important opportunities to achieve electricity savings in a cost effective way, avoiding at the same time the emission of tens of millions of tons of carbon. The reduction of energy consumption through improvements in energy efficiency is one of the major instruments for developed and developing countries to meet the Kyoto commitments. Energy efficiency is also a key element of the European Union (EU) energy policy, since it improves the efficiency of the economy, increases energy supply security, and decreases harmful emissions due to electricity generation. Electric motor systems use over half of all electricity consumed in developed countries. Typically about 70% of the electricity which is used in the industrial sector and about 35% of the electricity used in the commercial sector in the EU is consumed by motor systems. In industry, a motor on average consumes an annual quantity of electricity which corresponds to approximately 5 times its purchase price, throughout its whole life of around 12 to 20 years. Motor systems are by far the most important type of electric load. They are used in all sectors and in a wide range of applications, such as: fans, compressors, pumps, conveyors, mills, winders, elevators, transports, home appliances, and office equipment. As motors are the largest users of electrical energy, even small efficiency improvements will produce very large energy savings, across the EU. Although individual components in electric motor drive systems perform relatively well, there are sources of losses throughout the power drive system. Motor electricity consumption is influenced by many factors such as motor efficiency, motor speed controls, power supply quality, harmonics, systems oversizing, distribution network, mechanical transmission system, maintenance practices, load management, and the efficiency of the end-use device (e.g. fan, pump, compressor VI etc.). In order to benefit from the available savings potential, in most cases it is necessary optimise the whole motor system. Motor systems improvements produce substantial electricity savings contributing to improve plant efficiency, to reduce the use of fossil fuels, and to reduce greenhouse emissions. Additionally, the profitability and competitiveness of many economic activities can be significantly improved through the use of energy efficient motor technologies. The 2nd International Conference "Energy Efficiency in Motor Driven Systems" (EEMODS '99) held in London, 20-22 September, 1999, follows on from the very successful First International Conference "Energy Efficiency Improvements in Electric Motors and Drives ", Lisbon, 29-31 October 1996. There is evidence that the discussions and networking resulting from these motor conferences play an important step forward to better define research, development, standardisation, policies and programmes to promote energy-efficient motor systems around the world. EEMODS '99 brought together around 200 prominent experts from all over the world, providing a variety of experiences and perspectives, to discuss the latest developments covering: • New technology developments, covering both research results as well as innovative applications • Policies and policy instruments, including labelling and minimum performance standards • International programmes for market transformation and energy efficiency improvements • Novel alternatives for financing and promoting energy-efficient motor systems projects This book contains all the key presentations made in the plenary sessions, as well as the papers presented in the four workshops: "Test Methods for Induction Motors ", "Examples of financing Energy Efficiency in Motor Systems ", "Minimum Standards and Motor Labelling" and "Pump Design and Applications". Summary papers of the posters on display during the conference are also included. It is hoped that the availability of this book will enable a large audience to benefit from the presentations made in EEMODS '99. Potential readers who may benefit from this book include researchers, engineers, policymakers, energy agencies, electric utilities, and all those who can influence the design, selection, application and operation of electric motor systems. The book is structured into the following chapters: VII • Introduction • Technology Developments • Motor System Characterisation and Applications • Pump Design and Applications • Test Methods for Induction Motors • Policies • Minimum Standards and Motor Labelling • Programmes • Examples of Financing Energy Efficiency in Motor Systems EEMODS '99 had as its main sponsors the SAVE II Programme (Specific Actions for Vigorous Energy Efficiency), which was adopted by the Council of the European Communities, and the UK Government's Energy Efficiency Best Practice programme. We also wish to acknowledge the following organisations that helped by sponsoring the event: ABB AUTOMATION, ALSTOM, BROOK CROMPTON, CONTROL TECHNIQUES, EASTERN ENERGY, SIEMENS and the United States' Department of Energy. The support of all the sponsors and their generous funding was very important in ensuring the success of EEMODS '99, and is greatly appreciated. The Editors Anibal T. De Almeida Paolo Bertoldi Hugh Falkner ENERGY EFFICIENCY Contents Preface.......................... ......... .................. ............ ...... ....... V Introduction Energy Efficiency in a Competitive Economy ................................ . Hans-Joachim Jiihne Ethics & Answers: Engineering Efficiency for a Sustainable Future .... " . 7 Richard J. M Hamilton Technology Developments Integration of Motors and Drives...... ............... ... ... ... ... ... .... .... .... 13 Donald Jackson Design of Motors for Inverter Operation....................................... 26 Tapio Haring Die Casting Copper Motor Rotors: Mold Materials and Processing for Cost-Effective Manufacturing................................................... 39 Dale T Peters, John G. Cowie, Edwin F. Brush Review ofthe System Compatibility and Ride-through Options for AC and DC Drives Including Multilevel Inverters................................ 52 Annette von Jouanne, Ben Banerjee Introduction to the Permanent Magnet Motor Market. . . . . . . . . . . . . . . . . . .. . . .. 81 Toshihiro Sawa, Kaneyuki Hamada High Efficiency Motors - Performance, Economy & Reliability, by Optimisation........................................................................ 95 P. Caselotti, A. Conchetto, P. J. Tavner The Influence of Selected Losses Components on Induction Squirrel- Cage Motor Efficiency.. .. .. .. .... ... ... .. .... ... .. . .. . .. .. . .. .. ...... . .. .. .. ..... 102 Konrad Dabala x Inverter Fed High-Speed Solid-Rotor Induction Motors for Industrial Applications...... ... ...... ... ...... ... ... ... ......... ... ... ......... ... ...... ..... 107 Huppunen Jussi, Pyrhonen Juha, Alamiiki Jarmo Switched Reluctance Drive for Mass Application. ....... . . . . . .. .. . .. . . .. .. .. 113 M G. Bitchkov, NF. Ilinski, V. A. Sementchuk The Written-Pole™ Motor: High Efficiency - Low Start Current...... ... 117 Brian Beck, Dale Friesen Motor and Drive Integration with Passive Components Realised Using the Stator Core................................................................ .... 124 S. D. Garvey Efficiency Improvement of Variable Speed Electrical Drives for HVAC Applications......................................................... ........... ... 130 Flemming Abrahamsen, Frede Blaabjerg, John K. Pedersen Higher Efficiency Drive for Fluid Treatments............................ .... 136 Aldo Boglietti, MarioLazzari, Michele Pastorelli Motor System Characterisation and Applications Characterisation ofEU Motor Use... ... ...... ... ... ......... ... ...... ... ... ... 143 Anfbal T. De Almeida, Paula Fonseca Minimising Efficiency Loss Caused by Motor Rewinds... ... ... ...... ..... 168 David Walters Improving Efficiency in Motor Driven Systems - The Iron Ore Industry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Lennart Mukka, Bernt Engstrom Optimising Fan Systems for Energy Efficiency.............................. 205 W T. W Cory Energy Optimized Drive Systems Design.................................... 239 Herbert Auinger Using Collaboration to Achieve Industrial Market Change............... ... 252 Aimee T. Mckane Pump Design and Applications Pump System Effectiveness...................................................... 269 Gunnar Hovstadius XI Driver Selection Matched to Demand: A Consideration for Maximising Lifecycle Costs by Using the Correct Driver.......................... ..... .... 278 Ian Metcalf Environmental Impact Assessment (LCA) Energy and Re-cycling for a Circulator........................................................................... 285 Nils Thorup Promoting the Purchase of More Efficient Pumps, A SA VE 287 Study ................................................................................ . David T Reeves, Hugh Falkner On Site Testing..................................................................... 296 Ikka Sintonen SQ - Submersible Pump with Integrated Permanent Magnet Motor Drive.... ......... ... ...... ... ... ......... ...... ...... ... ... ...... ................ .... 300 Henrik 0rskov Pedersen Test Methods for Induction Motors Induction Motor Efficiency Measurement..................................... 307 S. Williamson, H.P. Sam bath Experience Factors When Testing for Efficiency and Correlating Results with Design......................................................................... 314 Joseph A. Kline Approaching the Truth in Induction Motor Efficiency....................... 320 Haataja J, Pyrhonen J Precise Efficiency Data for Electric Motors - an Illusion?. . ... .. . . .. .. . . .. 328 Herbert Auinger Calorimetric Method to Measure Total Losses of the Induction Motor.... 335 Elzbieta Ogonowska - Schweitzer Precision Calorimetry for Stray Load Loss Determination...... ............. 343 K. J Bradley, A. Ferrah, R. Magill, P. Mcleod, J C. Clare, P. Wheeler, P.Sewell A Test and Measurement System for Test of Electrical Drive Systems... 353 P. Sandholdt, E. Ritchie, J K. Pederson Induction Motor Efficiency Standards.......................................... 361 P. Van Roy, B. Slaets, K. Hameyer, R. Belmans