Table Of ContentEnergy 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
