NEW EFFICIENCY STANDARD PRESENTATION BY Bhalchandra Bansod Regional Manager-Industrial

INDIAN STANDARS SCENARIO INDIAN STANDARS SCENARIO IS8789(1978, REVISED 1998) IS SUPERCEDED BY IS12615(1996, REVISED 2004) IS8789(1978, REVISED 1998) IS SUPERCEDED BY IS12615(1996, REVISED 2004) IS8789 MOTORS ARE NOT MANUFACTURED BY REPUTED MANUFACTURERS IS8789 MOTORS ARE NOT MANUFACTURED BY REPUTED MANUFACTURERS IS12615 PRESENTLY USES IEC EFFICIENCY MEASUREMENT METHOD. IS12615 PRESENTLY USES IEC EFFICIENCY MEASUREMENT METHOD. IS12615 IS JUST REVISED EFFECTIVE JUNE 2011 IS12615 IS JUST REVISED EFFECTIVE JUNE 2011 REVISED STANDARD USES IEC METHOD OF EFFICIENCY MEASUREMENT. REVISED STANDARD USES IEC METHOD OF EFFICIENCY MEASUREMENT.

TOMMORROWS EFFICIENCIES TOMMORROWS EFFICIENCIES IS IS IE1Eff2 IE2Eff1 IE3Premium Eff IE4Super Premium

Efficiency Comparison across the Globe

EFFICIENCY MEASUREMENT IS APPROXIMATE EFFICIENCY MEASUREMENT IS APPROXIMATE

EFFICIENCY MEASUREMENT METHOD Motor Loaded by Generator Motor Loaded by Generator Input given equal to output by Name plate efficiency Input given equal to output by Name plate efficiency Stator resistance is measured to calculate Stator copper loss Stator resistance is measured to calculate Stator copper loss Slip is measured to calculate rotor copper loss Slip is measured to calculate rotor copper loss Friction and windage loss assumed as 1% of output Friction and windage loss assumed as 1% of output Stray Loss assumed as 0.5% of Output. Stray Loss assumed as 0.5% of Output. Input-losses=Output and Output/Input=Efficiency Input-losses=Output and Output/Input=Efficiency

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 REVISION IN LINE WITH HARMONISED GLOBAL STADARD IEC IN LINE WITH HARMONISED GLOBAL STADARD IEC LARGE RANGE FROM 0.37KW TO 375KW. LARGE RANGE FROM 0.37KW TO 375KW. INCLUSION OF 6 POLE MOTORS INCLUSION OF 6 POLE MOTORS REVISED PUBLICATION IN JUNE 2011 REVISED PUBLICATION IN JUNE 2011 PROPOSED WITHDRAWL OF IE1- JAN 2012 PROPOSED WITHDRAWL OF IE1- JAN 2012 PROPOSED WITHDRAWL OF IE2- JAN 2014 PROPOSED WITHDRAWL OF IE2- JAN 2014 INTRODUCTION OF IE3- JAN 2014 INTRODUCTION OF IE3- JAN 2014 INTRODUCTION OF IE4- TO BE DECIDED INTRODUCTION OF IE4- TO BE DECIDED

Super E Gives Better Part Load Efficiencies. Nema Super E compared with Eff2

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 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 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 INSIDE More Wire volume More Wire volume Improved slot design Improved slot design ISR (Inverter Spike Resistant) magnet wire is up to 100 times more resistant to voltage spikes ISR (Inverter Spike Resistant) magnet wire is up to 100 times more resistant to voltage spikes End turns laced both end End turns laced both end Low temp. raise (< 80°C) Low temp. raise (< 80°C) Class F insulation systems Class F insulation systems Each 10°C below max allowed temperature double insulation life 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 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 INSIDE Thinner lamination Thinner lamination Improved steel properties for lower losses and also allow same performance after rewind Improved steel properties for lower losses and also allow same performance after rewind Optimized air gap. (Hardened and thicker inside shaft) Optimized air gap. (Hardened and thicker inside shaft) More steel - Longer stack More steel - Longer stack How to improve motor Efficiency and provide longer life? IRON AND STRAY LOSS REDUCTION

What Motors To Replace Non Branded Non Branded Old motors having no efficiency written on name plate(IS8789) Old motors having no efficiency written on name plate(IS8789) New motors having lower efficiecy on name plate New motors having lower efficiecy on name plate Motors which are rewound more than once. Motors which are rewound more than once.

WHY BALDOR MOTORS Online Greasing facility even for 1 HP motor. Online Greasing facility even for 1 HP motor. All motors are Inverter ready by Default. All motors are Inverter ready by Default. Highest levels of efficiencies IN THE WORLD, Ex stock at Pune/Mumbai/Ahmedabad warehouse. Highest levels of efficiencies IN THE WORLD, Ex stock at Pune/Mumbai/Ahmedabad warehouse. Customised Compact Motors Customised Compact Motors Motors and Drives Packages like Cooling Towers to replace the Gearbox with Direct Drives. Motors and Drives Packages like Cooling Towers to replace the Gearbox with Direct Drives. Motors with IEC Dimensions for exact replacement. Motors with IEC Dimensions for exact replacement. Distributor in Major Cities. Distributor in Major Cities. Service Centers in Major Cities. Service Centers in Major Cities.

High Mechanical Maintenance 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 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 IP56 Protection with Enpro Sealing+ Flinger Permanent Magnet Laminated Yoke Sync Motor Permanent Magnet Laminated Yoke Sync Motor Encapsulated winding. Encapsulated winding. Online Greasing once in a year Online Greasing once in a year Unity power factor Unity power factor 13% Guaranteed Savings at Full Speed. 13% Guaranteed Savings at Full Speed. Upto 50% Energy savings at Low rpm Upto 50% Energy savings at Low rpm Installation at Ruchi Infra Kakinada. Installation at Ruchi Infra Kakinada. New Direct Drive Technology

Affinity Laws for Centrifugal Loads 100%90%80%70%60%50%40%30%100%73%51%34%22%13%6%3% SpeedVolume HorsepowerRequired Pressure/Head 100%81%64%49%36%25%16%9% 100%90%80%70%60%50%40%30%

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