ADVANCED MANUFACTURING OFFICE A SOURCEBOOK FOR INDUSTRY Improving Motor and Drive System Performance DISCLAIMER This publication was prepared by the Washington State University Energy Program and the National Renewable Energy Laboratory for the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy. Neither the United States, DOE, the Copper Development Association, the Washington State University Energy Program, National Electrical Manufacturers Association, nor any of their contractors, subcontractors, or employees makes any warranty, express or implied, or assumes any legal responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process described in this guidebook. In addition, no product endorsement is implied by the use of examples, figures, or courtesy photos. ACKNOWLEDGMENTS Improving Motor and Drive System Performance: A Sourcebook for Industry was developed for the U.S. Department of Energy’s (DOE’s) Advanced Manufacturing Office (AMO) with support from the Copper Development Association (CDA). AMO undertook this project as a series of sourcebook publications. Other topics in this series include: compressed air systems, pumping systems, fan systems, process heating, and steam systems. For more information about program resources, see AMO in the “Where to Find Help” section of this publication. Thanks are extended to AMO and to Rolf Butters, Scott Hutchins, and Paul Scheihing for their support and guidance during this publication update project. Thanks are also due to Prakash Rao of Lawrence Berkeley National Laboratory (LBNL, Rolf Butters (AMO)) and to Vestal Tutterow of PPC for reviewing and providing publication comments. The original motor sourcebook was prepared by technical staff at LBNL and the Resource Dynamics Corporation (RDC). The update was completed by technical staff at the Washington State University (WSU) Energy Program. Technical editing and graphic design were provided by the National Renewable Energy Laboratory (NREL). DOE, CDA, LBNL, RDC, WSU, and NREL wish to thank the many organizations that so generously assisted in data collection, and to acknowledge the helpful reviews and other contributions provided by the following individuals (those with bolded names participated in the update of this current Sourcebook edition): Dale Basso, Rockwell Automation Ilene Mason, Consortium for Energy Efficiency Bruce Benkhart, Director, Applied Proactive Solutions Gilbert McCoy, Energy Systems Engineer, WSU Energy Program Thomas Bishop, P.E., Senior Technical Support Specialist, Electrical Apparatus Service Association (EASA) Sally McInerney, University of Alabama Austin Bonnett, EASA Cynthia Nyberg, EASA Rob Boteler, Director of Marketing, Nidec Motor Corporation Howard W. Penrose, Ph.D., Engineering and Reliability Services, Dreisilker Electric Motors Dennis Bowns, Bowns & Co. Linda Raynes, President and CEO, EASA Dave Brender, National Program Manager, Electrical Applications, CDA Tim Schumann, SEW-Eurodrive Wally Brithinee, Brithinee Electric Charles Straub, P.E., Marathon Electric Kitt Butler, Director, Motors and Drives, Advanced Energy Edward J. Swann, Rockwell Automation John Caroff, Marketing Manager for Low Voltage Motors, John Tolbert, Bristol Compressor Siemens Industry, Inc. Chuck Yung, EASA Don Casada, Diagnostic Solutions Prepared for the U.S. Department of Energy Jasper Fischer, Industrial Motor Repair Office of Energy Efficiency and Renewable Energy Advanced Manufacturing Office Ken Gettman, National Electrical Manufacturers Association (NEMA) By Lawrence Berkeley National Laboratory Berkeley, California William Hoyt, Industry Director, NEMA Resource Dynamics Corporation John Kueck, Oak Ridge National Laboratory McLean, Virginia John Machelor, Motor-Vations, LLC Washington State University Energy Program Olympia, Washington John Malinowski, Senior Project Manager, Baldor Electric Co. Produced by the National Renewable Energy Laboratory Golden, Colorado Cover photo from iStock 13079160 IMPROVING MOTOR AND DRIVE SYSTEM PERFORMANCE: A SOURCEBOOK FOR INDUSTRY | i CONTENTS GLOSSARY . iv ACRONYMS ......................................................................................viii QUICK START GUIDE ..............................................................................1 SAFETY CONSIDERATIONS....................................................................... 2 SECTION 1: MOTOR AND DRIVE SYSTEM BASICS ................................................ 3 Overview ............................................................................................3 A Systems Approach ..................................................................................3 Indications of Poor System Design ..................................................................... 4 Types of Electric Motors .............................................................................. 4 Motor Operating Characteristics ........................................................................9 Matching Motors and Drives to Their Applications .......................................................13 Load-Duty Cycles ....................................................................................17 Common Motor Selection Problems....................................................................17 Summary ...........................................................................................19 SECTION 2: PERFORMANCE OPPORTUNITY ROAD MAP ........................................21 Overview ...........................................................................................21 Efficiency Opportunity No. 1: Assessing Motor and Drive System Operating Conditions ......................21 Efficiency Opportunity No. 2: Establishing a Motor Management Program................................. 24 Efficiency Opportunity No. 3: Providing Basic Maintenance ...............................................27 Efficiency Opportunity No. 4: Selecting the Right Motor..................................................31 Efficiency Opportunity No. 5: Using Variable Frequency Drives ...........................................37 Efficiency Opportunity No. 6: Addressing In-Plant Electrical Distribution and Power Quality Issues . 40 Efficiency Opportunity No. 7: Using the Service Center Evaluation Guide.................................. 45 SECTION 3: MOTOR SYSTEM ECONOMICS ......................................................47 Overview .......................................................................................... 47 Understanding Corporate Priorities ................................................................... 47 Measuring the Economic Impact of Efficiency Improvements ............................................ 47 Presenting the Finances of Efficiency ................................................................. 48 Relating Efficiency to Corporate Priorities ............................................................. 48 Summary ...........................................................................................51 SECTION 4: WHERE TO FIND HELP .............................................................53 Advanced Manufacturing Office (AMO) Overview ...................................................... 53 Federal Energy Management Program (FEMP) ......................................................... 56 Directory of Contacts ............................................................................... 56 ii | IMPROVING MOTOR AND DRIVE SYSTEM PERFORMANCE: A SOURCEBOOK FOR INDUSTRY Other Resources and Tools........................................................................... 58 Publications ........................................................................................ 59 Software and Tools.................................................................................. 67 Additional Websites of Interest ....................................................................... 67 Periodicals ......................................................................................... 68 Training Courses .................................................................................... 68 APPENDICES.....................................................................................69 Appendix A: Motor Systems Energy Tip Sheets..........................................................71 Appendix B: Minimum Full-Load Efficiency Standards for Energy-Efficient and Premium Efficiency Motors ....73 Appendix C: Motor Repair Service Center Checklist ......................................................77 Documents and Record Keeping.......................................................................81 FIGURES Figure 1. Types of motors .............................................................................5 Figure 2. Induction motor .............................................................................7 Figure 3. Squirrel-cage rotor ..........................................................................7 Figure 4. Typical motor part-load efficiency curve .......................................................9 Figure 5. Typical NEMA Design B induction motor speed-torque curve.................................... 11 Figure 6. Effect of speed reduction on the power used by a pump........................................13 Figure 7. Energy losses in a pump system when a throttle valve controls flow .............................14 Figure 8. Energy losses in a pump system when an ASD controls flow ....................................14