Determining Electric

Motor Load Factor

M ost likely your operation's
motors account for a large
part of your monthly elec-
trical bill. Make certain your mo-
tors are properly loaded. This
will increase their reliabiZity and
efjciciency-saving you money
and energy, and helping you
' avoid potential problems. This
Technology Update enables
you to determine the load factor
and efficiency of your electric mo-
tors-information you can use to
identify motors that should be re-
placed with a different size or in-
creased efficiency model.
Reasons to Determine Motor Loading
Most electric motors are designed to run at 50 to 100 percent of rated
load. Optimum efficiency is at 75 percent of rated load. Thus, a 10 horse-
power (hp) motor has an acceptable load range of 5 to 10 hp; peak effi-
ciency is at 7.5hp (see Figure 1).Surveys of installed motors indicate
that a large portion of motors in use are improperly loaded.
Underloaded motors, those loaded below 50 percent of rated load, are
ineffiaent and exhibit low power factor (see Figure 2). Power factor is a
measurement of the phase angle lag between electrical voltage and cur-
rent, with 100%as optimum. (See Technology Update, Reducing Power
Factor Cost for more information.) Low power factor results in in-
creased electrical distribution system losses. For this reason an increas-
ing number of utilities charge a penalty for low power factor. Replacing
underloaded motors with correctly sized motors improves efficiency
and raises power factor.
I a
0
r
Motor Part Load Efficient
Y
as a Functlon of % Full Load E ficiency

.-: s o %
G
i;i
u 8oo/c
m
0

--
J

LL
3
40%
Lad Ranger:

c
c
Q1 20%
$
p.

0% 20% 40% 60% 80%

e
Percent Full Load

0 - 1 P .....lO..hP . ?!:SP. hP
P
1.5-5 hp ..........
15-25 hp I ------
75-100 hp

Toll-free Hotllne 1-800-872-3568 FAX 1-800-872-3882 Electronic Bulletin Board 1-800-762-3319

Bonnwille
POWER ADMINISTRATION
 Figure 2
%O%j as a Function of % Full Load Amperage
i5% 45% !k'o
Percent Full Load Amperage
Overloaded motors can overheat
and lose efficiency. Many mo-
tors are designed with a service
factor that allows occasional
overloading. Service factor is a
multiplier that indicates how
much a motor can be over-
loaded. For example, a 10 horse-
power motor with a 1.15service
factor can handle an 11.5 horse-
power load for short periods of
time without incurring signifi-
cant damage. Although many
motors have service factors of
1.15,running a motor above the
rated load reduces efficiency,
and if done frequently, reduces
service life.
If your operation uses equip
ment with motors that operate
for extended periods under 50
percent load, consider making
modifications. Sometimes mo-
tors are oversized because they
must accommodate peak condi-
tions, such as when a pumping
system must satisfy occasionally
high demands. Options avail-
able to meet peak condition
needs include two-speed mo-
tors, adjustable-speed drives,
and management strategies that
Motor Power Factor
i5% kyo 85% k0/, 1do%
maintain motor loads within the
design range.
Determining if your motors are
properly loaded enables you to
make informed decisions about
when to replace motors and
which replacements to choose.
Measuring Motor Loads is rela-
tively quick and easy when you
use the worksheet provided in
this Technology Update. You should
perform a motor load and effi-
ciency analysis on all your major
working motors as part of your
preventative maintenance and en-
ergy conservation program.
Determining Loads
A relatively simple way to deter-
mine the load on a working mo-
tor is by measuring "slip." Slip
refers to the difference between
the motor's synchronous speed
and loaded speed. Synchronous
RPM is the speed of the motofs
rotating electric field, usually
either 3,600,1,800,1,200,or 900
RPM. An unloaded motor ro-
tates at approximatelyits syn-
chronous speed. Full load FWM
is the speed that the motor
2
rotates under its full rated load
and is usually about 3 to 5 per-
cent slower than synchronous
speed. Most electric motors have
a full load RPM rating stamped
on their nameplate.
Slip is characteristically linearly
proportional to load (see Figure
3). For example, a motor running
with 50 percent load factor has a
slip halfway between full load
and synchronous RPM. By using
a tachometer to measure actual
motor speed, it is possible to cal-
d a t e motor loads.
First, determine fullload slip
and measured load slip. The
formulas are listed in Figure 4.
Then calculate load using the
formula in Figure 5.
Motorlat
Rep acement
Annual Savings and
"9
Simple Payback
The "Motor Load and Efficiency
Analysis" form (on page 4) pro-
vides a stepby-step process for
determining motor load and effi-
ciency, and calculating the po-
tential annual dollar savings
and resulting simple payback
I Figure 3
Percent Motor Slip
as a Furctlan of M
ob Load
0
ND
Load
Full
Load
Load
full
load Slip = synchronous speed (RPM) - rated fullload speed (RPM)
measured
load Slip = synchronous speed (RPM)- measured load speed (RPM)
-
Example:
synchronous speed = 1,800 RPM
full load speed (f" nameplate) = 1,740 RPM
full load slip = 1,800 - 1,740 = 60 RPM
measured load speed (bytachometer) = 1,778 RPM
-
measured load slip = 1,800 1,778 = 22 RPM
from replacing a significantly
oversized and underloaded mo-
tor with a more efficient, prop-
erly sized model. (Simple
payback is a measurement of
how long it will take for the effi-
ciency savings to compensate for
the increased cost of the more ef-
ficient motor .)
We recommend that you survey
and test all motors operating over
, OO hours per year. Using the
1O
analysis results, divide your m e
tors into the following categories:
H Motors that are significantly
oversized and underloaded-
replace with more efficient,
properly sized models at the
next opportunity, such as
scheduled plant downtime.
Motors that are moderately
oversized and underloaded-
replace with more efficient,
properly sized models when
they fail.
Motors that are properly
sized but standard effi-
ciency-replace most of these
with energy-efficient models
when they fail. The cost effec-
tiveness of an energy-efficient
motor purchase depends on
the number of hours the mo-
tor is used, the price of elec-
tricity, and the price premium
of buying an energy-efficient
motor.
load = motor HP x (measured running slip/full load slip)
Example:
10 HP 1,800 RPM synchronous motor
full load speed = 1,740
full load slip = 60
measured load speed = 1,778 RPM
measured load slip = 22 RPM
10 x 22/60 = 3.7 HP load, or 37%o hull load
to rounding errors and vari-
ations. For example, full load
H The slip technique should not ratings are often rounded to
be used for rewound motors the nearest 5 RPM, and a spe-
or motors operating at other cific motor may have an ac-
than design voltage since full tual speed slightly different
load RPM nameplate data is than the nameplate value es-
no longer accurate. tablished for that model.
These differencescan lead to
H This analysis is designed for significant variation and un-
motors operating under certainty in this analysis,
steady load conditions. If which should be considered
loads vary, you'll need to per- when evaluating results.
form a separate analysis for
each portion of the load m e 4 Many utility energy conser-
to obtain annual energy sav- vation programs offer rebates
ings. for the purchase of energy
efficient motors and other
4 This analysis may be inappro- industrial conservation activi-
priate for motors driving con- ties. Contact your utility con-
veyors or crushers, since servation department for
oversizing may be required information.
due to startup torque require-
ments, transient loads, or ab-
normal operating conditions.
4 This analysis requires use of a
tachometer to measure motor
RPM, and a Multimeter to
measure voltage and current.
Such monitoring is poten-
tially hazardous and requires
proper equipment calibration;
it should only be performed
by trained personnel.
4 Several of the values used in
this analysis, including rated
full load RPM, measured
RPM, and current are subject
3
Company Plant Datemime

Building Dept. Application

Motor Shop Number Phase and HZ

Make Frame size

Model/Type Insulation class

Serial number Efficiency rating

Service factor NEMA torque type

Enclosure type Temperature rise

A) Full load HP

B) Volts N) Running slip (E-K)

C) Amperes P) Per cent load (N/F)(~00%)

D) Full load speed Q) HP Output (A)(P)(l 00%)

E) Sync. speed R) kW output (cq(o.746)

2 pole = 3,60O,4 pole = 1,800, 6 pole = 1,200)

F) Full load slip (E-D) S ) Eff. per cent (w~)(loo%)

T) kVA input (G)(H)(1.732)/(1000)

G) Average volts U) Power factor (J)/(r)(i 00%)

H) Average amperes v) kW IOSSeS (J-R)

J) Average kW W) $/Year operation (J)(L)(M)

K) Operating speed, RPM X) $/Year losses (v)(L)(M)
L) Full load operating hours Y)' Annual energy savings due to changeout with a h p
high-efficiency motor (R)(L)(M)(lOO/S - 1WIEFF)

W) Average electricity price including demand charges Z)* Replacement motor cost
($/kWh)

Simple payback, years (Z)/(Y)

@

EFF Is the efflclency (%) of a mpiacement premium efflclency motor at the appropriate load factor.
!Costis the total cost of purchaslngand installing an optlmaiiy slzed, high-efficiency motor

4
V Electric Ideas Clearinghouseis a
comprehensive information Bibliography
source for and indus- McCoy, G., T.Litman, and J. Douglas. Energy-Efficient Electric Motor Selec-
trial energy users. It is operated tion Handbook. Prepared for the Bonneville Power Administration by the
by the WashingtonState Enflu Washington State Energy Office. DOE/BP-34623-3. October 1991.
Office and is part of the Electric
Ideas technology transfer pro-
gram sponsored by participating
utilities and the Bonmille
Power Administration.
V Neither the United States nor the
Bonneville Power Administra-
tion, the state of Washington, the
WashingtonState Energy Office,
nor any of their contractors, sub-
contractors, or their employees
make any warranty, expressed or
implied, or assume any legal re-
sponsibility for the accuracy, com-
pleteness, or usefulness of any
information,apparatus, product,
or process disclosed within the
publication or through the Clear-
inghouse Bulletin Board System.
V Technology Update CH-17
'
I Toll-free Hotline:
1-800-872-3568
Fax: 1-800-872-3882
Electronic Bulletin Board:
1-800-762-3319

DOYBP-1768
lune 1992
15C