Experimental Evaluation, Diagnosis, and Prediction of the Impacts of Power Quality Disturbances in IE2, IE3, and IE4 Class Efficiency Motors.

The content of this introduction paper is based on the article "EXPERIMENTAL EVALUATION, DIAGNOSIS, AND PREDICTION OF THE IMPACTS OF POWER QUALITY DISTURBANCES IN IE2, IE3, AND IE4 CLASS EFFICIENCY MOTORS." published by [UFPA/ITEC / PPGEE].

1. Overview:

• Title: EXPERIMENTAL EVALUATION, DIAGNOSIS, AND PREDICTION OF THE IMPACTS OF POWER QUALITY DISTURBANCES IN IE2, IE3, AND IE4 CLASS EFFICIENCY MOTORS.
• Author: JONATHAN MUÑOZ TABORA
• Year of publication: 2024
• Journal/academic society of publication: UFPA/ITEC / PPGEE
• Keywords: Voltage variation, voltage unbalance, harmonics, temperature, efficiency classes, permanent magnet motors, predictive maintenance.

2. Abstract:

Electric motors remain the largest end-use of electricity in the world and a fundamental part of the industrial sector. In addition, with technological advances, their applications have expanded into new categories such as electric vehicles, transportation, and navigation, among others. Europe has started to upgrade to IE4 efficiency motor classes, and it is expected that other regions will follow the transition to higher efficiency motor classes. In some regions, the operating voltage may differ from the nominal voltage according to IEC 60038-2009. This, together with other disturbances such as unbalance and voltage harmonics, can affect the performance of these new technologies. In this context, significant efforts have been made in predictive maintenance to improve existing techniques with new proposals that increase their effectiveness in diagnosing the health of rotating machines in the presence of different disturbances present in SEPs. This work evaluates the impact of voltage variations, voltage harmonics, and different percentages of under and over-voltage unbalances on the temperature and performance of low-power induction motors of IE2, IE3, and IE4 classes. The study includes technical, economic, statistical, and thermal analysis to obtain important indicators related to energy consumption, efficiency, power factor, and temperature. In the search for innovative and complementary techniques, this study also presents a new Electric Motor Degradation Indicator (EMDI) based on frequency domain analysis of electric motor current waveforms for the diagnosis of rotating machinery integrity. The results show that under ideal operating conditions, the permanent magnet motor of the IE4 class has a better performance in terms of power consumption and temperature, but it has a non-linear characteristic. Then, in the presence of certain disturbances, the scenario changes, with lower performance compared to squirrel-cage induction motors under the same operating conditions. The analysis performed will allow to identify and quantify the impact of the different perturbations present in the electrical power systems on the performance of the new electric motor technologies to be introduced. Regarding the proposed motor health diagnostic indicator, the results presented strongly support the effectiveness of the proposed approach in facilitating the implementation of predictive maintenance practices. Another important contribution of this thesis is that its results will form the basis for the implementation of a new regulation for the introduction of minimum efficiency requirements for electric motors in Honduras.

3. Introduction:

In 2015, the Paris Agreement represented a significant global step in addressing climate change. Since then, it has driven the implementation of policies and regulations focused on energy efficiency, playing a key role in achieving environmental goals and promoting sustainable practices internationally. In this context, Induction motors (IMs) represent an important category for energy savings with about 53% of the world's final electrical energy consumption [1].

4. Summary of the study:

Background of the research topic:

Electric motors remain the largest end-use of electricity in the world and a fundamental part of the industrial sector. With technological advances, their applications have expanded into new categories such as electric vehicles, transportation, and navigation, among others. Europe has started to upgrade to IE4 efficiency motor classes, and it is expected that other regions will follow the transition to higher efficiency motor classes. In some regions, the operating voltage may differ from the nominal voltage according to IEC 60038-2009. This, together with other disturbances such as unbalance and voltage harmonics, can affect the performance of these new technologies.

Status of previous research:

Significant efforts have been made in predictive maintenance to improve existing techniques with new proposals that increase their effectiveness in diagnosing the health of rotating machines in the presence of different disturbances present in SEPs.

Purpose of the study:

This work evaluates the impact of voltage variations, voltage harmonics, and different percentages of under and over-voltage unbalances on the temperature and performance of low-power induction motors of IE2, IE3, and IE4 classes. The study includes technical, economic, statistical, and thermal analysis to obtain important indicators related to energy consumption, efficiency, power factor, and temperature. In the search for innovative and complementary techniques, this study also presents a new Electric Motor Degradation Indicator (EMDI) based on frequency domain analysis of electric motor current waveforms for the diagnosis of rotating machinery integrity.

Core study:

The results show that under ideal operating conditions, the permanent magnet motor of the IE4 class has a better performance in terms of power consumption and temperature, but it has a non-linear characteristic. Then, in the presence of certain disturbances, the scenario changes, with lower performance compared to squirrel-cage induction motors under the same operating conditions. The analysis performed will allow to identify and quantify the impact of the different perturbations present in the electrical power systems on the performance of the new electric motor technologies to be introduced. Regarding the proposed motor health diagnostic indicator, the results presented strongly support the effectiveness of the proposed approach in facilitating the implementation of predictive maintenance practices. Another important contribution of this thesis is that its results will form the basis for the implementation of a new regulation for the introduction of minimum efficiency requirements for electric motors in Honduras.

5. Research Methodology

Research Design:

The effects of voltage harmonics, voltage unbalance, and voltage magnitude variations were evaluated using the test benches shown in Figure 1-9 and Figure 1-10. The bench comprises a three-phase alternating current (AC) programmable source (1), in which different voltages applied to the IE2, IE3 and IE4 Class Induction motors (4) were configured. The induction motors input parameters were measured using a class “A” power-quality analyzer (2), and an electromagnetic brake (3) was used as the electric load.

Data Collection and Analysis Methods:

The tests were conducted at the Amazon Energy Efficiency Center (CEAMAZON) of the Federal University of Pará (UFPA). At first, the induction motors were subjected to a perfect three-phase sine voltage of 220 V for 1 h and 10 min so that they reached their thermal equilibrium, and, in a second moment:

• The value of each voltage harmonic (2nd, 3rd, 5th, and 7th) increased by 2% every 10 minutes until it reached 25%;
• Each motor was individually subjected to 1 hour and 10 minutes of 1%, 3%, and 4% NEMA voltage unbalance until thermal equilibrium was restored;
• The LSPMM was supplied with a nominal voltage of 220V (1.00 p.u.), which was used as the base voltage to define the undervoltage and overvoltage values per unit. The LSPMM was then subjected to VV conditions of 0.90, 0.95, 1.0, 1.05 and 1.10 p.u. with loads ranging from 0% to 125%.

Research Topics and Scope:

This work presents a series of methodologies aimed at analyzing the performance of 0.75 kW output power electric motors in the presence of different disturbances present in current electrical systems, such as voltage variation, voltage harmonics and voltage unbalance, in order to establish conclusions and guidelines to be considered by specialists in the substitution between technologies.

6. Key Results:

Key Results:

• The IE4 class permanent magnet motor shows the lowest currents, consumption, and operating temperature, as well as quieter operation, but with a higher percentage of harmonic distortion and a lower power factor compared to the IE3 class motor at the same load.
• The analyzed negative sequence harmonics (2nd and 5th) are individually more harmful than the analyzed positive sequence harmonic of 7th order.
• The third zero-sequence harmonic did not produce significant variations in electric motors, where the parameters showed variations around their initial values.
• The combination of all the harmonics turns out to be more harmful than any single harmonic analyzed, of which the second harmonic had the largest contribution.
• The models can be used to estimate the temperature increase based on the harmonic present for the analyzed power.
• The developed model reliably represents the performance of the motor under non-ideal conditions, such as in the presence of the negative sequence voltage harmonic.
• The proposed indicator has been successfully validated under different disturbances commonly found in electrical systems that motors may encounter in real operating conditions.

Figure Name List:

• Figure 1-1 - Energy efficiency classes classification and consumption
• Figure 1-2 - Countries with MEPS for electric motors in 2024.
• Figure 1-3 - Methodology for literature review based on the PRISMA statement.
• Figure 1-4 - Publications related to electric motors in recent years.
• Figure 1-5 - Distribution of publications related to energy forecasting worldwide.
• Figure 1-6 - Distribution of studies by subject area.
• Figure 1-7 - Thematic map of keywords separated by relevant categories.
• Figure 1-8 - Publications related to electric motors diagnosis in the last 20 years.
• Figure 1-9 - General test setup for the power quality disturbances tests.
• Figure 1-10 - General test setup for the electric motor degradation index tests.
• Figure 1-11- Thermographic images of the LSPMM
• Figure 2-1 - Induction Motor components [2]…….
• Figure 2-2 - Distribution of motor losses and percentage of losses for 0.75 kW – 160 kW IM's.
• Figure 2-3 - Typical fraction of losses in 50-Hz, four-pole squirrel cage induction motors
• Figure 2-4 - Impact of possible areas of improvement for induction motor performance
• Figure 2-5 - Permanent magnet motors
• Figure 2-6 - Structure of a four-pole LSPMM [28]…
• Figure 2-7 - Typical rotor configurations for LSPMM's
• Figure 2-8 Starting torque in LSPMM and SCIM
• Figure 2-9 Comparison between IE2, IE3 and IE4 efficiency class motors
• Figure 2-10 - Consumption in IE2, IE3 and IE4 class motors
• Figure 2-11 - Temperature rise for IE2, IE3 & IE4 IM's classes
• Figure 3-1-Additional Negative and zero sequence losses in induction motors.
• Figure 3-2 - Flowchart of methodology used to obtain the results from the measurements.
• Figure 3-3 - Current increase for 2nd, 3rd, 5th, 7th and all harmonic order combined for induction motors
• Figure 3-4 - Total current harmonic distortion (THDI) variation for 2nd, 3rd, 5th, 7th and all harmonic order combined for induction motors
• Figure 3-5 - Reactive power increase for 2nd, 3rd, 5th, 7th and all harmonic order combined for induction motors
• Figure 3-6 - Power factor decrease for 2nd, 3rd, 5th, 7th and all harmonic order combined for induction motors
• Figure 3-7-Temperature rise in the presence of voltage harmonics of 2nd, 3rd, 5th, 7th and all harmonic order combined for induction motors
• Figure 3-8 - Thermographic images of the LSPMM in presence of 2ndvoltage harmonics in frontal and lateral view
• Figure 3-9 - Thermographic images of the LSPMM in presence of 5th voltage harmonics in frontal and lateral view
• Figure 3-10 - Correlation matrix between temperature and input parameters in IE2 class SCIM
• Figure 3-11 - Temperature regression versus motor input parameters for IE2 class SCIM
• Figure 3-12 - Correlation matrix between temperature and input parameters in IE3 class SCIM
• Figure 3-13 - Temperature regression versus motor input parameters for IE3 class SCIM
• Figure 3-14 - Correlation matrix between temperature and input parameters in IE4 class LSPMM
• Figure 3-15 - Temperature regression versus motor input parameters for IE4 class LSPMM
• Figure 3-16 Incremental Impact of Voltage distortion on Temperature
• Figure 3-17 - Temperature as a function of 2nd voltage harmonic
• Figure 3-18 - Adjusted coefficient of determination (adjusted R2) for generated models presented in Table 2.
• Figure 3-19 - Line-start permanent magnet motor simulation on FEMM
• Figure 3-20 - Density flux plot for (a) Nominal conditions; (b) 2nd voltage harmonics and (c) 5th voltage harmonics.
• Figure 3-21- Quarter section of motor illustrating the areas with convection boundary conditions.
• Figure 3-22 - Temperature distribution (in Kelvin) in the motor from the FEMM thermal simulation for
• Figure 3-23 - Comparison between the model and measured temperature for 25% voltage harmonic distortion of 2nd and 5th order harmonics.
• Figure 4-1 - Power derating curve for Induction Motors
• Figure 4-2 - The Complex Voltage Unbalance Factor Diagram [13].
• Figure 4-3 - Induction motor subjected to voltage unbalance
• Figure 4-4 - Voltage Unbalance supply on a delta-connected IM and the resulting positive
• Figure 4-5 - Induction motor voltages when subjected to voltage unbalance
• Figure 4-6 - Positive and negative sequences for impedances for IE2, IE3 and IE4 Class motors
• Figure 4-7 - Flowchart of methodology used to obtain the results from the measurements.
• Figure 4-8 - Line and average current for VU in IE4 LSPMM with
• Figure 4-9 - Average Current for under and over voltage unbalance conditions for
• Figure 4-10 - Power Factor (a-c) and Positive-Phase sequence voltage variation (d-e) with Under and Over Voltage Unbalance
• Figure 4-11 - Total power variation with Under and Over Voltage Unbalance for
• Figure 4-12 - Current Total Harmonic Distortion for under and over voltage unbalance conditions for
• Figure 4-13 - Frame Temperature with 1% under voltage
• Figure 4-14 - Frame Temperature with 1% over voltage
• Figure 4-15-Temperature increase in IE2, IE3 and IE4 class IM's with
• Figure 4-16 - Correlation matrix for IE3 Class SCIM motor parameters in the presence of VU with
• Figure 4-17 - Correlation matrix for IE4 Class LSPMM motor parameters in the presence of VU with
• Figure 4-18 - Temperature for the IE4 Class LSPMM
• Figure 4-19 - Residuals versus fitted or predicted temperature values.
• Figure 4-20 - Adjusted coefficient (Adjusted R²) for generated models presented in Table 7
• Figure 5-1 - Steps toward the implementation of energy efficiency actions on induction motor policies.
• Figure 5-2 - Methodology flowchart.
• Figure 5-3 - Speed variation for IE2, IE3 & IE4 Class motors in presence of 2nd, and combined 2nd, 3rd, 5th and 7th voltage harmonics.
• Figure 5-4 - Speed variation for IE2, IE3 & IE4 Class motors in presence of 5th and 7th voltage harmonics.
• Figure 5-5 - Harmonic currents present in IM´s with harmonic voltage distortion of
• Figure 5-6 - Speed variation for IE2, IE3 & IE4 Class motors in presence of 0%-4% Voltage Unbalance Conditions with under and over voltages;
• Figure 5-7 Fifth harmonic currents variations for phases a-b-c for the IE3 Class motor for
• Figure 5-8 - Fifth harmonic currents variations for phases a-b-c for the IE4 Class motor for
• Figure 5-9 - Seventh harmonic currents variations for phases a-b-c for the IE3 Class motor for
• Figure 5-10 - Seventh harmonic currents variations for phases a-b-c for the IE4 Class motor for
• Figure 5-11 - Phase “a” harmonic current variation for 4% Voltage unbalance with undervoltage for
• Figure 5-12 - Phase “a” harmonic current variation for 4% Voltage unbalance with overvoltage for
• Figure 6-1 - Image of Table 1 of the IEC 60038-2009 standard in relation to allowable voltages in power systems worldwide
• Figure 6-2 - Three-phase nominal voltage by region for a nominal 220 V LSPMM in a delta connection.
• Figure 6-3 - Line-start permanent magnet
• Figure 6-4 - Experimental input current as a function of load for 0.75 kW
• Figure 6-5 - Methodology flowchart.
• Figure 6-6 - Experimental input current as a function of load at different voltage magnitudes.
• Figure 6-7 - LSPMM under VV conditions
• Figure 6-8 - Experimental power factor as a function of load under VV conditions.
• Figure 6-9 - Ridgeline plot of power factor under VV conditions for the LSPMM.
• Figure 6-10 - Contour plots for power factor variation with power and load for IE4 Class motor with
• Figure 6-11 - Experimental efficiency as a function of load under VV conditions.
• Figure 6-12 - Frame temperature variation in the LSPMM under VV conditions. Frontal temperature with
• Figure 6-13 - Frame temperature variation in the LSPMM under VV conditions. Lateral temperature with
• Figure 6-14 - Measured absolute temperature under VV conditions
• Figure 6-15 - Correlation matrix between voltage magnitude and input parameters in the LSPMM for
• Figure 6-16 - Consumption as a function of voltage magnitude under different load conditions.
• Figure 6-17 - Representation of the time-of-use tariff pricing scheme considered in the economic analysis.
• Figure 6-18 - Payback for the initial cost of a new motor by changing the LSPMM voltage supply level
• Figure 7-1 - Graphical representation of the Electric Motor Degradation Index (EMDI) methodology.
• Figure 7-2-General test setup.
• Figure 7-3-Methodology Flowchart.
• Figure 7-4-EMDI calculation in dB for the nominal voltage operation condition and loading varying from 30% to 125% of nominal for
• Figure 7-5-Single phasing triggered in IE3 Class motor to evaluate the EMDI.
• Figure 7-6-EMDI calculation in dB for a single phase-loss in the IE3 Class motor.
• Figure 7-7-Input current variation as a function of load in VV conditions.
• Figure 7-8 - EMDI calculation in VV conditions for nominal load condition.
• Figure 7-9 - Pumping System at the Federal University of Pará
• Figure 7-10- Voltage magnitude variation for the electric motor input.
• Figure 7-11- Measured input line currents as a function of time.
• Figure 7-12-Electric motor diagnosis indicator comparison in VV conditions.
• Figure 10-1-IE2 Class induction motor nameplate.
• Figure 10-2 - IE2 Class induction motor parameters.
• Figure 10-3- IE3 Class induction motor nameplate.
• Figure 10-4-IE2 Class induction motor parameters.
• Figure 10-5-IE4 Class line-start permanent magnet motor nameplate.

7. Conclusion:

The results showed that the presence of voltage harmonics may result in amplification of current harmonics in electric motors for distortion percentages greater than 8% as well as in significant variations of other harmonic currents in the analyzed electric motors including negative and positive sequence harmonics, which ends up increasing the total harmonic distortion rate of the network. It was also observed how these new harmonics presented higher percentages for the higher efficiency motor analyzed (line-start permanent magnet motor).

This chapter also presented how the voltage unbalance results in an increase in the current total harmonic distortion for the three technologies, with higher percentages for the LSPMM. Finally, from the results presented, it is possible to establish some general guidelines that may be considered as recommendations:

• Replacing old/non-efficient electric motors with higher efficiency motors results in better economic benefits for the end user.
• New technologies can represent a challenge for electric utilities mainly in terms of power quality and large-scale uses.
• The study also recommends that consideration be given to oversized motors, given their prevalence in industry and the impact of oversizing on motor efficiency.
• Regulatory institutions must also observe the power quality impacts of higher efficient motors, so that manufacturers implement solutions to the challenges that the implementation of new technologies in induction motors can bring to the electric power systems.

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9. Copyright:

• This material is a paper by "JONATHAN MUÑOZ TABORA". Based on "EXPERIMENTAL EVALUATION, DIAGNOSIS, AND PREDICTION OF THE IMPACTS OF POWER QUALITY DISTURBANCES IN IE2, IE3, AND IE4 CLASS EFFICIENCY MOTORS.".
• Source of the paper: [N/A]

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