Technical and economic considerations on induction motor oversizing

In industry, due to conservative system design, safety factors associated with uncertainty in the load requirements, discrete availability of commercial rated power, and/or load power variation, most three-phase squirrel-cage induction motors are oversized. Besides the extra capital investment, the oversizing of direct-on-line fixed-speed induction motors can lead to a significant efficiency and power factor reduction. However, the part-load efficiency of oversized motors can still be higher than the full-load efficiency of well-sized smaller motors because, in general, the nominal efficiency increases with the rated power. In this paper, an analysis of potential benefits and drawbacks of motor oversizing is carried out. On the basis of the catalogue technical data provided by one of the largest motor manufacturers for IE1-, IE2-, IE3-, and IE4-class four-pole induction motors, the main results of a simulation-based study on the oversizing energy efficiency and cost-effectiveness are presented. A method to estimate the motor efficiency and power factor for any load level using commercial catalogue data is proposed and applied. Some technical issues associated with motor oversizing are also briefly addressed. It is shown that, if the additional reactive energy consumption due to poorer power factor and the slight speed increase are ignored, for IE1-, IE2- and, to a much less extent, IE3-class motors, oversizing can be cost effective for many motor rated powers, resulting in a higher average efficiency and a lower motor lifecycle cost, as well as in an extended motor lifespan. For most IE3- and IE4-class motors, the oversizing is not cost effective because of the lower nominal efficiency gain when moving to a higher oversized rated power. Additionally, the oversizing impact on the motor energy consumption strongly depends on the load profile of the application. When an old motor fails, it will probably be an IE0- or IE1-class equivalent motor, and this situation provides a golden opportunity for replacing the old motor with a properly sized IE3- or IE4-class motor, which offers significantly higher efficiency for a wide range of loads.