Türkiye imalat sanayisinde kullanılan asenkron motorların verimliliğinin incelenmesi
Analysis of the efficiency of induction motors used in manufacturing industry of Turkey
Yazar: TEKİN VARLIK
Danışman: DOÇ. DR. ÖZGÜR ÜSTÜN
İstanbul Teknik Üniversitesi / Fen Bilimleri Enstitüsü / Elektrik Mühendisliği Ana Bilim Dalı / Elektrik Mühendisliği Bilim Dalı
Derece: Yüksek Lisans, 2018
Konu: Elektrik ve Elektronik Mühendisliği = Electrical and Electronics Engineering
Dizin: Alternatif akım motorları = Alternative current motors ; Asenkron motorlar = Induction motors ; Elektrik enerjisi = Electrical energy ; Endüksiyon motorları =   ; Enerji verimliliği = Energy efficiency ; Sürdürülebilir enerji = Sustainable energy ; Tek fazlı asenkron motorlar = Single phase induction motors ; Üç fazlı asenkron motorlar = Three phase induction motors ; İmalat endüstrisi =   ; İndüksiyon motorları =

Özet:
Günümüz dünyasında, enerji talebi ve kullanımı hızlıca artmakta ve bunun kaçınılmaz sonucu olarak da enerji kaynakları hızlıca tükenmektedir. Yükselen hayat standartlarının ve ekonomik gelişmenin sürdürülebilirliğinin sağlanabilmesi adına en önemli kaynak durumundaki enerji zorunlu temel bir ihtiyaç halini almıştır. Enerji türlerinden biri olan elektrik enerjisi; iletiminin ve kullanımının kolay olması sebebiyle hayatın her alanında en çok bilinen, talep edilen ve kullanılan enerji türlerinden birisi olmuştur. Türkiye'de de nüfus artışı ve buna bağlı olarak, gelişen sanayi ve ticaretin artan enerji talebi dolayısıyla, elektrik talebi-tüketimi her yıl artan bir grafik izlemektedir. Ayrıca talep - tüketim ve (sınırlı) enerji kaynak rezervleri arasındaki ilişki, enerji fiyatlarının ciddi oranda artışına sebep olmakla birlikte bu durum var olan enerjinin daha verimli kullanılmasının zorunluluğunu da ortaya çıkarmaktadır.
Özellikle son dönemlerde, enerji verimliliği meselesi, dünyada olduğu gibi, Türkiye'de de üzerinde çokça tartışılan (popüler) konulardan birisi olmuştur. Bu bağlamda enerjinin verimli kullanılması amacına yönelik girişimler her geçen gün artarken, toplam enerji tüketiminin en büyük kısmının gerçekleştiği imalat sanayisi sektöründeki enerji verimliliğinin arttırılması, öne çıkan konulardan birisi olmuştur.
Bu bağlamda Türkiye imalat sanayisinde kullanılan asenkron motorlarının verimlilik durumlarının tespiti amacıyla belirli bir örneklem (887 sanayi işletmesinin, 7,5 kW ve üzerindeki çıkış gücüne sahip, alternatif akım asenkron motor verileri) üzerinden verimlilik analizleri gerçekleştirilmiştir. Bu kapsamda yapılan çalışmaların sonucunda, Türkiye imalat sanayisinde ağırlıklı olarak IE1 standart verim sınıfındaki düşük verimli eski asenkron motorların kullanıldığı tespit edilmiştir. Bu verimsiz motorların yerine daha yüksek verimli (IE2, IE3 ve IE4) asenkron motorların kullanılması sayesinde ortaya çıkacak olan verim artışı ve bunun olumlu sonuçlarından sadece birisi olan ekonomik faydanın niceliği incelenmeye çalışılmıştır.
Sonuç olarak, bu tez kapsamında yapılan analiz çalışmaları ışığında, Türkiye imalat sanayisinde kullanılan asenkron motorlarının verimliliğinin arttırılmasının gerekliliği ortaya konulmuş olup, sanayi işletmelerinin yüksek verimli motorlara yönelmelerinin kendilerine ve dolayısıyla ülkeye sunabileceği faydalar ve bu konuda yapılması gereken çalışmalara yönelik bazı öneriler sunulmuştur.

Abstract:
In today's world, energy demand and usage are increasing rapidly, and energy resources are rapidly consuming as an inevitable result. In order to ensure the rising standards of living and the sustainability of economic development, the most important source of energy has become a fundamental necessity. Electric energy, one of the energy types; it is one of the most known, demanded and used energy types in all areas of life because of its ease of use and transmission.
As a result of population growth in Turkey, thereby increasing energy demand of the developing industry and commerce is followed by an increased demand and consumption of electricity every year. In addition, the relationship between demand-consumption and energy resource reserves (limited) has led to a significant increase in energy prices, which in turn has led to the need for more efficient use of existing energy.
In today's world, energy demand and usage are increasing rapidly, and energy resources are rapidly consuming as an inevitable result. In order to ensure the rising standards of living and the sustainability of economic development, the most important source of energy has become a fundamental necessity. Electric energy, one of the energy types; it is one of the most known, demanded and used energy types in all areas of life because of its ease of use and transmission. As a result of population growth in Turkey, thereby increasing energy demand of the developing industry and commerce is followed by an increased demand and consumption of electricity every year. In addition, the relationship between demand-consumption and energy resource reserves (limited) has led to a significant increase in energy prices, which in turn has led to the need for more efficient use of existing energy.
Nowadays, fossil fuel reserves, which are meeting a large part of the energy demand, are rapidly depleting. On the one hand, it is on the other side that the optimal utilization of the available resources is on the way while looking for alternative energy sources to fill the rapidly consuming fossil fuels. Price movements in the world energy market and global warming climate changes; energy-environment sustainability. Accordingly, efficiency and efficient use of energy in every aspect of life; has become a priority agenda of developed and developing world countries, especially those with high energy needs.
Especially in recent times, the issue of energy efficiency, as well as in the world, has been the subject of hot debate over one in Turkey. In this context, as the initiatives aimed at the efficient use of energy are increasing day by day, increasing energy efficiency in the manufacturing industry sector, where the greatest part of the total energy consumption is realized, is one of the outstanding issues.
Because of the high energy consumption (and hence the high cost) and the high energy saving potential at the same time, is a sector that needs to be emphasized firstly in energy efficiency studies. In this thesis prepared in this context; energy efficiency in the context of sustainability in general will be addressed and it will be tried to explain how conversion to high efficiency motors to be realized in electric motors can be used as energy saving method considering that most of the energy consumed in the manufacturing industry sector is derived from electric motors.
It is known that a large proportion of electric motors used in manufacturing industry are AC asynchronous motors. Therefore, in the energy efficiency transformation program to be realized in the industry; AC asynchronous motors, one of the most preferred motor types, should be considered as priority.
The world's industrial production is based largely on electric motors, and electric motors are doing the jobs that billions of people can do. It is estimated that an annual energy savings of 20 Billion kWh can be achieved thanks to savings realized at 1% of the amount of electric energy consumed by asynchronous motors worldwide, which is equivalent to the energy obtained from 36.5 million barrels of oil. It is estimated that approximately 36,500 GWh of energy savings can be made if all of the industrial motors to be offered to the market in our country in the next decade are in the high efficiency class.
The purpose of this thesis is to examine energy efficiency in terms of electric motors. It is of utmost importance that electric motors are of high efficiency class. As in our country, the industrial sector in all countries is the one that consumes the most electricity. In developed countries, about 75% of the energy used by the industry is consumed in electric motors. Therefore, it is estimated that the efficiency improvements that can be realized in electric motors can provide significant energy savings.
Efficiency in asynchronous motors is basically the ratio of power taken from the motor shaft to the amount of power the motor spends. The difference is the losses that decrease motor efficiency. In 2008, four IE (international efficiency) classes for all electric motors are defined in IEC 60034-30: 2008 standard for efficiency classes issued by the International Electrotechnical Commission (IEC). According to the new standard, new motor efficiency classes are defined as Standard Efficiency Class (IE1), High Efficiency Class (IE2), Premium Efficiency Class (IE3) and Super Premium Efficiency Class (IE4). By way of example, when comparing IE1 and IE4 motors, all other features are the same; It has been determined that IE4 is higher in efficiency than a motor, IE1 is higher than 14% in one motor.
The minimum legal mandatory efficiency class for electric motors of 2, 4 and 6 poles, up to 1000 V, 50 and 60 Hz in the power range of 0,75 kW to 375 kW in 2011 is IE2. As of 01.01.2015, the IE3 class, which is a super high efficiency class in the EU, has become the minimum legal requirement, and as an alternative it is said to be standard compliant by adding IE2 motor converter.
In Turkey, the first in 2010 under compliance to European Norms, Turkish Standards for electric motors supplied directly by the network (TS) as a standard for determining the efficiency class EN 60034-30-1 has been published. This standard is covered by cascaded asynchronous motors with 2.4 and 6 poles, rated voltage not exceeding 1000 V and power range from 0.75 to 375 kW.
From 01.01.2015, the new standard indicates that the efficiency of the motors to be driven on the market at the power range of 7,5 kW to 375 kW will not be lower than the IE3 (Premium Yield) yield level or should be supplemented with a motor and Variable Speed Driver (VSD) at least at the IE2 (High Yield) report. As of 01.01.2017, the new standard extends the power range to 0.75 kW, which is not lower than IE3 efficiency level.
As a result of the motor inventory studies carried out on the sample through the sample of 887 industrial operations; 7,5 kW and above, as well as AC asynchronous motor information have been obtained and analyzed. In the analysis studies AA asynchronous motor data were analyzed and the average power value, domestic / foreign ratio, efficiency class, etc. results were obtained.
While field inventory analysis was carried out, the sectoral coding and definitions specified by the Ministry of Science, Industry and Technology for sector selection were used for the sectoral classification system, as specified in the following Statistical Classification Rev.2 of the European Community Economic Activities.
In this context, efficiency analysis of electric motors used in Turkey manufacturing industry, on a given sample (7.5 kW of output power on the alternating current induction motor data of 887 industrial enterprises) were performed. As a result of studies conducted in this respect, it was found that mainly old asynchronous motors are used in the Turkey manufacturing industry which is in standard efficiency class IE1. Instead of these inefficient motors, we tried to examine the amount of economic benefit, which is only one of the resultant increases in efficiency and the positive results that would result from the use of higher efficiency (IE2, IE3 and IE4) asynchronous motors.
All these evaluations are an effective motor of change in the perspective of Turkey / determination of the transformation strategy and is emerging as an obligation to implement it. When examining the international examples in this respect, the basic arguments used in the policies and strategies regarding the change / transformation of electric motors; financial incentives, minimum energy performance standards (MEPS), training, awareness-raising and capacity building activities for the parties. For the purpose of carrying out the transition to all these arguments efficient motors must be used in an integrated manner in line with Turkey's energy policy.
Consequently, the results of the analyzes made under this thesis, the necessity of increasing the efficiency of electric motors used in Turkey manufacturing industry are revealed. And also it has been demonstrated of the motor conversion program for offering benefits to Turkey. It is also stated that the program of motor conversion to high-efficiency motors can only be successful if only the participation of all stakeholders is provided.