If a 25 hp motor is running at 40% of its flc is it time to resize the motor for better effiency, if possible ? The motor is running continuous most of the day. Motor is 480 volt and no vfd or soft starts.
Replacing it with a 10HP motor running at full load
might save you 1 or 2 percent of the energy cost, a lot more if your original motor was not a newer energy efficient design and the new one is (will be). If you look at a motor's efficiency rating, it is a curve that peaks at between 75 and 100% of full load and declines slightly starting at (typically) around 50% loading, dropping about 4% between 50% load and 10% load. So depending on your motor's specific curve (they vary), if you are truly at 40% load continuously you
may be heading into the lower parts of that efficiency curve. But this must be weighed against the possibility that the original design engineer knew what he/she was doing and considered occasional overloading or acceleration torque into the decision to use a 25HP to begin with. In other words, a 10HP motor that stalls saves you nothing.
Read this.