Renew Magazine - Quarter 1, 2021. Circular Economy Focus by GC Touchwave

r new FOR THE MAINTENANCE, REPAIR AND REPLACEMENT OF ROTATING MACHINERY

The journal f rom

Quarter 1 2021

FOCUS ON: The Circular Economy

The repair industry's role in a circular economy You must take responsibility for Ex-rated motor repairs Industry News

Innovations

Applications

Expert Opinion

Re-Conditioned Motors       

Cage up to 1mw Ex Stock Slip-Ring up to 500kw Ex Stock D C Motors High Tension Motors 3.3Kv Geared Motors Two Speed Motors Vibrator Motors New Motors

  

Cage up to 400kw Ex Stock Slip-Ring up to 315kw Ex Stock Geared Motors and Vibrators

Large Stocks of Electric Motor Spares Both Current and Obsolete Including:Brook Crompton Series 7 Steel Motor Spares Brook Crompton Series 6 Cast Iron Motor Spares        

Fan Covers Terminal Box Assemblies Endshields Bearing Covers Slip-Ring Assemblies Brushgear Carbon Brushes Cooling Fans Variable Speed Drive Specialist

Schneider Altivar Range of Variable Speed Drives from 0.18kw to 315kw available Ex—Stock

87 Kingstown Broadway, Kingstown Industrial Estate Carlisle, Cumbria, CA3 0HA Tel : 01228 552000 Fax : 01228 552001 E-Mail: electrics@park-gate.co.uk

CONTENTS 3 Editor Chris Callander chris@renew-mag.com +44 (0)1732 671123 Contributing Editor Suzanne Gill suzanne@renew-mag.com Publisher Andrew Castle andrew@renew-mag.com +44 (0)7785 290034 Accounts Touchwave Media Ltd accounts@renew-mag.com Production G and C Media Ltd production@renew-mag.com

Founded in 1945, the Association of Electrical and Mechanical Trades is an International Association representing companies in the electrical and mechanical service and repair industry.

AEMT Tower House Business Centre Fishergate York YO10 4UA www.theaemt.com

elcome to the second issue of Renew. Firstly, I would like to thank everyone who took the time to give us their views on our launch issue. It was encouraging to get so much positive feedback, and also some great ideas to bring to future issues. In this issue, our theme is the circular economy. With so much focus rightly placed on preserving our planet and its resources, adopting a circular approach to producing and using goods makes so much more sense than the traditional make-use-dispose model we are more used to. And with governments across the world setting themselves strict targets for carbon emissions reduction, resource use is becoming an increasing focus of emerging legislation and standards. Therefore it is important that users of electromechanical equipment understand the role they can play in supporting these aims, and understand the benefits that can be achieved – such as increasing reliability, reducing energy costs, improving efficiency and more. To help explain the scope of the circular economy and the advantages of embracing it, across a series of features in this issue of Renew we outline the basic concepts, what it means in the context of electromechanical repair, how it looks in the real world, and how it relates to emerging standards. I hope you enjoy this issue and please keep your comments, feedback, and suggestions coming. You can reach our editor, Chris Callander, at chris@renew-mag.com. David Hawley, President, AEMT

NEWS 6 Industry news 10 AEMT news

26 Clever idea to commercial failure

12 AEMT Awards update

32 Plant optimisation for fertiliser manufacturers

30 Selecting the right gear

14 Product news

Focus on Circular Economy

18 Project updates

34 The circular economy in action 38 Circular economy: What does it mean?

Twitter @AEMT_Updates Renew is a controlled circulation journal published quarterly on behalf of the AEMT by Touchwave Media and G and C Media. For a copy of the magazine’s terms of control and to request a copy please email circulation@renew-mag.com The content of Renew magazine does not necessarily reflect the views of the editor, publishers, or the AEMT. The publishers accept no legal responsibility for loss arising from information in this publication and do not endorse any products or processes mentioned within it. No part of this publication may be reproduced or stored in a retrieval system without the publisher’s written consent.

www.theaemt.com

40 The repair industry’s role in a circular economy

updates 20 Compliance and the circular economy 22 Skills: Keep an open mind to develop the best engineering talent

OPINION

features

46 You must take responsibility for Ex-rated motor repairs Quarter 1 2021

Megger Electrical Test and Measuring Equipment For over 130 years, Megger has been the premier provider of portable test and measuring instruments for electrical power applications. Although Megger is best known for its world-famous range of insulation testers, we can assist your acceptance, commissioning and maintenance testing for predictive, diagnostic or routine purposes. By working closely with electrical utilities, standards bodies and technical institutions, Megger contributes to the dependability and advancement of the electrical supply industry.

TC3231

Image capture frequency 9 Hz Thermal sensitivity (NETD) ≤150 mKn Hot spot and cold spot tracking

DCM305E

Earth Leakage Clampmeter n n

0.001 mA resolution Up to 100 Amp range for standard ac current measurements Low pass filter to aid stability of readings

AVO835

True RMS Multimeter n

High/low sensitivity live circuit detection Phase sequence measurement for 3 phase circuit and motor testing 10 MΩ and 10 kΩ input impedance switching

DLRO2

MPQ1000 MPD SCAN

TC3231 DCM305E AVO835

DLRO2

Thermal Camera

2 Amp DucterTM Low Resistance Ohmmeter n

New “difference meter” for quick data comparisons Safely tests the resistance of inductive loads at 1A <600 V active protection against inadvertent live connections without blowing a fuse

MPD Scan

Handheld Scanner for PD Surveying n

Fast verification of partial discharge activity in MV and HV plants Universal application range due to a wide variety of sensors Integrated camera and QR code scanner

MPQ1000

Power Quality Analyzer n n n

Automatic CT recognition Onboard data analysis 1000 V ac and 1000 V dc range

www.megger.com n +44 (0) 1304 502100

Megger Baker Electric Motor Analyzers The Baker Instruments family of electric motor analyzers provides a comprehensive suite of tests which characterize the health of your motors and generators. These testers are valuable in industrial settings for predictive maintenance, and in motor repair/rewind shops for troubleshooting and QA.

AWA-IV

High voltage tests, Surge, Surge PD, IR, DAR, SV, Ramp and HiPot from 4kV up to 15kV

Winding Resistance, Inductance, Capacitance, Impedance, RIC test, D/Q

Test results can be stored on the DX or transferred to PC for analysis and reports with Surveyor DX software

Static Motor Analyzer

AWA-IV

Static Motor Analyzer

NetEP

NETEP

Permanently installed, fully automated machine system monitoring solution which evaluates each component of the electromechanical system and identifies electrical and environmental factors that will accelerate insulation degradation The system continuously acquires health and performance data on up to 32 electric motors and the rotating machine systems they operate

Adjustable IR from 10v up to 1kV and 200GΩ using: 3 Phase Spot, PI, DAR, IRt and Guard Terminal

4 wire Low Resistance (uni and bidirectional measurements) , LCR, Temperature, Motor rotation, diode test

Voltage (measures ac 10 mV up to 1000 V; dc 0 to 1000 V; TRMS), Frequency (15Hz to 400Hz), Phase Rotation

www.megger.com/baker n 800-752-8272

Test results can be stored on the AWA or transferred to PC for analysis and report generation

The Megger Baker EXP4000 is a portable Dynamic Motor Analysis System

Test domains: Power quality, machine performance, current, spectrum, torque, variablefrequency drives, continuous monitoring, transient analysis (e.g. start-up), motor efficiency

High Voltage Motor Tester

PPX

MTR105

Low resistance measurements from 1mΩ to 800Ω

PPX

Rotating Machine Tester

Full colour graphic display built to CAT III, IP54 and for use up to 3000 metres,

Dynamic Motor Analyzer

MTR105 n

High voltage tests, Surge, IR, DAR, SV, Ramp and HiPot from 2kV up to 12kV

EXP4000

Site Installed Dynamic Monitoring System

For high voltage machines and large form-wound coils, the Baker PPX series extends HiPot and Surge test voltages of the DX and AWA up to 40 kV.

Available models: PPX30 (30 kV) - PPX40 (40 kV) - PPX30A (30 kV with armature testing capability)

6 INDUSTRY NEWS

TWO PUMPS PROVE BETTER THAN FOUR REPLACING FOUR FIXED-SPEED pumps with two variable speedcontrolled pumps has increased pumping capacity, improved reliability and significantly reduced noise for Anglian Water’s Kentford Moulton site, near Newmarket. Four 11 kW line shaft-driven pumps, first installed in 1992, were running without any form of variable speed control. They have been replaced with two 45 kW submersible sewage pumps, the flow rate of which is controlled by two ABB water drives. The upgrade increases pumping

capacity and delivers substantial energy savings, as the ABB drives ensure that the pumps only operate at the speed required. Before the upgrade, the average pump running time was 14 hours per day. Following the upgrade, the average run time is reduced to three hours per day. This reduction in energy led to an estimated £4,000 annual saving for Anglian Water. The project was part of a large pump upgrade at the Kentford Moulton site and carried out by ABB Value Provider, Gibbons Engineering Group.

MEGGER APPOINTS NEW DISTRIBUTOR MEGGER LTD HAS ANNOUNCED that PAR Insulation & Wires Ltd has been appointed as a UK & Ireland distributor, covering the Megger Baker range of motor testing equipment. Commenting on the announcement, Mike Herring, Megger Baker’s Regional Sales Manager, said: “We welcome PAR to the Baker team, and look forward to a mutually beneficial partnership. PAR is a leading supplier into the electric motor market, and a logical choice for us to better serve that sector.” Paul Hirst, Commercial Director at PAR, added: “The Megger and Baker brands are synonymous with high-quality test equipment in the electric motor industry. PAR is excited

to add another trusted global brand to its product portfolio, and I look forward to discussing the Megger Baker range with our customers soon.” Baker test units have been used within the UK electric motor industry for more than 35 years, helping companies to verify the integrity of the insulation systems within their motors. The ‘Baker test’ is a common phrase used by Industry, when specifying what tests should be applied to their motors. Whilst modern-day Baker units provide multiple tests within one portable unit, the term ‘Baker test’ really applies to the surge test – a test used to check the condition of the inter turn insulation.

New COO supports growth plans for Edwin James Group EDWIN JAMES GROUP HAS appointed Christopher Kehoe as Chief Operating Officer to support its growth plans and drive integration across its operations. With a track record in developing customer-centric cultures, service delivery and focusing on people development, Christopher brings over 25 years’ experience in executive leadership to the Glasgow headquartered business. He joins from EMCOR UK Group where he was group executive director. In his new role, Christopher’s primary focus will be to align the Process Services business, establishing a longerterm strategic vision to empower the workforce to create growth. Quarter 1 2021

Edwin James Group offers mechanical, electrical, energy and process engineering to a range of long-standing clients from global brands and public bodies to thriving independents. Commenting on his appointment, Christopher said: “I’ve joined Edwin James Group at a key stage in its evolution. The highly capable operations team is delivering innovative work across the UK and a wide range of industry sectors. “The people, services and technology

create huge potential for expansion, and I’m looking forward to being part of the Group’s ongoing success story.” www.theaemt.com

Industry News 7 Sponsored Article

GES extends Nidec partnership

GES Group is now an authorised distributor for Nidec (Leroy-Somer) Motors Ireland.

BOTH GES GROUP AND NIDEC (Leroy-Somer) have worked together in partnership in Northern Ireland for several years. By expanding the distributorship to Southern Ireland, their partnership will create a more comprehensive infrastructure with enhanced experience and expertise. GES will stock and distribute the range of Nidec (Leroy-Somer) motors, and the new cloud-based condition monitoring systems FORECYTE from its new base in the Republic of Ireland. The company strongly believes that this change to its business model will enhance its customers’ experience ensuring fast and easy access to its full range of products, plus first-class product, service and support. Commenting on the announcement, GES Group CEO, David Moore, said: “To enable the growth and future-proofing of our energy market in the digital transition, we have taken a bold step to extend our collaborative portfolio in Ireland; building our product, skills and network structure within a collaborative group through the development of the Nidec Partnership deal programme. We are delighted with the opportunity to extend our all-Ireland market and have ambitious plans through collaboration within our industry. “That said we want to identify and tackle the underlying issues,

LIVERPOOL

WALLASEY

such as digital skills and innovation, through outreach with our new and existing clients, which is an excellent example of our focus on delivering and implementing actions to address the key challenges facing our future development in the motor and drive digital energy revolution.” Colin Ditchfield UK & Ireland Sales Director at Nidec, added: “In terms of GES commitment to quality and their long standing reputation in the industry GES more than matches the high standards required by our company to represent our product portfolio as an authorised distribution partner. “Having already enjoyed a successful partnership for the distribution of Leroy Somer products in Northern Ireland since 2018 its a perfect fit to now expand into to the Republic of Ireland. With a large investment from both companies in terms of staff and product inventory I am sure this new synergy will provide our customers with a first-class customer service experience.” info@ges-group.com 028 25656406 www.ges-group.com

MANCHESTER

NEW AND REFURBISHED BALANCING MACHINES At RJW, we have over 40 years experience dealing with dynamic balancing solutions to a range of different customers We have a range of fully refurbished balancing machines to suit your requirements including the following features: • Modern, easy-to-use electronics displays for accurate results. • Cost effective balancing solution for rotating equipment service companies. • Full training and commissioning assistance given. • Choice of hard and soft bearing units as well as drive type. Rewinds & J.Windsor & Sons (Engineers) Ltd. 81 Regent Road, Liverpool, L5 9SY T: 0151 207 2074 F: 0151 298 1442 E: enquiries@rjweng.com www.rjweng.com

WWW.RJWENG.COM

8 industry News

PUMP EXCHANGE SITE LAUNCHED WILO UK HAS LAUNCHED THE PUMP Exchange (www.thepumpexchange. co.uk), a website designed to provide customers with quick and simple pump replacement guidance for a range of applications, including circulation, multistage, borehole, drainage and sewage. With over 8000 pumps in the system, The Pump Exchange provides the most suitable Wilo pump replacement for both existing older Wilo pumps, and alternatives to other brands. Users of the site start by selecting

the existing pump type and then choose the pump’s brand. A product name checkbox then lists all registered pumps from that brand. On selecting the existing pump by name, all information including the recommended replacement pump, its technical description and fitting accessory details are displayed. Depending on the pump, several replacement options may

appear, and for each option, an exchange proposal document can be downloaded.

AEV SECURES MAJOR UK GOVERNMENT RESEARCH CONTRACT AEV, A MANUFACTURER OF electrically insulating resins, varnishes and compounds, has won a project bid as part of a Government assisted scheme from the Advanced Propulsion Centre (APC). The Advanced Propulsion Centre (APC) provides funding support to accelerate the industrialisation of technologies which will help realise net-zero emission vehicles within the automotive sector. AEV will be working on the project alongside Saietta a specialist in

propulsion motors for Electric Vehicles (EVs) and Brandauer a leader in precision stamping and progression tooling. Saietta has engineered a breakthrough in propulsion motors for electric vehicles (EVs). The company’s Axial Flux Traction (AFT) design is, patent protected and modular, meaning solutions can be provided from scooters to buses. The global reaction to AFT has been extremely positive across multiple EV product sectors and beyond into marine

and wind turbines. To fully capitalise on the commercial opportunity, it is vitally important that Saietta fast-tracks the AFT technology to mass production.

DERITEND SIGNS IESA PARTNERSHIP DEAL DERITEND GROUP HAS BEEN announced as a preferred supplier to procurement specialist, IESA in a deal that could be worth up to £1m per year. The company has completed the quality assurance exercise required to be listed in the Motor and Gearbox category. This means the firm will now be part of the global outsourcing specialist’s central list of suppliers that companies like Astra Zeneca, Bentley, 2 Sisters Food Group, Michelin and Molson Coors use for their maintenance, repair and operational (MRO) requirements. It is the result of a year-long discussion, several assessments and the creation of a specialist team to respond to enquiries within 24 hours and provide immediate technical support and access to industryleading equipment and solutions. Richard Hale, CEO of Deritend Group, commented: “This is a big moment for our Quarter 1 2021

business and one that will hopefully lead to lots of new opportunities for us across multiple sectors. “It’s a really good fit as IESA is looking to offer more than just products and want suppliers who can deliver solutions, something we are experts in. Our experience in motors, gearboxes and pumps is second to none and we have a team of engineers ready to meet emergency repair requirements and provide advice on getting the most out of these vital pieces of equipment.” Neil Jackson, Supplier Relationship Manager at IESA, added: “Our customers span a wide variety of industries and

we need suppliers who have experience in all of these areas. “Deritend meets this requirement and, importantly, can help us add value to our clients by providing technical advice that could overcome a production issue, achieve greater efficiencies and also reduce their costs.”

www.theaemt.com

www.brookcrompton.com

Keeping industry turning every second... every day...every year With over 110 years of technical and design expertise, Brook Crompton offers leading edge energy efficient electric motors across global markets. As the original innovator in electric motor development, Brook Crompton are trusted to power limitless industrial processes and its robust motor design drives fans, pumps, compressors, conveyors and more. Driven by technology and innovation, Brook Crompton has one of the widest available ranges of electric motors for operation in safe areas, hazardous atmospheres and hostile environments.

The extensive range of stock can be quickly modified to suit customersâ&#x20AC;&#x2122; needs and with a high level of technical support from our knowledgeable team we ensure the correct selection of motors is provided for your application. Brook Cromptonâ&#x20AC;&#x2122;s focus on product and service development ensures we continue to move forward to improve efficiency, offer lower cost of ownership throughout their lifecycle and to reduce environmental impact.

10 aemt news

UPDATE FROM THE AEMT SECRETARY

Thomas Marks shares the latest news from the Association. WE ARE AT A PIVOTAL MOMENT IN THE AEMT’S HISTORY, despite coming out of a damp squib of a year. The lockdowns have encouraged moments of reflection, clarity, and focus, which have presented a clear route forward for when we step out of the pandemic and a sense of normality returns. Pivotal, because we say goodbye to a true champion of the association, Tim Marks, who was Secretary of the AEMT from 2001 to 2017, and in a supporting role until he retired at the end of 2020. There will be more on the success he has brought the AEMT in the magazine’s next issue. He remains available to the association as a consultant and will continue to support the industry by representing AEMT members on the standards committees we are members of. I will continue my role as Secretary and will also become General Manager for the AEMT, working with the council to ensure the association remains relevant, progressive and above all else, valuable to its members. Our first priority this year is to ensure that our members are taken care

of, that those requiring Ex training are catered for, and that the association is in a position to start growing again. We begin by hiring back in-house a full-time administrator, who will be the members’ new point of contact for membership enquiries and course bookings, filling the shoes of Jane Garnett who retired in 2019. We also move office in February to a new location in York, which will become our new base to run the association from. We look forward to publishing details of this soon. For the Ex courses, we are working hard on improving our online offer to easily train workers from afar and in the UK, who are looking for a more flexible learning experience. And for those who enjoy the classroom-based courses, we also look forward to bringing these back where we can and as soon as we can (COVID permitting). Upcoming course dates can be viewed below, and I encourage early booking to avoid disappointment. Before the end of the first quarter, we aim to have completed our membership outreach project, which ChordUK initiated and ran for us in November 2020. This will mean all membership profiles and records will be accurate, current, and logged in our new management system and on the AEMT website. With this system in place, more staff hours, and a new office, members will see much better interactions from the secretariat. I wish you all the very best for 2021 and really look forward to reuniting later this year when our face-to-face events return.

Forthcoming AEMT led Courses on Hazardous Area Equipment Repair, Overhaul and Reclamation MODULE

COURSE TITLE

START DATE

END DATE

LOCATION

Ex Theory

25 January 2021

26 January 2021

Online UTC +7

Ex Hands-on

27 January 2021

29 January 2021

Online UTC +7

Ex Refresher

09 February 2021

11 February 2021

Online UTC +7

Ex Refresher

23 February 2021

24 February 2021

Loughborough

Ex Refresher

09 March 2021

10 March 2021

Online UTC

Ex Refresher

16 March 2021

18 March 2021

Online UTC +4

Ex Theory

19 April 2021

20 April 2021

Loughborough

Ex Hands-on

21 April 2021

22 April 2021

Loughborough

Ex Refresher

27 April 2021

28 April 2021

Loughborough

Ex Refresher

11 May 2021

13 May 2021

Online UTC +7

Ex Refresher

18 May 2021

19 May 2021

York

Ex Refresher

08 June 2021

09 June 2021

Aberdeen

Ex Refresher

15 June 2021

17 June 2021

Online UTC +4

Ex Theory

21 June 2021

22 June 2021

Kuala Lumpur

Ex Refresher

23 June 2021

24 June 2021

Kuala Lumpur

Ex Hands-on

23 June 2021

24 June 2021

Kuala Lumpur

For more information or to book any of the couses listed please visit www.ex-repair.com

All classroom-based training is scheduled subject to the COVID-19 restrictions in place at the time. Full details of the safety procedures being applied to classroom-based courses can be found on the course website. Quarter 1 2021

www.theaemt.com

+44 (0) 1952 208 730

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12 awards update

NOMINATIONS SOUGHT FOR INDUSTRY AWARDS Having endured a 12-month hiatus, brought about by the various Coronavirus restrictions, the AEMT is delighted to bring back the annual awards programme it successfully launched in 2017, and again delivered in the following two years. As such, and in recognition of all those who have helped make this event such an important showcase for commercial and engineering excellence in our sector, we can announce that the online entry process is now open.

ostponed from its usual November timeline in 2020, the event will now take place on the evening of Thursday 18th November 2021. The Doubletree by Hilton Hotel in Coventry will again play host to this special evening, as it will for the associated AEMT Conference which will be staged throughout the day. This, the fourth staging of the AEMT Gala Awards Dinner, will once again bring together the entire electrical and mechanical trades sector in a celebration of business and professional excellence. Recognising and rewarding both individuals and companies operating within the electrical & mechanical maintenance and repair sector, personal endeavour, product innovation, skills training, engineering advancement and commercial acumen will once again be acknowledged and celebrated. INDUSTRY-WIDE ENGAGEMENT Operated by the Association of Electrical and Mechanical Trades (AEMT) and produced by Touchwave Media, the awards acknowledge the skill, effort and sheer dedication of the people and businesses serving this important sector of industry. With sponsorship provided by a host of leading industry names, which to date has included ABB, Avonmore Electrical, Axflow, Drives & Controls, EMIR Software, Fanuc UK, Fletcher Moorland, Menzel, Musk Process Services, Plant & Works Engineering, Sulzer, TEC Motors and WEG UK, well deserved industrywide recognition will be given to those businesses who are excelling in their commercial endeavours.

Quarter 1 2021

AWARD CATEGORIES The following categories make up the 2020/21 awards programme: • Product of the Year – sponsored by Plant & Works Engineering • Project of the Year – sponsored by EMIR Software • Service Centre of the Year – sponsored by ABB • Supplier of the Year – sponsored by Drives & Controls • Contribution to Skills & Training – sponsored by Musk Process Services • Rising Star – sponsored by FANUC UK • Lifetime Achievement – sponsored by AEMT CALL FOR NOMINATIONS Entries are being sought for any company, product, application or individual involved in the supply, installation, service, maintenance and repair of industrial machinery technology such as electric motors, drives, pumps, fans, gearboxes, generators, transformers, switchgear and ancillary equipment. Individuals can put forward entries for themselves and their own company; or nominate others

that they believe merit recognition. The online entry process couldn’t be easier, so anyone wishing to play their part in highlighting engineering excellence should visit the AEMT Awards website – www.aemtawards.com. CLOSING DATE FOR ENTRIES Given the new date for the presentation ceremony, the closing date for all entries has been extended to 5.00 pm on Friday 10th September 2021, so for those wanting industry-wide recognition for a job well done, be it for product innovation or project management, for application know-how, or service and repair, they should make a note of this date. It is free of charge to enter the awards, but the promotional value associated with being selected as a finalist is worth many hundreds of pounds. And for those individuals and companies fortunate enough to be announced as one of the seven winners during the charged atmosphere of the gala awards dinner, the promotional benefit is even greater. TIMES-CIRCLE www.aemtawards.com www.theaemt.com

Your Asset Care Partners Working with us to ensure the care of your assets means having an experienced team on hand to help you meet your manufacturing targets cost-effectively. Ou team will help keep your Our assets safe and achieving their full potential through reliability-centric care and can help deliver fast-track o your entire improvement of plant maintenance regime, reduced costs and increased productivity.

Plant Maintenance Reliability Improvement Condition Monitoring Engineering Compliance For further information and case studies visit www.ejmusk.co.uk

14 product news

SPARE PARTS INVENTORY SERVICE LOOP WINDING LINE AIMS TO REDUCE DOWNTIME RISKS HAS 1000MM LOOP NORTHERN INDUSTRIAL HAS launched a new service aimed at safeguarding manufacturing businesses from downtime during obsolete equipment breakdowns. SparesVault offers guaranteed access to a bespoke automation spare parts inventory to balance the cost of holding obsolete and end-of-life spares against the threat of machine downtime. The subscription-based service starts with a comprehensive review of system-critical assets to create a detailed obsolescence report with recommendations for automation parts to be included in the bespoke SparesVault inventory. The agreed inventory is then sourced by Northern Industrial, with all parts serviced, tested and checked before being held in a secure bonded warehouse facility. Back-ups of relevant parameters and programs are also securely stored on cloud-based servers. Parts considered most likely to be needed are provided for storage at the customer’s site for immediate access in the case of a breakdown. Any further parts required, covered by the SparesVault inventory, are delivered to the customer’s site within a contractual response time. Inventory levels are reviewed at least annually with adjustments proposed where necessary.

LENGTH CAPACITY

JohnJoe McGonagle, Northern Industrial Area Sales Manager, said: “According to research it’s estimated that downtime costs UK manufacturers £180 billion per year. Downtime costs are detrimental to all manufacturing businesses, with prolonged downtime becoming more likely when running obsolete equipment. “Having a robust plan in place not only protects a business but can increase growth.”

PRECISION TAPING AND WINDING machine manufacturer, Ridgway Machines, has recently designed and manufactured a loop winding line with 1000mm maximum loop length capability. The loop winding line comes complete with the LWDS2 two-position drum stand, a W-LMP1000 loop winder with 1000Nm torque capability and the LWWB1000 winding beam – fabricated and machined with a minimum loop length of 350mm and a conductor gathering box which includes two sets of vertical/horizontal rollers arranged in pairs, mounted on a single post to bring individual conductors together as a single bunch. Key features include fully adjustable winding pins, available in a range of diameters, latest vector drive technology – a variable speed geared motor with high torque capability and soft start. The machine also includes an electrically released brake to prevent runback and eliminate tension loss whilst stopping and starting.

nicontrols.com/uk

www.ridgwayeng.com

E-LEARNING PLATFORM LAUNCHED FOR EMiR USERS SOLUTIONS IN IT, THE COMPANY behind the EMiR business management solution for companies working in the electromechanical sales, service, repair and assembly sector, has launched a new e-learning system, eMiRLearning. A survey carried out by the company found that most of its customers’ new employees learn from existing EMiR system users. The downfall to this is that some training received by the existing user may have been forgotten, or they may not fully understand the Quarter 1 2021

functionality a new user requires for their role. This means a new user may not be getting the most out of the company’s system and may be unaware of how they can use it to best perform their job. To solve this, Solutions in IT created eMiRLearning to supplement the in-depth EMiR training provided by an instructor. It is designed to help train new starters and introduce them to the key functionality in EMiR with overviews of each of the software’s modules.

The courses are comprised of screencaptured videos walking learners through an overview of the EMiR functionality. At the end of each course, an exam tests the learner’s knowledge of the content, and successful candidates are awarded with a certificate. Each course is between 45 and 90 minutes in length and can be completed over the space of a month, giving users the flexibility to control their own learning. www.solutionsinit.com www.theaemt.com

Wilson Fans, Pumps & Motor Group Generating Solutions Since 1951 @Wilson Fans, Pumps & Motors Group

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Consultation

Design

Supply

Installation

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Unrivalled attention to customer requirements. Generating solutions derived by us based on the requirements set by you.

Completed by our experienced expert engineers at our workshop.

Complete and extensive stock of Fans, Pumps, Motors and Inverters and other equipment. Also, a large network of suppliers offering short delivery times.

Installed by our fully trained, accredited expert engineers to get the very best from your system.

Service and maintenance for all newly installed equipment and existing installations via Wilsons 30+ Point Plan.

16 product News

IIOT Asset Condition monitoring THE FORECYTE ASSET CONDITION monitoring platform enables users to minimise unexpected downtimes and loss of production by providing an IIoT wireless equipment monitoring solution based on simplicity, reliability, connectivity and diagnostic intelligence. Available from Nidec partner, GES Group, the standalone remote condition monitoring platform solution enables monitoring, collection, visualisation and analysis of vibration and temperature data to determine equipment health. This allows asset owners to transition from reactive/ preventive maintenance to predictive maintenance. Defining the ideal time and

scope of such maintenance minimises unexpected equipment failure, reduces operating costs, and extends service life. “FORECYTE has potential for a range of sectors in Northern Ireland, and we are excited to be able to deliver such innovative technology to our customers at incredibly cost-effective prices,” explained David Moore, GES Group CEO. GES Group can provide significant value to its customers by combining technical capabilities and expertise through its partnership with Nidec. As an authorised partner, value-added services include express availability and local stocks; project management, sizing and on-site

Nidec’s FORECYTE system is available from GES.

commissioning preventive and predictive maintenance; repairs, overhauls and rewinds; and equipment efficiency analysis. ges-group.com

PLATFORM BRINGS TOGETHER MOTOR BUYERS AND SELLERS EASY MOTOR, WHICH ITS CREATOR believes is the first platform of its kind, has been launched to bring together buyers and sellers of all makes of motors, new and second hand. The platform’s creator, Laurent Clair, has been working in the supply of electric motors components to end-users, OEMs and repair shops for more than 30 years. During that time he regularly saw how difficult it could be to find the right motor when an unexpected production shutdown occurred due to a motor failure. He knew that many of the repair shops had a range of new and used motors on their shelves – many of which were no longer in production and

were difficult to source. But there was no way of knowing which business had what products in its stores. So, Easy Motor was launched to provide a link between those in need of a specific motor and those that had products in stock. It makes it easier for those with a specific need to find what they require and gives a far greater reach to those businesses who might otherwise work on a relatively local basis. With the platform’s scope to bring buyers and sellers of motors together, it was of course, obvious to extend the coverage to motor manufacturers and distributors. Designed to offer a new sales

channel to repair businesses and manufacturers of motors, Easy Motor makes listing products as easy as possible. Potential buyers simply register on the site and can request a quote from any of the registered sellers. The platform then facilitates communications between the buyer and seller to discuss the products and agree terms before posting a purchase order and completing a transaction. Since its launch, Easy Motor has already built a network of 3,000 registered buyers and sellers, and is growing daily. www.easy-motor.com

Single-point automatic lubricator now available in the UK INDUSTRIAL AND AUTOMOTIVE supplier, Schaeffler, has launched its CONCEPT1 single-point automatic lubricator into the UK market. Engineered to ensure optimal lubrication in a broad range of industrial machines and devices – including electric motors, bearing housings, fans, blowers and pumps – CONCEPT1 eliminates the need for time-consuming manual lubrication procedures, while preventing lubrication mistakes such as over- or under-greasing, which can cause unplanned equipment downtime. “Approximately 60% of electric motor failures can be traced to bearing-related problems that are typically due to lubrication issues”, said David French, Quarter 1 2021

Product Manager for Industry 4.0 solutions at Schaeffler. “Because of this, we designed CONCEPT1 to provide our customers with a versatile and easyto-use solution that delivers the right grease in the right quantity at just the right intervals.” CONCEPT1 uses an electromechanical reaction to precisely and continuously supply the correct amount of lubricant to rolling bearings inside electric motors and other industrial machinery. Easy to install and

operate, the lubricator is said to be able to reduce plant maintenance costs by as much as 25% compared to manual lubrication procedures. www.schaeffler.co.uk www.theaemt.com

18 project updates

WASTEWATER TREATMENT TANK REPAIRS AT THE 18TH HOLE AT THE BEGINNING OF MARCH 2020, the WGM Engineering team was called out to attend and repair a mechanical failure within the primary settlement tank located at North Berwick wastewater treatment works. This was an interesting project for the company, because the entire sewage works is located under the 18th tee of the Glen Golf course. After an investigation which involved draining and cleaning the primary

settlement tank, the team identified the root cause of the failure and was also able to suggest some improvements on the scraper arms. To extend the lifespan of the asset, the scraper arms were shot blasted and coated, removable scraper poles were added and new blades/scrapers were fitted. Safety was key throughout the project, as work needed to be undertaken within a confined space

and there was restricted access to the primary settlement tank. Additional social distancing requirements also needed to be considered due to the ongoing Covid-19 pandemic. The success of this project has led to WGM Engineering being further tasked with preventative maintenance works on a second primary settlement tank within the treatment works. www.wgmengineering.co.uk

Improvised solution overcomes unacceptable delay AS THE MAIN AUTHORISED DISTRIBUTOR FOR LEROY Somer in the Midlands, Alpha Electrics prides itself with always being on hand to help solve problems for its customers. When the company received an urgent request for a 15kW, 4P, B3, 160 frame motor, with a right-hand terminal box, it was quickly able to overcome a big problem – the seven week delivery time from the factory for this particular motor. Such a long delay for a replacement motor was unacceptable for the customer so Alpha Electrics had to improvise to provide its customer with a speedier solution and was able to modify a standard motor, with a top terminal box, in order to deliver the required motor within just a few hours of receiving the order. alphaelectrics.com

Driving the world’s largest lift irrigation project ELECTRIC MOTOR MANUFACTURER, WEG, has supplied electric motors for the world’s largest lift irrigation project, the Kaleshwaram Lift Irrigation Scheme (KLIS) in Telangana, India. Following two years of construction, the project was completed in June 2020. The multi-purpose project that commenced in 2018 reinforced the storage of water available for irrigation in the region — 8,000 km2 of land across 13 districts of the state — and increased groundwater levels in the Godavari River Basin. The increased river water supply is set to improve subsistence for the population through fishing and tourism. To complete the project, WEG supplied 14 40MW 30-pole motors to Xylem India, one of the world’s largest hydraulic pump manufacturers. Xylem India coupled Quarter 1 2021

these motors to its high-capacity pumps, specified by Megha Engineering & Infrastructures, the company responsible for the engineering, procurement and construction of KLIS. The electric motors were the largest

ever manufactured in the WEG India factory, each weighing 262 tonnes and they were assembled and tested at the project site. weg.net www.theaemt.com

project updates 19

LONG-LIFE BEARING SOLUTION FOR BAKERY OVEN FAN A UK BAKERY WAS EXPERIENCING regular, unexpected stoppages due to the premature failure of pillow-block ball-bearing mounted units fitted to the recirculation fan of a high-temperature oven. Failures of these bearing units were causing significant disruption to the bun production line at the bakery, leading to high downtime costs and spoilt product. With bearing failures occurring every six weeks, the management team set out to find a solution, and invited NSK to investigate the issue as part of its AIP Added Value Programme. Upon completion of a full application review and failed bearing analysis, NSK engineers concluded that the bearings were seizing from excessive pre-loading and the use of incorrect lubricant. The existing bearings were found to be inadequate for the operating conditions of the oven fan unit – which is belt-driven in a vertical orientation. Fan reliability is vital as it recirculates air within the oven to ensure uniform temperature and evenly baked products. NSK proposed the adoption of its SNN

series plummer blocks with spherical roller bearings and labyrinth seals, and recommended the correct bearing location, radial internal clearance (RIC) and lubrication. This solution would offer higher axial and radial load support, aided by a ´floating´ arrangement to accommodate thermal expansion of the shaft and tolerate any fan imbalance. A trial was conducted and the solution resulted in an immediate improvement, with bearing life extended from 6 to 27 weeks, and this resulted in a reduction of both machine downtime and maintenance costs. In combination with plummer blocks, adoption of the spherical roller bearings

and labyrinth seals has enabled the bakery to make large cost savings via fewer bearing replacements, less breakdowns, reduced maintenance technician costs and less spoilt product, ultimately leading to improved production efficiency and better equipment reliability. www.nskeurope.com/en

One day turnaround for new gear unit ASSEMBLY AND DELIVERY OF AN INDUSTRIAL GEAR unit, requested by Brammer Buck & Hickman, for an end customer in the sand and gravel industry, was achieved by SEW Eurodrive in just one day following a gear failure. The unit was ordered via SEW Eurodrive’s new ATO1 service which offers assembly and delivery in just one day. A parallel helical gear unit with additional fan cooling, rated at 36,000Nm, was built to replace a failed unit on a sand and gravel scrubber, known as a trommel. The trommel is a large cylindrical drum that rotates sand and gravel in the first stage of a washing operation that

processes material at a rate of 350 tonnes an hour. This is a critical part of the plant and Brammer Buck & Hickman needed a supplier that was able to quickly respond to its requirements and provide a solution to get the customer back in to production. Taking advantage of SEW Eurodrive’s new Assemble-toOrder services, with the ATO1 premium one day service, has helped Brammer Buck & Hickman get the plant up and running again with minimal downtime. www.sew-eurodrive.co.uk

HELICAL GEARED MOTOR REBUILD FOR BRAKE TESTING SYSTEM WHEN A COMMERCIAL VEHICLE BRAKE tester system, belonging to a company that MOT’s commercial vehicles, started to fail the company set out to get it fixed. The problem was found to be down to a helical geared motor with a two-stage gearbox, which was showing signs of wear. Excessive noise had been reported when the motor was running in a clockwise direction, but no noise at all when running anti-clockwise. The brake had also not been operating efficiently. The customer initially www.theaemt.com

enquired with the machine manufacturer about the problem, but as the gearbox was licensed to the manufacturer, it insisted on a new one being fitted, which would be a costly expense and would have a long lead time that was unacceptable for the

commercial vehicle MOT company. The company contacted Rotor Technical Services in the hope that the original geared motor could be repaired, rather than replaced. New gears, bearings, seals, components and a brake kit, allowed Rotor Technical Services to provide a full rebuild of the gearbox, offering a fast and more cost-effective option than having to purchase a complete new unit. www.rotortechnicalservices.co.uk Quarter 1 2021

FEATURE 20 Compliance

Compliance and the circular economy There is a growing awareness of global warming’s dire effects and the need for everyone to play their part to save energy and improve our carbon footprint. In addition, we all have a duty to ensure that we pass on to our grandchildren, a planet with enough resources to support their needs and the needs of their grandchildren. Tim Marks, AEMT Consultant, asks how can the repair industry help?

ll of us – the equipment repair sector, manufacturers and end-users – have a role to play in tackling global warming. Are people aware of it, and how do we ensure that we are doing all that we can to save the planet and its resources across industry? To date, the repair industry can be proud that it has helped its customers by ensuring that they are offered the chance to upgrade to a more energy-efficient option at the time of repair or replacement. This on its own has led to considerable energy savings. However, the task is ongoing and upgrading to IE4 and IE5 motors is not always the best or most economical answer, so where do we go now? Many companies are now locked into the box pushing system of always replacing a failed machine or pump with another new energy-efficient machine. But is this really the best course of action? Service and repair centres now have all the tools they require to ensure that: • Energy-efficient motors in the market maintain their rated energy efficiency after repair – which recent major studies by the AEMT and EASA have confirmed. • By repairing or remanufacturing a motor, the machines life is effectively doubled every time it is repaired, i.e. another 20,000 hours in modern scrupulously clean, air-conditioned factories. • Machines repaired to International Standards are as reliable as a new machine, last as long as a new machine and normally carry the same warranty as a new machine. • Hazardous area machines, as well as meeting the above requirements, maintain the safety of their protection concepts if repaired using International Standards. • All the items replaced during an overhaul, maintenance, or repair, are recycled as ‘green’ highquality scrap, making the industry self-sufficient in a Circular Economy with the copper, steel, iron, and aluminium that it uses. • The carbon footprint of a repaired machine is a fraction of the carbon footprint of a new machine. These are impressive credentials for any industry, but what are the standards required? For normal machines, the international standard to repair machines is IEC 60034 23 Rotating Electrical Equipment: Repair, Overhaul, and Reclamation, together with other International IEC 60034 series standards named within the above standard. Manufacturers use these standards for the Quarter 1 2021

parameters and test procedures that new machines must comply with. Using the same tests and checks as the manufacturers, a service repair centre can ensure that a repaired machine is truly repaired or remanufactured to conform with the original specifications. In addition, for hazardous area and ATEX machines the International Standard IEC 60079 19 Explosive Atmosphere Equipment: Repair, Overhaul, and Reclamation should be used to maintain the safety of the product in hazardous areas.

“The machines’ energy efficiency stayed within the rated band of efficiency after repair.”

EFFICIENCY IS MAINTAINED DURING REPAIR A recent study by the AEMT and EASA on IE3 machines has confirmed that using recognised standards and an independent test centre, machines’ energy efficiency stayed within the rated band of efficiency after repair. This backs up the findings of the earlier 2004 study on machines up to IE2. In conclusion, the master craft of repairing and rewinding electric machines is vitally important to make sure we make the best use of the world’s dwindling resources. TIMES-CIRCLE The IEC 60034 23 the International Standard on Rotating Electrical Machine: Repair, Overhaul, and Reclamation sums up the importance of the repair process in a circular economy... 4.7 Circular economy The repair process complies with all aspects of the circular economy, doubling or trebling the active life of rotating electrical machines and the use of materials in them. The rotating electrical equipment market has undergone a process of upgrading to more energy efficient machines to save on power usage, with the focus of standardisation on IE3 machines, or equivalent. The repair/refurbishment of energy efficient machines ensures the most efficient use of the world’s dwindling resources. When repairing/ maintaining a typical 110 kW machine with new bearings, the effective life is doubled and 99 % of the original machine is maintained. The old bearings, making up 1 % of the machine, are recycled as high quality “green” steel scrap. If the machine is rewound 90,5 % of the machine is reused during refurbishment. www.theaemt.com

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22 Skills

Keep an open mind to develop the best engineering talent

With many businesses in the industrial sector experiencing difficulty finding young engineers to bring into their business, maybe the answer to the engineering skills shortage lies elsewhere. James Henson, Operations Manager (Design & Compliance) at Musk Process Services, explains how his company saw the potential, supported his development, and reaped the rewards.

sk someone to think of a ‘typical’ engineering career path and they will likely say something along the following lines: Specialised apprenticeship at 16 or 18, qualify, become a team leader, then supervisor, working towards heading up a team or site and possibly and eventually becoming the senior leader of their firm. However, what if some of your potentially best engineers did not, or could not follow that path? Are you and your organisation thinking outside the box when it comes to recognising and developing engineering talent and future business leaders? If you are not, my story might help you to see how you can... My current role is as Operations Manager at Musk Process Services. In this position, I lead the Engineering Compliance and Design department; however, my journey to where I am now definitely wasn’t straightforward. Without other engineers and mentors offering me the opportunities that I couldn’t access on my own, I certainly wouldn’t be where I am today; a professionally registered chartered engineer and leading our Design Department. I always knew I wanted a job that I could develop into a career for life. I began as a semi-skilled carpenter, which I did immediately after leaving school as I was unaware of the direction I wanted to take. I also began an apprenticeship as a car mechanic leading on from this role, but could not support myself on the wage so retuned to the previous role to pay bills and save. This allowed me to eventually pursue my ultimate goal, as an apprentice engineer. It was after this that I first was made aware of Musk, (then Peme) and was successful in joining the company as a computer-aided design (CAD) technician. It wasn’t an apprenticeship; however, it offered the opportunity to get into engineering, which was my goal. The position also came with the potential to develop further and turn it into a lifelong career. Although my title was CAD Technician, I was an ‘office lackey’, taking on many jobs and tasks from the engineers. I worked hard, though, starting early and staying late, which caught the Managing Director’s eye. He offered me the opportunity of pursuing an apprenticeship with the company despite the fact I wasn’t the typical ‘straight out of school’ new recruit. The academic year had already started when I was offered this new and exciting role, which required further hard Quarter 1 2021

James Henson (ctr.) with colleagues Stef Smith (l) and Clive Wardle (r).

work, catching up with several weeks of college work. Nonetheless, I finally completed the apprenticeship that I had always wanted, qualifying in Mechanical engineering and Design. I am not the only late-starter apprentice at Musk, by far. Some of our best engineers have been offered the opportunity to train and qualify when already working for the organisation. This Includes one of the design engineers within my team who was working in a factory before starting his apprenticeship. Furthermore, one of our most newly qualified apprentices has just finished his course in his late 30’s, after working for us as a fitter’s mate. I really believe that engineering companies can benefit from having an open mind when it comes to apprenticeships and offering development opportunities to their existing and older staff, as well as taking on recruits directly from education. My opportunities to expand my skills and knowledge continued after my apprenticeship, and much of this can be attributed to the mentorship I received from my managers and more senior engineers at the time. Once I had qualified through the apprenticeship, I was encouraged to lead design and

“Some of our best engineers have been offered the opportunity to train and qualify when already working for the organisation.”

> 24

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24 Skills

installation projects which gave me a good grounding in most aspects of our business and my trade. After broadening my knowledge, I was offered the opportunity to move into the Reliability Engineering Department, to widen my knowledge of asset care and the business. Under the guidance of Senior Reliability and Condition Monitoring Engineers, I completed an HNC. I also furthered my skills and gained a qualification in Specialised Condition Based Monitoring Techniques, such as Thermography and Ultrasound. Again, without my peers’ support, I would never have had the opportunity to expand my engineering knowledge and develop into the engineer I am today. The Senior Management Team within Musk really believe in others and make it a priority to encourage and enable other colleagues to develop internally. I was extremely fortunate to be mentored by Steve Wiles, an experienced Design Manager, and Darren Martin, our current Operations Director, who included and supported me in establishing the engineering compliance arm of the business that I currently influence. I recognise the mentorship that I have received, and now I want to give that back. I’m grateful to be in a position where I can support other engineers in the business to develop their careers in the same way as I’ve been supported during mine. Musk has been an Enterprise Partner of the Institution of Engineering and Technology (IET) for many years, but in the most recent year, Darren and I decided to begin the Professional Registration Programme with the IET. This Professional Registration, which we jointly developed, demonstrates to our clients the high level of engineering skill, experience and expertise within our business. It also provides recognition for our more experienced engineers and key talent within the business. Within the development of this new programme, I was able to offer the opportunity to Quarter 1 2021

eight engineers. The areas of specialisms and levels varied hugely, evident in the presence of a Reliability Engineer and also our head of Asset Care. This was a new opportunity for me to provide support not only to my direct reports but to my peers and senior engineers. Currently, half of the initial cohort has been awarded the Chartered Engineering Status CEng, including myself. This is something I would never have considered a possibility at the age of 16 when I was doing carpentry but it has been made possible by the open-mindedness of my engineering colleagues throughout my career. I’m not sure what’s next in my career plan, l like to keep an open mind to all opportunities. My ultimate goal is to prioritise gaining the knowledge of all opportunities so I can share them with others and enable my team to reach their highest potential, while I continue to develop. I have learnt so much during my career with Musk, and I am so fortunate to have been given the roles and learning opportunities throughout this time. Mentoring by fellow colleagues has been truly life-changing. I feel that apprenticeships are often stereotyped to young, school leavers; however, many others can benefit hugely from them. Every day we are learning, and there is so much more knowledge to acquire. We have recognised that it really doesn’t matter at what stage you are within your career; you can always advance yourself. We have developed learning opportunities which not only benefit colleagues but also our wider business partners. TIMES-CIRCLE

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26 Motor Design

The Pipe Cage Motor: Clever Idea to Commercial failure AEMT life member, Prof. David Walters OBE C.Eng., was responsible for designing a motor that was technically very interesting, but not commercially successful, with less than 100 ever sold. David explained to Renew how something which seemed so promising ended so badly.

n 2018, Matt Fletcher of Fletcher Moorland, assisted by Steve Cockerham of HPC Laser, wrote an excellent article in Renew’s predecessor, the Journal, about repairing a Brook Crompton pipe cage motor, the like of which he and most others had never seen before. David explains how the motor came to be, and where it all went wrong… The story starts in the early 1970s when I was Motors Product Manager at Crompton Parkinson’s Guiseley factory near Leeds. At that time, there were about six UK manufacturers of LV Industrial AC motors, and we were the second largest with about 15% of the market. Brook Motors, with whom we later merged to form Brook Crompton, was the market leader with about 25%. Others included GEC, BTH, Lawrence Scott and Newman – all names familiar to the older readers of Renew. Most of our production was in cage motors up to frame 315, but about 10% was in slipring motors mostly for the crane and hoist industry, where variable speed was important. These motors sold at a considerable premium to cage motors and in theory our profits from them should have been excellent. However, the theory hid a nasty cost, very high slipring and/or brush wear, often within the warranty period, on many but not all machines. Sometimes all three rings would wear rapidly, sometimes only one or two. Despite attempts to analyse the failure pattern, it seemed completely random. We tried alternative copper alloys for the rings and many different grades of brushes; some worked some of the time; none worked all the time. We knew from informal contacts with our competitors that they all experienced the same problems, but this was cold comfort. FINDING A SOLUTION It was against this background that a brief trade press article about a cage motor capable of speed variation by stator voltage control alone caught my interest. The motor had been invented by a Hungarian steelworks engineer, details were sketchy, but eventually, with the help of the Foreign Office and the Hungarian Embassy in London, we had enough information to justify a trip to Budapest for myself and a colleague. Arriving at the steelworks just outside Budapest, we witnessed the pipe cage motors working and spent time discussing them with their inventor, the works’ chief engineer. Whilst the motor certainly gave

Quarter 1 2021

Prof. David Walters OBE C.Eng., AEMT life member.

seamless variable speed by stator voltage control alone, I was immediately concerned by the high temperatures generated in the pipe cage itself. It is perhaps useful to recap on the pipe cage motor and its method of operation to understand this. In a pipe cage motor, the rotor bars are extended to more than twice their normal length, and a steel pipe is fitted over part of each bar extension. These pipes are then welded to steel rings and so form a single turn short-circuited tertiary winding. The rotor bars themselves are brazed to a normal cage endring outboard of the pipe cage. In operation, when the stator voltage is reduced, slip increases, rotor current increases at slip frequency and a corresponding current flows by transformer action in the pipe cage. This effectively adds impedance to the rotor. The amount of added impedance depends on rotor frequency, it is greatest at standstill (which gives the motor excellent starting characteristics) and automatically reduces as motor speed

“A brief trade press article about a cage motor capable of speed variation by stator voltage control alone caught my interest.”

www.theaemt.com

Motor Design 27 increases. It is this property which enables speed variation by changing only the stator voltage. The penalty for this clever speed control method is that the pipe cage becomes very hot during prolonged periods of low-speed running. In the Hungarian steelworks, they overcame the problem by cutting large holes in the sides of the cast iron stator frames over the pipe cage area and operating the motors as effectively open drip-proof machines. I knew this solution would be unacceptable to our UK and European customers. However, we were also developing the Series 7 steel frame motors which had much better heat transfer characteristics than cast iron framed motors, and I thought there might just be a possibility of using this property to build a successful tefc pipe cage motor. To ascertain this, we needed to build prototype motors using the basic design information from Hungary. The steelworks engineer would cheerfully have given us his designs, but Hungary was a communist country, and all negotiations had to be conducted through the Ministry of Industry who wanted ÂŁ100,000 for a manufacturing licence. I had no authority to spend this sort of money, nor did I want to, given my concerns about pipe cage heating. After some discussion, it was agreed that under a no-cost confidentiality agreement, they would give us the basic design data for one rating which we could

The pipe cage motor during the repair process.

use to design and build not-for-sale prototypes. We agreed to share the results of our prototype tests, and if these were successful, we would return to negotiate a full manufacturing licence. Meanwhile, the Hungarians would not grant a licence to any other manufacturer. Returning to England with the design data, I started discussions with our engineering and

> 28

28 Motor Design marketing teams. The engineers’ reaction varied from cautious enthusiasm to deep scepticism; the marketing team was more optimistic and produced a flyer to gauge potential customers’ reaction. Initially, the reaction from the crane and hoist industry was extremely positive. Customers were all exasperated by slipring problems. The only other alternative was an inverter drive, but inverters were then very expensive and not really trusted by the conservative crane and hoist users. Based on this, we ramped up our development programme, but in doing so, we rather lost sight of what was happening elsewhere in the market. This was to prove a costly mistake. Speed control was not a problem both on and off load; the heat generated in the pipe cage was a different matter. In initial prototypes, the heat from the pipe cage caused the stator winding temperature to rise beyond class H levels and bearing temperatures were also uncomfortably high. We tried many ways to improve cooling and reduce the motor’s temperature. A separately driven external fan did not work (although if we had had the type of fan subsequently developed for the ‘W’ Series motor, it might have done). Eventually, after many experiments, wafters welded to the pipe cage (figure 1) provided the answer. These wafters directed hot air from the pipe cage outwards to the stator cooling fins, but their design proved critical. Axially too long, they did not allow room for cooled air to return inwards and they behaved like a baffled fan; too short and they did not drive enough hot air outwards. Eventually, a satisfactory design was achieved, but it all took considerable time: time we were to find we did not have. Once we were satisfied that the design worked, our marketing team went back to our customers, but they received a very different response this time. In the time we had taken to get the pipe cage motor ready for market, some four major competitors who had backed inverter drives had moved quickly. Inverter costs had dropped, and more importantly, perceived reliability had improved enormously. Also, the marketplace was shrinking. Whilst some customers were still investing, many were fighting for survival. There were other potential markets for this type of motor such as crushers and some high inertia pumps, but our penetration of these was small compared to the crane and hoist market. Should we go ahead or not? It was a difficult decision. Eventually, the Board decided that we should proceed if we could obtain better terms with the Hungarians and our sales force gave priority to targeting new high torque variable speed applications. Whilst it was a Board decision, I was the project sponsor and it was clear who would get the blame for failure! The Hungarians were invited to Guiseley to view our finished product and production facilities and negotiate a final deal. They were treated as VIPs, something the Guiseley workforce excelled at, and we did secure a better deal. I cannot remember the Quarter 1 2021

Figure 1. Wafters directed hot air from the pipe cage.

exact terms, but it was a much lower down payment of about £30,000 plus a royalty on each motor sold. At the time, everyone seemed satisfied. Unfortunately, satisfaction did not last. The 1970s saw the start of the decline in traditional UK manufacturing, which continued for many years. Our second customer survey had already indicated a downturn, but the rate of decline took us by surprise. Some of our crane and hoist customers went out of business; those that were left were too busy fighting for survival to have time to consider anything new. Our penetration of the crusher and high inertia pump markets was disappointing and so, after about ten years, production of pipe cage motors ceased with less than 100 ever sold. I learned several valuable lessons from this. Firstly, the timing of new developments is crucial. Secondly, don’t get so interested in what you are doing that you fail to notice changes in the market. Thirdly, if a project is running over time and over budget, look at it carefully and do not hesitate to abandon it if you cannot see a way to get it back on track. The pipe cage motor was a disaster. Fortunately for my career, the much larger Series 7 project for which I was also responsible was a commercial success. I kept my job and lived to fight another day – with important lessons learned. TIMES-CIRCLE

“Fortunately for my career, the much larger Series 7 project for which I was also responsible was a commercial success.”

The journal article referenced at the beging of this feature can be accessed here: bit.ly/AEMTPCM www.theaemt.com

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30 Gears

Selecting the right gear Helical gears, bevel gears, parallel shaft gears and worm gears each account for 20% of the global industrial gear market. Despite the market dominance of these four gear types’, choosing a gear unit involves several design factors that depend on the application and operating conditions. Marek Lukaszczyk, European and Middle East Marketing Manager at WEG, introduces each gear type along with their defining features.

ears are among the most important industrial machinery elements – often used in conjunction with an electric motor. Their main purpose is to transmit the right amount of force to ensure a machine’s smooth running. The right gear type also allows deceleration without negatively impacting and stressing the mechanics. With all this to consider, how do endusers and machine builders know which gear type to use? HELICAL GEARS Helical gears are among the best-known gear types and are the most cost-effective. The teeth on a helical gear cut at an angle to the face of the gear. When two of the teeth start to engage, the contact is gradual — starting at one end of the tooth and maintaining contact as the gear rotates into full engagement. This gear unit has a longer design, mainly due to the way that the input and output axes are arranged in one line, meaning it is used where sufficient space is available. BEVEL GEARS If the axial installation space is limited, a bevel gear is typically used. Bevel gears are used on shafts with intersecting axes, and in some cases on shafts where axes do not intersect. These are used to change the direction of a shaft’s rotation. Among defining characteristics, bevel gears have teeth that are available in straight and spiral shapes. If the tooth profile is straight, then the two mating gears’ teeth come in sudden contact, imposing impact load on the tooth increasing vibration, noise, and wear rate. Teeth that are cut in the form of a spiral curve of the bevel gear blank can offer gradual contact. This minimises the detrimental effects of straight teeth and offers a longer gear life. PARALLEL SHAFT GEARS Parallel shaft gears are usually a multi-stage helical gear unit with parallel shafts, compromising an output shaft, which allows the gear to have easy accessibility to mount onto an existing shaft. The input and output shafts are offset and parallel to each other – as far as possible, compared to the conventional helical gear. Due to their design, their axel dimensions are compact and therefore good at saving space.

Quarter 1 2021

WEG’s WG20 range of geared motors

WORM GEARS Despite their low-efficiency level, worm gears are commonly used due to their wide range of applications and large ratios. By design, the worm gear consists of the worm and worm wheel. Just like the bevel gear, the input and output shafts are set at a right-angle position. Also, the number of teeth in the gear wheel corresponds to the number of gears in the worm. As multiple teeth of the wheel may be engaged simultaneously, high torques can be transmitted with this unit. Despite this, these gears can operate quietly due to the continuous sliding. Lubrication and additional cooling for high power outputs can result in better efficiency to combat friction on the worm’s flanks and on the wheel. Choosing a gear unit that works well with your application is a priority. These four main gear types can cover a wide range of operational functions within machinery, which can be modified and adapted based on bespoke needs. TIMES-CIRCLE

“Choosing a gear unit that works well with your application is a priority.”

www.weg.net

www.theaemt.com

32 Chemical Manufacturing

Plant optimisation for fertiliser manufacturers Paul Richardson, Service Center Manager at Sulzer’s Middlesbrough Service Center, looks at how revitalising existing rotating equipment can offer a cost-effective improvement in efficiency and reliability in the manufacturing process for fertilisers and other chemicals.

he equipment used to manufacture fertiliser in the chemical industry operates in a challenging environment, which can cause accelerated wear, reducing efficiency. The need to minimise capital expenditure means that replacement of machinery is not always a viable strategy. Rather than purchase new machinery, it can be more cost-effective to repair or modify existing plant equipment to extend its service life and make it more effective. PROACTIVE MAINTENANCE Generally, turbines, compressors and pumps are all subject to a variety of process-driven Stator rewinds extend the service lives of generators and large motors. conditions that contribute to corrosion, erosion, fouling and various other processrelated issues and can be managed through effective maintenance performance, allow remedial actions to be planned in during intervention. Rotating equipment that is in direct contact with regular maintenance windows. the process media and under constant attack presents a major The advance warning also ensures that all the necessary challenge. It is possible, however, to reduce degradation to a personnel and parts can be assembled to ensure the most efficient minimum by selecting the correct protective coating. use of time and any external resources that may be required. In the harshest of operating conditions, solid and/or liquid particles can pass through the equipment causing erosion. REDUCING DOWNTIME This can result in moderate to severe material loss and change Shutdown periods provide an extended opportunity to carry out aerodynamic efficiencies significantly. If left unattended, it can even maintenance as well as refurbishment and upgrade work. As affect the critical components’ strength and lead to premature such, they allow companies to improve the performance and blade/vane wear and failure in service. reliability of their equipment without affecting productivity. In situations where these circumstances exist, and their However, with many legacy pieces of equipment used in the effect needs to be minimised, specialised coatings can improve chemical manufacturing sector, some may no longer have support protection against fouling and erosion. These can be applied to from the OEMs, which means that alternative solutions need to both stationary and rotating blades as well as diaphragms, guide be found when repairs and upgrades are required. In other cases, vanes, rotors and impellers. The exact composition of these OEMs’ lead-times may not meet the needs of the business, and an coatings can be tailored to specific applications and will include independent maintenance provider could be the best solution. an aluminium base coat for corrosion protection as well as an In situations where the speed of response is essential to inorganic sealer and a specialist non-stick final layer. minimise downtime, taking advantage of an experienced maintenance provider’s services and expertise could be the best IMPROVING RELIABILITY solution. The most effective way of avoiding downtime caused by machinery breakdown is to employ preventative maintenance CASE STUDY: RAPID REWIND techniques, such as vibration monitoring, partial discharge analysis For example, a CO2 compressor powered by an ageing 1,300 and thermal imaging. These procedures can be very useful in kW high voltage motor had been identified for a complete rewind monitoring the overall condition of equipment and its remaining during a planned shutdown period. Sulzer identified the rewind lifetime. option as the most cost-effective solution to extend the motor’s Analysing trends can reveal issues that would otherwise not reliable service life without impacting productivity. be seen without disassembling the machine. Early indications The project called for a complete rewind to be delivered within of issues with bearings, coils, vane clearances or just general a 30-day window, which would require a fast turnaround. Since

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www.theaemt.com

Chemical Manufacturing 33 the OEM drawings were brazing, taping, varnishing not available, the coilsâ&#x20AC;&#x2122; and testing, before the dimensions could not be motor was returned to the established until the motor customer. arrived in the service centre to be dismantled. EXTENDING AND As part of the repair, the OPTIMISING LEGACY coil designers created the EQUIPMENT necessary drawings that Modern design and would also deliver improved manufacturing techniques, efficiency and performance as well as advanced alloys Replacement impellers can be manufactured quickly. for the refurbished motor. and specialised coatings, can In cases such as this, all have a beneficial effect where a motor has been in on the expected lifetime of service for a few decades, the coil insulation will be of a lower legacy equipment. In situations where either the lead time or the specification than the materials used today. scale of the expenditure for new equipment do not fit the businessâ&#x20AC;&#x2122; Using class F insulation, which is thinner than the original expectations, alternatives, such as retrofit projects, can deliver costmaterials, as well as improved processes, it is possible to effective solutions within reduced timeframes. increase the copper content of the coils to fill the gap that The key to implementing the most effective solution is the would otherwise be present. This additional copper also experience and expertise of the solution provider. Turnkey projects provides an incremental increase in efficiency and helps to are best delivered by those with all of the necessary skills and reduce the operating temperature of the coils. By improving resources in house. For the end-user, a single point of contact that efficiency, the design modification also helps to reduce annual provides a full range of project options and continuous updates on running costs. progress ensures the management of any upgrade is efficient and In all, 60 coils were designed, manufactured and installed cost-effective. TIMES-CIRCLE within the 30-day period. This was a complex operation, and the engineers worked through the night to complete the www.sulzer.com

34 Circular Economy

The Circular economy in action

The financial benefits of improving motor efficiency are generally well understood. However, the environmental advantages are less commonly considered. Chris Callander spoke with Peter Isberg, Digital Lead, Motion, at ABB Sweden, to better understand how following the circular economy’s principles can deliver enhanced financial gains and significant environmental benefits.

hen considering the challenge of reducing carbon dioxide (CO2) emissions, the role played by motors, and their potential to affect the situation, cannot be ignored. It has been widely reported that motors and electric drivetrains consume around 50% of global electricity, while electricity production accounts for 40% of global CO2 emissions. It is no surprise then that over the last 10 years minimum efficiency performance standards legislation has driven a revolution for electrical motors. Today motors are rated according to their efficiency class. In less than 20 years we have moved from using motors below IE1 to the current position where new motors have to reach a minimum of IE3, with many exceeding this. However, just 10 years ago, the requirement to use motors that met any legislated efficiency classes was voluntary. Because some motors can remain in operation for many years a large number of motors with low-efficiency ratings are still in use today. “I recently analysed a paper mill in Sweden which had an installed base of 1,800 motors,” explained Peter Isberg, Digital Lead, Motion, at ABB Sweden. “Of course, there were IE3 and IE2 motors, but around half of the motors were IE1 or less, particularly among the large quantities of small to medium-sized motors.” The analysis Peter carried out showed that at this single site, upgrading the inefficient motors would have the potential to save a minimum of 9 GWh of electricity per year. Clearly, this would amount to a significant cost saving for the paper mill. Electrical motors and drive systems are estimated to use 33 TWh of Swedish industry’s total annual electrical energy consumption of 51 TWh. Taking the paper mill’s situation a stage further, if all the inefficient motors in Swedish industry were upgraded, and the use of variable speed drives was increased to further maximise their efficiency, Peter believes, conservatively, that the potential energy savings could be more than 4TWh per year. That is more than 8% of Swedish industry’s total annual electricity consumption and enough energy to charge 2.1 million electric cars that travel 12,000km per year each. Alongside the cost savings for industry, this would also result in a notable reduction in CO2 emissions. THE CIRCULAR APPROACH But is replacing large numbers of motors which are still working well contrary to the circular economy’s aspiration to maximise the use of resources? Peter

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says not. “Some 97% of the impact a motor has on its environment comes from the energy used in its lifetime,” added Peter. “So, if you can minimise the energy losses from a motor in use, then the payback in terms of CO2 reduction can be relatively short, considering the initial CO2 debt when manufacturing the motor” In practice, Peter Isberg, Digital Lead, Motion, at ABB Sweden replacing an old 110kW IE1 motor that runs for 8,500 hours per year with a new IE4 equivalent would have a CO2 payback time of around 120 days in the UK*, and this product will last for at least 30 years, so the environmental and cost benefit of replacing inefficient motors is clear. Of course, the extent of the gains will depend on how the motors being replaced are disposed of. There are two choices here. The products can be placed in landfill or placed at the end of the circular loop and used to make new products. Following the circular option and recycling is the better option for the environment, and there are key reasons for this. Take the materials used to make motors as an example. To produce the metals, you have to start by mining oxides which requires large amounts of energy and water. Then converting the oxides into metals also takes large amounts of energy. > 36 “When you compare producing virgin metals with

“Some 97% of the impact a motor has on its environment comes from the energy used in its lifetime.”

www.theaemt.com

+44 (0) 1952 208 730 www.wes.uk.com

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36 Circular Economy

recycling existing materials, the energy savings are significant,” continued Peter. “When considering iron, there is a 75% energy saving between creating iron from mineral and re-melting existing material, for copper that figure rises to 85% and aluminium is higher still at 95%. “Using this model, when analysing the recovery of ten tonnes of outdated motors in Sweden – including the impact of transporting them from a customer to the recycling centre – savings equivalent to 31 tonnes of CO2 can be made, along with 301kWh of energy and 91,000m3 of water.” And as the circle closes, and these recycled materials are used to produce the replacement higher efficiency motors, the CO2 payback for the new products reduces, offering further benefits. So, to gain the maximum environmental benefit, if the installed base is being replaced to gain the energy efficiencies, the materials need to be reused under the circular economy model. CIRCULAR ECONOMY IN ACTION In Sweden, ABB has signed a long-term cooperation agreement with Stena Recycling in a pilot designed to deliver this circular benefit. The partnership has been developed to ensure that the efficiency advances gained by the installation of new products are backed up by the effective recycling of the waste products. In the company’s circular model, ABB’s starting point is to use its digital monitoring solutions to understand the power and energy usage of a customer’s assets. After the energy evaluation, the customer then decides on a possible energy upgrade by phasing out old inefficient motors. Stena Recycling then collects the redundant motors to ensure the effective recycling of the old assets’ materials. The companies working with this model receive a discount on their new motors based on the Quarter 1 2021

decommissioned motors’ scrap value and get environmental reports demonstrating how much energy, water and CO2 the recycling initiative has saved. There are wider environmental benefits too. Recycling also ensures that obsolete products are not simply transported to areas with less stringent environmental standards. At the same time, proper controls over the recycling process ensure that the scrap material is not transported to countries that do not have the knowledge or infrastructure to recycle it in an environmentally-friendly way, which would result in an enhanced negative effect on the environment.

“If the installed base is being replaced to gain the energy efficiencies, the materials need to be reused under the circular economy model.”

CONCLUSION Low-efficiency and /or wrongly-dimensioned motors have a negative environmental impact and add cost to energy bills. Simply replacing them can bring significant cost savings and lead to reductions in CO2 emissions. If this is done with the right approach to collecting the obsolete motors and reusing their materials, the environmental impact is lowered further, and the recovered metals can be used in new products – the essence of the circular economy. TIMES-CIRCLE www.abb.co.uk/energy * Based on a carbon footprint for UK energy generation of 0.18 kg of CO2 per kWh of electricity. Source: Department of Business Energy and Industrial Strategy, ‘2018 UK Greenhouse Gas Emissions, Provisional Figures’.

www.theaemt.com

38 Circular Economy

circular economy: What does it mean? The circular economy has been talked about for a number of years now, but what does it mean? Renew introduces the concept.

n recent years, an alternative to the traditional linear economy approach of ‘make-use-dispose’ has gained prominence, in the form of the circular economy. While the concept is by no means new – having first started to gain momentum in the late 1970’s – an increasing emphasis on the environment and climate change has more clearly highlighted the need for change. While the circular economy will mean different things to different industry sectors, as a concept it does appear to still be widely misunderstood and this needs to change if the environment and businesses are to reap the benefits it can offer. The Ellen MacArthur Foundation website (www.ellenmacarthurfoundation. org) offers a good source of information for those wishing to gain a better understanding of circular economy concepts. According to the Foundation, the circular economy is an economic framework that focusses on carefully managing resources so that nothing is wasted. The aim is for products and materials to be kept in use – reused, remanufactured and recycled continuously – to achieve maximum value from them. This restorative and regenerative approach aims to create a closed-loop supply chain that designs out waste. Because the circular economy maximises economic, natural and social capital, it should also be viewed as a valuable tool for empowering businesses, helping them successfully tackle environmental priorities, drive performance and stimulate economic growth. A SYSTEMIC SHIFT For the industrial sector the circular economy has often focussed heavily on reducing energy and carbon emissions. However, according to a Bureau Veritas report, transitioning to a circular economy should look much further than this. It necessitates a systemic shift in the way new products are designed, how their

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input materials are sourced, how they are manufactured and how sub-products are reused and how wastes are recycled. So, transitioning to a true circular economy model demands control of all materials and processes used in production. Offering an example, Bureau Veritas cites the sale of a T-shirt in a circular economy business model – it requires responsible sourcing of the cotton and chemicals used, and the working conditions in the factory used to manufacture it; control of the energy used in manufacturing, transportation and distribution; and a process for collecting, breaking down and recycling the T-shirt post-use. A project being undertaken in China offers a good real-life example of the circular economy in action. The Chinese domestic automotive industry has boomed since 2000 and, in 2018 it had a stock of 310 million cars. Assuming an average life span of 10 years, it was estimated that 10 million cars would reach end-of-life annually by 2020. This opened up huge market potential for automotive parts remanufacturing businesses and one company to see the potential was Huadu Worldwide Transmission. The company has partnered with a retail franchise to collect used vehicle parts and remanufacture them into as-new certified spare parts. Remanufacturing conserves the value of machine products and components, returning them to a good condition so they can be used again and again. It offers material and energy savings while providing customers with high quality affordable spare parts.

A CRITICAL ROLE “Having a great deal of experience as repairers and traders of rotating electrical machinery, Association of Electrical and Mechanical Trades (AEMT) members obviously have a critical role to play in circular economy initiatives,” explained Thomas Marks, Secretary of the AEMT. “As repairers, AEMT members can help extend the lifespan of machinery. They can monitor machinery to ensure it continues to run efficiently and can maximise its lifespan. At the end of life, AEMT members are able to recommend suitable replacements – possibly with higher efficiencies – and are also able to break down old machines to recover reusable parts and materials.” Thomas says that users of rotating electrical machinery who are interested in adopting a circular economy approach, should talk to AEMT members, who will be able to offer help and advice. In conclusion, he said: “By participating in circular economy principles, AEMT members are able to help make better use of the world’s natural resources and can help customers to reduce their carbon footprint and in doing so, reduce costs, reduce waste, and increase productivity.” TIMES-CIRCLE

“AEMT members can help customers reduce their carbon footprint, reduce costs, reduce waste, and increase productivity”

www.theaemt.com

Visit www.theaemt.com Call +44 (0)1904 674 897

Is your machinery repaired to standard? IEC BS or EN 60034-23:2019 The new international standard to ensure the efficiency of rotating electrical machinery is maintained after being repaired, overhauled, or reclaimed. 9 A more sustainable future can be achieved if service centres follow the best practices outlined in this standard. 9 Carbon emissions can be reduced when rotating electrical machinery is put back into service, rather than scrapped and replaced. 9 The cost-savings of a good repair over a poor repair can save disruptions in production down the line.

5 Questions to ask your AEMT Service Centre: Should I repair or replace the equipment? Your service centre should present you with the facts so you can make an informed decision on whether the equipment should be repaired, or replaced with a more efficient machine. Is the efficiency maintained after service? Your service centre should be able to maintain the efficiency of the machine or improve it after servicing. What is the end-of-life recycling practise? To ensure a sustainable future, you should confirm if your equipment is split into its component parts for recycling, so as not to sell it onto the secondhand market. Do you follow best-practise guidelines? Service centres must use the best practices outlined in the international 60034-23 standard to ensure all work and procedures are carried out correctly What quality system do you have in place? Your service centre should have a suitable quality system in place, such as ISO 9001 to ensure your project is managed properly.

Promoting Engineering Excellence

40 Circular Economy

The repair industry’s role in a circular economy Dr Hugh Falkner, Innovation Lead on the BEIS Industrial Strategy Challenge Fund Transforming Foundation Industries Challenge at Innovate UK, looks at how the rotating equipment repair industry fits the aims of a circular economy.

o understand more about what the circular economy is, and why it is relevant to the motor market, we need to look back at the history of motor efficiency regulation. What emerges is an unexpected story of how the motor repair industry turns out to be a leading example of how the circular economy can work in practice, and further the business opportunities that this presents. In Europe, the Minimum Energy Performance Standards (MEPS) are called the Eco-design regulations, but historically, when you looked carefully at the methods for assessing just how far it is justifiable to push legislation, the Eco bit was not quite complete. This is because while the financial lifetime costs of ownership to the end-user and the environmental emissions to water and air are considered, it is now recognised that the Ecodesign analysis doesn’t adequately address the important question of product durability and the need to reduce material consumption. THE CIRCULAR ECONOMY This is where the circular economy comes in. It aims to ‘minimise waste through reusing, repairing, refurbishing and recycling existing materials and products’, ideas which look to be helpful in achieving the right energy versus material balance in any future Eco-design regulations impacting motors. This brings more focus on material use, which compliments the traditional focus on product energy consumption that the motor repair sector has supported. It is fundamentally different from the linear take-makedispose economy that underpins most material use. In practice, reducing global material consumption might mean making things that use less material, last longer, use fewer premium materials, or simply are easier to repair or recycle. As an example, Figure 1 shows how a bottle might travel around several loops between first use and eventual landfill. In one sense, all that we have achieved is to extend the time between a product’s raw materials being dug out of one hole, used, and then put back into another hole. But it does reduce the amount of raw material that needs extracting and processing, and so conserves resources for future generations. This resource life extension is the best that can be hoped for from most manmade systems. This is what industrial equipment repairers have always done – in fact it’s hard to think of any other sector placed so centrally to take their part in the circular economy. In terms of the above diagram, the repair sector sits in the second

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Figure 1. The Circular Economy (image credit to the European Commission)

smallest loop, with tighter loops being the most efficient in terms of minimising waste. Governments recognise the benefits of the circular economy through the following: • More local and higher-skilled jobs. • Fewer imports, and so improved balance of payments. • Exports of remanufactured parts. • Less exposure to fluctuating material prices or material scarcity. As we will see, the motor repair sector is an excellent example of what is possible and can demonstrate the value of these benefits to the economy. However, it will be important to moderate the circular economy ambition to what is best overall for both the motor user and the environment. In a 2016 presentation, the European Committee of Manufacturers of Electrical Machines and Power Electronics (CEMEP) was similarly positive about the circular economy but equally cautious that any new regulation must take account of the advances in motor technology, and maintain a balance between energy efficiency and material use considerations. THE REPAIR INDUSTRY: AN INDUSTRY LEADER In a report by the Ellen MacArthur Foundation on how Scotland might benefit from the circular economy, six

> 42 www.theaemt.com

To give special thanks and recognition to the repair and service centres underpinning our health service, infrastructure and manufacturing sectors throughout the COVID-19 crisis, we have decided to postpone the awards until November 2021.

New date for the diary... Thursday, November 18th 2021 Doubletree by Hilton Hotel, Coventry The awards are a global celebration of business and professional excellence. They recognise the achievements of both individuals and companies manufacturing, distributing, maintaining and repairing industrial machinery such as electric motors, drives, pumps, fans, gearboxes, generators, transformers, switchgear and ancillary equipment. There are 6 categories to choose from including: Product of the Year, Project of the Year, Supplier of the Year, Service Centre of the Year, Contribution to Skills & Training and the Rising Star Award. Make sure you enter now to be recognised as a leader in your industry.

Endorsements:

“Westin Drives were thrilled and delighted to receive the Service Centre of the Year Award. It was a great pleasure to be recognised for the effort we have expended in establishing our new facility.”

“The awards are a great way to recognise achievements in the industry. We were honoured to collect the Project of the Year Award, and great to catch up with everyone. Thank you to AEMT for another fantastic event.”

Michael Limb Westin Drives

Shaun Sutton Central Group

Enter Now: www.aemtawards.com

...with thanks to previous sponsors:

Deadline: Fri, 10th September 2021

42 Circular Economy diagnostics were given to show the different aspects of the circular economy as they might appear in practice. When the motor repair industry is tested against the same set of diagnostics, it is clear how it can call itself part of the circular economy: 1. Circular product design and innovation: Product redesign promotes standardisation and modularisation so that they can be easily disassembled, and the value of resources is retained within tight reverse circles. A commonality of designs which means that it is possible to keep replacing motors from many different suppliers, without carrying large and expensive inventories of spares. • The capability to manufacture spare components makes it possible to keep obsolete or unusual models working. • The careful sorting of scrap materials helps to maximise sale value. • Valuable materials like copper and permanent magnets are extracted from DC brushless motors for reuse. 2. Product reuse, repair and remanufacturing: Ensuring longevity of use requires manufacturers to enable reuse and remanufacture products in the system for as long as possible. This tips the balance away from ‘production’ to ‘maintenance’. It also demands new competences to ensure the effective collection and sorting of products along reverse cycles. • Repair of products is what the industry does. • The motor repair industry has an underlying philosophy of stretching life and reliability, avoiding obsolescence. • Many repairers offer condition monitoring services to help optimise maintenance interventions and reduce unplanned downtime. 3. Innovative business models: Creating value-adding business propositions around better-designed, longlasting products. Disruptive business opportunities based on performance (e.g. shared ownership, hire and leasing and pay-for-use models) can compete successfully against low-cost, ownership-based linear models. They also enable much closer interaction with customers (‘users’) and increased personalisation and customisation. • ‘Keep you running services’ are already offered that incentivise the service provider to ensure reliable operation, through pre-emptive monitoring, repair and replacement programmes. This is a classic indicator of the circular economy in practice. • Advice is readily shared on reasons for failure to enable operational changes to be made to extend lifetimes. • Making small changes to motor design, such as winding and insulation design, helps to better match real-life operating conditions. • There is a wider use of low-cost condition monitoring sensors that will indicate when service is required, allowing intervention before failure. 4. Renewable energy and materials substitution: While circular systems help optimise efficient resource use, they also avoid unnecessary exploitation of resources Quarter 1 2021

in the first place. Switching from fossil fuels to renewable energy, and substituting non-renewable and scarce resources for renewable alternatives are important aspects. • The sector is not involved in the design. However, it is careful to keep products as close as possible to their original design by avoiding unnecessary substitution of inferior parts. 5. Effective supply chain and cross-sectoral collaboration: A circular economy demands changes at all levels of the economy to drive collaborative solutions. Policy alignment, incentives, industry standards, access to finance, infrastructure and education are all vital elements. • The motor repair sector has a highly developed infrastructure that provides local 24hour service. • Rapid turnaround times reduce the financial and environmental costs of motor failures. • Suppliers of new motors work handin-hand with motor repairers – it’s a symbiotic relationship where both have a shared long-term incentive of doing what is best for the customer. • Testing iron and no-load losses as a useful proxy to formal efficiency measurement gives the security that the repaired motor is fit for service. • The AEMT, with its counterpart EASA, has led the way on defining best practice in repair, giving user confidence in the conforming repairers. 6. Reuse of waste, heat and energy: Treating otherwise wasted outputs of business processes as the inputs for new processes reduces costs, boosts productivity and opens up new commercial opportunities. • Here, the repair sector is not involved in the use phase of motors.

“Rapid turnaround times reduce the financial and environmental costs of motor failures.”

CONCLUSION So, from this initial look at the circular economy, it is clear how the industrial repair sector emerges ahead of the pack in demonstrating how the circular economy works in practice. And for end-users, engaging with the repair sector to bring the principles of a circular economy into their business brings not only financial benefits from reduced costs and improved reliability but also other benefits of taking a green business approach. Customers are placing more emphasis on their supplier’s green credentials; younger generations entering the workforce are far more conscious of potential employers’ social responsibility; legislation is increasingly focussing on the environmental impacts of all aspects of business. TIMES-CIRCLE This article has been adapted from a piece first written by Hugh Falkner in 2018 when he was working as an independent consultant for the AEMT. www.theaemt.com

Coiltech International Coil&Winding Exhibition Pordenone / Italy 23-24 September 2020

Ulm / Germany 17-18 March 2021

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Two Exhibitions in the center of the market Leading companies of the Coil Winding Industry

Free entrance and free parking for registered visitors

Coiltech exhibitors offer the complete product range of the Coil&Winding Industry.Talk to suppliers and get updated twice a year to stay ahead of the market.

Go to www.visitcoiltech.com to sign up and: • download your free entrance ticket, • download the free parking voucher, • book a hotel room at discounted rates, • book the shuttle service.

Visitor Breakdown The #1 conference in the Coil & winding sector WMC

At the World Magnetic Conference, developers from industry and academia present their latest innovations and current research to make electrical machines and their production more efficient.

Topics In cooperation with:

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T1 T2 T3 T4 T5 T6 T7 T8

E-mobility Advanced integrated powertrains for electric vehicles Electric motor industries Special electrical machines and actuators Measurements and testing of electric machines Materials Manufacturing technologies Software

33.88%

Head of production Product and quality management

24.38% 13.02%

R&D Purchasing and sourcing staff

19.53%

President/CEO/Vice president

9.28% 15.65%

Owner/co-owner Other top management

1.80% 12.88%

Sales and marketing Other staff

3.74%

Source: information obtained by the Coiltech visitor marketing team on the base of personal phone interviews or encounters with visitors of Coiltech, and other research.

At the show

Machinery and materials for transformers and motors production

Floor plan always available online

Coiltech is the only Coil Winding exhibition that qualifies for UFI Approval.

Coiltech staff does its best to make all relevant information available on their website, however, they are always glad to give personal support on the phone or via email. Do not hesitate to contact them: +39 02 87 23 40 50 or coiltech@quickfairs.net.

44 Repair Service Directory GES Group SERVICES INCLUDE • Pumps • Motors • Gearboxes • Servo Motors • Spindle Motors

R.E. Field Services Ltd • • • • •

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EUROSERV LIMITED SERVICES INCLUDE • Pumps • Motors • Gearboxes • Fans • Servo Motors

SERVICES INCLUDE • • • • •

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0191 519 3344 martin.mcguffie@euroservltd.net www.euroservltd.net

Fyfe Wilson Ltd APPROVED BY NIDEC SIEMENS MAVILOR BOSCH TECMOTORS SCHNEIDER

Arfon Engineering SERVICES INCLUDE • Laser Alignment • Pumps • Condition Monitoring • Motors • Marine Repairs • Gearboxes • Thermography • Fans • Switchgear • Inverter Drives 0151 334 6808 (Wirral) 01286 675 853 (Caernarfon) sales@arfonrewinds.com www.arfonrewinds.com

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01279 653333 engineer@fyfewilson.co.uk www.fyfewilson.co.uk

EXCLUSIVE TO AEMT MEMBERS REACH THOUSANDS OF USERS OF ELECTROMECHANICAL EQUIPMENT WITH A LISTING IN THE REPAIR SERVICE DIRECTORY

ADYARD ABU DHABI LLC SERVICES INCLUDE • Motors • Fans • Instruments • Generators • Rewinds

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BOOK ONLINE AT WWW.BIT.LY/REPAIRDIRECTORY OR CONTACT ANDREW CASTLE ANDREW@RENEW-MAG.COM +44 (0)7785 290034

Never miss an issue of To continue to receive your free copy of Renew, in print or online, register at: renew-mag.com Stay up to date with the latest products, technical insights, news and innovations, for everyone responsible for maintaining the safe and efficient operation of electrical and mechanical plant and equipment.

r new FOR THE MAINT

ENANC E, REPAIR

AND REPLAC

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NG MACHI NERY

The journa l f rom

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FOCUS ON: The Circular Eco

nomy

The repair ind ustry's in a circular eco role nomy You must take for Ex-rated responsibility motor repairs Indus try News

Innov ations

Appli cation s

Exper t Opini

FEATURE 45 45 repair service directory Neu-Servo Repairs SERVICES INCLUDE • • • • •

Pumps Motors Gearboxes Fans Servo Motors

• • • • •

Spindle Motors Inverter Drives Thermography Mechanical Rewinds

APPROVED BY Siemens

01527 575888 info@neuservo.com www.neuservo.com

Wilson Fans Pumps and Motors SERVICES INCLUDE • Pumps • Motors • Fans • Laser Alignment • Panel Building

The coloured dots in the listings indicate areas covered, please call or email repairers to confirm exact details.

Inverter Drives Balancing Electrical Mechanical Rewinds

020 7228 3343 carly@wilsonelectric.co.uk www.wilsonelectric.co.uk

ADC Electrical Ltd

Houghton International SERVICES INCLUDE • Electric motors • Generators • Pumps • Gearboxes • Transformers

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• Condition Monitoring

• Electro-mechanical services • Onsite testing and analysis • Ex repairs - IECEx approved

APPROVED BY Baker Hughes

SERVICES INCLUDE • Pumps • Motors • Fans • Transformers • Balancing

• • • • •

Condition Monitoring Marine Repairs Mechanical Rewinds Ex Hazardous Area

0191 234 3000 info@houghton-international.com www.houghton-international.com

0191 4165222 info@adc-electrical.co.uk www.adc-electrical.co.uk

Mechanica Utilities Ltd

Fletcher Moorland Ltd

SERVICES INCLUDE • Pumps • Motors • Gearboxes • Laser Alignment • Condition Monitoring

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Marine Repairs Vibration Electrical Mechanical Generators

APPROVED BY

SPP Pumps Belzona Coatings Hydromarque Pumps Brown Europe Gearboxes

SERVICES INCLUDE • • • • •

Pumps Motors Gearboxes Fans Laser Alignment

• • • • •

Servo Motors Inverter Drives Condition Monitoring Rewinds Ex Motor Repair

01304 206690 sales@mechanica-utilities.com www.mechanica-utilities.com

01782 411021 hello@fletchermoorland.co.uk www.fletchermoorland.co.uk

Rotamec Engineering Solutions

Invincible Electrical Eng Co

SERVICES INCLUDE • Pumps • Motors • Gearboxes • Fans • Balancing

SERVICES INCLUDE • • • • •

Marine Repairs Electrical Mechanical Generators Rewinds

01934 743165 paul.pearce@rotamec.co.uk www.rotamec.com

APPROVED BY Lowara Grundfos Motovario Lenze TEC NIDEC Marelli

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Pumps Motors Gearboxes Fans Spindle Motors

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Inverter Drives Electrical Mechanical Rewinds

01384 261307 phil@invinciblerewinds.co.uk www.invinciblerewinds.co.uk

To feature in the Repair Service Directory, contact Andrew Castle: PHONE +44 (0)7785 290034 envelope andrew@renew-mag.com

APPROVED BY ABB

FEATURE 46 Opinion

You must take responsibility for Ex-rated motor repairs Karl Metcalfe, Technical Support for the AEMT, looks at the knowledge and responsibilities that are expected when it comes to managing electric motors in zoned areas.

perating equipment in potentially explosive atmospheres comes with a certain amount of responsibility, not least to use correctly designed components that have the features necessary for the environment. When maintenance and repairs are required, operators must understand what is expected of them to ensure continued safety and reliability. Potentially explosive atmospheres are commonly encountered in many industrial sectors including oil & gas, pharmaceuticals, water treatment and mining, as well as the food and beverage industry. Specific areas that may be affected are zoned according to the potential risks, and any electrical equipment in these areas must be designed and manufactured to specific standards. INTERNATIONAL STANDARDS Any business that has identified zoned areas within its processes is expected to adhere to several international and regional standards, including BS EN IEC 6007910:2019. This states the responsibilities of operators, managers and repairers to ensure that all equipment is properly maintained and fit for continued service. Equipment that is designed for Ex-zoned areas uses a variety of protection concepts to ensure safe operation. Different concepts can be used in similarly zoned areas, and site maintenance engineers must understand these concepts so that they do not compromise the equipment. For example, periodic inspections and maintenance checks involving the removal of a terminal box lid from an Ex-rated machine may discover corrosion. At this point, it may be necessary to check the flamepath gaps and establish if they are still sufficient for the zoned area in which the equipment is operating. REPAIR ESSENTIALS When the time comes for a repair or overhaul, Ex equipment needs to be sent to a qualified repairer to complete the work. The international standard emphasises that it is the operator’s responsibility to ensure that those with sufficient facilities and competencies deliver any maintenance work. Moreover, each piece of equipment should have its own dossier containing all the required paperwork, including details of any previous repairs and inspections. A copy of this should accompany the equipment to any approved service centre, ensuring that all available information is on-hand for the repair process. Quarter 1 2021

A properly qualified repair centre will ask for this information, and they will also provide all the evidence required to determine if it is qualified to deliver the repair. It is important to stress that the equipment owner is responsible for establishing this fact and retaining this evidence in the equipment dossier. MINIMISING RISKS Following the guidelines and taking on the responsibilities of operating ex-rated equipment goes a long way to minimising the risks associated with zoned areas, keeping both employees and equipment safe. Conversely, the implications of failing to adhere to the international standard could have significant consequences, hopefully not for any personnel, but the damage to a business can be substantial. If an incident involving equipment in a zoned area occurred – assuming no injuries were sustained – the first step to recovering the process would involve the insurance company. The investigation into the cause of the incident will start with the information dossier for all the equipment in the affected area, especially any component that is judged to be the root cause. If any repairs have been completed by service centres that did not comply with the international standard, this could be seen as a failure to meet the insurance policy’s terms. As such, this could have major implications for funding any repairs and increase the cost of future insurance policies. IMPROVING KNOWLEDGE Both managers and maintenance staff involved with Ex-rated equipment are encouraged to broaden their knowledge of this specialised area and attend training courses appropriate for their role. This will enable the business to implement the necessary operational and managerial processes to comply with the international standard. To provide further assistance, the AEMT has an Ex register (www.ex-register.com) which lists all members that hold various certifications including ISO 9001, and AEMT Ex Assessment Certificates. IECEx service centres are independently audited by a notifying body and maintain their 3-year refresher training to achieve certified accreditation. TIMES-CIRCLE www.theaemt.com

ALPHA E

CTRICS E L

Excellence through expertise Alpha Electrics is an industry-leading provider of specialist industrial electric motor and drive services, committed to ensuring your business keeps moving. As a family-owned business run on family-based values, we are proud of the reputation and client base that we have developed over the last 30 years. Our clients appreciate our high levels of customer service, transparency and sincere desire to always find the right solution to their needs. We are committed to excellence in everything we do and relish working in partnership with our customers.

Our Services include:

Authorised distributors for...

Supply New Motors & Drives Commerical Building Services Servo & Spindle Motor Repair Industrial Electric Motor Rewinds Mechanical Engineering Services Motion Control Solutions

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BUY ONLINE: www.alphaelectrics.com

24-7 BREAKDOWN SERVICE: 0116 276 8686

Custom Electric Drive Solutions Worldwide

Whenever project-related manufacturing and fast delivery is needed Motors up to 15 MW and 13.8 kV • • • • •

Low voltage slip-ring and squirrel cage motors up to 3,000 kW Medium voltage slip-ring and squirrel cage motors up to 15,000 kW Direct current motors up to 2,000 kW Frequency converter-proof drives In-house load test facility up to 13.800 V, 2.300 kVA, 120 Hz

More than 20.000 motors available from stock!

Customized special designs • • • •

Custom designs for special applications and operating conditions Optimized motor design for higher efficiency Mechanically and electrically interchangeable motors Commissioning worldwide

24/7 emergency service

Certified Management System

info@menzel-motors.com www.menzel-motors.com

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Renew Magazine - Quarter 1, 2021. Circular Economy Focus

Articles inside

GES extends Nidec partnership

Project Updates

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You must take responsibility for Ex-rated motor repairs

The repair industry’s role in a circular economy

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