Renew Magazine - Quarter 1, 2022. Circular Economy Focus by touchwavegc

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

The journal f rom

Quarter 1 2022

FOCUS ON:

Circular Economy

A licence to print... coils

A common root cause of insulation failure

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.

n each issue of Renew, we highlight projects carried out by members of the AEMT. This issue is no exception, and we have a look at three projects shortlisted for the AEMT Awards. The winning entry was a project that developed a method to test, repair and refurbish circuit boards used by robotic warehouse pickers. Since its development, some 600 PCBs have been refurbished rather than being thrown away as they were previously. Also recognised at the awards was a project to rewind wind generator motors to generate power at lower wind speeds. While a third project covered the development of repair protocols and training materials for use by locomotive repairers in Egypt – saving significant amounts of money while improving safety and reliability. Beyond the award entries, in this issue we also discover how an association member was able to react quickly when the only air compressor drive used to produce oxygen for Cuba's hospitals failed. And in past issues we have covered many more projects with similarly impactful outcomes. Why am I highlighting this? Well, I often wonder if the fantastic work carried out by the electromechanical repair sector is genuinely appreciated. The businesses that make up the association's membership make a huge impact that is not always recognised. Many members will work flat out to ensure critical systems and vital infrastructure remain operational – even through pandemics. And what is often less well-understood is the repair sector's environmental impact. The repair and refurbishment of assets supports a circular economy in terms of maximising their life, while careful disposal of waste materials ensures important resources can be reused. Plus, there are circumstances where equipment can be made more efficient – reducing energy use. That is why I plan to work with the Renew editorial team to share more of the benefits our repair sector delivers in coming issues. If there is something you would like to see covered, please email the editor at chris@renew-mag.com. Shaun Sutton, President, AEMT

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

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.

NEWS

www.theaemt.com

Heat: A common root cause of insulation failure

Industry news

A licence to print... Coils

AEMT news

Dielectric testing explained

AEMT Awards update

Product news

Project updates

Focus on Circular Economy 34

It pays to find a happy home for used kit

Tackling the world’s e-waste problem

features

Hazardous Areas - Is your ex equipment repairer up to the task?

Did you know? 42

The humble cable tie goes where no one has gone before Quarter 1 2022

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

HV assets offered as power-as-a-service IN COLLABORATION WITH Vattenfall, Bowers Electricals can now provide high voltage (HV) electrical assets via Vattenfall's Power-as-a-Service offer, reducing upfront investment requirements and providing ongoing maintenance and support. Power-as-a-Service enables businesses to benefit from the latest technologies, upgrades, and innovations without additional CAPEX investment. Modern energy-efficient technology and

active network management can help reduce costs while delivering carbon savings. The model sees Bowers Electricals supplying new assets and Vattenfall owning and operating them – taking full responsibility for IOM (installation, operating and maintenance), compliance (safety, technical and environment), planning and management. Vattenfall adopts the assets for an initial 10-year term.

The offer applies to any sector and any size business where the client owns a HV private network, which can include heavy industry, data centres, process and manufacturing, healthcare, mining and aggregates, and local authorities. Vattenfall can adopt all HV assets downstream of the distribution network operator (DNO) equipment; primary switchgear, secondary ring main units (RMU), transformer's, cables, and HV generators.

FLEET RENEWAL MAINTENANCE PROGRAM FOR TYNE & WEAR METRO

SWISS TRAIN MANUFACTURER Stadler has signed a contract with electro-mechanical repair specialist, Houghton International, to extend maintenance support for the Tyne and Wear Metro until October 2023. Houghton International will work with Stadler to deliver an accelerated maintenance plan, increasing contracted volumes to extend the life of the current fleet of trains until the transition to a new fleet of trains from 2023. The scope of the agreement covers both planned maintenance and emergency repairs and encompasses assets including traction motors, motor alternator sets and compressor motors. The renewal of the maintenance contract follows the announcement that Stadler will be providing Nexus Metro with a complete fleet renewal and a new depot by 2025. Stadler assumed Quarter 1 2022

responsibility from Nexus for servicing and maintenance of the Metro's fleet in October 2020. Commenting on the project, Chris Robson, Sales Director at Houghton International, said: "Having worked closely with Nexus and Tyne and Wear Metro for almost 15 years, it is great to start a new journey with Stadler and continue to support the existing vehicles until their end of life. "It is satisfying to know that Stadler will continue to trust Houghton International to support the ongoing maintenance of traction motors, as well as other components, as they condense the maintenance programme to coincide with the depot demolition and new depot build. Our expertise in traction motors and other light rail assets means Houghton International is well placed to continue to provide support.

Marc Robson, fleet manager at Stadler, said: "Houghton International is already working with us to support our traction motor maintenance programme, so when we required further rotating machinery support for our accelerated maintenance plan, they were a natural choice. "Their commitment and willingness to serve Stadler and the community as a whole has always stood out, and communication at all levels has been consistently excellent. "Houghton International has proved quick to mobilise and provides high-quality overhauls with a speedy turnaround. The fact that they are based locally means that together, we can work nimbly to resolve any issues that may arise. We look forward to our continued close working as we move from the old fleet to the new one." www.theaemt.com

Industry NEWS 7

SULZER OPENS NEW BIRMINGHAM SERVICE CENTRE FOLLOWING THE RECENT completion of Sulzer's purpose-built service centre in Birmingham, the facility was officially opened by His Royal Highness, The Duke of Kent, on October 27, 2021. The investment in this state-of-the-art service centre represents Sulzer's ongoing commitment to delivering the next generation of service excellence and provides 24/7 support to customers around the world. Located on the Birmingham Business Park, the latest enhancement to Sulzer's network of service centres has been specifically designed to optimise workflows. It ensures customers receive best-in-class service in terms of quality and speed of repair. Following the official opening, guests were given a guided tour of the new facilities and shown how their businesses will benefit from the latest in advanced repair technologies provided by Sulzer. Chris Powles, Head of ElectroMechanical Services - EMEA, commented: "We have created a centre of excellence that operates on

EDWIN JAMES JOINS THE 5% CLUB EDWIN JAMES companies, Parker, Musk and Peak, have been accepted into The 5% Club, a dynamic movement of employers committed to 'earn and learn' in order to build and develop the workforce they need as part of a socially mobile, thriving and cohesive nation. Joining The 5% Club demonstrates a commitment to the UK's growth agenda and acknowledges the chronic skills shortage and youth unemployment that the UK faces. It also recognises the importance of developing people – making a public declaration about the commitment to reaching 5% of the workforce as apprentices and graduates within the next five years. www.theaemt.com

lean manufacturing principles and sets the benchmark for the maintenance and repair of all vital equipment. Our engineering expertise and experience mean we deliver the highest quality of service, and we encourage customers to visit us and see for themselves." As part of the relocation, Sulzer has invested in new equipment,

including larger, 50-tonne overhead cranes and constructed an upgraded overspeed balancing pit, which is the only independent facility in the UK. The company offers optimised overhaul projects for all crucial industrial equipment, including cutting-edge additive manufacturing and state-ofthe-art digital technologies.

SPP PUMPS KEEPS ON GROWING SPP PUMPS HAS OPENED ITS NEW Aberdeen Service Centre, which is in a prime location near the heliports in Dyce. The facility features a large workshop complete with an overhead crane, joined open-plan offices, boardroom, offices and welfare facilities. Recent and ongoing recruitment has enabled SPP to grow its Aberdeen based team with exceptional pump repair and industry knowledge. SPP's Scotlandwide onshore and offshore operations are further supported by 15 UK-based field service engineers. The company has also relocated and upsized from its previous Portlethen address in Aberdeen, following contract awards and continued growth as it supports preventative and unplanned maintenance scopes for centrifugal pumps, gearboxes, diesel engines and valves. SPP is also continuing to invest in its local support facilities, personnel and equipment in line with our commitment

to its UK customer base. With a dedicated Engineering Service Division, SPP can support all pump types and repairs, upgrades and rerates paired with onsite servicing, commissioning, removal, fault finding and upgrades. Quarter 1 2022

8 industry News

AEMT MOURNS THE LOSS OF A GREAT FRIEND WITH GREAT SADNESS, THE AEMT announced the passing of Prof David Walters OBE, a longstanding friend and supporter of the association. The AEMT and the wider rotating machinery sector has lost a strong, valuable, and committed supporter of many years. In 2019, David was presented with a Lifetime Contribution Award by the AEMT to recognise his tremendous work around energy efficiency and electric motor design. He was pivotal in many technical developments for both industry and the association. At the turn of the millennium, David was influential in developing the AEMT's joint project with American counterparts

to publish the 'AEMT/EASA Rewind Study' and the 'Good Practice Guide to Maintain Motor Efficiency,' which now forms the backbone for the new international repair standard that all service centres should be working towards. The study was important for determining that electric motors can be repaired or rewound without losing efficiency. The diligence and time David put into raising the sector's profile was illuminated when, in 1997, he was made an Officer of the Order of the British Empire for his service to energy efficiency. In his memory, the AEMT has made a donation towards the charitable work carried out by Marie Curie.

LITHIUM-ION BATTERY RESEARCH FOLLOWING A PREVIOUS announcement by Morgan Advanced Materials about its partnership with The Faraday Institution, which is powering the battery revolution in Britain, the company has recently announced its involvement in a new Industry Sprint project focused on lithium-ion conducting fibre for composite solid-state electrolytes. Initial studies have indicated that a composite material using lithium-ion

conducting fibres can be an effective solidstate electrolyte. As a key member of the ZeST project, targeting the development of a lithium-ion conducting fibre material for use in a composite solid-state electrolyte for next-generation batteries, the Thermal Ceramics business at Morgan Advanced Materials will work with the novel glass group at the University of Southampton to develop a process to manufacture specialist fibres of a new composition to a

tight tolerance with high yield. The University of Southampton is contributing world-leading experience and equipment in drawing novel glasses into fibre form to the project, which targets early commercial scale-up using greener and more efficient processes. Morgan's Thermal Ceramics business is engaged with a leading battery producer with a view to supplying the material commercially if the project is successful.

WÖLFER WINS LARGE MOTOR CONTRACT FOR OFFSHORE WIND TURBINE INSTALLATION VESSELS GERMAN MOTOR MANUFACTURER, Wölfer has won a large follow-up contract for various hoist applications on an offshore wind turbine installation vessel (WTIV) currently under construction. This is the second order from the same large international maritime engineering firm. The current order is for 45 motors with outputs up to 510 kW for various drive applications in the main hoist – main drive, boom, whip, slewing etc. Wölfer will supply all motors in marine design, many with brakes, encoders and various technologically demanding solutions. The WTIV market is expected to continue growing, with next-generation vessels being equipped for larger wind turbines installed in deeper waters. Wölfer has set up its production to cater to this Quarter 1 2022

industry. Two sets of challenging requirements must be combined to achieve high-quality motors that ensure operator safety, overload capacity and efficiency over a long lifetime. Wölfer motors provide rated performance over the full control range, thus ensuring full functionality of the entire system under harsh marine conditions. The rugged, steel-welded motor casings and dedicated rotor constructions are

produced in-house, and the motors are fitted with a C5M surface finishing to ensure full compliance with maritime and hoist requirements. 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 customers’ 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 Crompton’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. HAPPY NEW YEAR TO EVERYONE! AS ONE YEAR DRAWS to a close another year of promise begins, and we have plenty to look forward to in 2022. We launched our revised mission statement at the end of 2021 with the circulation of our annual Yearbook. If you haven’t already read them, I recommend visiting our website to view the full statement, including our vision for the future and the values we work by. People are at the heart of our association, and we want to ensure all individuals find something of value in the AEMT offering. We have members from all over the world; the diversity in people, organisations, and ways of working are a resource we should learn to tap into. In 2022, we will be focusing on bringing people together in ways that aim to build relationships, core skills and opportunities. The rewind and repair industry is almost as old as the electric motor itself – as a mature industry, it faces tight competition and squeezed margins. To remain competitive, businesses in mature industries look for ways to create innovative new products and services to engage with customers, increase margins and stay

relevant. Being innovative can be difficult though, one must think differently to others and embrace the change it brings. Fortunately, as engineers we enjoy problem solving, and in 2022 we’d like to help you innovate. On Friday, January 28th, we will host our first session with Eureka! Europe on this subject and encourage company owners and directors to attend this session. We are particularly hampered by a lack of engineering talent in the UK. The young aren’t interested in engineering anymore because they aren’t being taught the skills they need in schools. We would like to team up with an organisation called Primary Engineer to play our part in remedying this. Primary Engineer works with primary schools to provide teaching aids and teacher information so that engineering can be taught better in these schools. By engaging children before they move to secondary school, we’re paving the way for future engineers to recruit. Look out for more information in future issues of Renew Magazine to see how you can do your part to help too. I look forward to finding ways to innovate and engage the young this year. If you’ve any comments or suggestions on what you would like to see from the AEMT, please don’t hesitate to get in touch with us, one of the council members or the President. You can email me at thomas@aemt.co.uk or call +44 (0)1904 674 899.

Forthcoming AEMT led Courses & Events COURSE TITLE

START DATE

LOCATION

Ex Refresher

25 January 2022

Online (UK)

Innovation Engineering System

28 January 2022

Online

Ex Theory

01 March 2022

York

Ex Hands-On

03 March 2022

York

Ex Refresher

03 March 2022

York

AEMT Networking Meeting, UK Northern Area

10 March 2022

UK, Northern Area

Ex Theory

14 March 2022

Indonesia

Ex Refresher

16 March 2022

Indonesia

Ex Hands-on

16 March 2022

Indonesia

AEMT Football Event

02 April 2022

Goals Sheffield

Ex Refresher

05 April 2022

Loughborough

AEMT Networking Meeting, UK Midlands Area

05 May 2022

UK, Midlands Area

Ex Theory

10 May 2022

Loughborough

Ex Hands-On

12 May 2022

Loughborough

Ex Refresher

12 May 2022

Loughborough

Ex Refresher

17 May 2022

Loughborough

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 2022

www.theaemt.com

Profile 11

Advertisement feature

GES GROUP

AN AWARD-WINNING INDUSTRY-LEADING ORGANISATION, PROVIDING POWER AND ENERGY SOLUTIONS FOR SMES AND LARGE MULTINATIONALS ACROSS A RANGE OF INDUSTRIES IN THE UK, IRELAND AND BEYOND. Founded in 1946 by Grant & Hector, established in 1972 as Grants Electrical Services (NI), we have grown into GES Group, an award-winning electrical and mechanical engineering company serving customers throughout Ireland, the UK, and beyond.

e have managed energy effectively for many of our internationally recognised clients through good planning, organising, commitment and understanding, through successful implementation of the agreed programme and by ensuring the relevant controls and monitoring are in place. We have a strong and long-standing trading history extending in growth across a significant number of industry sectors in our drive to develop the renewable energy goal. Providing power and energy solutions for small local businesses, as well as large multinationals across a diverse range of industries, such as plastic manufacturers, AD plants, wind farms, food & drink manufacturers, engineering specialists, ship & aerospace manufacturing, water treatment facilities, power stations, etc. The most basic plant and machinery, and the most advanced communication networking systems, all rely on electricity. If this is not available, the resulting power failure renders a business entirely un-operational. Today, almost all business functions are dependent on a steadfast and clean electrical supply - one that is well designed, maintained, automated & controlled, energy-efficient, and mechanically vibration-free. RECENT ACHIEVEMENTS • IET Approved Apprenticeship Scheme and IET Enterprise Partner • Deloitte Best Managed Company 2018, 2019, 2020 and achieved Gold for 2021 • Investors in People Silver Accreditation - 2020 • Silver Level Innovator - 2021 VALUED BUSINESS PARTNERS: • Schneider Electric • Siemens Approved Partner for Motor Repair Services in Ireland. • ABB – Drives • Nidec- Leroy Somer Motors • Brook Crompton Motors OUR RANGE OF SERVICES INCLUDE: • Laser alignment, dynamic balancing, motor overhauls and rewinds, servo motor repair, as well as machining and fabrication. • We are experts in the design, build, installation and commissioning of distribution and control panels, as well as innovative power quality systems and on-site PLC programming. • We are experienced in many forms of renewable systems, including biogas, wind, hydro and solar. • Wind turbine remanufacture & repair • Energy surveys • Power quality offering • Energy Storage www.theaemt.com

• HV & LV substation switchboards & turnkey installations, and maintenance of these units. In January 2021, Nidec (Leroy-Somer Motors) appointed GES Group as an official distributor within the Republic of Ireland. GES Group will stock and distribute the range of Nidec motors and the new cloud-based condition monitoring systems, FORECYTE, from both its’ Northern Ireland base and the Republic of Ireland base. “To enable the growth and future-proofing of our energy market in the digital transition, we have taken a bold step to further develop our collaborative portfolio in Ireland," explained David Moore, CEO at GES Group." We are developing further 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 with ambitious plans through collaboration within our industry. That said, we want to identify and tackle the underlying issues, 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 & Drive digital energy revolution”. INTEGRITY: GES Group employees act with integrity in all actions and interactions with colleagues, clients, suppliers and subcontractors. Our relationships with each other and our customers are built on respect and trust. Our aim is to work collaboratively with our colleagues, customers and suppliers, communicating in a straightforward, clear and concise manner. Provide high-quality products and services to customers and clients at a fair price. EXCELLENCE: GES Group has built a strong reputation for reliability, technical excellence and customer service. As a market leader, we offer technical solutions based on proven practice, and our Engineers complete a thorough and rigorous training process. We keep up-to-date with the latest technological innovations and efficiency systems.

www.ges-group.com info@ges-group.com 02825 656406 Quarter 1 2022

Awards Update 12 NEWS

AEMT Awards: and the winners are... The winners of the 2021 AEMT Awards were announced during a gala presentation ceremony in Coventry on Thursday 18th November. Attended by around 200 people from across the electrical and mechanical trades, the event proved to be a great evening of reward and celebration.

aving been postponed from its original 2020 dateline, due to the pandemic, there was a great deal of anticipation with attendees eager to reunite and re-engage with their colleagues and peers. The evening did not disappoint, with many commenting that it was the best event to date. The atmosphere was fuelled, no doubt, by the excitement of being at a live ‘in-person’ event and the awards programme attracted some excellent entries across the seven categories. The judging session was held virtually and employed comprehensive assessment protocols and a supporting ‘points scoring system’ to determine the finalists in each category and then the winners. The 2021 AEMT Awards winners were as follows: PRODUCT OF THE YEAR – Sponsored by PLANT & WORKS ENGINEERING Menzel Motors: IP67 motors which defy flood conditions. Developed for remote water pumping stations, where accidental flooding can occur, Menzel IP67 protected motors are also occasionally used in very harsh industry conditions. The motors are not capable of operating whilst under water, due to their external fan, however, as soon as the flooding subsides, they can be started. The motors have been tested and certified by TÜV as being able to endure 24-hours under water – without any water entering the motor or terminal box. PROJECT OF THE YEAR – Sponsored by EMiR SOFTWARE Fletcher Moorland: iBOT PCB card refurbishment. Due to its commitment to future sustainability, and helping its customers achieve this by finding innovative solutions to their problems, Fletcher Moorland was tasked with finding a way for the online retail giant, Amazon, to repair and reuse circuit boards on its iBOT robots. The iBOT robots are warehouse pickers, which are crucial to efficiency, and each time one of their PCB boards failed it was thrown away and replaced with a new one. The company has been able to successfully repair over 600 iBOT cards in under 12 months, saving both money and having a positive impact on Amazon’s carbon footprint by reducing waste. SERVICE CENTRE OF THE YEAR – Sponsored by ABB ADC Electrical ADC Electrical’s small but dedicated team has worked hard throughout the pandemic in circumstances that proved to be both physically and mentally challenging. Without the dedication of every member of the team, ADC would not have achieved its outstanding customer service in the rewind, repair of rotating equipment in addition to being able to continue with the development and manufacture of specialised products for the global market. Its customers have really appreciated the high level of service the company is able to consistently offer.

Quarter 1 2022

SUPPLIER OF THE YEAR – Sponsored by DRIVES & CONTROLS Preformed Windings Preformed Windings manufactures high voltage coils and armature coils in a state-of-the-art manufacturing facility in Rotherham. It is able offer high quality coils while maintaining very fast lead times. As a member of the AEMT, it is a trusted partner to many OEMs and rewind shops globally, while its technical team offers a 24/7 service. CONTRIBUTION TO SKILLS & TRAINING – Sponsored by MUSK PROCESS SERVICES EMiR Software The pandemic quickly changed the way we all worked and highlighted the need to accommodate home working. EMiR Software responded swiftly to this need and developed the eMiRLearning Platform, an online learning solution designed and dedicated for its customer base. It created ten learning modules that allowed users to log in anywhere and at any time, to ensure that skills and training levels were kept to an optimum. The eMiR-Learning Platform now boasts over 100 users and 150 certificates have been issued and continues to grow. RISING STAR AWARD – Sponsored by FANUC UK Jack Rowe, Fletcher Moorland Jack Rowe is a conscientious and committed Fletcher Moorland employee who has become an integral part of the team over the past three years. Jack has developed a passion for engineering and has spent time fully immersing himself in the business, going over and above his administration role. Jack goes the extra mile to help his colleagues and demonstrated this when the Workshop Manager was absent due to illness. Jack took on the role to manage time, served engineers, and went on to identify potential improvements and devise solutions which would contribute to a more efficient workplace.

www.theaemt.com

Awards Update 13 DIVERSITY IN ENGINEERING AWARD – Sponsored by PREFORMED WINDINGS Joint winner - Central Group Central Group is a family owned and managed business specialising in the maintenance, repair, and refurbishment of motor, drive and pump systems. Through strong vision and values, and by putting people at the heart of the business it has steadily grown since brothers Tim and Shaun Sutton took control in 2001, following the retirement of their father. Equal opportunities and a strong commitment to continuous personal development has ensured exceptional staff retention and a dedicated and loyal workforce. Joint winner - Heasell Electromechanical Services Heasell has built a reputation for fast, reliable service to all branches of industry, agriculture, and commerce. The company’s industrial department undertakes the installation, maintenance, and repair of all types of electrical, electronic, and mechanical equipment. As an equal opportunities’ employer, a key objective is to maintain a working environment where customers’ and employees’ needs, and aspirations are anticipated and exceeded on all levels – developing relationships based on trust, consistency, and respect. LIFETIME CONTRIBUTION AWARD – Sponsored by AEMT Tim Marks (Retired) Tim was presented with this award as the person who has probably put more work into the AEMT than anyone else in the history of the organisation, except maybe the founders. He served on the AEMT council in the 80’s and was AEMT President twice. At the turn of the

millennium Tim became secretary to the association on a part time basis, which soon became a full-time job. In the 20 years since, the AEMT has gone from strength to strength, and has become a global association representing, promoting, and supporting members from all over the world. He was convenor of the standards committee which developed a new and overhauled repair standard for rotating machinery; the first standard to mention the circular economy and the importance of considering a repair over a replacement. Commenting on the awards dinner, Thomas Marks, Secretary and General Manager at the AEMT said: “We were delighted with the entire event from start to finish. The venue, food and drink were all excellent, the stage-set and overall presentation was fantastic. For me, seeing so many people from across our sector coming together to recognise and celebrate the excellent work which it collectively conducts every day, was wonderful. Sincere congratulations go to each of the finalists and of course to the winners.” The ‘call for nominations’ for the 2022 awards programme will open in the Spring, so if you or your company have a product, project, service or other achievement which you feel is deserving of industry-wide recognition, be sure to submit an entry. The PR value associated with being a finalist is highly desirable, but if selected as a winner, the value is even greater! What have you got to lose? For more information on the AEMT Awards and to review the image gallery from the recent ceremony, please visit: www.aemtawards.com

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14 product News

NEXT GENERATION CLOUD SOLUTION EMIR SOFTWARE – A PROVIDER of business management software for companies working with electric motors, drives & gearboxes, pumps, generators, hydraulics, compressors, electronics, conveyors and their control systems – has been offering a cloud solution since 2015 – today it manages around 400 users virtually. The company has just announced the introduction of a next generation Cloud Server Solution for its cloud customers which is said to offer a secure, reliable and available Cloud Server solution with 24/7/365 key service support. Commenting on the announcement, Gary Downes, Managing Director at EMiR Software, said: “Many of our customers have moved towards a cloud solution as it negates the need to manage and maintain an IT system in house. The flexibility and speed of the EMiR-Cloud solution offers many of our customers a way to run EMiR and remove the effort associated with

managing IT. “We wanted to ensure that we could offer a scalable and futureproofed solution as our user-base increases and the demand for more software management also increases. We chose to partner with Node4 to achieve this, because it pro-actively monitors our customers’ platforms for issues or vulnerabilities around-theclock, and the UK-based, ISO 20000 certified service desk team is available 24 hours a day, 7 days a week, 365 days a year.” The hosted server solution avoids the responsibility that comes with an onsite server – there is no need to maintain software updates, email services and ensuring accurate backups, as the cloud does it all. Indeed, the EMiR-Cloud is said to really come into its own when faced with an emergency that would previously have left business systems down for days. www.emirsoftware.com

RESIN-RICH, CLASS H COIL PASSES THE TEST PREFORMED WINDINGS HAS invested over 12,000 hours of research and development into collaboration with leading OEM’s and insulation manufacturers over the past three years. The result is the launch of the QualCoil H range of resin rich coils that are said to offer low Partial Discharge (PD) levels. QualCoil H has been independently tested and has successfully achieved over 2,000 hours on Voltage Endurance (VE) testing at 28kV at a temperature of 120°C without failure. Voltage endurance testing is designed to simulate the typical life of a motor or generator and the pass criteria for the test carried out on QualCoil H was 400 hours, which demonstrates the potential benefits to end users. Motors and generators will be able to operate for longer, will be more efficient and will require less maintenance. www.preformedwindings.com

TÜV-APPROVED IP67 MOTORS AND TESTING PROCEDURES TÜV SÜD HAS RECENTLY ATTESTED the dust- and waterproof construction according to protection class IP67 of an entire low voltage motor series for Menzel Elektromotoren, a manufacturer of IP67-rated low and medium voltage squirrel-cage motors up to size 355. The series extends to outputs of 400kW and voltages of 1000V. TÜV Süd has also attested Menzel’s procedures for IP67 testing, which the manufacturer offers for medium voltage motors from its own brand, up to 11kV. Menzel builds IP67 motors with minimal tolerances, waterproof encapsulated cast-iron casings and terminal boxes. It holds stock of all basic components for dust- and waterproof squirrel-cage motors so is able to offer short delivery times for standard designs. The motors are used worldwide, mainly in pump stations, flood-prone areas, food and drink industries and maritime

Quarter 1 2022

applications. They can be fully immersed at standstill for a period of 24-hours without any ingress of water. Subsequently, when water has

receded, the motors are ready to be switched on again directly. www.menzel-motors.com

www.theaemt.com

Product NEWS 15

APP GIVES ACCESS TO MOTORS’ TECHNICAL INFORMATION BEFORE THEY ARE SUPPLIED, every WEG electric motor undergoes rigorous quality testing according to the main international standards applicable in the country where it will be used. Continuously investing in innovation and technology, WEG has developed a mobile application that provides access to technical documents, such as datasheets, performance curves, technical drawings, nameplates, and the results of electrical testing performed on motors. Available for the Android and iOS platforms, WEG Data Viewer can be accessed by anyone who wants more information about every motor that leaves WEG’s factories. Using a QR code provided on a label attached to the fan cover, shaft end or the inside of the terminal box, it is possible to obtain, at any time, the motor’s technical information. In motors without the QR code, it is possible to access the

information by entering the serial number available on the nameplate. Rodrigo Fumo, Director of Engineering and Technological Innovation at WEG, commented: “WEG Data Viewer was designed to simplify routines, comparative analyses and maintenance since it provides quick and easy access to key product information. It is an

application that all WEG customers can use.” In future updates, the application will gather other technical information, such as operation and installation manuals, catalogues and dimension testing reports. www.weg.net

16 Projects - AEMT Awards

Repair Projects recognised at AEMT Awards Ceremony At the recent AEMT Awards, three projects were shortlisted for the Project of the Year category, which recognised the most innovative project carried out in the previous 24 months covering the installation, maintenance, repair or service of electro-mechanical equipment. The award, sponsored by EMiR Software, went to Fletcher Moorland for its work refurbishing iBOT PC Cards. Renew magazine looked at the projects that made it to the finalist stage. FLETCHER MOORLAND: IBOT PCB CARD REFURBISHMENT The robot warehouse picker, iBOT, is integral to Amazon's efficiency. It can move in all directions to allow automated picking of goods in the company's warehouses. To maintain efficiency, every time a circuit board failed in the iBOT, Amazon replaced it with a new board – a wasteful and costly exercise. When a member of the Fletcher Moorland team became aware of this practice, they became determined to find a better solution, driven by the company's mission to repair and recycle, reducing waste and helping the environment by moving away from a throwaway society. So, having worked with Amazon on other projects, Fletcher Moorland was tasked with finding a way to repair and reuse the circuit boards on the iBOTs. A faulty board was brought to Fletcher Moorland's workshop to be inspected. The company's engineers developed a test rig specifically for the iBOT circuit boards that enabled failing components to be identified and replaced. In addition, the team now overhaul the complete circuit board,

returning it with more effective and robust parts than when they arrived at Fletcher Moorland. Fletcher Moorland now repairs iBOT circuit boards for Amazon across the UK. It has successfully repaired over 600 iBOT cards in under 12 months, saving both money and positively impacting Amazon's carbon footprint by reducing waste. Beyond its work with Amazon, the potential for this project is enormous – the pandemic has accelerated online shopping and delivery services, with many online retailers having an

automated robotic warehouse picking system. The success of this project can be seen in terms of savings to Amazon – both financially and environmentally – in that they are not simply throwing away and replacing circuit boards. Furthermore, they now receive more robust products from Fletcher Moorland, with a longer life. This has only been made possible due to Fletcher Moorland's 'can-do' approach.

> 18

www. fletchermoorland.co.uk

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BEATSON

Suppliers to Industry Since 1928

Industrial Fans, Electric Motors, Pumps, Geared Motors, Inverters, Starters, Fan Impellers, Fan Balancing, Repairs, Rewinds and all related products... Beatson Fans & Motors are one of the longest established suppliers of electric motors & industrial fans in the UK. Founded by Herbert Beatson in 1928, we have remained an independent family run business ever since. We are committed to offering unparalleled service and an unrivalled range of stock to our customers. Our engineers have over a hundred years of collective experience, with some having worked for the business for over 30 years. In addition to this hands-on knowledge, we also have access to an exhaustive back-catalogue of industry information.

Call us on 0114 244 9955 sales@beatson.co.uk www.beatson.co.uk

Celebrating over 90 Years in Business

18 projects - AEMT Awards GES GROUP: WIND TURBINE GENERATOR RE-DESIGN Northern Ireland has a substantial wind power capacity of 1.4 gigawatts. A significant number of turbines here are around 250kW (798 with a total installed capacity of 214MW). The wind fleet in Northern Ireland contains 1,236 sites of 5,000 kW in capacity or less, with a total capacity of 218 MW. Deploying larger capacity turbines with a reduced output capability has become extremely viable as the machines can produce the maximum 250kW at lower wind speeds, making for a potentially more efficient machine. GES has been working closely with the industry in developing the generator winding design to accommodate this capacity change. Recently GES has completed machine winding conversions which have been installed at several sites across Northern Ireland and Europe. The feedback from customers and service providers has been excellent, and the machines' performance has met all expectations. www.ges-group.com FLETCHER MOORLAND: PROMOTING MAJOR NEW EFFICIENCIES AND RAISING STANDARDS IN THE REPAIR OF CLASS 66 LOCOMOTIVES. Over several years, Fletcher Moorland had developed a relationship as a trusted repair partner for the Electro-Motive Diesel depot close to its workshops in Stoke-on-Trent. As a result, the company was approached to assist in the creation of formal repair procedures and the associated service kits for the repair of Class 66 locomotives in Egypt. Electro-Motive Diesel had won a contract to oversee locomotive repairs in Egypt and needed to standardise repairs in that country. The task was compounded by the Egyptian government's insistence that all repairs were carried out in the country and by Egyptian railway workers. Due to tight Egyptian government restrictions, there was no possibility of shipping locomotives to the UK to be overhauled. Standardisation was vital. For years the locomotives had been repaired using random parts and methods. This impacted on safety and reliability, with Quarter 1 2022

Machine winding conversions carried out by GES

locomotives breaking down repeatedly. workshops. Its engineers stripped down Fletcher Moorland brought in locomotive parts and repaired them, UK-based Class 66 locomotives and logging every piece of work and then stripped down all engine parts. As the describing each step for the online company's engineers went through the manual. processes of stripping down, cleaning The result is a comprehensive guide and renovating every mechanism, they used by every locomotive repairer were asked to write down and video across Egypt, which has been placed their actions. on Fletcher Moorland's extensive This was extremely complex. Fletcher database, and can be easily located Moorland's work in England with the via a password. Service kits were also train company meant it had to strip prepared for each part, containing all down, repair or replace engine parts in materials used to work on the Class 66 real-time before delivering them back Locomotives, even down to items such to the Electro-Motive Diesel depots in as cans of WD40. Stoke-on-Trent and Darlington working Electro-Motive Diesel believes that to a normal repair schedule. the project undertaken by Fletcher This meant that to create the manual, Moorland has saved a substantial the repair company had to piece amount of money and made a together actions on engine parts, as they significant impact with their overseas came and went from its workshops, over repair contracts. several months. Taking this approach, Fletcher www. fletchermoorland.co.uk Moorland was able to develop a bespoke repair manual with stepby-step instructions on how to maintain the Class 66 locomotives – the workhorses of the Egyptian railway network. The manual was the result of hundreds of hours of work in Image from the locomotive repair documentation Fletcher Moorland's prepared by Fletcher Moorland Stoke-on-Trent www.theaemt.com

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20 project updates

AIR COMPRESSOR DRIVE TO THE RESCUE A GERMAN MANUFACTURER OF industrial gases turned to Menzel when it faced a dire emergency. Cuba had lost the country's only air compressor drive which is used to produce oxygen for all hospitals across the island nation. When the drive failed unexpectedly Menzel was called upon to supply a suitable drive solution from stock within a very short time. Facing extreme time pressures – as lives literally depended upon it – Menzel was able to customise a compressor motor from stock which was delivered to where it was needed by passenger aircraft. What added to the difficulty was the fact that during the installation and commissioning on site in Cuba no structural modifications would have been possible. The replacement air compressor motor had to fit perfectly. All details were therefore coordinated directly by telephone between Menzel’s

engineers and the plant operator in Cuba. The customer requested an adaptable 6,000V motor that would be able to cope with the required 3,600rpm at 60Hz. In record time, the required connections for cooling water and lubricating oil were moved to ensure a quick and seamless replacement of the old failed motor. Because there are no cargo flights to Cuba, the 6.3 tonne motor needed to be dismantled to allow for transport on a passenger plane. On site, the Menzel team was able to coordinate the reassembling

and commissioning of the new air compressor drive, including assembly of the sleeve bearings. Just seven days had passed between the initial emergency call and the commissioning of the air compressor drive in Cuba. www.menzel-motors.com

IE5 motors help realise energy savings BMW GROUP’S MINI manufacturing plant in Oxford has upgraded its original IE1/IE2 motors with IE5 synchronous reluctance motor (SynRM) and drive packages from ABB, increasing plant efficiency, reducing costs and lowering the carbon footprint of operations. An energy assessment, carried out by APDS – an ABB Value Provider – estimated that the project will reduce energy costs by £40,000 annually and will significantly reduce carbon dioxide emissions. Payback for the SynRM packages and installation is estimated to be under three years. A large collection of motors has been upgraded to IE5 SynRM in the plant’s paint shop, powering a network of supply and exhaust fans for the paint spraying booths. The motors, which range between 55 – 132 kW, are paired with ABB general purpose drives and were chosen primarily for their energysaving capabilities. The drives are integrated into the plant’s new PLC system, improving operational communications across the paint shop. The paint shop operates with a positive air pressure, meaning

Quarter 1 2022

more air is introduced into the area than is removed. This ensures dust in the air does not settle on the painted products, helping deliver a blemish-free finish. The PLC functions by monitoring the air pressure and triggering the drive to increase power to the fans if, for example, a door is opened. The drives also enable an underload function. This indicates if there is a reduced load on the belt-driven fan systems used for

ventilating the spray booth, alerting maintenance staff and reducing the potential for expensive downtime. Other benefits of the IE5 SynRM motor and drive packages include lower ambient noise and lower running temperature which results in reduced heat losses and lower ongoing maintenance requirements. new.abb.com

www.theaemt.com

Machines for all applications Our ZB20,000 HS/G/GV is from our comprehensive range of precision, hard bearing horizontal balancing machines. With a capacity of up to 20,000 kgs, it is a high-speed balancer designed to run armatures up to 4,200 rpm with a maximum rotor diameter of 2,400mm. All machine installations are backed up by the most comprehensive support and parts service available in the UK. So whatever your balancing requirement we’ve got you covered.

For further information contact us on

T: 0161 872 3123 or E: enquiries@cembhofmann.co.uk www.cembhofmann.co.uk

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22 Hazardous Areas

Is your ex equipment repairer up to the task? When it comes to repairing or overhauling Ex rated equipment, the competency of the repair provider is critical to end-users maintaining the safety of their sites and staff. Karl Metcalfe, Technical Support at the Association of Electrical and Mechanical Trades (AEMT), highlights five key questions a prospective repair partner should be asked before it works on Ex rated equipment, and shares the answers users should expect.

nd-users looking to repair Ex rated equipment for use in hazardous areas should ask a repair provider if it follows the international repair standard, BS EN IEC 60079-19:2019. The answer should, of course, be yes. When end-users send hazardous area equipment away for repair, overhaul or reclamation, it is essential that they understand their responsibilities, as it is their equipment, and they will be fitting it into a hazardous area on its return. Written within the international standard is the definition of a “user”, which states they are “primarily responsible for the repair”. If the repairer does not use the international Ex repair standard or follow its guidelines, the user is primarily responsible for this. So end-users should understand this standard, be able to ask the correct questions of a repairer, know what documentation to expect, and be confident the Ex equipment has been returned fit for purpose. It is also important to ask the repair provider who their responsible person is. The responsible person at a repair facility is the person that checks the operatives work, creates the paperwork and obtains the correct standards for the equipment in question. They also issue the documentation for the end-user to agree on the work to be carried out and are responsible for ensuring it is carried out. The responsible person and the enduser should be in close contact throughout the time the equipment is in the repair facility, and so it is important for the repair provider to identify a competent, responsible person. End-users should also ask a repair provider what quality management systems they use. A quality management system is part of many workplaces, but traceability is vital when looking at Ex equipment repair.

Quarter 1 2022

The international repair standard requires repairers to keep documentation on all Ex repairs for a minimum of ten years. If an end-user had an incident at its plant, would it be confident that it could produce the documentation for a repair? If not, could it be confident that the repair facility it used could issue it for a repair it carried out eight years ago? If the repair facility uses a recognised quality management system, this will give the confidence that the documentation will be available if needed. Confirmation that staff training certificates are still valid should also be sought. The international Ex repair standard states that staff involved with Ex repairs should undergo training and assessment at intervals not exceeding three years. To comply with this requirement, AEMT members trained in the repair of Ex equipment have their training certificates refreshed every three years. Finally, it is crucial to establish whether the repair facility’s measuring equipment is traceable and adequately calibrated. It is important to have complete

confidence, backed by documentation, that the repairer only uses calibrated measuring equipment – for both electrical and mechanical measurements. Not only should the equipment be calibrated, but the repairer should be sure that the equipment was measuring correctly at the time of use. There should also be a record of which vernier, micrometre, surge tester etc., was used to measure the enduser’s equipment. As mentioned earlier, traceability is a vital part of any repair, but when the equipment can cause a major incident, traceability and responsibility become a necessity. Possibly the surest way to ensure a repair facility is competent in the repair of Ex rated equipment, meets the international standard and gives the correct answers to the questions outlined above, is to choose a repairer from the AEMT’s Ex register. All companies listed on the register have been trained in Ex equipment repair to the International and European standards BS EN IEC 60079-19, and have been assessed as competent. TIMES-CIRCLE bit.ly/ExRegister www.theaemt.com

Contact Electrom’s trusted partner in the UK: Wire Electric Supplies

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+1 720-491-3580 info@electrominst.com

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24 Motor Testing

Excessive heat in electric motors:

A common root cause of insulation failure Megger, the manufacturer and supplier of the Baker range of electric motor test and monitoring solutions, outlines the most sommon causes of excessive heat – and in turn insulation failure – in electric motors.

aintenance professionals widely accept predictive maintenance (PdM) as a significant means of cost savings. However, preventive maintenance (PM) is still viewed as a viable option when it comes to motor maintenance. This assertion is based upon the inability of conventional technologies used over the past decade to perform credible root cause analysis. With respect to the diagnostic electrical tool-belt, the days of the handheld multi-meter and the meg-ohm meter as sole tools in cost-effective maintenance are over. Modern online motor monitoring technologies permit easy assessment of the entire motor/machine system, including the power source, motor and the load placed upon the motor. By focusing on the entire motor system instead of one or two components, true troubleshooting solutions become available. Maintenance experts agree that excessive heat will cause rapid deterioration of the winding insulation within motors. The common rule states that, for every 10°C of additional heat to the windings, motor insulation life is cut in half. For example, a motor that would normally last 20 years in regular service is running 40°C above rated temperature; under these conditions, the motor would only have a life of about 1/16 of its expected span, or a little more than one year to run until it failed. Many articles and studies written over the years agree with this rule. Leading standards organisations have concluded that 30% of motor failures result from insulation failure, and 60% of those are caused by excessive heat in the motor.

Quarter 1 2022

There are typically five main reasons a motor will overheat. These items include excessive load placed upon the motor, a poor power condition, a high effective service factor, excessive stops and starts, and environmental influences. EXCESSIVE VOLTAGE Stator current is a frequently used measurement of load level, but it can easily be masked by an overvoltage condition. A common mistake is made in the practice of operating at an over-voltage to reduce the stator current. The intention is to proportionally reduce the introduction of heat. It has been shown that in motors ranging from 10 to 200hp that the decrease of losses obtained by operating at a 10% over-voltage would typically only be about 1-3%. Though the current of a motor may vary considerably with the application of excessive voltages, any heat

in the motor will not decrease. A 10% (or greater) load error can be introduced simply due to reliance upon stator current readings to assess probable load and expected heat levels. Under fullload conditions, this can mean life and death to a motor. In an example taken from a coal-fired power plant in the United States, a 7,000hp 6.6kV motor was running at just 7% over-current, but with an 8% overvoltage. Two identical applications had previously undergone unscheduled outages within the previous 12 months. When the stator current of this motor was analysed, a mild overload was detected. However, over-loading of nearly 20% was determined after looking at the true load to the motor. This explains why these motors were failing. Costs for repairs to each of these motors ran in the hundreds of thousands of dollars, underscoring the > 26

For every 10°C of additional heat to the windings, motor insulation life is cut in half.

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Remote Condition Monitoring by

For a free demonstration, contact Rich meerkat@fletchermoorland.co.uk or call 01782 411021

ONE

PRO

26 Motor Testing are evident. This scenario shows a NEMA derating of 0.7, which allows the motor to be operated at 70% output.

Figure 1: NEMA derating curve.

critical importance of performing root-causes analysis in the context of the motor’s operational environment. In real-world applications, perfect voltage conditions are rare. Losses, and not current level alone, are a cause of excessive heat. These losses are not only destructive to windings, they contribute to bearing damage as well. This underscores the need for accurate knowledge of operational load levels. Only accurate load-level calculations can provide reliable measurements of excessive losses and consequential overheating conditions with a motor. POWER CONDITION Because power conditions are often poor within industrial facilities, electric motors need to be derated to maximise useful life. NEMA MG-1 sections II and IV specify what voltage quality, as a function of balance and distortion, allows what level of percentage load. Figure 1 shows the NEMA derating curve for the percentage of unbalance. This figure is defined in the following formula:

The use of the derating curve is best described as the higher the level of unbalance, the lower the Quarter 1 2022

acceptable level of steady-state load. For example, if a 100hp motor had an unbalance factor of 3%, it would need to be derated to 0.9, or 90% of its capacity (meaning 90hp). The increased use of variablefrequency drives (VFDs) has revealed that they have detrimental effects upon electric motors, and largely due to the condition of power within manufacturing facilities. Figure 2 shows the voltage that a VFD (running at nearly a six-pulse mode) will send to the motor. The distorted currents are the motor’s reaction to poor power condition. Very severe distortions

EFFECTIVE SERVICE FACTOR It is not a trivial matter to bring voltage and current level, operating speed and input power standards to the field. There haven’t been accurate measurement-based load estimation methods available – that is, until recently. The key to finding the most frequent reasons for overheating is proper load level identification. To perform this, it is crucial to have the best possible accuracy in the estimation of load level. This can be obtained by looking at only currents and voltages. In the past, less accurate methods led to major miscalculations, in particular in cases where voltage conditions weren’t optimal. Unfortunately, these conditions are all too common in the field. The formula for calculating effective service factor is:

Losses, and not current level alone, are a cause of excessive heat.

Effective service factor is beneficial because it offers the combination of professional standards and real-life applications, which in turn enables a solid determination of stress on any particular motor-

Figure 2: Extreme distortion in a slow-switching VFD (50hp, 4-pole).

www.theaemt.com

> 28

28 Motor Testing load application. With the use of a dynamometer, a 300hp motor under test was running at nearly full load (99.7%). Voltage distortion was poor due to a previously-unidentified SCR defect in the power supply. The resulting NEMA derating factor of 0.85 rendered an effective service factor(s.f.) of 1.17, which signalled an alarm condition. Regardless of the nameplate service factor, any motor that operates above 1.0 s.f. is under stress. A service factor greater than 1.0 signifies a motor’s capacity for overload only for short periods of time, not longer steady-state operation. Again, because poor voltage conditions are frequent and can be caused by a variety of reasons, NEMA specifies the load level that is permitted for poor voltage conditions. Only preventive maintenance online tools capable of accurate calculations of operating load can ensure that a plant operates with healthy limits. FREQUENT STARTS AND STOPS Table 1 displays the maximum number of starts and stops for line-operated motors as a function of rating and speed. This underscores the importance of limiting the frequency of startups, which place the most stress on a motor during operation. A number of well-documented cases of recurrent motor failure were related to increases in the horsepower rating of the motor. This often shortened the time between failures, but the root cause of the failure was really the high number of starts and stops. This makes it very important to closely monitor the number of starts, which can be as frequent as hourly for small or medium motors and daily for larger motors. Today’s online motor monitoring equipment helps ensure full compliance to professional standards. It identifies reasons for failure when faced with an operation that does not comply with standards by including these standards into long-term unsupervised monitoring. Quarter 1 2022

Table 1: Maximum number of starts and stops for line-operated motors.

ENVIRONMENTAL CONDITIONS Thermography is frequently used to determine the heat electric motors are operating under. Poor thermal conditions such as high ambient temperature, clogged ducts, etc., are typical examples of non-electrically induced temperature stress to both the motor and insulation system. Chemical abrasive substances in the air, wet operation, and high-altitude operation are a few common environmental stresses.

maintenance and monitoring is to test according to NEMA and other professional standards. Effective service factor is a reliably good measurement that allows difficult standards to be interpreted for day-to-day plant operation. Even though the instrumentation has not been available to monitor the frequency of starts and stops, it is an important aspect to consider in management for motor integrity. Automated assessment is necessary to effectively ensure motor health. The more successful root cause analysis of motor failure or stress, the more suitable predictive maintenance becomes for plant management. This point represents good news for business; since electrical online monitoring technology has successfully become an equal partner with vibration in maintenance management to maximise plant operation and uptime. TIMES-CIRCLE

The best way to ensure successful preventive maintenance and monitoring is to test according to NEMA and other professional standards

CONCLUSION Bearing and winding failures are the most common motor failures. The fundamental reason is excessive heat. Today’s preventive maintenance practices frequently limit online electrical measurements to interpreting current levels. While tremendously valuable, this method is inconclusive when it comes to failures caused by excessive winding heat. The best way to ensure successful preventive

bit.ly/MegBaker www.theaemt.com

30 Coil Technology

A licence to print... Coils Chris Callander finds out how a German company is transforming the production of motor coils, and explores what impact that may have on the motor repair sector.

dditive Drives was born after two of its cofounders, Dr. Jacob Jung and Alex Helm, realised their expertise in the automotive sector and additive manufacturing, respectively, could be brought together to solve a challenge presented by the fast-growing demand for traction motors. It is well recognised that it is challenging to create working prototypes of motors for automotive applications. Setting up for prototyping or sampling motors often requires a lot of tooling, particularly when it comes to hairpin windings and large copper conductors. Plus, designs are restricted in terms of their geometry by conventional coil manufacturing. But Jacob and Alex recognised that if they could find a way to 3D print coils and, in doing so, benefit from optimised designs, they could overcome the limitations and speed up the production of prototypes, while in many cases doing so more cost-effectively than conventional methods. Officially launched in July 2020, Additive Drives, which is based in Dresden, Germany, primarily works with high-performance applications such as motors for racing and aviation applications, producing short- to medium-run production batches and fastturnaround prototypes. Coils are printed using selective laser melting, otherwise known as powder bed fusion. This additive manufacturing process uses high-power lasers to melt metal powders and fuse them together to form the desired solid mass. However, existing 3D printing machinery had to be adapted by the team at Additive Drives to make it suitable to work with the oxygen-free copper Quarter 1 2022

powder required to manufacture motor coils. MORE THAN SIMPLY PRINTING For Additive Drives, additive manufacturing is just the enabler that makes a range of benefits possible. As well as accelerated development times, additive coil production can deliver improvements in weight, volume, and performance. Alongside printing clients' coils to their design, Additive Drives also offers design optimisation, utilising the benefits available through 3D printing. Based on electromagnetic and

thermal simulation of a coil's CAD design, the Additive Drives team can save up to 40% of the copper mass, meaning only the remaining 60% needs to be printed. This makes it possible to identify areas where the copper cross-section can be reduced as it is not critical – such as in the connections – potentially reducing size, weight and cost. Equally, in areas where the analysis identifies hot spots, the copper crosssection can be increased to compensate – meaning greater performance and reliability. Creating the geometry through 3D printing allows coil geometries that are more complex than is

The design of bending radiuses can be optimised with insulation in mind.

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Coil Technology 31

SIZE MATTERS

About 80% of the motor coils produced by Additive Drives have an outer diameter of less than 250mm and are typically for traction motors used in electric vehicles. If coils are printed in a single part, the equipment limits their outer diameter to around 350mm. But, if a coil is printed in sections, greater sizes are achievable. possible with traditional methods. This allows insulation to be designed in a different way to conventionally manufactured coils. For example, the design of bending radiuses can be optimised with insulation in mind. While in hairpin windings, for example, air gaps can be far more accurately managed. In addition, the integration of connection technology can be optimised, and end turn lengths can be reduced. MOTOR REPAIR POTENTIAL Currently, Additive Drives' focus is on designing and developing coils for use by motor OEMs. But the technology and approach

can, in theory, be used to produce replacement coils as part of motor repair or overhaul. The technology can also be used to create coils that are in part traditionally wire wound and part 3D printed. This allows 3D printing's benefits when it comes to complex shapes as part of the connection technology to be integrated with a traditional approach. In reality, though, it will be some time before repair shops are routinely using 3D printing to create replacement motor coils. While series production of coils can be more cost-effective than other production methods, the cost and complexity of 3D printing

coils mean it is not really viable for one-off replacements in most cases. But, as motors become more complex and the cost of the technology reduces, there will come a time when this approach is far more viable and, in turn, common. TIMES-CIRCLE www.additive-drives.de

32 Insulation Testing

Insulation testing: Dielectric testing explained Houghton International outlines how systematically testing an electric motor's insulation can support an informed motor maintenance strategy.

motor's insulation system prevents winding faults, but time, usage, moisture and other contaminants will inevitably cause the insulation to deteriorate. Around 30% of electric motor failures result from electrical insulation breakdown, the second biggest cause of failure after bearing issues. Therefore, it is important to identify and predict early signs of insulation degradation for a clear picture of motor health, reducing the risk of unplanned downtime and catastrophic failure. A properly implemented testing regime can find early indications of insulation weakness and faults in windings, between Quarter 1 2022

phases or coils, and in ground wall insulation. It can also detect problems with connections, such as feed cable insulation weakness, motor imbalances, and open or high resistance. Houghton International begins a testing routine by checking the balance between the motor's phases using a phase resistance test. The reading for each phase is compared to identify any anomalies that may indicate problems. High resistance in a phase may be a sign of bad electrical joints or

breakage within the coil or copper. To check suitability to carry out high voltage testing, Insulation Resistance (IR) and Polarisation Index (PI) are then tested. These two tests provide a good indicator of the strength of the windings' external (coil to earth) insulation. The IR reading is taken after applying the test voltage for one minute. A second reading is taken at 10 minutes then divided by the first reading to calculate the PI. Houghton International would consider a PI of below two a fail. This may be a sign of a

A properly implemented testing regime can find early indications of insulation weakness.

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Insulation Testing 33 fault in the coil to earth insulation or the presence of moisture or contamination, requiring further investigation. If the IR and PI results are satisfactory, a High Potential test is then performed. Tests carried out at operating voltage may not detect smaller instances of insulation deterioration, so the High Potential test uses a higher voltage to stress insulation and detect these smaller dielectric breakdowns. Insulation breakdown may not only occur in the external insulation, but also between turns (the individual strands of copper) within the motor windings. All coils should be nearly identical, so surge test readings from a coil or phase can be compared to identify indications of breakdowns in turn to turn insulation, dry joints or incorrect winding connections. High voltage motors can exhibit high partial discharge (PD) levels, where localised corona discharge causes deterioration, eventually

leading to insulation breakdown. Standard diagnostic tests don't detect this, so a motor can appear healthy despite high levels of corona discharge. PD testing identifies these localised weak and aged points of the insulation. Electrical testing can be carried out in situ, making the process relatively quick and easy with minimal disruption. It can be carried out as a one-off assessment, but testing at regular intervals is recommended to provide a trending measure of dielectric integrity and build a more complete picture of machine health. For instance, high PD levels may be present in a motor, but if these levels remain consistent without worsening over time, they may not impact the operation of the motor. This is why results require

interpretation, and experienced electrical motor repair engineers can draw on their knowledge of a wide range of machinery to interpret tests and provide recommendations on required maintenance and repairs. Visual checks are key and can be just as illuminating as advanced electrical testing when you know what you're looking for. The most advanced equipment on the market is only as good as those who operate it, so it is essential to understand what you are looking for to fully benefit from the insights of electrical testing. However, the right knowledge and equipment provides a valuable picture of motor health to inform operational, maintenance, and capex decisions. TIMES-CIRCLE

The most advanced equipment on the market is only as good as those who operate it.

www.houghton-international.com

Wire Electric Supplies Ltd We take pride in manufacturing Copper & Aluminium conductors covered with: • Mica

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34 Circular Economy

It pays to Find a happy home for used kit As interest in the ecological and economic benefits of re-use rather than recycling gathers pace, David Lenehan, Managing Director at Northern Industrial, explains the options when it comes to disposing of old kit and how taking the right approach can provide financial income from old machinery that might otherwise have just been sent to the crusher.

n July 2020, a statement issued jointly by the Department for Environment, Food and Rural Affairs (Defra), the Department of Agriculture, Environment and Rural Affairs (DAERA), the Welsh Government and the Scottish Government confirmed the UK’s ongoing commitment to the EU’s Circular Economy Package (CEP), which introduces a revised legislative framework, identifying steps for the reduction of waste and establishing an ambitious and credible long-term path for waste management and recycling. The Ellen MacArthur Foundation defines a circular economy as looking beyond the current take-make-waste extractive industrial model. It says that a circular economy aims to redefine growth, focusing on positive society-wide benefits. It entails gradually decoupling economic activity from the consumption of finite resources and designing waste out of the system. Underpinned by a transition to renewable energy sources, the Foundation says the circular model builds economic, natural, and social capital, based on three principles: 1. Design out waste and pollution 2. Keep products and materials in use 3. Regenerate natural systems With a clearer focus on item two above, it is possible to make a significant contribution to this global commitment whilst also maximising the overall investment efficiency of new and replacement assets by Quarter 1 2022

profiting from the ongoing use of used machinery and equipment that has become surplus to requirements. If we move to a focus on selling used equipment to extend its working life within the global economy, rather than recycling it simply for materials, industrial equipment users and repair professionals can contribute massively to worldwide environmental goals. The ability now to sell used kit to eager buyers worldwide provides a financial stimulus that goes beyond environmental altruism and can boost the economic efficiency of industry as a whole.

DISPOSAL OPTIONS When disposing of old kit, the options currently available are WEEE recycling, auctions, eBay, or selling to a reseller. All have their pros and cons, but some provide opportunities for cash returns, which can be used to offset the investment costs in new or replacement equipment, often with very little time commitment if you choose the right option.

Industrial equipment users and repair professionals can contribute massively to worldwide environmental goals.

WEEE RECYCLING The most common form of old kit disposal is to call in a WEEE recycling company. According to the WEEE Regulations, there are 14 main types of WEEE www.theaemt.com

> 36

Coil Manufacturing Winding & Taping

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36 Circular Economy (Waste Electrical and Electronic Equipment) waste that must be disposed of legally and responsibly. WEEE waste typically contains a large combination of materials, possibly including toxic materials such as arsenic, cadmium, lead and mercury, which are obviously bad for the environment when they leak into and contaminate soil, waterways and surrounding areas. A WEEE recycling company will collect your old equipment for a fee and ensure it is disposed of in compliance with the WEEE regulations. Once your WEEE waste has been collected, the WEEE recycler will take it to a specialised reprocessing plant, where it is shredded into small pieces ready for recycling. After the equipment has been shredded, strong magnets are used to remove precious metals while electronic currents are used to remove nonmetallic elements, with plastics also separated for material recycling. The upside of taking this approach is the ease of disposal and the assurance of regulatory compliance. The downside is the fees that add to the burden of any investment in new or replacement kit. Also, some would argue that base materials recycling is the lowest common denominator in terms of the circular economy. Although WEEE recycling is fully regulatory compliant, the sad fact is that perfectly useable equipment can end up in the shredder along with everything else. AUCTIONS One way to see your old equipment dodge the shredder, while also having an extended useful life, and possibly providing you with a pretty penny in return, is to send it to an auction. Specialist auction houses will sell off your used kit and give you a share of the sale price, after their cut. This can be a great way to make cash from what might otherwise have cost you for disposal by a WEEE recycler. Quarter 1 2022

David Lenehan, Managing Director at Northern Industrial

The downsides, though, are that auction houses will generally not pick up your kit – it’s down to you to transport it to them. Also, most auction houses are only interested in the large, fully intact pieces of kit you might want to sell. They are not interested in smaller items that may form a large part of your waste, and they may be reluctant to include items that need reconditioning. Once you have taken your larger items to auction, you may still need to call upon a WEEE recycler for the smaller or poorer condition items that couldn’t be auctioned.

worth it in the context of their prime responsibilities – keeping current kit going. SELL TO A RESELLER One solution that takes minimum time and provides risk-free returns is selling to a reseller. The internet has opened up a global market for used kit and obsolete machinery. Companies such as Northern Industrial buy-up used equipment wholesale for a fair market price. They then recondition it and sell it under warranty, often to customers from all over the world. Possibly buying the equipment as a job lot, they will handle the WEEE compliant recycling of any equipment they buy that they cannot recondition or sell. The immediate benefits are that disposal operations are simplified while costs are turned into income. As the world moves towards achieving a much more circular economy, huge growth is expected in this type of operation as globally we move towards making greater use of our resources and the culture of waste goes into decline. TIMES-CIRCLE

The immediate benefits are that disposal operations are simplified while costs are turned into income.

EBAY If you want to avoid auctioneer fees, eBay is an option. You may get a good price for your kit, but the downsides are the extended responsibilities and times in disposal. Do you want to spend your time as a part-time e-tailer, dealing with random and sometimes volatile customers? The truth of the matter is that, while auctions or eBay can provide cash for your old kit, they can both be a huge drain in terms of risk, time and effort, which most people don’t see as being

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