Renew Magazine - Quarter 2, 2022. Preventative maintenance and condition monitoring focus

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

The journal f rom

Quarter 2 2022

FOCUS ON:

Condition monitoring

Static and dynamic testing to inform predictive maintenance

Breathing new life into a wind turbine

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.

F

rom its origins in rewinding electrical motors, the scope of services offered by the AEMT’s membership has expanded massively since the association was formed in 1945.

Rewinding and repairing motors is still a core service, and advances in technology and materials mean that a modern repair can produce a motor that is better than it was when originally supplied in some cases. From expansion into the repair of other rotating equipment, such as pumps and other mechanical equipment, the sector went on to offer repairs of electronic equipment such as variable speed drives. Today, there is no end to the electromechanical equipment which can be repaired, and we see an ever-wider range of projects, many with a very short turnaround, carried out by our members. Of course, this is so important as we look to reduce waste and develop a more circular economy as part of a drive towards net-zero.

One of the more recent areas to fall under the scope of the electromechanical repair sector is condition monitoring – the ability to monitor machinery and processes to pre-empt possible faults and react before they cause issues. This topic is a focus in this issue of Renew. We have a feature exploring static and dynamic testing of electric motors where the latter supports ongoing condition monitoring. We also look at the myth that introducing condition monitoring will put maintenance team roles at risk. Taking a proactive rather than reactive approach to the maintenance of plant and equipment can offer huge benefits, not least significant cost savings from reduced downtime.

Elsewhere we have our usual roundup of news, product launches and projects. Plus, we have other features looking at wind turbine maintenance, the issue of fake bearings and the impact the conflict in Ukraine could have on the ongoing supply of motors and drives.

As ever, I hope you enjoy this issue, and if there is something you would like to see covered in a future issue, 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. © AEMT. All rights reserved.

NEWS 6

Industry news

8

AEMT news

10

AEMT Awards update

12

Product news

14

Project updates

24

Three ways Russia’s assault on Ukraine could affect motor supply

26

Breathing new life into a wind turbine

28

Finding fake bearings stops machine failure

26

Focus on condition monitoring 14

features 18

Businesses urged to join the skills revolution

20

Built-in safety sets the standard

22

ATEX fans: An explosive issue

30

Static and dynamic testing to inform predictive maintenance

36

Condition monitoring: Enhancing not replacing maintenance teams

Opinion

PEFC Certified This product is from sustainably managed forests and controlled sources PEFC/16-33-254

www.pefc.org

www.theaemt.com

42

Don't let a focus on capital expenditure cost you in the long term

Quarter 2 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

n

n

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

DCM305E

Earth Leakage Clampmeter n 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

n

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

n

MPQ1000 MPD SCAN

TC3231 DCM305E AVO835

DLRO2

Thermal Camera

2 Amp DucterTM Low Resistance Ohmmeter n

n

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

n

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.

DX

AWA-IV

n

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

n

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

n

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

DX

Static Motor Analyzer

NetEP

NETEP

n

n

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

n

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

n

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

n

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

n

The Megger Baker EXP4000 is a portable Dynamic Motor Analysis System

n

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

n

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,

n

Dynamic Motor Analyzer

MTR105 n

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

EXP4000

EXP4000

Site Installed Dynamic Monitoring System

n

n

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.

n

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

6 INDUSTRY NEWS

Quartzelec to supply AmericaN chemical plant FOLLOWING AN EXTENDED tendering process, Quartzelec’s Rugby Rotating Machine Services business has been awarded a contract to manufacture and supply a spare main loop compressor motor for a chemical plant in the USA. The new machine is from the company’s UNIPAK ‘heritage’ range of cage induction motors, rated at 7,000HP, on frame size CC710U2000 and will

run on the local industrial 13.2kV, 60Hz supply.

The motor is required to be air-cooled via a NEMA WP-II enclosure with side-mounted filtration units fitted to reduce the ingress of any small particles into the motor’s internal air circuit.

The design engineers based in Rugby, UK, have extensive experience in enhancing, updating and modifying original machine

specifications and, for this particular machine, were able to update and adapt the air-filter design allowing the filters to be easily removed and replaced whilst the motor is in operation – which will result in significantly reduced downtime and lower ongoing maintenance costs for the client.

The compressor motor build is in progress, with the delivery of the new motor scheduled later this year.

SMALLER BUSINESSES DON’T UNDERSTAND ‘CARBON JARGON’, RESEARCH REVEALS ALMOST THREE IN FOUR (74%) smaller businesses don’t understand how the term ‘net-zero’ applies to them.

According to new research commissioned by the British Business Bank, the majority of smaller businesses in the UK don’t understand how common environmental terms such as ‘net zero’, ‘carbon neutral’ and ‘carbon footprint’ apply to their businesses.

The Opinium survey of 1,000 senior decisionmakers in smaller businesses found that more than half (54%) believe the language, terminology, and information around reducing carbon emissions is overcomplex.

Over three-in-five (61%) say they would find more information and advice about taking action to measure and reduce their business’ carbon emissions helpful, with over half (53%) of those wanting advice on measuring their business’ carbon footprint and a similar proportion (51%) wanting information to help work out if reducing carbon emissions makes financial sense for their business.

Nearly half (44%) of those surveyed don’t know where to get information on reducing their carbon emissions and how best to approach related commercial or financial opportunities.

The British Business Bank’s recently launched #GreenToGrow campaign aims to demystify and alert smaller businesses to the commercial benefits of investing in decarbonisation. Resources include Quarter 2 2022

a new ‘Green Decoder’, an online guide co-created with Nottingham Business School, Nottingham Trent University to help smaller businesses decipher the terminology surrounding decarbonisation.

The British Business Bank’s online Finance Hub also provides a series of guides and information about sustainability issues and how smaller

businesses can start their journey towards net zero.

Terms often misunderstood by businesses include: 1. Greenhouse gas emissions 2. Decarbonisation 3. Net-zero 4. Carbon neutral 5. Carbon footprint Shanika Amarasekara, Chief Impact Officer at British Business Bank, said:

“Smaller businesses are far too often put off by the over-complex ‘carbon jargon’ that comes with reducing emissions.

By helping decipher some of the terminology around decarbonisation, the British Business Bank hopes to show smaller businesses that simple, incremental changes, such as switching off equipment when not in use, can make a difference in their net-zero transition.

“This will become an increasingly important businesses requirement.

Given that many consumers now consider sustainability when they make a purchase, by becoming greener, smaller businesses can enhance their competitive edge and expand their customer base.”

Dr Muhammad Mazhar, Senior Lecturer in Sustainability, Nottingham Business School, Nottingham Trent University, commented: “Smaller businesses are key to our economy and have a significant carbon emissions impact. They can act as agents for change to meet the UK government’s netzero targets. Most smaller businesses are at the initial stage of their carbon management journey and will benefit from the support provided through the British Business Bank’s #GreenToGrow campaign. Smaller businesses have been overlooked in the past, and this is changing. The business case for carbon management is stronger than ever, and smaller businesses have an opportunity to act now to remain competitive.” www.theaemt.com

Industry NEWS 7

IT'S LIGHTS OUT AND AWAY EMIR GOES THREE YEARS AFTER IT LAST welcomed customers and industry representatives to its popular open day, EMiR, a specialist in software and IT solutions for the electro-mechanical repair, sales and service industry, is hosting a gathering at the Silverstone Interactive Museum on May 12, 2022.

During the Covid-enforced threeyear gap since the last EMiR open day, there have been plenty of exciting new developments as the solution constantly evolves to meet the developing needs of users. In a packed and informative morning, visitors will be able to find out about all the latest additions and enhancements to the EMiR platform, plus gain sneak previews of what’s to come in the company’s product roadmap.

Then in the afternoon, visitors will be able to delve into the history of Silverstone, the home of British Motor Racing. An exciting tour of the

interactive Silverstone Museum will include the grid lineup, interactive displays, bikes, cars, memorabilia and a 3D experience of the ultimate lap.

And those who registered early enough will be able to take to the track in one of four Formula 1 simulators. They will be up against other attendees to

record the best lap time, with industry bragging rights as the ultimate prize.

Places are limited, and anyone interested in attending should contact the EMiR team via the company website. www.solutionsinit.com

NEW MOTOR PLANT FOR MENZEL ELEKTROMOTOREN MENZEL ELEKTROMOTOREN HAS signed the construction contract for a new, larger motor plant in Hennigsdorf, near Berlin. The manufacturer has experienced substantial growth in recent years and has outgrown its present headquarters in central Berlin. “Our new location will feature state-of-the-art machinery, efficient logistics, larger hoist capacities for optimised production processes and high energy efficiency,” said CEO, Mathis Menzel, on the occasion of the signing of the contract. “We will also expand our team and create around 100 new jobs in production and administration in the medium term.”

The new site offers optimal conditions for the planned growth with a gross floor area of around 8500m², which will accommodate a motor plant with production, testing and storage areas, and offices. The extensive plot allows for flexible expansion to meet future growth requirements. Construction starts in the summer of 2022, with final acceptance scheduled for August 2023.

The Vollack Group, an expert in methodical building conception, will www.theaemt.com

Left to right: Cornelia Uhlig, Commercial Manager and Matthias Jordt, Partner and Project Supervisor, both of Vollack GmbH & Co. KG, Dirk Achhammer, Commercial Director and Paul Bernhardt, Business Unit Manager and Construction Project Supervisor, both of Menzel Elektromotoren GmbH.

oversee planning and construction.

Thanks to resource-saving building technology with heat generation from the local heat network, the building will meet the EG40EE energy efficiency standard and thus qualify for state funding. “In planning and implementing this project,

we emphasise lean processes and resource conservation at all levels,” said Matthias Jordt, partner at Vollack.

With this investment and the move to the new location, Menzel Elektromotoren is positioning itself sustainably for the future.

Quarter 2 2022

8 AEMT Update

UPDATE FROM THE AEMT SECRETARY In his latest update, Thomas Marks shares details of recent work carried out by the Association of Electrical and Mechanical Trades.

T

here are mounting threats we read in the news every day, from pandemics to Putin’s assault on Ukraine and the looming crisis of climate change. It’s hard to see the way forward with so much gloom surrounding us.

I believe we are going through a significant shake-up, there will be winners and losers, but ultimately if we manage these threats properly, then we will be able to advance ourselves further and quicker than we would have done otherwise. By collaborating, reminding ourselves of our strengths and the opportunities, and being mindful of our weaknesses, humanity’s ingenuity can overcome almost anything!

Trade associations are particularly helpful at guiding businesses in times of uncertainty. We are connected to organisations and institutions which are at the centre of policy change. We distil what our members tell us to influence policy direction, and members can unite to share burdens with likeminded individuals.

In this first quarter, we have reached out to an organisation called the Manufacturer’s Alliance, which we believe excels at

developing good leadership – endorsed by none other than our honorary President Shaun Sutton at Central Group. Its facilitation of peer groups has helped like-minded people share challenges and aspirations so that others can learn from it.

It has helped hold leaders accountable, and to break through boundaries. We will be initiating our first pilot group with the group in this second quarter – if this interests you, please get in touch with me.

We have also launched our brand new BSI AEMT Standards Portal, enabling members to access the most current and relevant standards, specifically curated for AEMT members.

Members can access over 50 standards via our website for a modest annual fee, including the 60034 series for rotating electrical equipment, ISO quality systems, and 60079 hazardous area standards.

We have also produced a brand new repair label for all members who are committed to quality repairs, which reads ‘Sustainably repaired to IEC 60034-23’. For all machines repaired to this standard, members can affix this label to raise awareness of quality repairs, highlighting your affiliation with the AEMT, and promoting good practice.

For both the BSI Standards portal and the new repair labels, please email us to place an order or refer to the website for more details.

In terms of training, we are excited to be starting our project

Forthcoming AEMT led Courses & Events COURSE TITLE

START DATE

LOCATION

Ex Theory

Tuesday, 10 May 2022

Loughborough

Ex Hands-On

Thursday, 12 May 2022

Loughborough

Ex Refresher

Thursday, 12 May 2022

Loughborough

Ex Refresher

Tuesday, 17 May 2022

Loughborough

Ex Theory

Tuesday, 24 May 2022

Ireland

Ex Hands-On

Thursday, 26 May 2022

Ireland

Ex Refresher

Thursday, 26 May 2022

Ireland

Ex Theory

Sunday, 12 June 2022

Kuala Lumpur

Ex Hands-On

Tuesday, 14 June 2022

Kuala Lumpur

Ex Refresher

Tuesday, 14 June 2022

Kuala Lumpur

Ex Refresher - UK Online

Tuesday, 21 June 2022

Online

Ex Refresher – SE Asia Online

Tuesday, 28 June 2022

Online

Ex Theory

Monday, 11 July 2022

Aberdeen

Ex Hands-On

Wednesday, 13 July 2022

Aberdeen

Ex Refresher

Wednesday, 13 July 2022

Aberdeen

Ex Awareness Course for End Users

Thursday, 14 July 2022

Aberdeen

Ex Refresher - UK Online

Tuesday, 19 July 2022

Online

For more information or to book any of the couses listed please visit www.ex-repair.com Quarter 2 2022

www.theaemt.com

AEMT Update 9 with York University in May to develop our truly online learning and assessment environment for practical courses. The project will take two years to complete, with phase one being launched one year into the project, which includes online theory learning and assessments. In the meantime, we are filming a course into the repair/rewind of electric motors sponsored by Fletcher Moorland. We hope to have this available for all members by the end of this year.

Finally, our important work with Primary Engineer is bearing fruit, with several members up and down the UK pledging donations towards the charity aimed at raising awareness of engineering careers among young children. At the time of writing, members ADC Electrical in Tyneside, Preformed Windings and Rotary Engineering in Sheffield have already made pledges, with many more in talks with Primary Engineer. If you are interested in supporting this initiative, please contact me for more details.

Internally, we are sad to say goodbye to Nicola Adie, who has been helping us co-ordinate our training courses for over a year. Her replacement, Rebecca, will be starting with us on April 7. She brings a wealth of event coordination and marketing experience, and we believe she is an excellent fit for the role. I hope you will all join me in making her feel most welcome at the AEMT. If you’ve any comments or suggestions, or would like to speak to me about any of the above points, 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.

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10 FEATURE Awards Update 10

Nominations for the AEMT awards are officially open

Following the highly regarded 2021 awards ceremony in November of last year, the nomination process for the 2022 Association of Electrical and Mechanical Trades (AEMT) awards programme is now officially open.

B

uilding on its past successes, the fifth outing of this sectorspecific awards scheme will again culminate in a gala presentation ceremony on Thursday, 17th November, at the Doubletree by Hilton Hotel in Coventry.

Centrally located for easy access from all over the UK, this venue will also play host to the supporting AEMT Conference – a must-attend event for all members. The full programme will be announced during the summer, but its focus will be on providing AEMT members with help and guidance on a range of topics of primary interest to the development of their businesses. Staff recruitment, development and retention, the adoption of smart technologies, the commercial value associated with circular economy and sustainability initiatives, and the support networks that can be accessed by those operating in the sector are all expected to feature in the conference programme.

A panel of renowned speakers will be invited to share their knowledge and expertise throughout the day in a series of talks and presentations specifically designed to be of tangible value and relevance to AEMT member organisations.

Then, during the evening, the AEMT Gala Awards Dinner will bring together the electrical and mechanical trades sector to celebrate business and professional excellence.

INDUSTRY-WIDE ENGAGEMENT Operated by the AEMT and produced

by Touchwave Media, the awards will again acknowledge the skill, effort, and dedication of the people and businesses serving this important industry sector. With sponsorship provided by a host of leading industry names, including ABB, Drives & Controls, EMIR Software, Fanuc UK, Menzel, Musk Process Services, Plant & Works Engineering and Preformed Windings, well deserved industry-wide recognition will be given to those businesses, that are excelling in their commercial endeavours.

Quarter 2 2022

AWARD CATEGORIES The seven categories that make up the 2022 awards programme are: • 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 Award – sponsored by Musk Process Services • Rising Star Award – sponsored by Fanuc UK • Diversity in Engineering Award – sponsored by Preformed Windings • Lifetime Achievement Award – 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 more straightforward, and anyone wishing to play their part in highlighting engineering excellence should visit the AEMT Awards website – www.aemtawards.com.

CLOSING DATE The closing date for all entries is 5.00 pm on Friday 9th September 2022, so those wanting industry-wide recognition for a job well done, be it for product innovation or project management, application know-how, or service and repair, should be making a note of this key date.

It is free of charge to enter the awards, but the promotional value associated with being selected as a finalist is worth 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 For more information, visit www.aemtawards.com or contact the awards programme producers, Touchwave Media, on 07785 290034 or via andrew@touchwavemedia.co.uk.

www.theaemt.com

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

12 Product News

Final form winding machine is a first ROTARY ENGINEERING UK HAS designed and built the first ever ‘final shape’ winding machine to wind and form round wire diamond coils in just one process. When a leading UK motor repair business won a high-volume contract, they needed to be able to manufacture coils as efficiently as possible. Rotary’s engineering team took up the challenge by looking at the problem from first principles, and the final form winding machine was developed.

The new machine has been in service for a number of months and has proven to be highly efficient and reliable with excellent repeatability.

Creating an accurate former, able to guide multiple wires into the final form, required some innovative design work and several iterations were produced before the optimum shape was developed. Working from coil drawings, formers were developed and produced using 3D printing technology.

Trials took place at the company’s Sheffield factory, where the machine was thoroughly tested prior to despatch. The machine

incorporates touch screen PLC control with fully variable speed and accurate turn count with automatic stop.

Commenting on the new product, Simon Swallow, Managing Director at Rotary Engineering, said: “We are keeping up to date with developments in motor technology and regularly contribute to design groups working on research in this

area. This allows us to share our experience with others, and it ensures we are up to date with future requirements. This project was a perfect example of bringing together our experience with new innovative methods of manufacture to give our customer a great outcome.” www.rotary.co.uk

Smart monitoring tool for industrial assets

MOTOR MANUFACTURER, WEG, has launched Motion Fleet Management (WMFM), a control and monitoring tool for the operation and maintenance of industrial assets. Deployable across fleets of motors, drives, gearboxes and other equipment, WMFM promises to reduce unscheduled downtime, optimise maintenance, and improve efficiency in large industrial operations.

WMFM is part of a growing portfolio of digital solutions from WEG. It uses cloud computing and the Internet of Things (IoT) technology to monitor the operational status of several industrial assets. Through data collection and processing, WMFM generates valuable real-time insights to share with plant managers and engineers, ultimately leading to improved asset management.

WMFM’s data processing is managed both on edge and in the cloud – allowing for fast reactions at the device level while also enabling comprehensive data analysis in the cloud. The tool also boasts specialist modules with artificial intelligence (AI), allowing automated

Quarter 2 2022

fault diagnosis based on historical reports and trends.

These reports provide a holistic view of an entire fleet’s performance, allowing plant managers to monitor several assets or even whole plants in a single environment. This data is presented in an intuitive dashboard with indicators, graphics and a history of measured data to allow for easy-to-understand analysis.

Among the insights provided by WMFM is condition monitoring of assets.

Combined with WEG Motor Scan and WEG Drive Scan – sensors to monitor the vibration, temperature and running hours of these respective assets – WMFM can analyse the forecasted deterioration of equipment and advise on predictive maintenance requirements. This can significantly reduce unplanned downtime and costs.

“Motion Fleet Management is an invaluable tool for asset management for most applications,” explained Marek Lukaszczyk, Europe and Middle East Marketing Manager at WEG. “In addition to motors and drives, WMFM is deployable across pumps, fans,

compressors and much more, providing operators with complete transparency regarding their equipment and its performance. Infrastructure, power generation, water, chemicals and mining are among the most obvious use cases, but this tool can be utilised in any industry for the protection of assets." bit.ly/MoFeMa

www.theaemt.com

LOW COST ALTERNATIVE TO OEM HIGH QUALITY SPECIFICATION SHORT LEAD TIMES CUSTOM / BESPOKE DESIGN & BUILD

SUITABLE FOR MOST MAJOR MOTOR MANUFACTURERS INCLUDING

MANUFACTURER’S WARRANTY DELIVERIES THROUGHOUT THE UK CREDIT CARD PAYMENT OR ACCOUNT

AND MANY OTHERS

ARFON REWINDS (PUMPS, DRIVES & MOTORS) LOCATIONS : NORTH WEST ENGLAND & WALES UNIT 4 STADIUM COURT, BROMBOROUGH, WIRRAL, CHESHIRE CH62 3RN TELE: 0151 334 6808 / FAX: 0151 346 1763 / E-Mail: sales@arfonrewinds.com

14 Project Updates

Spare motor for sugar plants MENZEL ELEKTROMOTOREN HAS configured a flexible spare motor for one of Europe’s leading sugar producers, which can replace motors of various other makes if necessary. While the customer can basically employ the three-phase squirrel cage motor in any of its plants around the world, it is, in fact, specifically designed for the sugar beet pulp dryers in four plants in Germany and Sweden. With a rated output of 1400kW, it covers the drive power requirements of four separate systems, ranging from 1000kW to 1400kW. It is designed as a vertical motor for flange mounting (IM V1 standing or IM V3 suspended). In addition, an adapter also manufactured by Menzel enables foot mounting in a system with a V2 flange. The motor with cooling type IC 616 meets the protection class IP55. The customer was on site for acceptance testing at Menzel’s Berlin plant.

The modular MEBKSL motor series

enables a variety of cooling types and ingress protection ratings as well as various mounting options at optimised production costs. The tried-and-tested design meets

Retrofit keeps textile firm's mangle operational A CUSTOMER IN THE TEXTILE industry called on the Westin Drives team to work on a mangle.

The mangle was powered by a 40+-year-old 9.5kW Elektra-Faurndau variable speed brushed AC motor direct coupled to a W.Bothner & Co gearbox.

The motor's commutator had failed badly, resulting in the speed not varying as it should.

Whilst this would have been repairable, it would not have been a quick task, and the machine would have had to be offline whilst the motor was in the workshop.

A retrofit solution was opted for to minimise downtime, and the Westin Drives team assembled a WEG 5.5kW IE3 motor with Force vent kit and a Radicon K-Series Helical Bevel gearbox. To vary the speed, a WEG CFW500 IP66 inverter was used and controlled from a potentiometer on a dancing arm which created a very efficient system.

The shaft centre height was maintained, so no significant modifications were required other than the existing coupling being machined to suit the new shaft and

four new holes added for the feet.

With the mangle back in operation and with the benefit of time, the old unit will now be repaired as a spare for another machine.

high size, performance, cost-effectiveness, and reliability standards. www.menzel-motors.com

2000KVA EMERGENCY GENERATOR INSTALL

DUE TO A FAULT IN THE HV network of a food factory in Northern Ireland, JJ Loughran was asked to source and install a 2000kVA backup generator to get the factory up and running for the following day.

By 4.00 pm, a network fault on the 11kV/415v transformer was traced and confirmed. A backup generator and fuel storage were sourced and loaded for transport by 8:30 pm. The generator was onsite at the food factory by 12:30 am, and the factory was operational and running on the generator by 4:00 am, just in time for factory production to start at 06:00 am, and 150 staff were able to work.

www.westindrives.com www.jjloughran.com

Quarter 2 2022

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Remote Condition Monitoring by

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

ONE

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FEATUREUpdates 16 Project

Improved performance for milk transfer pump A CHANGE IN THE STYLE OF PUMP used in a milk transfer application resulted in significant benefits for a food manufacturer in North Yorkshire.

The original design for the milk transfer system had a lobe pump fitted; however, this wasn't performing properly and was struggling to pump the milk. In an attempt to rectify the situation, the customer had then fitted a diaphragm pump which offered a slight improvement but was still not satisfactory.

After Rotor Technical Services' pump specialist carried out an onsite inspection, it was confirmed that the diaphragm pump wasn't the correct pump for this application either. Rotor proposed a fully stainless steel Fristam Hygienic Rotary Screw pump, arranging a one-month trial to allow the customer

to assess the recommended pump's performance and ensure it was entirely satisfied with it before committing to a purchase.

The trial proved successful, and the rotary screw pump offered the customer several benefits. The air required to drive a diaphragm pump is considerably more expensive than the electricity needed to drive an equivalent screw pump. Diaphragm pumps have high running costs due to failing diaphragms, non-return valves, air valves, etc. They are also notoriously difficult to clean effectively without proper operator protocols, where the rotary screw pump supplied was suitable for clean in place (CIP) procedures. www.rotortechnicalservices.co.uk

Brake motor upgrade WEBB-ELEC WAS RECENTLY ASKED to engineer a brake motor upgrade solution for a customer who had issues with brake motors that were continually failing in production.

The motors were used in a brick packaging application. In this instance, the customer was suffering from premature brake failure with the existing brake motors. The fault was the same in all instances, with the brake coils being the point of failure. The customer called Webb-elec to discuss the problem, and the next day an engineer attended site and inspected the problematic motors as they ran through their full operation.

The engineer noted that the customer had increased its production rate and

that the duty cycle of the existing brake unit was now far in excess of its designed operating window. Hence the brake was running very hot, resulting in the coil finally burning out.

The solution was to supply a new SEW Eurodrive unit. This is a brake motor complete with a force ventilation fan that would enable a constant stream of cooling air to keep the motor and brake unit cool during its operating cycle. This was not possible with the standard motor shaft-mounted fan due to the continual stop-starting action of the production

process. In addition, the brake rectifier was reconnected to shorten the brake response time to ensure it was already released upon motor startup. www.webb-elec.co.uk

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FEATURE 18 Skills

Businesses urged to Join the skills revolution

New research has revealed that a huge 80% of workers in the manufacturing and utilities industries are interested in learning new work skills in 2022, higher than the nation's average of 70%.

T

he new Censuswide survey of over 4,000 of the UK's workforce showed a clear national appetite for skills development and indicated that employees are hungry to learn more and progress further in their careers this year compared to 2021 – with 69% wanting increased job satisfaction in 2022 and 67% feeling that gaining new skills will be key to achieving their work goals.

Over a quarter (28%) of workers said that progression and opportunities to learn were paramount goals in their working life.

This research coincides with the launch of the government campaign which urges employers to 'join the skills revolution', aiming to help businesses across a wide range of industries gear up for economic recovery by skilling up their workforce.

The campaign highlights the range of training and employment schemes available for businesses wanting to boost their workforce capabilities, including apprenticeships, traineeships and T levels.

SKILLING UP Sector-specific findings from the survey have indicated that a massive 80% and 77% of respondents working in manufacturing and utilities industries, and engineering respectively, are also interested in learning new skills relating to their work in 2022. The top areas workers say they are most keen to explore include IT and digital (20%), finance (16%) and business (16%), with 1 in 9 (11%) expressing an interest in learning more about green industries this year. Businesses are being encouraged to grasp this development opportunity to boost their business growth.

Quarter 2 2022

The 'Join the Skills Revolution' campaign will showcase hundreds of government-funded skills opportunities and help businesses upskill their employees, find new talent, and train the future workforce.

Commenting on the survey and the campaign launch, Nadhim Zahawi MP, Secretary of State for Education, said: "It is no secret that a skilled and motivated workforce is the key to driving better performance and boosting productivity. There has never been a better time to make skills a top priority. To support businesses to unlock untapped talent, there is a huge range of training available to help upskill their staff for free, from online courses to boost numeracy to apprenticeships, traineeships, T Levels or our Skills Bootcamps."

A DEMAND FOR LEARNING The research found a considerable demand for on-the-job training, with 39% of workers saying they would find this particularly

useful. A further 31% of workers wanted courses specific to their sector, as well as encouragement and practical support from their employer – with 1-in-3 saying they felt held back by a lack of time (36%), a lack of confidence (31%) or knowing where to start (30%).

The opportunities on offer, as part of the Join the Skills Revolution campaign, have been designed by and in partnership with employers, listening to businesses to help meet their recruitment needs and address skills gaps, through flexible, free or subsidised courses. Skills Bootcamps, for example, provide fast-track sector-specific training in areas such as construction, HGV driving, green skills, digital, manufacturing and engineering, as well as creating a pool of skilled staff ready to recruit with the right training.

Businesses are urged to join the skills revolution and drive better performance, by visiting: www.gov.uk/skills-support

www.theaemt.com

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

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20 Machine Safety

Built-in safety sets the standard Marek Lukaszczyk, European and Middle East Marketing Manager at electric motors, drives and gearboxes manufacturer, WEG, explains the use and importance of safety certifications for variable speed drives.

I

n the pursuit of quality and productivity, machines and production systems progressively become more sophisticated. Following this evolution, the demand for equipment safety in industrial processes also grows.

Functional safety is a reality, and its presence in the machinery sector has become a legal requirement in many countries.

For example, variable speed drives (VSDs) need to have their safety features certified. This is done by an unbiased third-party body that follows the applicable safety standards for VSDs and machine safety, approving them for different safety levels.

But what is the meaning of functional safety, its rules, acronyms and terms quoted by those who sell, apply, certify and use this type of equipment? And how are VSDs related to machine safety?

INTEGRATED SAFETY FUNCTIONALITIES Built-in safety functions for VSDs ensure safe cleaning and maintenance of processing machinery. For example, according to IEC 61800-5-2, the safe torque off (STO) safety function prevents force-producing power from being provided to the motor, corresponding to an uncontrolled stop in accordance with stop category zero of EN/IEC 60204-1.

This means that once triggered, this safety function will virtually eliminate any possibility of electromagnetic torque production on the motor shaft. Therefore, if a motor is rotating, it will coast to a stop after the STO activation.

The main application of this safety function is to prevent unexpected start-up of a machine or equipment when an engineer needs to come into direct contact with dangerous

Quarter 2 2022

moving parts during either commissioning, operation or maintenance.

Another safety function – safe stop one (SS1-t) – is described in EN/IEC 61800-5-2 as a function that initiates the motor deceleration and performs the STO function after a specific time delay.

This corresponds to a controlled stop in accordance with stop category one of EN/IEC 60204-1.

Differently from the plain STO, this safety function will wait a predefined delay time in which the VSD imposes a deceleration ramp to the motor before the torque-generating energy cuts off. SS1-t is especially useful in applications where inertial loads need to be quickly decelerated, before removing torque from the motor.

With the SS1-t safety function integrated into the VSD, the use of an external safety relay is no longer necessary to perform the controlled stop in accordance with stop category 1 of EN/IEC 60204-1. This lowers costs in the design of a machine or equipment and reduces the occupied area within the panel.

WEG’s VSDs are recognised for their ease of use, reliability and updated safety functions – STO and SS1-t. For example, WEG’s CFW500 series uses safety

integrated level (SIL) three and performance level (PL) rating, according to EN/IEC 61508 and EN ISO 13849-1 – the highest levels of reliability for industrial VSDs. Using a VSD with safety features makes it possible to reduce the number of safety devices needed to comply with the required PL or SIL. Built-in safety features in VSDs, like these, make it easier to achieve safe operation of processes and protect maintenance staff working on motor-driven machinery. And, by temporarily cutting the voltage to the motor, there is no need to shut down the drive so processes can resume safely. TIMES-CIRCLE

This safety function will virtually eliminate any possibility of electromagnetic torque production on the motor shaft.

www.weg.net

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FEATURE Areas 22 Hazardous

ATEX fans: An explosive issue O

Air movement specialist, Axair Fans, explains the steps needed when specifying and sourcing fans for use in potentially explosive environments. utside of major users such as chemical, petrochemical and process industries, enquiries for flameproof fans tend to come from specifiers, resellers and end-users, many of whom may not be aware of the ATEX Directives.

ATEX is an acronym derived from the French expression ATmosphères EXplosibles and exists in the form of two European directives for controlling explosive atmospheres.

The first ‘equipment directive’ 94/9/ EC (ATEX 100) covers manufacturing standards. The second ‘workplace directive’ ATEX 99/92/EC (ATEX 137) seeks to ensure that people are protected against the risk of blast injuries or asphyxiation by dangerous substances. The 2016 updated legislation is Directive 2014/34/ EU and assists with establishing a uniformity to the approach taken when supplying and distributing equipment such as industrial fans for explosive atmospheres.

Everyone involved in the specification, manufacture, installation, and use of equipment in flameproof zones has some responsibility in ensuring that the law concerning flameproof equipment is upheld.

Unfortunately, a lack of practice with the subject tends to give rise to enquiries that begin with statements like “there is a slight risk of explosion, but we don’t think we need a flameproof fan”, which places manufacturers and suppliers in an awkward position because they are not ATEX consultants and are not qualified to know what the client can lawfully install.

What can the fan supplier do with casual enquiries that must at some point turn into tightly specified orders?

The first option is a blunt “come back when you know exactly what is

Quarter 2 2022

required” and the second is to issue a questionnaire, usually with tick boxes and a bit of guidance appended, which may then be returned with conflicting selections.

What is needed in every case however is an ATEX code that provides a well-defined minimum standard for the product that is required. For example, the code Ex II 2G IIC T4 essentially means European flameproof, surface industry (not mining), Category 2 (Zone 1), gas group II, type C (hydrogen or acetylene gas), maximum surface temperature 135ºC. It is strictly the responsibility of the end-user to perform a DESEAR (Dangerous Substances and Explosive Atmospheres Regulations 2002) risk assessment to ensure that flameproof zones are properly defined in terms recognised by ATEX 99/92/EC. It is recommended in 99/92/EC that an Explosion Protection Document be produced, which will help to define the ATEX code for any equipment to be installed in the flameproof zone.

There are many other coding permutations, including slightly different formats for dusty atmospheres (Zones 21 & 22). If codes cannot be provided there is lingering uncertainty over what is required.

Once an ATEX code has been established by the end-user, the process of selecting a fan model and its essential features demands a degree of application knowledge.

For example, the type of electrical supply is important. Often the response to “what electrical supply do you have”, is “can be single- or threephase”. Single-phase is an expensive option and not widely available from ATEX motor manufacturers.

It may be cheaper to run a 3~ line than to buy a ~ fan on a long manufacturing lead-time Any fan motor that is to be speed controlled with a VSD must also have thermistors fitted to protect against motor shell temperature at low speeds causing spontaneous gas combustion. By not mentioning the VSD aspect at the enquiry or order stage the purchaser is likely to ultimately face time and product replacement costs.

Other matters include motors that vary from the most secure specification EEx d (explosion proof) through EEx e (increased safety), down to EEx nA (non-sparking) which has many similarities to a standard nonflameproof motor.

ATEX must be understood as being an ever-evolving subject requiring competence and training. Anyone requiring a better understanding of flameproof requirements would be advised to source training which is available from a wide range of industry bodies and organisations. TIMES-CIRCLE

ATEX must be understood as being an ever-evolving subject requiring competence and training.

www.axair-fans.co.uk

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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.

Contact us at: T: +44 (0)1484 557200 E: sales@brookcrompton.com

24 MArket Analysis

Three ways Russia’s assault on Ukraine could affect motor and drive supply

Blake Griffin, Senior Analyst at technology insights specialists, Interact Analysis, looks at the potential impact the conflict in Ukraine could have on the production of low voltage motors and drives.

T

he war that Russia has waged on Ukraine has rocked global commodity markets. While oil & gas supply disruption and the resulting increase in price continue to dominate headlines, there are a number of other key materials exported by Russia and Ukraine which have been equally disrupted.

The disruption of many of these materials will have both direct and indirect impacts on costs associated with producing a motor or drive.

After the extremely turbulent price levels experienced around the world in 2021, further supply disruption off the back of conflict was the last thing the global economy needed. Unpacking the impact this will have on the most crucial areas of the motor and drive supply chain can help suppliers prepare their businesses for what is to come and manage the expectations of their customers as the situation continues to unfold.

ALUMINIUM AND COPPER The impact on the supply of key materials is two-fold. First, the economic sanctions placed on Russia will impact its ability to sell

Quarter 2 2022

various products to its historically largest customers. Second, the physical devastation experienced in Ukraine will impact its ability to produce and ship its key exports.

As it pertains to the production of motors and drives, the most direct impact stems from the disruption of aluminium and copper supply chains.

According to CNBC, Russia is responsible for approximately 6% of the global aluminium supply.

After significant COVID-19 related supply disruptions, which resulted in a steady rise in price over 2021, it appeared that supply and demand were beginning to normalise in the last months of the year. In late 2021, the world bank had forecast a price increase for aluminium of ~5% during 2022. Now that a war has broken out, Interact Analysis expects that price forecast to be on the conservative side. As shown in Figure 1, the impact is already being felt, with aluminium

prices climbing to record highs in February this year.

We expect this price to climb even further as transportation costs continue to rise amidst the disruption of the oil supply.

The story for copper is not much different. While Russia is not as significant a player in the raw copper market as it is in the aluminium trade, it still produces nearly 5% of the world's supply.

While the price has not yet reached record highs, it likely will next month, as indicated in Figure 2.

Perhaps more relevant is Russia's role in the copper wire market. Nearly 7% of the world's supply of copper wire, as used in induction motors, comes from Russia.

This will have an immediate and significant impact on the cost and availability of copper wire used in induction motors.

If you were to look at the bill of materials for an induction motor (including wages), copper and

Nearly 7% of the world's supply of copper wire, used in induction motors, comes from Russia.

www.theaemt.com

MArket Analysis 25

Figure 1: Aluminium price performance.

aluminium make up approximately 16% of the cost. The supply disruption these two commodities have seen due to war will be felt throughout 2022 in the form of a higher bill of materials. The motor market had already experienced significant price increases during 2021 as a result of increasing raw material costs. It would appear that price increases are likely to continue into 2022.

NEON When one thinks of commodities impacting the drives market, neon is not the first thing that comes to mind. However, the noble gas will likely play a significant role in the production of drives during 2022, albeit indirectly.

Figure 2: Copper price performance.

www.theaemt.com

The semiconductor shortage has been a major concern for motor drive suppliers. Throughout 2021, the shortage of this key motor drive component caused delays in the production process resulting in extended lead times across the motor drive market. While not directly used in the manufacturing of motor drives, neon gas is used heavily in the production of semiconductor chips. The gas is used in the etching of silicon using high-powered lasers during the lithography step of

the semiconductor production process.

According to an article by Reuters, two companies based in Ukraine account for about half of the world's neon supply. Both companies, Ingas and Cryoin, have shuttered operations amidst the Russian invasion. Resultingly, semiconductor suppliers, which are already facing a demand/ supply imbalance, are now likely going to face additional production challenges stemming from a significant neon shortage.

Semiconductor suppliers (before the war) had pointed to Q4 2022 into Q1 of 2023 as the timeline for when the shortage of semiconductors would begin to resolve. Fortunately, many of these same suppliers have since reported stocking up neon supply ahead of the war. However, if the conflict does not resolve in a timely manner, these stockpiles could run out. Should this occur, the semiconductor supply could once again fall into disarray and drive suppliers would face sourcing problems similar to the ones at the start of the semiconductor shortage in early 2021.

Two companies based in Ukraine account for about half of the world's neon supply.

FINAL THOUGHTS As this war unfolds, we will continue to review its impact on the markets we cover. Aluminium, copper, and neon are just three areas where this war will impact the production of motors and drives.

There are undoubtedly impacts we have not touched on here, including increased freight costs on the back of higher diesel prices, steel supply disruption, and the impact on end markets such as mining and oil & gas, which are extremely large sectors within Russia and Ukraine.

The impacts of this war are farreaching, and we have only just begun to bear the consequences of Putin's ill-intended actions. TIMES-CIRCLE www.interactanalysis.com

Quarter 2 2022

26 WIND TURBINES

Breathing new life into a wind turbine In 2021, electro mechanical engineering specialist Houghton International carried out the repair and rewind of an 850kW direct-drive wind turbine generator. Renew found out more about the project.

T

he Enercon E48 wind turbine was erected and commissioned in 2019 on a farm in the village of Llanwnnen in Ceredigion, Wales,

by Grannell Community Energy, a locally-funded Community Benefit Society. It was purchased from a wind farm in the Netherlands, where it had previously been in operation.

In late 2020 the turbine failed in service due to an earth fault, and Grannell Community Energy approached Houghton International to carry out repair work. Based in North England, Houghton International accommodated the 26-tonne generator in its large machine repair shop, which is specifically designed for large-scale projects.

Lindsay Thomas, Director at Grannell Community Energy,

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commented: “As a community energy group, we have invested significant time, effort and funds into our wind turbine project, so when it came to repairs, it was particularly important to us to find a repairer that could offer the highest quality of service.

“From our first contact with Houghton International, we were impressed by their professionalism, enthusiasm and support for the project. Not only did they have the facilities to accommodate a project of this size, but they also gave us full confidence in their experience and

technical expertise.”

Considering the age and condition of the asset, and previous works carried out on the turbine, Houghton International’s project team recommended a full rewind of both the rotor and stator to minimise the risk of further faults and extend the operational lifespan of the turbine.

Houghton International has developed a range of processes and intellectual property inhouse, several examples of which were used during this project, as Chris Measor, Winding Assistant

"To rewind the DC pole shoes from the rotor, we used a system we had first developed for use on high speed trains."

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Wind turbines 27 Manager at Houghton International, explained: “We agreed with the customer that we would make improvements to the insulation systems on both the rotor and stator to give them peace of mind of a long-lasting, quality repair.

“To rewind the DC pole shoes from the rotor, we used a system we had first developed for use on high-speed trains, which is tried and tested with a proven track record. Whilst running on the railways, this system is exposed to high levels of moisture and temperature extremes, making it an ideal choice for the conditions the wind turbine is likely to see.

“We also uprated the insulation on the stator to a Class 3 enamel copper, which has a breakdown voltage of about 15,000V. The generator runs at around 480V, so this gives it a very high dielectric strength.”

The project was the first of its kind to be completed at Houghton International, requiring the manufacture of a bespoke

frame and motorised jig for the winding of over 50 miles of continuous copper wire from three drums.

Houghton International provided regular reports and progress updates to Grannell Community Energy throughout the project and continued to deliver support after the turbine had been transported back to Wales for reinstallation.

Lindsay concluded: “The support from Houghton International has been excellent even after the generator left their facility. We were able to come back to them with further questions during the installation, and we are reassured to know they are on hand in future for any spares or maintenance support needed.

“Having recently reinstalled the generator, initial impressions are that it is generating exceedingly well, and we are optimistic it will meet our most ambitious projections for power generation.

As a result of the comprehensive and diligent work carried out, we effectively have a brand new turbine in operation, and we have every confidence that it will meet its 20year lifespan expectation.” TIMES-CIRCLE bit.ly/HIgce

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Bearings 28 FEATURE

Finding fake bearings stops machine failure Identifying counterfeit bearings – and taking them off the market – is vital in order to prevent costly machinery failure, according to Andrew Mynett, Key Account Manager at SKF.

C

ounterfeiting is usually associated with luxury consumer products such as designer handbags and watches. However, the problem is also prevalent in the engineering sector.

The numbers are astronomical. The Organisation for Economic Co-operation and Development (OECD) estimates that, in 2019, more than 3.3% of all traded goods that crossed borders were counterfeit. In monetary terms, this exceeds €400 billion, or US$500 billion.

When a counterfeit consumer product such as a watch fails, the effect is little more than hurt pride (and a bruised wallet).

In industry, the effects of a counterfeit bearing can be catastrophic – and far more expensive than the cost of the bearing itself.

It can lead to both expensive downtime and machinery damage.

Bearings are precision products designed to work under specific conditions.

Processes such as heat treatment – and the use of high-grade steel – help them withstand tough conditions such as high loads and extreme temperatures. You would never use the wrong bearing in an application, yet it is impossible to know what you are getting with a counterfeit.

The product quality is unknown; hence performance is unreliable.

A fake bearing will appear identical to the product it is trying to emulate. However, the similarity will end there. An ‘original’ may be made from surface-treated, high-grade steel with accurate tolerances; the counterfeit version will have none of these things.

Oblivious to this, a customer will install the fake bearing into their machine.

It is no accident that counterfeit bearings are sold in place of the genuine article.

Typically, non-branded bearings – which are widely produced – are bought in by the counterfeiters and branded with the logo of a leading bearing manufacturer, including SKF. These bearings are then typically put onto the market through online sales.

The deception is enhanced by the

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packaging, which will feature highly sophisticated company logos, barcodes and branding – all of it false.

In some instances, counterfeiters supply a ‘certificate’ with the product. Again, this will not be genuine.

With such a high prevalence of fakes, users and distributors need to be on their guard. One tip for avoiding fake bearings is pure common sense: do not buy if the deal seems too good to be true. This is especially important for a product like a bearing. However, fake bearings are not always offered at knock-down prices – as a Rolex watch might be. Typically, counterfeit bearings are sold online by distributors that have been duped into buying them.

The distributor will then sell them on – often unwittingly – which will typically result in an angry customer.

The best way to safeguard product authenticity is to purchase SKF products from authorised distributors. Being an authorised SKF distributor comes with responsibilities, implying that sourcing practices are at the highest level.

Because of the huge damage that fake bearings can cause, SKF takes the issue of counterfeiting very seriously. It regularly collaborates with authorities to ensure that fake products are taken off the market. One recent case in China tracked down a fake distributor. In the Middle East, authorities

seized 20 tonnes of counterfeit, SKF-branded bearing grease. It was identified because the buyer was alert enough to realise that it literally did not smell right. Even in the UK – where the problem is less widespread – Trading Standards have seized counterfeit bearings from a small supplier.

Non-branded bearings may be genuine products with legitimate uses in engineering.

However, they are typically inferior to highly engineered bearings – which are designed for specific, demanding applications.

Users who unwittingly buy fake products are not only cheated of their money.

Their machinery is also at risk of severe damage – which can have huge financial consequences. For this reason, it is critical to stay vigilant about the practice of counterfeit bearings. TIMES-CIRCLE

In the Middle East, authorities seized 20 tonnes of counterfeit, SKF-branded bearing grease.

This article was originally published by Hayley Group at bit.ly/hlySKF

www.theaemt.com

30 Predictive Maintenance

Static and Dynamic Testing to inform Predictive Maintenance Electric motor analysis specialist, Megger Baker Instruments, looks at current electrical test methods and trend analysis of the operational health of electric motors designed to support successful predictive maintenance programs.

P

redictive maintenance programs are crucial to an organisation’s ability to avert unplanned or unnecessary downtime that can adversely affect its ability to produce or operate. Unlike time-based or run-to-failure approaches to maintenance management, condition-based programs are ideally geared to pay for their cost of implementation by extending the service lives of motors and rotating equipment, averting costly unplanned downtimes and minimising the costs of replacing expensive equipment. Predictive maintenance programs are most effective when all available means of measuring health and analysing health trends of electric motors, cables, power quality and load are rigorously implemented.

In other words, the safe and continuous operation of plants and facilities drives revenue and profit and depends upon high motor reliability. Predictive maintenance of motor systems is a necessity when it comes to supporting reliability objectives that, in turn, support an organisation’s business objectives. The power generation industry, as an example, ranks at the top of this requirement for uninterrupted operation and safe, continuous production. A number of motors run equipment that is ancillary to the production or health of a company (e.g., one of a few rooftop motors for a HVAC system, which won’t have an immediate impact on the HVAC system if it stops working). Other motors, however, are critical to a company’s ability to conduct business; that is, they are

motors that drive such things as conveyor systems, fluid pumps, or production-line machinery that a company relies upon to generate revenue and profit every day.

MOTOR SYSTEMS Whether used to drive conveyors, pumps, cooling fans, or any other machinery, motors are best viewed as core parts of “systems.”

These are often referred to as “motor systems,” or sometimes “machine systems” (see Figure 1). These systems include the motor, the source of the motor’s power, and the equipment or machinery driven by the motor.

Today, electric motor test equipment is generally categorised into two types: static motor test equipment and dynamic motor test equipment. The first type can simulate real world situations when motors are off-line. The second type is used for safely acquiring accurate and valuable health data across a working motor system or a motor’s in-service environment.

Static motor test data provides visibility into the integrity and condition of a motor’s insulation and motor circuit. Modern equipment helps maintenance technicians predict or identify imminent failures before they cause costly unplanned downtime of

motors and the rotating machinery they support. The most effective static test equipment can test the components of motors at voltage levels similar to those the motor will see in its normal operation without destructive currents.

Static testing should include the surge test, which is the most effective method of ensuring the integrity of a motor’s turn-to-turn insulation. The best static motor analysers produce trend logs and reports, which allow technicians to track any decline or degradation in a given motor’s health.

The latest dynamic test equipment can locate and identify problems that adversely impact motor health and life that are on either side of the motor within the motor system.

These are generally power-related issues and load problems, but can include vibration or circuit condition problems within a motor while the motor is in-service.

Dynamic motor analysers can often calculate speed and torque, define rotor bar problems, and measure distortion. Dynamic motor testing can also identify several mechanical issues, such as bearing problems or motor shaft misalignment. Dynamic testing helps isolate the mechanical (system) issues from electrical (internal to the motor) > 32

Static motor test data provides visibility into the integrity and condition of a motor’s insulation and motor circuit.

Figure 1: A typical motor system comprising a power source, motor and the driven equipment.

Quarter 2 2022

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32 Predictive Maintenance issues, while providing valuable information to discern the root causes of motor failures.

The goal of a predictive maintenance program is almost always to reduce unscheduled downtime. An effective predictive maintenance program is measured by how well it works to predict imminent failures and identify potential problem areas before they fail, and create expensive recovery costs for an organisation. They should also work to determine the root causes of failures and, ultimately, save money by extending the service life of motors and rotating equipment.

This is why the electrical testing of motors is such a critical component of predictive maintenance. Static and dynamic analysis, along with trend data acquisition and analysis, provides the information technicians need to make good decisions regarding the use or maintenance of a given motor.

OFF-LINE TESTING Static testing (or off-line testing of motors in their static, powered-down state) is commonly performed just once in a given period of months, usually up to a year. It’s also performed opportunistically during outages when a motor is shut down for other reasons.

Off-line testing is often used as a quality assurance measure when receiving new, reconditioned or rewound motors from a supplier or motor shop. This is to assure they work as expected before they are stored or returned to service. Tests of these motors serve to prove the motor shop is doing its job correctly, and they create new baselines for future trend analysis.

Static motor test equipment can troubleshoot motor problems or failures. Any time a problem occurs, the motor involved should first be tested for insulation integrity.

Out-of-spec voltages, motor loads and contaminants are examples of problems that can adversely impact a motor’s internal insulation.

Typical static tests include winding resistance, meg-Ohm, polarisation index (PI), DC step voltage and surge testing. These tests should be performed in that sequence with modern, state-of-the-art test equipment.

These surge-test analysers can reproduce real-world experiences without causing damage to a given motor’s insulation system, and underscore the importance of testing motors at voltage levels and conditions a motor experiences in normal operation.

Winding resistance tests confirm that a motor’s phases are balanced; such tests discern shorts and opens in the motor’s windings as well as high, out-of-spec resistance connections. A static meg-

Quarter 2 2022

ohm test can determine if the motor’s windings are grounded or contaminated.

The megohm meter is probably the mostused test instrument in the field, but it has its limitations. Meg-ohm testing is usually performed at voltages slightly above line voltage.

It is important to note that a meg-ohm test can determine if a motor is bad, but cannot confirm it is good. Low meg-ohm results indicate impending failure, but high meg-ohm values do not ensure that a motor is free of other faults. A polarisation index (PI) test can also confirm poor/degraded insulation within a motor, but while it can indicate when a motor’s insulation is old and brittle, it does not find potential turn-to-turn faults.

A DC step-voltage test involves exposing the entire winding to a voltage equal to that commonly seen at start up or shut down, and looks for weak ground-wall insulation.

Weak or damaged cable problems can also show up during this test, and it may be necessary to separate the motor at its junction box to determine the root cause of the problem.

DC step-voltage testing is commonly performed at double the line voltage plus an additional 1000 volts but has no adverse impacts on the motor or motor insulation when properly applied.

Lastly, a surge test should be applied once a motor has passed all the other tests. Surge testing is the only way to locate weak turnto-turn insulation. These copper-to-copper faults are the primary cause of more than 80% of all winding-related failures, and they will go undetected if not for the surge test.

When allowed to run to failure, most motors will blow to ground in a slot. That is because a slot provides a ready path to steel, but most such shorts will have started as a copper-to-

copper/turn-to-turn fault. Locating the weak insulation before they become hard-welded faults allows a maintenance professional time to plan for repairs before a catastrophic failure causes unscheduled downtime, expensive repairs and lost production. Once these turn-to-turn faults have become hardwelded faults, a motor typically only has about 15 more minutes of service life.

ON-LINE (DYNAMIC) MONITORING Dynamic or online monitoring is performed while the motor is powered on and working within its normal system or application.

Data collection with dynamic motor testers is safe, fast and non-intrusive. Dynamic testing provides information regarding power quality and conditions such as voltage levels, unbalances and distortion. A small amount of voltage unbalance, coupled with minor harmonic voltage distortion, may result in a NEMA (National Electrical Manufacturers’ Association) derating that will not be seen with simple multimeters and amp probes. Current levels and unbalances also affect motor performance, and monitoring them is essential for trending motor health.

Dynamic testing can and should be performed more often than off-line testing with a frequency of testing similar to vibration analysis.

Besides electrical issues with motors that the technology can monitor, many mechanical issues with a motor and its system are also discernible with data that dynamic analysers can collect. Torque and current spectra have proven to be highly useful in determining mechanical issues, including bearing faults, looseness (vibration or misalignment) and eccentricity. Again, > 34 considering a motor is part of a system

Dynamic testing can and should be performed more often than off-line testing.

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34 Predictive Maintenance with three components (power source, load source, and the motor itself), a good dynamic analyser provides relevant condition information about all three. Many motor problems are created by adverse or mismatched loads or poor supply power.

Without a means of analysing data from monitoring across a motor system, the true root cause of motor failure often goes undetected. The ability to acquire and define such adverse impacts as torque provides a maintenance professional the means to separate the mechanical from the electrical issues, improve decisionmaking concerning repair or replacement, and otherwise extend the service life of the motor (see Figure 2).

Dynamic testing provides health information about motor systems across power source, motor and load source. It monitors power quality and conditions such as voltage levels, unbalances and distortion.

Current levels and current unbalances also affect motor performance, and monitoring them is essential for analysing motor health trend data.

Another challenge with electric motors is tracking the condition of their rotors.

Today’s dynamic motor analysers help predict rotor bar failures or potential failures if the load is relatively steady. A pump, fan or blower operating at a steady frequency will show very clear rotor bar signatures that make rotor fault diagnosis easier.

During normal operation, a motor’s rotor is stressed by its load. Torque waveform analysis provides a picture of those stresses, and when they reach levels out of spec for the motor, they can be an indicator of a number of mechanical problems.

Cavitation and belt flapping, for example, are easily seen in a torque waveform signature. Motor analyser manufacturers continue to improve upon the ability of test equipment to discern other mechanical motor system issues earlier and with greater accuracy.

Nearly all modern static and dynamic testers are portable. Static testers can be used in a shop or easily carried into the field. Dynamic testers are by nature used in the field (wherever running motors are located), but often test via a motor control centre. However, emerging new technology has spawned a dynamic motor analysis tool known as an online motor analyser that is permanently installed. The concept is to perform all of the same tests a portable dynamic motor tester does, but with the additional benefits of continuous monitoring and viewing the status of a

Quarter 2 2022

Figure 2: Extending motor life with predictive maintenance testing.

given motor from a central office location – or for that matter, anywhere in the world with a PC and a good Internet connection.

This technology enables maintenance professionals to make better decisions faster than the “spot-testing” method of testing that is characterised by route-running once every few months to yearly. It captures information that cannot be captured in a single testing session performed with a portable tester. Alerts can be set to flag maintenance professionals of the need to investigate or replace critical motors the online analyser is monitoring.

Moreover, the trend data from months of monitoring provides valuable insight that informs predictive maintenance planning and helps prioritise resources and actions. Finally, because the monitoring is effectively performed remotely, online dynamic analysers all but eliminate safety hazards associated with testing in-service motors in the field.

Dynamic monitoring also provides efficiency information allowing maintenance professionals to make wise and practical decisions when confronted with choices to repair or replace a given motor. Improving efficiency by just 2% may result in thousands of dollars in excessive annual energy costs.

CONCLUSIONS Static and dynamic testing of electric motors is critical for successfully implementing predictive maintenance programs. Static testing is the most effective means of measuring the integrity of the motor’s insulation system and can be used for quality assurance when a motor is out of service. Dynamic testing provides valuable information about motor systems, including power condition, load, and the motor, including physical aspects that can affect the life or operation of the motor. Online motor monitoring adds the dimension of gathering motor system health data at regular intervals throughout the day, 365 days a year. Combined, they present a comprehensive picture of motor and motor system health that can be a foundation for successful predictive maintenance programs. They provide the full spectrum of motor condition information required to diagnose and predict imminent failures accurately and, as a result, solidify electrical motor testing’s place as an essential part of a complete predictive maintenance program. TIMES-CIRCLE

Static and dynamic testing is critical for implementing predictive maintenance programs.

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“Thanks to Houghton International for their continued professional and efficient service. Without HI we would not have identified the deteriorating condition of a number of critical motors that could have failed in service with implications leading to potentially large commercial costs for the terminal. I would gladly recommend HI to colleagues and others in the industry.

It has been a pleasure to work with them and I look forward to our continued working relationship.”

Ashley Smith, National Grid

• Repair, maintenance and life extension • High voltage coil manufacturing • In situ HV testing and condition monitoring • Reverse engineering and performance improvement

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36 Condition Monitoring

Condition monitoring: Enhancing not replacing maintenance Teams Matt Fletcher, MD of Fletcher Moorland, the company behind the Meerkat condition monitoring system, looks at the advantages a condition monitoring solution can offer, and busts the myth that the technology is putting maintenance teams out of a job.

T

he Meerkat condition monitoring system was developed in early 2017 for a customer who had a critical piece of equipment in a location that was not easily accessible. It was their main pump on a floating pontoon at a quarry.

If the pump failed, the feed to the processing plant stopped. So they needed a way to monitor it.

Due to the location, a wired system was out of the question, so a wireless solution was needed.

The Fletcher Moorland team found a suitable sensor with a wireless node and receiver. This was combined with a standalone HMI for signal processing. Whenever a predetermined level of vibration or temperature was breached, a signal light lit on the 'shore-side' equipment and the maintenance office. The maintenance team were then able to react to the problem.

Pretty quickly, with the growth in awareness of the Industrial Internet of Things and Industry 4.0, interest in the system grew. The team knew that it needed to develop the system further. An early addition was a GSM gateway which enables the system to SMS message a mobile phone when an alarm is breached. This allowed an entire maintenance team to be alerted to a problem happening wherever they were.

The next development involved moving sensor data from a standalone system to the cloud and a web-based dashboard. Anyone with the correct access could then view the data; trends could be seen, alarms and notes acknowledged.

As customers saw the advantages of the condition monitoring system, requests to monitor more than vibration and temperature began to be made. As a result, sensors

Quarter 2 2022

Figure 1: Temperature trace showing a significant jump in a dryer motor.

monitoring current, humidity, airflow, pressure, oil condition, fluid level and sound level were added to installed systems.

As the solution continues to develop, the latest evolution is the addition of edge computing capabilities. Monitoring systems can create a massive amount of data, and edge computing can handle this more effectively and efficiently.

Couple this with a Raptor gateway, and the system can benefit from artificial intelligence and machine learning capabilities which can help identify potential issues starting to happen with equipment.

Of course, one issue often faced is concern that condition monitoring solutions will replace people and cost jobs. But, like many forms of automation technology, that isn't the case. What should happen is that existing staff are able to step away from mundane, time-consuming tasks, or unplanned interruptions to focus their expertise in areas where they can add more value to a business – and gain greater satisfaction from their work.

Condition monitoring solutions should be the first line of maintenance. For example, if there

is a threshold breach, say a fan's vibration velocity has changed, someone needs to investigate this.

Used correctly, condition monitoring solutions reduce the need to drop everything when something unexpectedly fails, or spend time investigating or checking something that doesn't need to be checked.

It enables maintenance teams to focus more on proactive rather than reactive tasks.

A recent situation caught by a Meerkat remote condition monitoring system is a good example.

At a site that produces bricks, the Meerkat system alerted that there was an over-temperature alarm on one of the dryer motors. As the dashboard graph in Figure 1 shows, the temperature jumped significantly from a normal operating temperature of around 25-30°C to almost 100°C. In this case, the site maintenance team were alerted to investigate what was causing the over-temperature warning. It turned out that the force vent fan on the motor had failed.

A new one was pulled from stores and replaced, and very soon the temperature was within normal limits.

Left unattended, the motor would have undoubtedly stopped working

www.theaemt.com

Condition Monitoring 37 due to a motor winding insulation failure caused by the excess heat.

Vibration monitoring would have probably not seen anything. Thermal surveys would not have seen anything until the force vent unit failed, and being there at that exact moment is very unlikely. It is also unlikely that there would have been any warning of this failure, so having a continuous monitoring system was the saviour.

Having a system installed has, without question, saved this site from having product quality issues from the non-uniform drying of its product; it has probably saved them from having waste product and lost profit as well.

The early warning meant that the maintenance team were not required to spend valuable time dealing with the aftermath of a motor failure and were able to instead spend that time on other tasks which supported the ongoing productivity and reliability of their plant.

As well as allowing teams to carry out more beneficial work, condition monitoring solutions can

also reduce the need for staff to carry out some more hazardous tasks. Take the maintenance and testing of roof fans. If the condition is being monitored, it negates the need for periodic checks, where a staff member must face the risks associated with working at height.

The number of times this needs to be done can be significantly reduced to only when maintenance has been shown to be required.

And no matter how sophisticated a condition monitoring solution is, there is no alternative to the intuition of a trained engineer.

Someone with experience 'walking the floor' can still pick up on signals that something is not right. They may notice sounds that might not be picked up by vibration monitoring, smells that could indicate a change, or movement that is not normal.

With the core monitoring being taken

care of automatically, more time is also available for this type of activity. But the experience is still very much needed.

It is also true that maintenance teams have generally not grown following the COVID pandemic; indeed, many have shrunk. And alongside this, we have a skills shortage across the engineering sector. So allowing those staff who are carrying out maintenance functions to focus their time on more valuable tasks is invaluable to many businesses today.

Some vendors are selling condition monitoring solutions as an alternative to maintenance resource but that simply isn't the case.

Expertise is needed to understand where to place sensors and interpret the information they provide.

Indeed, for businesses introducing condition monitoring solutions, their maintenance teams see real benefits rather than threats to their roles. TIMES-CIRCLE

There is no alternative to the intuition of a trained engineer.

www.fletchermoorland.co.uk

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38 Predictive Maintenance

PARTIAL DISCHARGE COUPLING CAPACITOR FOR HV ROTATING MACHINES UP TO 17KV QUARTZTEQ, PART OF QUARTZELEC, has expanded its portfolio of LIFEVIEW condition monitoring solutions with the addition of the QCC17, a new partial discharge (PD) coupling capacitor designed specifically for HV rotating machines rated up to 17kV. With PD monitoring for HV machines indicating insulation health, the newly developed QCC17 sensor bridges the gap between the existing QCC12 and QCC34 counterparts, ensuring cost-effective monitoring for any size machine. The sensor is now available from the LIFEVIEW range, allowing for a condition-based maintenance regime to be implemented across some of industry’s largest assets.

“Our new offering sits neatly in the middle of our existing PD sensor portfolio and means we can now offer owner/operators of high voltage equipment more cost-effective support specifically for machines rated between 12kV and 17kV,” explained Seoras Shaw, Product Manager at Quartzteq.

“This R&D project commenced in late 2019 and focussed on designing highly sensitive and reliable PD sensors for use on ‘mid-range’ machines rated up to 17kV.” The group’s LIFEVIEW solution for condition monitoring already offers online and offline monitoring in both safe and hazardous area environments, plus there is a range of compatible

sensors and modules designed to measure PD, shaft voltage and airgap flux.

Key features of the new QCC17 range include high electrical endurance and thermal stability, high sensitivity, a robust and compact design, compliance with UL 94V-0 requirements for fire resistance and self-extinguishing

characteristic, along with applicable standards compliance and enhanced safety.

Electrical Engineer for Quartzteq, Dr Benjamin Cella, explained the key issues addressed in designing a sensor built for reliability whilst conquering some of the fundamental challenges of partial discharge monitoring. “The harsh electrical and environmental constraints must be considered, as must restrictive installation area conditions. We have ensured product design compliance to European and International standards, which would prove the QCC17’s reliability and safety whilst remaining compact enough for ease of mounting.”

One specific development is the inclusion of the integrated voltage divider, which will also enable synchronisation to the HV supply.

Whilst coupling capacitors with a higher capacitance have a higher sensitivity, too high a level can be detrimental to the correct distinction between PD and surrounding noise.

Dr Cella further commented: “Our research, combined with multiple years of on-site experience and readings taken, have highlighted that values near 1nF are an appropriate compromise between effective PD monitoring for the majority of the machine winding and resistance to noise sources.” www.quartzelec.com

AUTOMOTIVE PLANT CONFIRMS HUGE SAVINGS THANKS TO CONDITION MONITORING A UK AUTOMOTIVE PLANT HAS CONFIRMED A £264,000 saving in just six months thanks to a Meerkat remote condition monitoring system.

This site specified a system to monitor vibration, temperature and current on its paint plant air handling units. Paint plants can suffer fan failures due to several factors. One is paint build-up on the fan impellor. The build-up can cause imbalance on the fan causing excessive vibration, which, if left alone, will eventually cause a failure on the direct-drive motor. On this particular paint plant’s air handling units, the Meerkat system detected changes early on and alerted the maintenance Quarter 2 2022

teams so they could take action to prevent in-service failures.

Unplanned stoppages and downtime are unwanted in all industries. Those in automotive plants can cause significant headaches, scrutiny, and massive losses.

Having a system to monitor and alert when there is a problem in the early stages is undoubtedly preferable to dealing with the aftermath of a failure, and this is a powerful example of just how valuable, timely preventative maintenance data can be for an organisation. www.fletchermoorland.co.uk www.theaemt.com

Giving special thanks and recognition to the repair and service centres underpinning our health services and infrastructure during the pandemic

Call for nominations now open...

Endorsements:

“It is so important that we as an organisation, and an industry, invest in the younger generation.

Supporting the Rising Star Award at the AEMT 2021 Awards is just one way we can acknowledge the value younger employees bring to a company.”

“Winning Service Centre of the Year & being finalists in Product of the Year will significantly raise ADC Electricals profile.

No matter what the size of your business it is well worth making the effort & getting involved, there are opportunities to be had for all.”

Tom Bouchier Fanuc UK

Andy Patten ADC Electrical

Thursday, November 17th 2022 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 7 categories to choose from including: Product of the Year, Project of the Year, Supplier of the Year, Service Centre of the Year, Diversity in Engineering, Contribution to Skills & Training and the Rising Star Award. Make sure you enter now to be recognised as a leader in your industry.

Enter Now: www.aemtawards.com

2021 Partners:

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R.E. Field Services Ltd • • • • •

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REACH THOUSANDS OF USERS OF ELECTROMECHANICAL EQUIPMENT WITH A LISTING IN THE REPAIR SERVICE DIRECTORY

BOOK ONLINE AT APPROVED BY SIEMENS ABB

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FEATURE 41 41 repair service directory 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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The coloured dots in the listings indicate areas covered, please call or email repairers to confirm exact details.

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ADC Electrical Ltd

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

APPROVED BY ABB

FEATURE 42 Opinion

Don't let a focus on capital expenditure cost you in the long term Regina Leite, Head of Product Marketing, IEC Low Voltage Motors at ABB Motion, explains how making the right investment in motor-driven systems can offer significant lifetime savings.

F

aced with volatile energy prices and increasing pressure to cut emissions, decision-makers across every industry must contend with the same challenge: energy costs represent a major element of their operating expenses (OpEx). So how can they reduce it while maintaining high product or service quality and throughput?

Focusing on the energy efficiency of motor-driven applications is a natural place to start. This is because electric motors are an essential component of processes in almost every industry. Estimates suggest that industrial motors use approximately 45% of the world's power, much of it from nonrenewable sources and much of it lost to waste. Many older motors are extremely inefficient. And even motors installed in the past five years may not offer the highest levels of energy efficiency.

However, the energy efficiency of low voltage motors has increased dramatically in recent years due to technological advances and pressure from regulators.

The exact savings depend on the specific application, but as an example, ABB's IE5 Synchronous reluctance motors (SynRM) offer up to 40% lower energy losses compared to IE3 motors.

Furthermore, they significantly reduce energy consumption and CO2 emissions compared to commonly used IE3 induction motors.

The technoogy used in SynRM motors delivers up to 30°C lower winding temperatures and up to 15°C lower bearing temperatures which contribute to the lower energy losses.

But this also increases reliability and extends the motor's lifetime while reducing the need for maintenance,

Quarter 2 2022

which has the added benefit of reducing the total cost of ownership (TCO) of a system.

TAKING A SYSTEMS APPROACH Whereas industrial motors traditionally operate at full speed even when the load requirements are minimal – wastefully using a throttle valve to control the flow of water, for example – a variable speed drive (VSD) adjusts the speed and torque of the motor to match the precise requirements of the process. Because the relationship between motor speed and energy consumption is non-linear, even a 20% reduction in speed can result in energy savings of up to 25% or more.

With a moderate investment to update electric motor technology to a VSD and IE5 motor package, the return on investment (ROI) can be achieved within as little as one year. Further, due to its reliability, the system will continue generating savings for a decade or more, and reduced downtime and ease of maintenance also contribute to significant savings.

For most facilities, energy is by far the greatest OpEx, and the majority of it is used by motors to drive fans, pumps, compressors, conveyors, and other machinery. Cutting energy use, therefore, is a direct route to reducing OpEx. With VSDs reducing energy consumption, a facility would see corresponding cuts to its energy bill and a significantly lower TCO. This was the case for the Bocholt sewage treatment plant in North Rhine-Westphalia, Germany. The facility invested in four SynRM motor

Head of Product Marketing for ABB's IEC Low Voltage Motors, Regina Leite.

and VSD packages for its second sludge pumping station. Combined with modifications to the impeller geometry, and the use of the VSDs to adjust the power applied in response to hydraulic load, the plant has cut energy consumption – a significant ongoing expense – by 40%.

Ultimately, stakeholders face a classic CapEx-OpEx trade-off: a short-term increase in CapEx to invest in higher-quality, more efficient solutions that yield significant longterm OpEx savings and a far lower TCO. In addition, by failing to take advantage of more efficient technologies, facilities that do not upgrade are not only wasting money, but they are also failing in their obligation to tackle climate change. TIMES-CIRCLE

“The plant has cut energy consumption – a significant ongoing expense – by 40%.”

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ALPHA E

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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.

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