Renew Magazine - Quarter 3, 2022. Hazardous area focus

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

The journal f rom

Quarter 3 2022

FOCUS ON:

Hazardous Areas Commissioning motors for reliable and efficient service

Tackling supply chain challenges

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.

D

uring the COVID pandemic, the situation we faced was unprecedented, and it was testimony to our members that they all reacted swiftly and adapted to keep industry moving. They should all be immensely proud of that.

The electromechanical repair sector’s agility and flexibility very much define it. It was notable how people came together out of necessity to support each other. I witnessed and heard numerous examples of members reaching out to help other members. This was very much in keeping with the founding spirit of the AEMT when it was created after the second world war. But as difficult as COVID was, there are some positives we can take from the lockdown experience. This enforced downtime allowed us to take stock, reflect and consider the future needs of our members and how we might evolve to accommodate them. Now, as we face the challenges of rising costs, skills shortages and resource availability, it’s more important than ever that we find ways to work together to help each other and support our customers.

In doing so, the sector, particularly those represented by the AEMT, will become stronger and even better able to support the wider community of organisations reliant on the equipment they use to carry out their – sometimes – critical work.

My vision for the AEMT is to become a provider and facilitator of a broad range of business services to support our members and enable individual member organisations to develop, prosper and become world-class by encouraging a closer working relationship amongst all members. This, in turn, will result in even better service for our members’ customers.

I believe any community is stronger, more productive and more resilient when it works together. Sharing ideas and improving as a group is one of the cornerstones of the advancement of humankind.

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.

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

www.pefc.org

www.theaemt.com

NEWS 6

Industry news

8

AEMT news

10

AEMT Awards update

12

Product news

14

Project updates

24

Thinking outside the gearbox

26

The benefits offered by repair coatings and composites

28

Commissioning motors for reliable and efficient service

30

First time generator use: the dos and don’ts

26 14

Focus on Hazardous Areas

features

34

Ex repairs: the knowledge and skills required

18

The underestimated efficiency factor for machines

36

Motors in potentially explosive atmospheres

20

Ensure you get a quality repair

22

Transformer windings: Copper versus aluminium

Opinion 42

Tackling supply chain challenges Quarter 3 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

FOUNDATION STONE CEREMONY FOR NEW MOTOR PLANT MENZEL ELEKTROMOTOREN HAS launched the construction of its new plant in Hennigsdorf on the outskirts of Berlin with the laying of a foundation stone on 11 June 2022. More than 200 guests and employees attended the celebrations.

The new, purpose-built headquarters will be erected on a 24,000 m² plot. All administrative and production workplaces are to be relocated by January 2024.

When complete, the new motor plant with an effective floor space of 8,500 m² will increase the manufacturer's production capacities, allow the expansion of the workforce and earn significant efficiency gains through an optimised floor plan.

The production area of about 3,800 m² will accommodate the assembly, metal processing, fabrication and winding workshops, paint shops and three state-

of-the-art test fields. In addition, there will be roomy offices, logistics zones and storage areas. The spacious property allows for future expansions and is easy to reach via public transport, motorway or the Berlin Brandenburg International Airport.

The move heralds a new era for the motor company, which was founded in 1927. Under the management of Mathis Menzel, the third generation to lead the family business, Menzel has experienced significant growth in recent years. The new building allows for a streamlined and ergonomic layout for all production processes and a higher throughput.

Crane capacities will be significantly increased to meet the demand for everlarger motor systems from customers in all industries.

New test fields will also be larger to allow for future expansion of the company's testing services.

RECRUITMENT DRIVE TO SUPPORT EXPANSION ELECTRO-WIND, WHICH HAS BEEN designing and manufacturing single and three phase transformer products for customers in the UK, Europe, and Global Markets over the past 40 years, is looking for staff to support the company’s continued expansion.

As a second-generation family owned and operated company, over the past couple of years Electro-Wind has seen exponential growth, with both standard and custom-built products proving to be in demand. A shortage of materials in the general marketplace has boosted its UK manufacturing base and the company has expanded its premises to be based over the two sites.

With an ongoing recruitment campaign in place, Electro-Wind’s director, Rachel

Stanley-Cooper, commented: “We are continually looking for candidates that are passionate and committed to working in an established company with forward thinking values to sustain our growth and for succession planning and promotion.

“With a very low staff turnover, many of the long-established team members have worked for the company for over 20 years, however the business has expanded dramatically over the past few years with the addition of many new recruits.”

The most recent recruit to the business

is Jeff Roberts who has joined the sales team. With a strong background in the electrical distribution and wholesale markets he has had many years direct experience within the electrical industry.

Demand for custom built, British made products seems to be higher than ever and the drive to sustain growth and invest in staff is an ongoing priority for Electro-Wind.

ERIKS APPOINTED AS CERTIFIED SKF GEARBOX REBUILDER

ERIKS, THE SPECIALISED INDUSTRIAL service provider, has been appointed by SKF as a Certified Gearbox Rebuilder.

Gearboxes are used throughout industry, with the majority of gearbox failures being caused by worn, damaged or incorrectly specified bearings and seals. The SKF Certified Gearbox Rebuilder programme has been introduced to help accredited specialists analyse and identify the root cause of faults, and then to carry out the correct Quarter 3 2022

level of repairs using approved procedures and parts.

Peter Townsend at ERIKS explained: “We’ve been rebuilding and refurbishing gearboxes since 1982 and have always used the most advanced and highest quality components. The new SKF certification now provides independent recognition that our engineering processes, dismantling, mounting, assembly and inspection systems, plus the skills and knowledge of our production

teams comply with the highest standards.”

ERIKS’ gearbox engineering teams have received extensive training from experts at SKF. They will also routinely be reassessed and given ongoing access to SKF’s bearing applications and knowledge database. This will enable ERIKS’ engineers to ensure that new techniques for bearing failure analysis, together with the latest developments in technology can be deployed as quickly as possible to minimise gearbox downtime. www.theaemt.com

Industry NEWS 7

Coventry University to develop electrification skills hub COVENTRY UNIVERSITY WILL LOOK TO play a pivotal role in driving UK electrification by developing a national skills hub to support specialist training, after winning £1 million in funding.

The national skills hub, aimed at supporting the Power Electronics, Machines and Drives (PEMD) community, is set to be led and developed by Coventry University. It will be a digital platform bringing together providers of an extensive range of training and development opportunities to upskill the UK’s workforce and deliver clean solutions such as the next generation of electric transport and energy delivery innovation.

The PEMD skills hub will connect training and education course providers with employers and learners, as well as professionals already working in PEMD who want to develop expertise in specialist areas.

The project is being supported by funding from the ‘Driving the Electric Revolution’ challenge at UK Research and Innovation

Image courtesy of Coventry City Council

(UKRI), and could provide a significant boost to goals for a net-zero carbon economy by 2050. It also builds on the city’s growing reputation for electrification solutions, such as the National Battery Industrialisation Centre near Coventry Airport, and the West Midlands Gigafactory which is planned for the airport site.

The project got underway in April 2022 and seeks collaboration and input from across the country to build the right skills hub for the community.

Tributes as industry stalwart passes TRIBUTES HAVE BEEN PAID following the passing of Ray Brady, founder of RMB Engineering.

A GKN time served apprentice in Mechanical Engineering, Ray's career path included engineering roles at Cadbury and Butlers (a Lucas subsidiary) before setting up his own business, RMB Engineering, in 1981.

During his time as Managing Director of RMB, Ray built the company into one of the UK's leading industrial gearbox supply and repair organisations, with his success culminating in the integration of RMB into the maintenance services group Deritend Industries.

Commenting on his father's passing, Mark Brady, Managing Director of Hayley 247, said: "Many messages we have received describe my father as a legend, a pioneer within his field in which he achieved great things. But, he always remained humble, and he was proud of being a devoted husband, Dad and Grandad and a man who would have the back of anybody in his team."

EMiR software acquired by Commercial Software EMIR SOFTWARE, THE ERP SOLUTION DESIGNED FOR electro-mechanical engineering companies, has announced its acquisition by Commercial Software Ltd (CSL).

The deal was completed on 6 May and will see ownership of the business transfer to CSL over the next two years. During this time, the next generation Software as a Service (SaaS) version of EMiR will be developed under CSL’s .Net framework.

Existing EMiR users will continue to be supported with their current version of EMiR for many years to come by the teams at Solutions in IT and FHG Software.

Gary Downes, Managing Director, at EMiR Software, commented: “We have promised the next generation of EMiR on a SaaS platform to our customer base for delivery in 2024.

We are delighted that the deal with CSL not only ensures that the team and resources for this new product development are available but that the established development framework and team expertise at CSL will see us deliver the next generation of EMiR.” Geoff Perkins, Managing Director of Commercial Software Ltd, added: “We are delighted to purchase the EMiR Software brand and its associated companies. We have long searched for an established, proven software, with a loyal customer base, that we can add value to and establish as a SaaS product. We look forward to working with EMiR’s customers to ensure it continues to provide the best solution for them and provide the service and expertise they expect from such an industry-leading solution.” www.theaemt.com

Quarter 3 2022

UK

Part of the

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Universal Gearboxes Brake Motors Slip Ring B56 Fractional Forced Ventilation Coolant Pumps

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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

ouring around the Manufacturing Technology Centre (MTC) at the AEMT’s 77th AGM in June, I was struck by how automated the future of manufacturing looks.

Everything seems to be spat out of a box – including fully kitted out modular student flats for onsite automated assembly!

The factory in a box was particularly impressive; with the production line automatically ordering supplies and self-diagnosing operating conditions; the only input needed was someone to come along and maintain the moving parts.

We also looked at the future of the electric motor using additive manufacturing (or 3D printing). The MTC was able to produce a standard industrial electric motor with more power, a weight saving of 10%, and a size reduction of 30%; additional to that was reduced part counts, waste reduction, and lower running costs – there was even talk of repairability.

It seemed a fitting place to discuss where the AEMT is heading during the AGM, with some insightful comments from the participants of our hybrid online/offline meeting.

Our current strategy is three-pronged. Firstly we are investing in training so that the skills retiring from the industry are retained

for the future. Our project with the University of York to develop an online learning portal for practical hands-on teaching courses has started very well. We hope to have a beta site live in Q1 2023 with two or three courses available.

Once the project with the University of York is ended, we will have the capability to understand the true resource and investment needed to develop future online courses using the platform, so we are keen to hear from members about their needs.

Secondly, we see strength in the industry coming together to help each other overcome future obstacles. So, we are asking members to register their interest in a series of business support services in

Forthcoming AEMT led Courses & Events COURSE TITLE

START DATE

LOCATION

Ex Refresher - UK Online

Tuesday, 19 July 2022

Online

Ex Refresher - SE Asia Online

Tuesday, 2 August 2022

Online

Ex Theory

Tuesday, 6 September 2022

York

Ex Hands-On

Thursday, 8 September 2022

York

Ex Refresher

Thursday, 8 September 2022

York

Ex Refresher - UK Online

Tuesday, 13 September 2022

Online

Ex Theory

Monday, 26 September 2022

Bangkok

Ex Hands-On

Wednesday, 28 September 2022

Bangkok

Ex Refresher

Wednesday, 28 September 2022

Bangkok

Ex Refresher

Tuesday, 11 October 2022

Loughborough

Ex Refresher

Tuesday, 18 October 2022

Online

Ex Refresher

Tuesday, 1 November 2022

Loughborough

Ex Theory

Monday, 7 November 2022

Dubai

Ex Hands-On

Wednesday, 9 November 2022

Dubai

Ex Refresher

Wednesday, 9 November 2022

Dubai

AEMT Conference & Awards 2022

Thursday, 17 November 2022

Coventry

For more information or to book any of the couses listed please visit www.ex-repair.com Quarter 3 2022

www.theaemt.com

AEMT Update 9 coaching, mentoring, and peer-to-peer networks. We are pleased to say that several members have come forward with interest. It's worth noting here that anyone, at any level, can register interest – the AEMT is an inclusive association to support anyone employed in the industry. Please email rebecca@aemt.co.uk to register interest.

Our third strategic theme is to focus on our membership growth so that we are stronger and less reliant on training to subsidise membership overheads.

To grow our membership, we are focusing on improving our member value proposition, which will be published later this year.

We have also launched a 'refer a friend' scheme, with T&Cs available on our website: https://www.theaemt.com/membership/refer-afriend-terms. For any new members referred, a £30 gift voucher will be shared with the nominee and the new member.

We ended 2021 with a surplus, and we intend to end 2022 year with a surplus, too – even after investing in training technologies.

After a devastating year in 2020, we must build the association's reserves so we can continue investing in the industry while also using them as an insurance policy for any more unforeseen threats.

Finally, our important work with Primary Engineer is bearing some fruit, with ADC Electrical in Tyneside starting their partnership with the charity. We need many more members to pledge a little money and time so that we can engage with the future workforce.

Please visit Primary Engineer for more details. If you are interested in supporting this initiative, please contact me.

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 contact 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.

CONTRIBUTION RECOGNISED

Gary Downes (left) received his award from AEMT President, Shaun Sutton.

AT THE AEMT'S 2022 AGM, HELD AT THE MANUFACTURING Technology Centre in Coventry, Gary Downes, Managing Director of EMiR Software, was awarded lifetime honorary membership of the association. The award, presented by AEMT President, Shaun Sutton, was in recognition of over a decade of supporting the association on its council, including a period as President.

Commenting on the award, Gary said: "I'm delighted to become an honorary member of the AEMT; I have had a great time on council and have really enjoyed my various roles. I have met and worked with some great people along the way, and I'm sure the association will continue to go from strength to strength."

Wire Electric Supplies Ltd • Elantas Varnish & Resins • High Voltage Insulations • Adhesive Tapes • Woven Tapes • Nomex® & Nomex® Laminates • Low & High Voltage Cables • Electrical Sleevings • Copper Wire

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

10 FEATURE Awards Update 10

Awards entry deadline fast approaching

Time is running out to prepare and submit nominations for the 2022 AEMT Awards Programme. With the final entry date set as 5.00 pm on Friday, 9 September, the AEMT again looks forward to recognising and rewarding business and professional excellence across the electrical and mechanical repair sector.

B

uilding on its past successes, the fifth outing of this sector-specific awards scheme will culminate in a gala presentation ceremony to be held on the evening of Thursday, 17 November, at the Doubletree by Hilton Hotel in Coventry.

This venue will also host the supporting AEMT Conference throughout the day. The full programme is currently being finalised, 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 will all be featured. The speakers will share their knowledge and expertise in a series of talks and presentations designed to be of tangible value and relevance to all those companies operating across the engineering service and maintenance arena.

INDUSTRY-WIDE ENGAGEMENT Operated by the AEMT and produced

by Touchwave Media, the awards programme 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, Plant & Works Engineering and Preformed Windings, well-deserved industrywide recognition will be given to those businesses which are excelling in their commercial endeavours.

AWARD CATEGORIES The seven categories that make up the

Quarter 3 2022

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 – sponsorship available • 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 they believe merit recognition. The online entry process is quite 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, 9 September 2022, so those wanting industry-wide recognition for a job well done, be it for product innovation or project management, application knowledge, or service and repair, should be making a note of this key date.

It is free to enter the awards, but the promotional value associated with being selected as a finalist is worth many hundreds of pounds. For those individuals and companies fortunate enough to be announced as one of the seven winners during the presentation ceremony, the promotional benefit is even greater. TIMES-CIRCLE www.aemtawards.com www.theaemt.com

www.brookcrompton.com

Keeping industry turning every second... every day...every year With over 110 years of technical and design expertise, Brook Crompton offers leading edge energy efficient electric motors across global markets. As the original innovator in electric motor development, Brook Crompton are trusted to power limitless industrial processes and its robust motor design drives fans, pumps, compressors, conveyors and more.

Driven by technology and innovation, Brook Crompton has one of the widest available ranges of electric motors for operation in safe areas, hazardous atmospheres and hostile environments.

The extensive range of stock can be quickly modified to suit customers’ needs and with a high level of technical support from our knowledgeable team we ensure the correct selection of motors is provided for your application.

Brook Crompton’s focus on product and service development ensures we continue to move forward to improve efficiency, offer lower cost of ownership throughout their lifecycle and to reduce environmental impact.

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

12 Product News

New motor line combines efficiency and sustainability NEW FROM WEG, THE W51 HIGH Density (HD) motors are compact, customisable and suitable for use in a wide variety of applications, delivering better performance and longer durability.

Available in low and medium voltage, in IEC 315 to 450 or NEMA 5000 to 7000 frames, the W51 HD motors have a modern concept, in line with the market expectations for highly efficient products and rational use of natural resources due to their reduced size and weight.

To deliver more power in a smaller size and weight, the motors have a cooling system with an exclusive design and a larger heat exchange area, patented by WEG. Also noteworthy are

the bearings with an optimised cooling system, ensuring greater reliability, which translates into low maintenance requirements and longer service life. In addition, the innovative acoustic system, also patented, results in the lowest noise levels on the market.

Developed with the most advanced engineering tools, the design of this line features state-of-the-art technology.

The line is interchangeable with other motors, flexible to install and highly customisable according to the requirements of each application, offering a wide range of accessories. www.weg.net

Condition monitoring solution expands to offer extended monitoring capabilities THE MEERKAT SYSTEM FROM Fletcher Moorland has expanded into new applications as it continues to open up new monitoring opportunities for its customers.

Initially developed for a brickworks that wanted to monitor vibration in its industrial motors, Meerkat has vibration and condition monitoring at its heart and will always continue to. However, it was developed as a platform to which any sensor can be attached. Now the integration of a growing number of sensors is enabling a wide range of new applications.

In addition to providing trend data and triggering alarms when set parameters are exceeded, Meerkat can also integrate with SCADA (supervisory control and data acquisition) systems to support the control of assets based on identified conditions. This could, for example, be slowing or stopping a motor if its temperature exceeds a pre-defined level.

The system is also capable of working at scale. In one particularly interesting and topical application, a Meerkat installation is monitoring some 800 sensors. Working with a large mobile telephony provider, the system is being used to monitor desk occupancy and people traffic at a key office site. As the

Quarter 3 2022

company’s staff return to its offices after COVID, the company is looking to understand how its sites are occupied and how people move through them.

This is part of a wider project to review the company’s ongoing capacity needs.

The only real limitation with largescale projects such as the one above is the ability to transfer the large amounts of data collected by the sensors into the cloud for analysis and interpretation and the associated storage requirements.

To counter this, edge computing capabilities have been introduced, where the data can be processed close to where it is collected with less needing to be transferred, and stored, away from the site.

Commenting on the extension of Meerkat’s range of applications, Matt Fletcher, Managing Director of Fletcher Moorland, said: “We have evolved far beyond what we imagined when Meerkat first came onto the market in 2017. Condition monitoring of rotating equipment will remain a key application for the system, but the scope beyond that is virtually endless. We’ve monitored numerous machines’ energy usage, tank fill levels, process pH levels, humidity in a kiln and battery temperature in a distribution sorter system. Essentially, if a sensor can measure something, Meerkat can monitor it, and you can manage it.” www.fletchermoorland.co.uk

www.theaemt.com

Is your machinery repaired to standard?

IEC BS or EN 60034-23:2019 The new international standard to ensure the efficiency of rotating electrical machinery is maintained after being repaired, overhauled, or reclaimed.

9 A more sustainable future can be achieved if service centres follow the best practices outlined in this standard.

9 Carbon emissions can be reduced when rotating electrical machinery is put back into service, rather than scrapped and replaced.

9 The cost-savings of a good repair over a poor repair can save disruptions in production down the line.

www.theaemt.com | +44 (0)1904 674899

14 Project Updates

DC MOTOR REPAIR and OVERHAUL WEBB ELEC REPAIRED A 100KW Leroy Somer DC motor from a steel processing company which needed a thorough overhaul and rebuild.

The motor was fully dismantled, and it was clear that although it was still running, it needed a complete overhaul to place it into good working condition.

Once degreased and stoved, the field and interpole windings were Baker tested with step voltage, surge and hi-pot to ensure the winding insulation was adequate with regard to earth protection and to ensure that there was no insulation failure between turns of wire within each coil.

The armature coils were also individually tested and re-insulated, and the commutator machined because the brushes slowly wear grooves into the copper segments, which can cause problems with the commutation when new brushes are fitted, such as sparking and overheating. The aim is to remove as little copper as possible when turning the commutator down, as this can only be machined a finite number of times before it is too small to be serviceable.

Each separate bar on the commutator is connected to several copper coils in the armature, and in between each segment is a mica insulator. The mica is harder than the copper and has to be undercut, where a small blade is run down the slot to

cut down the mica below the level of the softer copper segments. It also removes any possible shorts between the segments which may be present after the machining process.

If this is not done, as the copper wears the mica will sit proud and the brushes will begin to bounce over the commutator, eventually breaking or causing sparking and serious electrical issues.

The carbon brushes are housed in the brush gear, which usually comprises four separate arms – sometimes more on larger machines. Each brush box contains a spring to maintain constant pressure on the brush while it creates a circuit on the commutator. This motor’s brush gear was cleaned, degreased and tested to ensure the insulation was fully serviceable.

After this, Webb Elec’s standard sequence of mechanical checks was carried out to ensure bearing journals and housings had not worn, along with drive shaft diameter and keyway. The armature

was then dynamically balanced, the windings re-insulated, and the bearings replaced with high-quality SKF bearings.

The last item was the force ventilation fan blower which was fully overhauled with a new motor fitted and the impeller balanced.

Once assembled, the motor was fitted with a new set of carbon brushes and run throughout its speed range in both directions ensuring the brushes were correctly bedded into the new commutator profile. www.webb-elec.co.uk

PAINT SHOP FAN BREAKDOWN REPAIR WHEN A MARKET LEADER IN PAINT shop design and manufacture experienced an untimely and frustrating paint shop fan breakdown during a crucial production run in its busy workshop, it turned to Gibbons Engineering Group for help.

The client advised that returning the fan to normal operation was urgent and that downtime must be kept to an absolute minimum, so the immediate collection of the fan from Milton Keynes was arranged.

The fan was inspected, and the motor was found to have an earth fault. The fan had seen plenty of service, resulting in a significant build-up of debris on the impeller blades.

Gibbons’ engineering team stripped the fan to its component parts, ready for repair.

Whilst the special fan motor went through its in-house rewind shop for repairs, the Quarter 3 2022

other parts were shot blasted and coated with a hard-wearing finish ready for reassembly.

The fan was rebuilt and tested before the entire assembly was returned to the customer.

If the uniquelydesigned motor had been replaced rather than repaired, a lead time of 13 weeks would have been required, but Gibbons was able to return the plant to service within just a few days.

Engineering Services Manager,

Matthew Gibbons, was delighted with the outcome: “We understand that a paint shop fan breakdown can be a very stressful and costly situation for our customer, who is naturally concerned that its production could be interrupted for weeks. Therefore, it’s always satisfying to be able to turn a repair round in such a short time and get our customer’s plant up and running.” www.gibbonsgroup.co.uk www.theaemt.com

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FEATURE 16 Q&A

Q&A

In this issue of Renew, Matt Fletcher, MD of Fletcher Moorland Ltd, answers questions around the correct approach to greasing electric motor bearings.

QUESTION: Should I grease the bearings on all motors at my site on a scheduled basis – such as every day, week or month?

MATT FLETCHER: Generally, bearings in electric motors do need greasing; however, just doing something because you believe it's right may have unintended consequences. Take the motor pictured here, which came into our workshop recently. The person tasked with greasing this electric motor's bearing thought they were doing the right thing. However, in this example, over-greasing has caused the bearing to fail. When my team stripped down the motor, they discovered the excess grease covering the motor internals and the windings. It's a common sight in many electric motor repair workshops, and this is not the worst we've seen.

In typical grease-lubricated electric motors, a chamber holds the bearing; the grease for the bearing is enclosed in this chamber. New grease is fed in through an external port when needed. Many motors have an exit for the old grease to escape, however, it seems that many motors don't. Grease doesn't just disappear; it has to go somewhere.

If the grease isn't coming out of the front of the motor, then it's passing through the grease chamber and into the motor.

Too much grease is as bad, if not worse, than too little grease in a bearing. What happens is the grease starts to churn, and excessive heat is generated. The operator notices this and thinks the bearing needs even more grease – a vicious and destructive cycle starts, which typically ends with a failed bearing and a stopped motor.

A secondary issue can also be caused by the grease coating the motor's windings. The grease can degrade the conductors' enamel coating, which can lead to a winding

Quarter 3 2022

insulation failure.

It may well be that the operator who did this was under production pressures to get as much life out of the motor as possible, but it was only delaying the inevitable.

There is no one-size-fits-all approach to greasing motors, but greasing every day, week or month, whether the motor needs it or not, could be a recipe for disaster. What I would recommend is that you check that your greasing program is fit for your motors and their application. In all likelihood, this will mean different timescales for different motors. Most bearing manufacturers will offer charts that calculate recommended greasing intervals based on the bearing type, size, and speed of operation.

If you are feeding grease into a motor on a regular basis. Stop to think about where the grease is going. You could be doing more harm than good without realising it.

QUESTION: Do you think there could be a way to measure how much grease is in a motor? With sensors, perhaps?

MATT FLETCHER: From my experience, ultrasound offers a good indication of whether a bearing has enough, too much or too little grease in it. It measures the ultrasound response to friction.

From there, with a conditionbased approach, a set dosing of grease can be filled to the bearing.

I don't think it's a matter of how much grease there is but 'the right amount', and that can be measured by sensors.

A lot of motors have 'sealed for life' bearings. That description is often misleading as it's the life of the bearing and lubricant that's referred to here (load and speed, of course, determine bearing life), not the life of the motor. So, there is a finite life for those bearings, typically of 2-5 years. I would much prefer to see an open bearing that can be properly lubricated, so the grease goes through the bearing completely and has an external grease relief. That way, a proper lubrication program can be followed, and the bearing can attain its design life – assuming proper fitting and alignment. TIMES-CIRCLE www.theaemt.com

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ONE

PRO

Energy Efficiency 18 FEATURE

The underestimated efficiency factor for machines

Many processes, particularly those that occur cyclically, have a high potential of regenerative energy that could be utilised easily and efficiently. However, when it comes to the technical solution and implementation of the machines, energy is often burned up in braking resistors, which is a waste and a fire hazard. Supply and regenerative units offer a practical and cost-effective alternative, according to Mark Checkley, Managing Director of KEB UK.

M

any drive applications could benefit from the use of supply and regeneration units, whereby kinetic energy from braking or recirculating can be reused and fed back into the DC circuit through the drive or fed back onto the mains power supply line.

Traditionally, if an application generated excess kinetic energy, it was simply dissipated electrically or mechanically – through a braking resistor or friction. By utilising regeneration drive systems, this unused, ‘lost’ energy now has valuable potential in many industrial applications by recirculating or feeding back onto the mains supply, reducing electrical running costs, as well as eliminating the heating effects from the braking resistors. The energy can also be put in ‘intermediate storage’ and harvested for use later to cope with any peak energy demands (due to heavy loads or high accelerations) from the application.

To identify suitable applications for supply and regenerative units, before system integration, a check will need to be made as to whether sufficient regenerative energy will be generated for sensible use.

In addition to transporting this energy away, the infeed and regenerative unit also serve as ‘feeders’. This allows the number of feed points to be reduced and significantly simplifies the planning of the control cabinet. The application itself and its utilisation must be considered to deduce the possible applications. This raises the question of where the regenerative energy is being generated. The answer lies in wherever masses are decelerated and, therefore, if kinetic energy can be converted.

STORAGE AND RETRIEVAL MACHINES A typical storage and retrieval machine consists of running gear, a hoist unit and a load handling device. These machines

Quarter 3 2022

Visualisation of the power using the example of a storage and retrieval unit: energy applied by the motor (red) and regenerative energy to be dissipated (green).

typically have a high mass – the optimal application for a power supply and regen unit. When accelerating such a mass by the running gear, very high power is required.

The same applies to the braking process.

Here, a drive controller can electrically decelerate the masses quickly and safely. A supply and regen unit can dissipate all the regenerative energy generated in this process.

Hoist applications are even greater sources of this energy, which is generated during each ‘lowering’ operation, depending on the load being handled. Even when all axes are coupled in a DC link to exchange energy, there is still a significant amount of energy left over.

Potential applications for supply and regen units in other industrial sectors include woodworking, textile machines, process technology, wind turbines and generators, theatre technology, theme parks, centrifuges, cranes, conveyor systems, elevators and test benches. In this context, KEB is often asked whether plant operators are allowed to feed back into the public power grid at all. The answer is ‘yes’ because they are not classed as power generation plants.

Regeneration becomes a compelling economic choice when the value of the recovered energy is large compared to the cost of a regenerative system. So, if the system requires frequent braking and starting, or where there is speed control of overhauling loads, it would be worth considering, provided a clear understanding of the system dynamics is known.

Active or passive feed-in are possible.

Passive feed-in means that the infeed and regen unit are grid-connected, and the DC link is fixed based on the infeed voltage. On the other hand, active feed-in means that the infeed and regen unit are actively controlled, for example, to regulate the DC link voltage.

Supply and regen units are an easy replacement solution for braking resistors, and they can be used for all common supply voltages of 180-528V AC, 50/60Hz. Most are compact and lightweight and often supplied with an integrated precharging circuit and optional choke or harmonic filter. TIMES-CIRCLE www.keb.co.uk www.theaemt.com

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Motor Rewinging 20 FEATURE

Ensure you get a quality motor repair

A poor-quality repair to an industrial motor can a have negative impact on a business that can cause increased costs and unnecessary downtime. Chris Callander looks at how you can ensure a quality result from your motor repair partner.

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here are several ways that a poor-quality motor repair can impact a business. Firstly, there could be issues with the energy efficiency of a badly repaired motor which can lead to unnecessary increases in costs. However, if repaired well, a motor should be at least as efficient as when it was new. This was demonstrated by a study carried out by the Association of Electrical and Mechanical Trades (AEMT) and the US-based Electrical Apparatus Service Association (EASA), which used independent testing facilities to confirm higher efficiency IE3 units are unaffected by a repair that uses good practice procedures.

A motor that has not been well repaired can also be prone to failure earlier than expected. Winding faults can lead to premature insulation breakdown, while poorly fitted bearings can fail sooner than expected. If these unexpected faults occur, the cost of unintended downtime could be massive for some businesses.

There are ways to identify a good quality repair, however. Generally, if the motor looks like it has been well treated on the outside, then it is likely that it will have been well treated on the inside. For example, when the motor is returned, are the mounting faces free of paint? If they have been well masked when the motor was painted, the motor will be much easier to mount accurately.

Andy Patten, Managing Director of ADC Electrical, believes there are some simple signs that a repairer has done a good job: “If the motor looks good on the outside, then generally it will on the inside too. For example, if the terminal box looks nice and clean and there are new nuts and washers on the terminals, that would be a sign that care has been taken.”

The sign of a good repair can start before the repairer even sets eyes on the motor.

Andy added that it can begin at the initial enquiry: “Another point I would look for is if the repairer takes the time to understand

Quarter 3 2022

what the client needs.

They should talk to the customer to find out about the motor, where and how it is being used, and what the customer wants from the repair.”

Matt Fletcher, Managing Director at Fletcher Moorland, agrees that attention to detail on a motor can reflect how it has been repaired: “We always fit new grease nipple caps. They cost a few pence but can make a big difference. I’d look for mesh wrap or some form of protection on the shaft. Also, are there silica gel packs inside the terminal box and anti-corrosion coatings? The motor may not go straight into service, so if it is in storage for any time, these small things can make a difference.”

THE REPAIR STANDARD One way to ensure a quality repair is to ask your provider if they follow the international repair standard (IEC 60034-23). The standard establishes the benchmarks for repairing rotating equipment, maintaining efficiency levels, high standards of quality control and improving efficiency in associated pieces of equipment.

The standard covers many other aspects of the repair process. It sets out requirements for the maximum temperatures used in an oven to burn off old windings to prevent damage to the steel laminations. It covers which insulation grades should be used, the approach to

rebuilding bearing seats, the selection of replacement bearings and grease, and a range of other factors.

IEC60034-23 also sets out what tests should be carried out on a motor before and after it is repaired and how the test equipment should be maintained and calibrated.

Matt Fletcher added what he believes is a vital component of a quality repair procedure: “In line with the repair standard, a good motor repairer should have a repair specification they can give to customers which shows what will be done. And when the motor comes back from repair, there should be an accurate record of what has been done, including certificates covering aspects such as balancing, vibration measurement, tolerances, and surge test results.”

So, to ensure you get levels of reliability and efficiency from your next motor repair, ask your repair provider if they work to the international repair, overhaul and reclamation of rotating equipment standard, IEC 60034-23. TIMES-CIRCLE

A motor that has not been well repaired can also be prone to failure earlier than expected.

www.theaemt.com

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FEATURE 22 Transformers

Transformer windings: Copper versus aluminium

Transformer specialist, Bowers Electricals, compares the properties of aluminium and copper when used in transformer windings, outlining the advantages each option can offer.

I

n the construction of a transformer, there are two main parts: the transformer core and the transformer windings.

The function of the transformer is to convert the voltage level of electrical power. Accordingly, one winding is connected at the high voltage side, and the other winding is connected at a low voltage side.

Therefore, it is also classified as high voltage (HV) winding and low voltage (LV) winding.

WHAT ARE TRANSFORMER WINDINGS? Transformers have at least two winding types – primary windings and secondary windings. There are a lot of variations as to how many windings you can have and their function, but for this example, we are keeping it simple.

The primary winding is the winding of a transformer that is connected to and receives energy from an external source. The secondary winding is the winding of a transformer that delivers the transformed energy – the changed voltage – to the load.

Copper or aluminium conductors can be used to make transformer windings. Aluminium is lighter than copper but has 50% lesser conductivity than copper. It is

Quarter 3 2022

also cheaper than copper. On the other hand, copper has excellent mechanical strength and twice the conductivity of aluminium.

COPPER VS ALUMINIUM Initially, all transformers were built with copper windings, as it was easily accessible and priced right.

During WWII, the use of aluminium in transformers increased as the industry experienced a shortage of copper which was in high demand by the military.

Due to this demand, copper prices skyrocketed, and aluminium became more popular for windings; in turn, previous technological problems were overcome, and these aluminium transformers became more reliable.

Choosing between aluminium and copper windings for your transformer comes down to personal preference. But there are advantages to both materials.

• Compact form (small dimension) compared to aluminium.

• Reduced physical expansion.

ADVANTAGES OF ALUMINIUM: • Low and stable market price.

• Lower weight compared to copper winding.

• Excellent malleability during the winding process.

• Very suitable for distribution transforme­rs and small power transformers.

Since both aluminium and copper transformers use the same insulation systems and have similar temperature rises, they have similar lifetime ratings.

Most distribution transformer manufacturers are now using aluminium windings, as opposed to the traditional copper windings. Aluminiumwound low voltage transformers will probably continue to gain increased acceptance because of their significant cost advantage over copper. TIMES-CIRCLE

Most distribution transformer manufacturers are now using aluminium windings.

ADVANTAGES OF COPPER: • Copper is stronger than aluminium.

• Current capacity is double that of aluminium.

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24 Gearboxes

Thinking outside the gearbox When there’s an issue of repeated gearbox failure, the obvious route to resolving it is via the gearbox. But the obvious answer is not always the correct answer – or the simplest, or the most cost-effective. That’s why there’s a big difference between knowledge alone and know-how, as Mahesh Patel, Engineering Manager at ERIKS, explains.

A

major pet food manufacturer operates four product extrusion lines, each incorporating a gearbox sourced from an American manufacturer. Initially designed to run with a nominal input speed of 1,400rpm, for operational reasons, the customer has increased this to 2,000rpm.

Unfortunately, the result has been repeated gearbox failures.

ERIKS’ Norwich Service Centre was called in to make running repairs as often as every three to six months. These repairs were made even more challenging due to the difficulty of obtaining spare parts for a gearbox made in America.

The customer felt it was time to upgrade to gearboxes with a faster running speed. But that wasn’t as simple as it sounds.

The customer’s co-axial extrusion line gearboxes have the input and output shafts directly in line. With gearboxes of identical design, size and footprint being impossible to source, a gearbox upgrade would mean reordering all four extrusion lines to accommodate them – with all the additional design and engineering costs involved.

In addition, between failures, the existing gearboxes are doing the job they are designed for. So if the root cause of failure can be addressed and rectified, then there’s no reason to go to the expense of replacing them.

ERIKS’ engineers assessed the situation and discovered that the higher running speed is causing the oil in the gearboxes to overheat.

The overheated oil then breaks down, so it no longer effectively lubricates and protects the gears and bearings.

For example, the gear case outer temperature was measured to be Quarter 3 2022

100°C; therefore, the oil temperature would be assumed to be up to 110°C – unsustainable without breaking down and failing as a lubricant.

However, the oil being used was the correct specification and viscosity for the application. So it’s not an option to change to a different oil to cope with the higher running speed and temperatures.

PLAYING IT COOL If the gearbox is the right gearbox for the application, the oil is the oil right for the gearbox, and the high operating temperature can’t be avoided at the required running speed, the problem isn’t the gearbox. It is how the oil behaves when the high operating temperature of the gearbox heats the oil.

This means the solution is not to change the gearbox but to resolve the overheating of the oil.

ERIKS’ answer has been to design and engineer a cooling system to remove the oil from the gearbox, cool it to a suitable temperature, and return the newly cooled oil to the gearbox.

The design involves the lubricant being drawn out of the box through a pipe, carrying the oil through a vessel full of chilled water.

This chilled water is already part of the production process on the extruder side, so providing it requires no more engineering or energy than simply piping it into the vessel.

Passing the oil through the vessel rapidly reduces the lubricant temperature to just 60°C; in just a fourminute cycle, the 40 litres of lubricant is cooled, at which point it can be

returned to the gearbox once more.

Not only has ERIKS designed and manufactured the solution.

They have also made all the necessary food-contact parts out of food-grade stainless steel, so there are no food safety complications arising from the new system.

Now installed on one of the extrusion lines, the oil cooling system has proved so effective at preventing gearbox failures that the customer has commissioned the same system for their remaining three identical gearboxes. TIMES-CIRCLE

The solution is not to change the gearbox but to resolve the overheating of the oil.

www.eriks.co.uk www.theaemt.com

26 Repair Coatings

The benefits offered by repair coatings and composites Darren Harris, Pump Services Manager at Hayley 24/7, looks at the range of coatings and repair composites available from Belzona and explains the benefits they can offer when repairing pumps.

I

ndustrial pumps are costly to run and maintain as they often require substantial capital investment and they consume significant volumes of power.

Industrial pumps also operate within challenging environments that can leave them prone to problems such as erosion, corrosion, and chemical damage.

High-performance polymeric repair composites and protective coatings from Belzona, a leader in the design and manufacture of these products, are proven to help negate these costly elements of operating pumping assets.

Hayley 24/7, the mechanical engineering services division of Hayley Group, has a dedicated Belzona-approved coating centre within its 35,000 sq. ft. Dudley facility. This gives the company a controlled environment to apply WRAS-approved Belzona coatings to its customers' damaged pumps.

This has proven to be a highly successful and popular service as part of the repair specialist's overall pump refurbishment offering, which includes repairs for all pumping equipment, a state-of-the-art testing facility, and dynamic balancing capabilities.

Let's take a look at the main benefits of Belzona coatings.

REDUCED CAPITAL EXPENDITURE There is no getting away from the fact that industrial pumps are expensive pieces of equipment.

By opting to repair, if economically viable to do so, instead of purchasing a replacement for a damaged pumping asset, capital expenditure (Capex) can easily be reduced. In some cases, customers

Quarter 3 2022

have saved more than £10,000 by choosing to have their pumps refurbished rather than buying a new unit.

Replacement of pump components also requires a significant investment, and conventional welding and fabrication repairs aren't always feasible.

By applying a product from the Belzona range of paste grade composites, rebuilding of pitted and worn wear clearances, eroded cutwater profiles, and ring seals on end casings is possible.

Products from the Belzona 1100 Series and 1300 Series help to prevent galvanic and uniform corrosion and slow the effects of erosion and cavitation. This process is exceptionally cost-effective when compared to the expense of replacement units or even physical repair work, representing an immediate cost-saving.

EXTENDED SERVICE LIFE Belzona protective coatings offer a durable and corrosion-resistant layer to defend both internal and external areas of pumping assets from the harmful effects of erosion and corrosion. By coating fluid-flow passageways and pump casings with Belzona, the challenges associated with pump maintenance, such as pressure and efficiency losses and reduced flow rates, can be tackled at their very source.

Rough surfaces within pump assets, caused by erosion and corrosion, is a major problem as it leads to impingement, where the turbulent action of the liquid bombards the equipment and further accelerates the corrosion process. This turbulence also gives rise to cavitation, generated by the implosion of fluid bubbles within the liquid, which results in a severely

Belzona protective coatings offer a durable and corrosionresistant layer.

www.theaemt.com

Repair Coatings 27 pitted surface.

All of this activity negatively affects the efficiency of pumping systems, and also cuts short their expected service life. When your pumps are running efficiently, and are better protected from the stresses that corrosion, erosion and cavitation cause with a coating of Belzona, their output can be better relied upon and maintenance intervals extended.

IMPROVED EFFICIENCY The smooth surface finish provided

by Belzona coatings enables an improved flow of pumped material, which improves the system's overall hydraulic efficiency as less energy is required to move product through it. It is estimated that worn and pitted components reduce pump efficiency by up to 20% – a significant amount, given that around 85% of an industrial pump's total cost of ownership is accredited to energy costs alone. This 20% figure also represents an opportunity for improvement in which Belzona

products excel.

For example, Belzona 1341 (Supermetalglide) has an ultrasmooth, hydrophobic surface, 15 times smoother than stainless steel, and is capable of improving efficiency by Before and after images of a pump repaired by Haley 24/7 using Belzona coatings and repair composites. up to 20% on refurbished assets and even initiatives.

7% on new equipment. Thanks The Belzona product range is to improved hydraulic efficiency, manufactured through stringent customers opting for a pump quality and environmental control refurbishment with a Belzona guidelines complying with coating can enjoy dramatic energy the internationally-recognised savings, reducing the total cost of requirements of ISO 9001:2008 ownership and providing a rapid and ISO 14001:2004. Belzona 1341 return on investment. A reduction (Supermetalglide) is suitable for in the operations' carbon footprint contact with potable water as it is is another welcome bonus to be certified to NSF/ANSI Standard 61 enjoyed here and is always valued and WRAS. TIMES-CIRCLE by customers who are progressively implementing environmental www.hayley247.co.uk

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FOCUS ON:

Hazardous Ar eas Commission ing motors for reliable and efficient servi ce

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Tackling sup ply chain challen ges

Stay up to date with the latest products, technical insights, news and innovations; for everyone responsible for maintaining the safe and efficient operation of electrical and mechanical plant and equipment

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COmMISSIONING 28 FEATURE

commissioning motors for reliable and efficient service

Karl Metcalfe, Technical Support at the Association of Electrical and Mechanical Trades (AEMT), outlines key steps that should be taken when installing and commissioning motors which have been in storage or removed for repair.

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areful installation of motors will help ensure their efficient and reliable operation, minimising the potential for costly downtime or sub-standard operation. It is therefore essential that particular care is taken when installing and starting motors that have been in storage or that have been subject to an off-site repair.

STORED MOTORS A motor which has been in storage should first be cleaned to bring it back to the condition it was in when placed in storage. If there are any signs of damage, such as broken cooling fins, they should be investigated to assess whether any internal damage could have occurred and, where necessary, the damage repaired.

In an ideal scenario, motors should be stored in a vibration-free environment; however, this is not always practical. If the motor under inspection may have been subject to vibration, there is a potential for the bearings to have been damaged.

Even minimal ambient vibration will cause motor bearings to wear over time and can result in fretting or false brinelling, which can lead to motor failure. Therefore, unless there is complete certainty that the stored motor was not subjected to any vibration, the bearings should be inspected for signs of wear and replaced if necessary.

Bearing lubrication should also be considered when taking a motor from storage. Where the motor uses sealed bearings, if it has been in storage for an extended period of around two years or more, it is highly likely that the grease inside the bearing will have separated and will not work optimally. If the date when the bearing was fitted is unknown, or the motor has been in storage for a long time, then it would be advisable

Quarter 3 2022

to replace the bearing.

Motors which utilise re-greaseable bearings should be regreased. And if there are any signs of water in the grease purged from the motor, there will likely be rust damage, and the bearings should be replaced.

All stored motors will be subject to some degree of temperature fluctuation, and this will cause the seals to expand and contract, allowing moisture to enter the motor.

Where the motor is oil-lubricated, it is, therefore, good practice to change the oil before starting it after a long period of inactivity. To minimise the likelihood that the motor’s windings are contaminated by oil, it is advisable to drain the oil before it is moved from its storage location and then refill it after it has been installed.

If good practice was followed when the motor was put into storage, an insulation resistance (IR) test, which measures the total resistance between any two points separated by electrical insulation, should have been carried

out. This test determines how effective the insulation is in resisting the flow of electrical current. Before putting a motor back into service, repeat this test to ensure that any decreases in insulation effectiveness that may have occurred during storage can be addressed.

REPAIRED MOTORS If an AEMT member has repaired the motor, it is likely to have been done following the international repair, overhaul and reclamation of rotating equipment standard, IEC 60034-23:2019, and it is a good idea to check if this has been followed.

The standard establishes the benchmarks for repairing rotating equipment, maintaining efficiency levels, high standards of quality control and, where possible, improving efficiency in associated pieces of equipment. As such, bearing checks, lubrication procedures and insulation resistance testing will all have been carried out to the highest standard.

In an ideal scenario, motors should be stored in a vibrationfree environment.

www.theaemt.com

COMMISSIONING 29 However, the following checks should also be carried out on repaired motors, as well as stored motors.

Before putting a motor into service, manual rotation of the shaft should be carried out if size allows. If the shaft doesn't spin freely by hand or doesn't quite sound as it should, the bearings should be checked for damage that may have occurred during transport.

It is essential that the wiring of a motor is carried out or checked by a suitably qualified electrician, and the equipment must be earthed in accordance with current regulations.

It is also essential that the motor is securely mounted and accurately aligned in all three planes – allowing for shaft end float and thermal expansion.

Before the motor is fully put into service, it should be briefly started. If any vibrations or unusual noises are experienced, the motor should immediately be de-powered to examine the causes. Vibration or noise caused by magnetic or electrical issues will typically improve

as soon as the power is switched off.

If there is no change when the power is disconnected, misalignment or balance issues are more likely to be the cause.

Assuming no issues have been identified, all safety measures have been put in place, and the parameters relating to the motor’s specification (such as supply voltage and cable sizes) have been met, the motor can be put into service. After around an hour of running at normal load, the vibration levels should be checked. If they are excessive, the alignment or belt tensioning should be re-checked. It is worth noting, however, that there may be a degree of bearing noise for the first few hours of operation as the grease settles, but this should soon disappear.

Once the motor and load are running as expected, the full load voltage and current for all phases should be recorded, along with the

input power under load. If the motor has the capability, the bearing and winding temperatures should also be recorded once they have stabilised.

This information will help with future maintenance and assessment of the motor. Where the application is critical, and a predictive maintenance programme is planned, the full vibration signature of the motor and its load should be recorded as a baseline.

It is essential that the motor is securely mounted and accurately aligned in all three planes.

CONCLUSION If the correct procedures are carried out when installing and commissioning a stored or repaired motor, it is far more likely to have an efficient and reliable operational life.

Of course, a sound maintenance programme is also required, but if the starting position is strong, the ongoing maintenance requirements should also be reduced. TIMES-CIRCLE www.theaemt.co.uk

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

• Glass

• Paper

• Nomex® • Kapton®

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

Generators 30 FEATURE

First time generator use: the dos and don'ts When the power goes out, a generator can be a lifesaver. However, it’s essential to know how they work before using them for the first time. Bellwood Rewinds, a leading supplier of generators, looks at the dos and don’ts of first-time generator use.

G

enerators are an excellent option for many industries, and they don’t need to break the bank; from new and used generators to generator hire, there is a wide range of options. But in all cases, safe and effective generator use requires some key steps.

DO’S Study – If you are using a generator for the first time, it’s essential to know how they work so you are prepared when you need to use one.

Study what your unit is capable of doing and whether or not it will meet your needs. Then take some time to test run the equipment before you need it. It’s also essential to determine how much power your generator will need in case of a break.

Make a plan – It is essential to have a generator that provides enough power for your appliances. Don’t overload the unit by plugging in items you do not need or do not use regularly.

If any devices will likely be plugged into the generator during a power outage, it’s a good idea to test them before the lights go out.

Know your limits – You need to understand how long your generator should last so that nobody gets caught off guard by its limitations.

It’s also wise to consider how long your other devices and appliances might last on a generator before you run out of fuel. This leads us to our next point.

Stock up on fuel – Make sure you have enough fuel on hand to refill your generator.

This is important as you can be left without power if you run out.

Do exercise caution when refuelling and avoid anything that might cause ignition.

Use quality extension cords – It’s essential to use heavy-duty extension cords for your electric and diesel generator, and it is

Quarter 3 2022

wise not only when charging things but also if you want a safe outing.

Grounded connections will keep the electricity from streaming out of control so that there are no accidents while using this power source.

DON’TS Refill your gasoline generator when it’s on – Don’t forget to turn off your generator when you are done. If there is still gas left in it, the heat source could cause an explosion and injure anyone nearby. Store your gas tank at least ten feet away from the generator.

If you need more than what’s in there, turn off and wait for it to cool down first before refilling again.

Leave your generator exposed – If you live in an area that experiences rain or snow, make sure not to let your generator run when exposed.

If it starts getting wet and if stormy weather comes up too quickly, then cover the unit with a tarp so as not to cause any damage – generators should always be kept dry.

Let your generator run out of gas – Generators should always be kept full to avoid breakage or overheating.

If you don’t have enough fuel, your generator may overheat and even catch fire.

This can cause a lot of damage, so make sure not to let this happen to your generator.

Use it with a broken fuel filter – If you think your generator’s engine is running fine, but there’s no electricity, make sure you check out the fuel system first.

A clogged filter can cause problems and dirt and debris that might have gotten into the device from being used outdoors.

Do exercise caution when refuelling and avoiding anything that might cause ignition.

Overrun your generator – It is important to remember that generators can only handle so much before they need to be refuelled. If you overload your generator, it could cause an explosion or even damage the equipment.

It’s best not to use too many appliances at once when using a device for the first time.

FINAL THOUGHTS Electric and gasoline generators are a great way to power your business during a blackout. Be sure that if this is not something you’ve done before that you follow the instructions carefully and ensure safety at all times. If required, don’t be afraid to ask for help from someone with more experience with this type of machinery. TIMES-CIRCLE www.bellwoodrewinds.co.uk www.theaemt.com

BEARING PROTECTION FOR EVERY INDUSTRY Protect your motors against bearing damage

AEGIS® Shaft Grounding Rings protect motor bearings against damage

Variable frequency drives (VFDs) are true miracles of efficiency. VFD-controlled motors often save more than 30% energy. They also have other advantages, such as higher machine availability and more precise process control, but their operation can have one serious disadvantage: VFDs also generate voltages on the motor shaft. Electric discharge machining (EDM) can then cause localized corrosion (pitting) and corrugations on the motor bearing.

AEGIS® Shaft Grounding Rings are already protecting over two million motors against damaging shaft voltages worldwide – safely and over the long term. Well-known manufacturers rely on motors with integrated shaft grounding rings.

AEGIS® Shaft Grounding Rings are available for motors with shafts up to 800 mm in diameter. Full rings or split rings allow simple retrofitting to almost any motor.

VFDs can save a lot of money. However, without bearing protection, motor failures can quickly wipe out savings, often in less than three months.

www.est-aegis.com

32 Coil design

Resin-rich HV coils for class H applications UK-based Preformed Windings, has launched QualCoil H, the first resin-rich diamond coil specification suitable for class H motors and generators.

T

he cutting-edge QualCoil H specification has been developed in-house within the Preformed Windings lab, and in collaboration with a leading insulation manufacturer, large OEM and industry thought leaders.

Commenting on the launch, James Stevens, Global Sales and Marketing Director, said: “We are very excited to announce the launch of QualCoil H, the first resin-rich HV coils specification suitable for class H applications. This specification offers all the benefits of resin-rich technology and is proving hugely popular in industries such as hydro, nuclear and critical industrial applications where reduced maintenance and longevity are key. Preformed Windings is very proud to be thought leaders in HV diamond coil design and manufacturing with a position as independent product manufacturers allowing us to collaborate with the most respected individuals and organisations in the industry”.

QualCoil H has successfully passed 2,000 hours of voltage endurance testing, where a pass criteria is typically 250 hours or 400 hours. The lab testing the coils had to ask permission to turn the test off as there were sets of coils queued behind the QualCoil H coils that required testing. The test coils were in exceptional condition despite the 2,000 hours of extreme testing and passed all typical type testing along with giving exceptional partial discharge and tan delta results.

Preformed Windings and its partners want to explore the capabilities of QualCoil H, and the specification is currently undergoing stringent through-life testing to include cyclic thermal cycle, voltage endurance, vibration and extreme temperature testing at a leading European test facility along with other QualCoil specifications.

While QualCoil H is suitable for Class H applications, it offers significant benefits to machines at lower temperature classes. The delta between a machine’s

Quarter 3 2022

actual operating temperature and the maximum allowable operating temperature of the insulation is typically a good indicator of the life of the coils insulation system. If this delta is larger, the insulation system will last longer, and therefore QualCoil H is offering longer service life to Class F motors and generators. This benefit is being experienced in the industry with GE Renewables saying: “Preformed Windings has supplied many sets of high voltage coils to GE Renewables over the years. The quality of product and service is exceptional, and it is a trusted partner in our supply chain. We enjoy collaborative and cutting-edge research and development with Preformed Windings, which positions both organisations as thought leaders in the hydro industry. Its products offer significant benefits such as very low partial discharge and long service life".

SUPPORTING SUSTAINABILITY Preformed Windings is passionate about sustainability, and QualCoil H was initially designed as a coil specification for the hydro repair market. The International Energy Agency (IEA) says there is a need to double hydropower capacity by 2050 to meet the Paris climate targets.

However, the development of new hydro facilities is slow and expensive. Many of the hydro facilities in North America and Europe are approaching the service life of their generators, and there is a huge opportunity not only to repair existing assets but improve them to offer longer service life and increased output.

Through the careful redesign of the

HV diamond coils and the utilisation of cutting-edge specifications such as QualCoil H, Preformed Windings can offer the industry a viable solution to utilise existing assets while increasing renewable energy outputs.

Another industry expert, Sidewinders LLC, said: “Preformed Windings’ engineers listen to each client’s needs and study the specific requirements of each project to provide precisely tailored solutions.

Preformed Windings uses its position as a trusted thought leader in the industry not simply to manufacture replacement coils, but to improve coil designs substantially.

Preformed Windings’ process and focus on continuous improvement results in superior machine performance that will endure for many years to come.”

As a member of the Association of Electrical and Mechanical Trades (AEMT), the Electrical Apparatus Service Association (EASA), and the National Hydropower Association (NHA), Preformed Windings is looking to collaborate further on developing this key product for the service industry and is inviting industry experts to open a dialogue and collaboration industry-wide to contribute to the circular economy and sustainability goals. TIMES-CIRCLE www.preformedwindings.com www.theaemt.com

Coil Manufacturing Winding & Taping

Ridgway Machines manufactures a full range of Coil Manufacturing Equipment, including Rotor Winders, Loop Winders and ancillary equipment such as Capstan Tension Units, Winding Beams and Drum Stands.

Ridgway Machines also manufacture a range of BCT Coil Taping Machines designed for the fast, precision application of tape insulation systems to a wide variety of components – including motor and generator stator coils and bars.

Loop Winders

Rotor Winders

Band Tension Units

BCT Coil Taping Machines

Straighten Strip and Cut Machine

Drum Stands

Leicester, UK

Coil Flyer 2019.indd 1

+44 (0) 116 289 9199

sales@ridgwayeng.com www.ridgwayeng.com 16/12/2020 11:31:27

Hazardous Areas 34 FEATURE

Ex Repairs: the knowledge and skills required Thomas Marks, General Manager and Secretary at the Association for Electrical and Mechanical Trades, explores the requirements placed on the individuals and organisations involved in the repair and service of Ex-rated electromechanical equipment.

T

he knowledge and skills required to service Ex equipment such as motors, pumps, fans, compressors, gearboxes and other mechanical equipment, rests on two different categories of person, as highlighted in the IEC 60079-19 standard: the ‘responsible person’ and ‘operatives’.

An Ex Service Centre should have at least one ‘responsible person’, usually the manager or supervisor in charge of the workshop where servicing of Ex or hazardous area equipment is carried out.

The responsible persons must be trained to fully understand the protection concepts of the equipment, what can and cannot be repaired, and what repair procedures may be used, so that they can fully support the workshop staff and verify any work carried out. The responsible person should be able to ensure that the correct records are kept and that quality control systems are in place for the Ex repairs. They should also be able to ensure that the company has the right tools for the equipment being repaired and the relevant standards and certificates.

Operatives are all the engineers and technicians that carry out the service and repair of hazardous area equipment. They should have attended the AEMT Ex Theory and Hands-on courses to fully understand the protection concepts of the equipment they are repairing, and, as above, what can and cannot be repaired, and what repair procedures may be used.

For a company to be on the AEMT Ex-Register, it should have an ISO 9001 quality control system or equivalent; the calibrated tools suitable for the work seen and the required certificates and standards; a minimum of one trained and

Quarter 3 2022

competent operative; as well as a minimum of one responsible person to sign off and supervise Ex repair work completed by workshop technicians.

Both responsible persons and operatives must be able to provide sufficient evidence that they are up to date with the theory, skills and understanding of the Ex work they are involved with. Their staff should attend regular refreshers every three years on the repair and overhaul aspects of Ex equipment through the AEMT. This means that Ex-registered companies remain up to date on the

practical aspects of repair and any changes in updated standards and ATEX. Competencies apply to each explosion-protection technique for which a company or person is involved. For example, a person can be competent in the repair and overhaul of Ex d motors only and not be fully competent in the repair of Ex d switchgear or Ex e motors.

In such cases, the repair facility management should define this in their documentation system. TIMES-CIRCLE bit.ly/Exregister

KNOWLEDGE AND SKILLS

RESPONSIBLE PERSON

OPERATIVE

General understanding of relevant electrical and mechanical engineering at the craftsperson level or above.

Yes

-

Practical understanding of explosionprotection principles and techniques.

Yes

-

Understanding and ability to read and assess engineering drawings.

Yes

-

Familiarity with measurement functions, including practical metrology skills, to measure known quantities.

Yes

-

Working knowledge and understanding of relevant standards in the explosion protection field.

Yes

-

Basic knowledge of quality assurance, including the principles of traceability of measurement and instrument calibration.

Yes

-

Understanding of the general principles of types of protection and marking.

-

Yes

Understanding of those aspects of equipment design which affect the protection concept.

-

Yes

Understanding of examination and testing as related to relevant parts of most recent 60079-19 standard.

-

Yes

Ability to identify replacement parts and components authorised by the manufacturer.

-

Yes

Familiarity with the particular techniques to be employed in repairs referred to in this standard.

-

Yes

www.theaemt.com

FEATURE Areas 36 Hazardous

Motors in potentially explosive atmospheres

Mawdsleys BER, a specialist in the repair, rewind, refurbishment and supply of electric motors, generators and pumps, looks at potentially explosive atmospheres, the safety standards that govern them and the types of motor that can be used to eliminate the risk of an explosion.

E

xplosion-proof motors, referred to as Ex motors or ATEX motors, are a special type of motor designed to be used in hazardous environments where the risk of an explosion is higher.

Whether it’s high humidity, extreme temperatures or dust in the air, an explosion-proof motor has safety features in line with the ATEX directive to keep the environment safe.

What Is a potentially explosive atmosphere? Under the ATEX (ATmosphere EXplosible) directive, which covers equipment used in potentially explosive atmospheres, a potentially explosive atmosphere exists when “a mixture of air gases, vapours, mists, or dusts combine in a way that can ignite under certain operating conditions”.

With electric motors, the most common causes of explosion are the surface becoming so hot during operation that it causes ignition or a single arc from a motor malfunction causing ignition.

For this reason, equipment such as motors used in these atmospheres must be specially designed so that they will not cause the atmosphere to ignite, with protections against environmental hazards such as dust, fire and moisture.

Examples of these potentially dangerous environments include fixed offshore platforms, mines, flour mills, wastewater processing plants, workshops that use spray paint and food production lines.

SAFETY STANDARDS There are two European Directives for controlling explosive atmospheres, which are known as ATEX. ATEX is implemented in the UK through DSEAR, the Dangerous Substances Quarter 3 2022

and Explosive Atmospheres Regulations, 2002. The two directives are: Directive 99/92/EC – also known as ATEX 137 or the ATEX Workplace Directive – imposes the minimum requirements for improving health and safety for workers who may be at risk from explosive atmospheres.

Directive 14/34/EU – also known as ATEX 95 or the ATEX Equipment Directive, concerns the standards of equipment and protective systems that will be used in potentially explosive atmospheres.

An ATEX certification is required to work safely on explosion-proof motors. At Mawdsleys, all of our specialist engineers are ATEX certified and can work on all types of Ex motor.

TYPES OF EXPLOSION-PROOF MOTOR There are several types of explosionproof motor for use in different environments. The most common types of protection offered by Ex motors are: Dust ignition proof (Ex t): dust entering a motor can cause damage and potentially ignite. Dust ignitionproof motors have a high ingress protection rating, meaning they can prevent any dust from entering the motor.

Flameproof (Ex d): a spark or flame from a motor can result in an explosion in hazardous environments. Flameproof motors have flame paths built into their shaft and inner bearing covers, joints with long spigots to prevent the flames from escaping and they are encased with a motor housing developed to

withstand internal explosions.

Increased safety (Ex ec & Ex eb): previously called ‘non-sparking’ motors, these motors do not spark during normal operation or on start up. There are also no hot surfaces within the motor during running or starting.

The most suitable motor for your operation will be dependent on the hazards present within the environment and the job the motor is required to perform.

INGRESS PROTECTION (IP) RATINGS A fundamental property of Ex motors that makes them suitable in potentially explosive atmospheres is that they can protect against moisture and solid foreign objects.

If dust, water, or a larger foreign object enters a motor, it can cause damage, motor failure or even a spark or flame that could result in an explosion.

The degree of protection offered

by Ex motors is shown by the IP rating, which will be found on the motor nameplate. The IP rating is made of two digits showing how well the motor is protected against solid foreign objects and water, respectively. The first number in an IP rating runs from 0, no protection, to 6, dust tight. The second number runs from 0, no protection, to 9, protection against high-pressure and temperature water jets. In our case, a rating of IP55 would therefore represent a motor which is dust protected and protected against water jets. TIMES-CIRCLE www.mawdsleysber.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

38 Hazardous Areas

EX N MOTOR REPAIR MINIMISES COST AND DISRUPTION HOUGHTON INTERNATIONAL WAS commissioned by Sabic, a Teesside-based petrochemical manufacturing company, to overhaul a 250kW, 3.3kV 4-pole Ex N GEC motor used in its Olefins 6 plant, the second largest liquid naphtha cracker plant in Europe.

Initially, the customer requested an inspection and report on the condition of the motor. The motor was received from the customer in poor condition externally with substantial corrosion across the entire surface of the unit, but upon dismantling, the internal components were found to be clean, with little ingress evident in the windings. It was suspected that this was the first time the motor had been dismantled since the original installation other than for routine bearing oil changes.

Based on these findings, Houghton International recommended a complete in-depth overhaul of the motor at its IECEx certified facility by a team of experienced electromechanical engineers.

The overhaul consisted of stripping down and steam cleaning the motor, stoving the stator windings and dynamically balancing the rotor to ISO grade 2.5. Being an Ex motor, the mandatory hazardous area checks were also carried out, with a

full report produced at the end.

Remedial repairs to the covers were also carried out, and they were shot blasted and primed. A new sound baffle cover, cooling fan locking nut and new gaskets were manufactured to specification, and the entire unit was rebuilt.

Following the rebuild, the motor underwent full testing, including a Baker test which ran a complete cycle of tests to ensure the integrity of all motor windings, an overall broad test run, and monitoring of vibration and all bearings before being returned to the customer's site.

To begin with, the customer thought the existing motor was beyond economical repair because of the external damage, and a new motor would be required. However, the overhaul minimised the cost implications and disruption to the customer.

Furthermore, midway through the overhaul, the customer requested a much quicker turnaround. Houghton International was able to meet the customer's demands and deliver the overhauled motor on time, ahead of the original schedule.

PETRORIO INVESTS IN ENERGY AND OPERATIONAL EFFICIENCY ON THE NORTHERN COAST OF RIO DE JANEIRO STATE, the Polvo-A platform and the Bravo FPSO (Floating, Production, Storage and Offloading), both run by PetroRio, have formed a cluster for the extraction and storage of thousands of barrels of oil per day.

To support the facilities, PetroRio purchased four WEG motors at the end of 2021, maintaining the interchangeability with the existing equipment on board. The objective is to increase operational efficiency, expanding production flow and ensuring energy efficiency in the operation.

These motors were produced and delivered in record time due to the customer's need for urgency, being part of the offshore operation of the largest independent oil and gas company in Brazil.

Altogether, four hazardous area motors were delivered.

Three 1300HP 4160 V motors were installed to drive the transfer of oil and gas from the Polvo-A platform. One 500HP 460 V motor was used in a gas compression skid at the FPSO Bravo, which previously used diesel oil to generate Quarter 3 2022

electricity. This system reduced diesel consumption by 60,000l a day, which is equivalent to filling the tank of 1,100 cars. In addition, there was a positive environmental impact, with the reduction in the monthly emission of CO2 (carbon dioxide) corresponding to the planting of 30 thousand trees.

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

2022 Partners:

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

R.E. Field Services Ltd • • • • •

Balancing Condition Monitoring Marine Repairs Mechanical Rewinds

APPROVED BY

Siemens LV Motors, Brook Crompton Motors, Nidec (Leroy-Somer)

+44 (0)282 565 6406 info@ges-group.com www.ges-group.com

• • • • •

Gearboxes Laser Alignment Condition Monitoring Marine Repairs Thermography

• • • • •

APPROVED BY BP E-ON SSE INTERGEN VEOLIA VIRADOR

Vibration Electrical Mechanical Generators Rewinds

0114 256 0425 campbell.edgar@refieldservices.com www.refieldservices.com

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

SERVICES INCLUDE • • • • •

Spindle Motors Inverter Drives Electrical Mechanical Rewinds

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

Fyfe Wilson Ltd APPROVED BY NIDEC SIEMENS MAVILOR BOSCH TECMOTORS SCHNEIDER

CEMB Hofmann UK Ltd

0161 872 3122 rob@cembhofmann.co.uk www.cembhofmann.co.uk

INTERNATIONAL REPAIR CENTRES ADYARD ABU DHABI LLC

00 971-2-5547722 Adeel.Rehman@Altrad.com www.adyardabudhabi.com LOCATION: UNITED ARAB EMIRATES

• • • • •

Transformers Balancing Machining Fabrication Rewinds

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

EXCLUSIVE TO AEMT MEMBERS

SERVICES INCLUDE • Condition Monitoring • Laser Alignment • Balancing Machine • Balancing Service & Calibration • Thermography • Vibration

SERVICES INCLUDE • Motors • Fans • Instruments • Generators • Rewinds

SERVICES INCLUDE • Pumps • Motors • Gearboxes Fans • Laser Alignment

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

BOOK ONLINE AT APPROVED BY SIEMENS ABB

WWW.BIT.LY/REPAIRDIRECTORY

OR CONTACT ANDREW CASTLE ANDREW@RENEW-MAG.COM +44 (0)7785 290034

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predictive main line: tenance

Breathing new into a wind turblife ine Indus try News

Innov ations

Appli cation s

Exper t Opini

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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

APPROVED BY

WEG Motors Wilo Pumps NORD Geared Motors Dertec Geared Motors Hoyer Motors Elmo Rietschle Pumps Robuschi Pumps Parker Drives Mitsubishi Drives Hidrostal Pumps Wistro Force Vented Fans

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

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

Inverter Drives Balancing Electrical Mechanical Rewinds

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

ADC Electrical Ltd

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

• • • • •

• Condition Monitoring

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

APPROVED BY Baker Hughes

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

• • • • •

Condition Monitoring Marine Repairs Mechanical Rewinds Ex Hazardous Area

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

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

Mechanica Utilities Ltd

Fletcher Moorland Ltd

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

• • • • •

Marine Repairs Vibration Electrical Mechanical Generators

APPROVED BY

SPP Pumps Belzona Coatings Hydromarque Pumps Brown Europe Gearboxes

SERVICES INCLUDE • • • • •

Pumps Motors Gearboxes Fans Laser Alignment

• • • • •

Servo Motors Inverter Drives Condition Monitoring Rewinds Ex Motor Repair

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

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

Rotamec Engineering Solutions

Invincible Electrical Eng Co

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

SERVICES INCLUDE • • • • •

Marine Repairs Electrical Mechanical Generators Rewinds

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

APPROVED BY Lowara Grundfos Motovario Lenze TEC NIDEC Marelli

• • • • •

Pumps Motors Gearboxes Fans Spindle Motors

• • • •

Inverter Drives Electrical Mechanical Rewinds

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

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

APPROVED BY ABB

FEATURE 42 Opinion

Tackling supply chain challenges

Companies are not powerless in the face of the unprecedented pressure on global supply chains. Lee Windsor, Director at RJW, believes that establishing more local supply chains, while also maintaining existing equipment effectively – reducing the need for replacement machinery and parts – are just some of the methods firms can use to chart a course through the storm.

T

he last few years have significantly impacted how businesses think about supply chains. The almost never-ending availability of cheap components was sometimes taken for granted. But several factors point to that now being a thing of the past. Building resilience into your supply chain and maintaining what you have – rather than simply buying new by default – will become more and more important in the coming years.

SUPPLY CHAINS UNDER STRAIN Even before the impact of Covid, the seeds of supply chain problems were being sown in the east. China had become a manufacturing powerhouse, producing components cheaply and in large quantities.

Trade tariffs imposed by the last US administration, coupled with labour and power shortages, had begun to impact China's ability to produce and export components at its previous rates and prices.

According to a survey of 260 global supply chain leaders by Gartner in 2020, 33% had moved sourcing and manufacturing activities out of China or planned to do so in the next two to three years. Even back then, there was a feeling that the good times were over for countries which depended on cheap and reliable goods coming from the east.

POST-COVID DEMAND The pandemic had a dual impact on supply chains. The first was the disruption to manufacturing caused by lockdowns and other COVID mitigation measures. Last August, for example, the Chinese Port of Ningbo – the world's third busiest – was shut down due to just one case of COVID-19 among the workforce.

The second impact of COVID was a drop in consumer demand which then rebounded swiftly. As economies were shuttered, they quite simply needed less.

But as they reopened, industries the world over suddenly needed things again – pretty much all at the same time and in mass quantities. The suppliers and logistics chains which served them could not cope and, to an extent, still can't.

Quarter 3 2022

BREXIT UNCERTAINTY The UK has had the additional uncertainty caused by the end of the Brexit transition period. Additional tariffs and delays at the port of Dover have led to disruption in the supply of goods coming into the country from mainland Europe. According to the Office for National Statistics (ONS), 5% of UK businesses have changed their supply chains because of the end of the EU transition period.

Lee Windsor, Director at RJW.

CONFLICT IN UKRAINE The conflict in Ukraine has added even more disruption to an already uncertain picture. A report by Dun & Bradstreet revealed more than 600,000 global businesses rely on Russian and Ukrainian suppliers.

THE RISE OF ESG One often overlooked issue with supply chain resilience is Environmental Social Governance (ESG). Unlike some of the more transient factors currently being grappled with, this is a long-term shift, which is here to stay, and must be factored into how companies rebuild their supply chains post-pandemic.

ESG is something which is becoming increasingly important to companies

and consumers. Firms now want to do business with other companies that can prove they are mitigating their impact on the environment.

It will become increasingly important to source materials in a way that keeps a company's carbon footprint to a minimum.

Similar to this is the growth of the 'right to repair' legislation in the UK, USA and Europe which means companies must create products which can be fixed rather than replaced. The significance of this is that the idea of repairing and maintaining things will no longer be seen as something born from necessity but an environmental imperative.

SOLUTIONS TO SUPPLY CHAIN CONCERNS Despite the uncertainty currently being caused to global supply chains, there are measures companies can take to ease the impact.

Diversification of supply chains is one of those measures. Building a supply chain which has both offshore and nearshore suppliers for each component or product builds redundancy into the process and increases resilience. With this in mind, firms should establish regional as well as global supply chains and be able to switch between them at short notice should any disruption be encountered.

MAINTAINING EQUIPMENT For many companies, bringing in new machinery and components will no longer be as affordable and straightforward as it once was. Reducing the reliance on the 'new' and maintaining what is already present will become more important.

To achieve this, firms should have maintenance routines that ensure their existing equipment is kept in top condition, reducing the demand for new replacement components and machinery. Condition monitoring, site visits and smart sensors all have a role to play in ensuring a firm's existing devices and components are kept in prime working order. TIMES-CIRCLE www.theaemt.com

ALPHA E

CTRICS E L

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