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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.
In this issue of Renew, alongside some interesting articles looking at condition monitoring in hazardous areas (page 30), how AI is helping maintenance teams (page 24), and how ultrasound detected a failure on a slow-speed motor bearing, we have an update on the AEMT Awards set to take place in November this year.
The deadline for entries to the awards’ eight open categories has been set for September 6, and we are encouraging anyone who feels they, their business, or a colleague deserves recognition, to put together an entry. The awards will be recognising exciting and innovative products, successful creative or challenging projects, and a service centre and a supplier that have gone the extra mile and exceeded expectations. We will be recognising a standout contribution to skills and training, rewarding one of the industry’s rising stars and celebrating the demonstration of sustainable engineering excellence.
Entering the AEMT Awards should not be an onerous process. Each category has guidance on what the judges will be looking for, and the best entries clearly and succinctly demonstrate how they meet the criteria. No advantage is gained from the amount of information supplied, the process is designed to be straightforward, ensuring that the focus remains on the quality of the entry, not the size. So it really shouldn’t take too long.
Details of the categories, how to enter, and what to expect on the evening of the awards can be found on page 12 of this issue. All I will say is if you are considering an entry, don’t put it off. The weeks between now and September 6, much like the great British summer, will be over before you know it.
Enjoy the issue.
James Stevens, President, AEMT
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.
SOME 30 YEARS AFTER moving to its Heanor works, Bowers Electricals has announced that, due to sustained business growth, it is further expanding its production and manufacturing facilities at the site, acquiring three additional production units.
The new 1,200m2 facility sits adjacent to the existing yard and warehouse facilities at Bowers Electricals Heanor Headquarters. The expansion adds over 900m2 of light industrial working and storage area and 230m2 of office facilities, all with direct access to the already substantial 6,042m2 site and facilities.
focussed on meeting the needs of our customers. By increasing our stock levels of distribution transformers, HV & LV switchgear and motor products, we can offer improved lead times to our expanding customer base.
Talking about the facility expansion, the Bowers Group CEO Michael Bowers stated: “This is a substantial investment
“I see this as a tremendous opportunity for Bowers in terms of delivering its current growth strategy. We
will also relocate our HV contracting division, E.P.E.S., into the new facility to allow closer integration between the two businesses.”
Bowers Electricals moved to its Heanor site in early 1994 and is celebrating 30 years at the facility. Over the years, many changes have been associated with the development of its transformer and switchgear offer, the growth of the motor and rewind business, and the development of a comprehensive service and maintenance business.
Michael added: “This is an exciting development for the Bowers Group and wouldn’t be possible without the hard work of all our staff and management team”.
SIEMENS SELLS INNOMOTICS TO KPS CAPITAL PARTNERS
SIEMENS HAS APPROVED THE SALE of its electric motors and large drives company Innomotics to KPS Capital Partners, LP (KPS). The deal, reportedly worth €3.5 billion, is expected to be concluded in the first half of fiscal 2025, subject to customary foreign investment and merger control approvals.
“By selling Innomotics to KPS, I am pleased that we have made further significant progress in optimising our portfolio. The search for the best new owner has been successful,” said Ralf P. Thomas, Chief Financial Officer of Siemens AG. “This decision gives customers and those who work at Innomotics clarity and paves the way for extensive opportunities for further successful business development.”
In November 2022, Siemens decided to combine its large drives and electric motors businesses under one roof and set them up independently, outside Siemens AG’s core business, under the Innomotics brand.
The positive responses from customers and the market, as well
as the growth of Innomotics during the carveout, underline Innomotics’ strong positioning as a leading supplier of large drives and motors capable of addressing its customers’ most demanding technical requirements.
Siemens believes that the future setup, with KPS as the new owner, will offer Innomotics the best framework conditions for sustainable and growthoriented development.
“The partnership with KPS will support Innomotics in further expanding our extensive track record of successful technological innovation and of providing our customers with world-class products, solutions and services,” said Michael Reichle, Chief Executive Officer of
Innomotics. “We look forward to working closely together with KPS and our talented people as we continue to deliver significant value for our customers around the world and enhance our strong technological leadership. Innomotics will continue to benefit from strong growth potential driven by the sustainabilityoriented demand for highly efficient electrification and energy consumption in industry and society.”
SKF APPOINTS ERIKS AS ITS FIRST UK MAINTENANCE PARTNER
SKF UK HAS ANNOUNCED THE LAUNCH of its Maintenance Partner programme in EMEA and that ERIKS is the first SKF Maintenance Partner in the UK and Ireland, a new status that recognises authorised distributors that can offer industrial customers more than just a traditional transactional relationship.
SKF Maintenance Partners have SKF’s support in implementing best practices, and always use SKF components for repairs. As a highly skilled service supplier, ERIKS uses its industry-specific knowledge to perform root-cause failure analyses and advanced troubleshooting. It is recognised by SKF as a knowledgeable advisor on maintenance
matters, trained by SKF and with access to the very latest SKF technology.
ERIKS UK & Ireland has been appointed by SKF due to its investment in the SKF brand and its strategic alignment in adding long term value to customers through engineering capability, innovation and knowledge and meeting the high-level criteria and accreditation process set by SKF. To support this partnership ERIKS is extending the range of SKF products it stocks and will exclusively use SKF products in its UK repair facilities.
WEG HIGHLIGHTS COMMITMENT TO SUSTAINABILITY AND INNOVATION IN ANNUAL REPORT
WEG HAS RELEASED ITS INTEGRATED Annual Report, which highlights its financial results and commitment to sustainability and innovation strategies in 2023.
The company ended the period with around 40,000 employees distributed across 52 manufacturing sites in 15 countries and achieved net revenue of R$ 32.5 billion (approximately £4.5 billion), reporting a solid year with consistent revenue growth.
The document highlights its growing quest to maintain sustainability aligned with the portfolio of products and solutions that require more economical and efficient production methods. It also highlights initiatives to reduce carbon emissions and responsible use of natural resources.
In addition, continuous innovation was also a highlight of the report, presenting investments in research and development of new technologies to better meet customer needs and contribute to a more sustainable future.
It also presents its governance and compliance model, which historically offers consistency, effectiveness and transparency. On the social side, following
its mission of continuous and sustainable growth and maintaining simplicity, the company brings significant numbers of investments focused on the development of people and the communities in which it operates.
The methodology used to structure the document is internationally recognised. It is based on the guidelines of the Global Reporting Initiative (GRI) and the International Integrated Reporting Council (IIRC). The document also publishes indicators from the Task Force on Climate Related Financial Disclosures (TCFD) and Sustainability Accounting Standards Board (SASB).
The Integrated Annual Report is available on the company's Investor Relations website at bit.ly/WEG23iar
NEW NAME FOR ESTABLISHED ENGINEERING SERVICES SPECIALIST
BRISTOL-BASED AVONMOUTH
Engineering Services, which became part of the Hidrostal Group in 2020, joining Bedford Pumps, has announced a rebrand.
With immediate effect, the company is trading under the name Hidrostal Engineering UK.
Commenting on the rebrand, a company representative said: “Becoming part of the Hidrostal Group in 2020
has given new drive and stability to our organisation. As part of this, the time is now right to rebrand our organisation to Hidrostal Engineering UK.
“This rebrand will forge an even closer allegiance with our sister company, HIdrostal and a stronger alliance with our fellow group member, Bedford Pumps.
“For the Hidrostal Group, it reinforces and expands their specialism within the
rotodynamic industry and gives them an award-winning service centre under their name.”
When asked what this meant for the organisation’s customers, the company explained: “On the face of it, nothing will change. Our customers will still be guaranteed the same fantastic service levels that they have always enjoyed; the only difference is in our contact details and our logo.”
ACQUISITION SEES IPS ENTER EUROPEAN ELECTROMECHANICAL SERVICES MARKET
IPS, A NORTH AMERICAN SPECIALIST
in the servicing, engineering and remanufacturing of electrical, mechanical, and power management assets, has acquired Houghton International. Newcastle-upon-Tyne-based Houghton is an electromechanical services provider with expertise in the repair and remanufacturing of electric motors, generators, pump systems, and of electric coils for electric motors, generators, and alternators for customers in the rail, power generation, industrial, water/wastewater, and mining industries. The acquisition represents IPS’s entry into new markets in the UK, Europe, and the Middle East and an expansion of its network of operations in the US and Canada. Financial details of the transaction have not been disclosed.
Houghton International was founded in 1984 by Ron and Christine Mitten. Since 2006, Michael Mitten has operated as Houghton’s CEO and has led the company into significant services expansion, resulting in a quadrupling of sales and a tripling of the employee base while expanding served markets into Europe and the Middle East. Houghton has highly integrated operations at the Ronnie Mitten Works service centre, a well-equipped, 124,000-square-foot facility with capabilities from electrical coil
manufacturing to pump repair, motor and generator repair, and testing. This facility’s addition to IPS makes it part of a 51-location service centre network spanning the US, Canada, UK, and Europe.
As a leading aftermarket provider of operating and maintenance services for Renewable Power generation customers in the US and Canada, IPS will now be able to build on and expand Houghton’s wind market asset lifecycle services with IPS technologies in power management, generator repair, pitch, and yaw systems. IPS will now look to bring its repair, distribution, and field service offerings to new customers in the on and offshore markets in the UK and Europe.
original equipment manufacturers and operating companies.
Houghton will also join 11 IPS locations that specialise in services for propulsion systems used in freight rail, people transit, and mining applications. This will build on IPS’s capabilities in undercar transformers, traction motors, alternators, inductors, fans, pumps, and field services supporting
“The acquisition of Houghton International not only brings a wellrespected, customer-focused company into IPS, it also marks a milestone in our company’s growth by expanding beyond the US and Canada into new markets in the UK, Europe and the Middle East,” said John Zuleger, IPS President and CEO. “IPS and Houghton have an incredible opportunity to expand and improve our service offering to new customers and markets. We are committed to delivering an unmatched customer experience and creating a special workplace where employees can grow and develop through our training programs.”
CONTROL TECHNIQUES AND KB ELECTRONICS COMBINE UNDER NIDEC DRIVES BRAND
CONTROL TECHNIQUES AND KB Electronics have announced that, effective May 1, 2024, they have combined under the new brand name of Nidec Drives.
According to the ‘new’ company, this decision has been made with strategic initiative and progression in mind. It said that Control Techniques and KB Electronics, with over 50 years of experience, represent innovation and trailblazing in the drives sector; becoming Nidec Drives aligns with their forwardthinking approach and dedication to staying ahead in an ever-evolving market.
Nidec Drives has emphasised that this change will not affect any products or services currently offered by Control
Techniques or KB Electronics. It said their product lines will remain at the same high level of quality, innovation, and service that their customers have come to expect. There will be changes to branding on social media channels, product labelling, and brochures, but Nidec Drives says its customers can rest assured that the same team of drive obsessives is behind the wheel.
This strategic decision is said to signify greater collaboration with Nidec, a global brand, giving further opportunities to produce more of what customers want and need. The company said that becoming Nidec Drives enables Control Techniques and KB Electronics to
harness the strength and resources of Nidec, meaning greater prospects and collective possibilities. The company also believes that this change will strengthen its valued stakeholder relationships and ensure a more efficient and effective experience for all.
Electrom Instruments is proud to introduce the new iTIG IV Series motor tester and winding analyzer. Smaller, faster, and lighter than ever! Now with faster automatic testing and a lightweight construction, the iTIG IV offers accurate and reliable testing in a rugged and compact case.
See what makes the iTIG IV more portable than any previous generation.
Scan the QR code to visit the iTIG IV product page for complete details.
NEW GUIDE FOR USERS OF EX-RATED EQUIPMENT
THE ASSOCIATION OF ELECTRICAL and Mechanical Trades (AEMT), which represents a membership of specialists in the repair, maintenance, and servicing of rotating electrical machinery and associated businesses, has published the latest in a series of guides for those working with electromechanical equipment.
The 'AEMT Introduction to Ex Repairs' has been designed to help users of Ex-rated equipment understand explosion protection techniques, the complexities of repairing Ex-rated equipment, and the critical roles of responsible personnel.
Initially created for member service centres to share with their customers to help educate and inform them on getting their ex-equipment repaired responsibly, the guide is freely available to download from the association's website
(bit.ly/AEMTExRepairGuide).
The guide covers several areas related to the repair of Ex-rated equipment, including proper maintenance and repair techniques and the consequences of not carrying them out, as well as an introductory overview of key legislation and standards involved. Explosion protection techniques and some of the differences in design between Ex- and non-Ex-rated equipment are also explained.
From a repair perspective, the guide outlines the complexities of repairing Exrated equipment alongside key roles and responsibilities of both the equipment user and the repair technicians. It also covers the importance of documentation and traceability, including what needs to be recorded and for how long.
Finally, the guide explains the benefits of choosing a repair facility from the AEMT's
Ex Register and outlines the requirements the repair facilities need to meet to be included on the register.
The 'AEMT Introduction to Ex Equipment
Repairs' joins previous guides, 'The AEMT Guide to Minimising Downtime', 'The AEMT Guide to Minimising Total Cost of Ownership of Motors', and 'The AEMT Guide to Ecodesign Regulations for Electric Motors (2021)', all of which are available to download from the association's website at bit.ly/AEMTGuides
Forthcoming AEMT led Courses & Events
UPDATE FROM THE AEMT GENERAL MANAGER
PROGRESS WITHIN INDUSTRY IS truly remarkable. Amidst the rapid global changes, it's understandable if some struggle to keep up. However, this is not the case for the repair industry, which is successfully navigating challenges related to skills, recruitment, AI, and emissions.
The last issue of Renew showcased Houghton International's collaboration with MSc students to reduce emissions in equipment repair and replacement. Siemens is employing AI to make machinery interactions more intuitive. Furthermore, recent discussions with members have highlighted innovative approaches to addressing the skills gap and reducing emissions. For example, AEMT member Rotamec has partnered with local colleges to develop a tailored apprenticeship scheme.
A new partnership between the AEMT and Climate Action for Associations (CAFA) aims to engage the repair industry in reducing their emissions while aiding other industries in doing the same. The Association's working groups, launched this year, generate excellent content, case
studies, and resources on these topics. The AEMT Resource Hub is continually updated with relevant content to support members in addressing their biggest challenges.
A key concern for members is the skills gap in recruits and the challenge of attracting talent to the industry. The AEMT is pleased to announce a partnership with UniFrog to strengthen the relationship between the industry and school graduates. This partnership will highlight the crucial role of the repair industry in maintaining the world's operations, ensuring power generation, water supply, product manufacturing, and maintaining low emissions within a circular economy.
priorities for them when considering potential employers. With the support of AEMT's services, the repair industry is wellpositioned to attract these young talents.
The next step is to ensure that electrical and mechanical apprenticeships include
comprehensive training on electric motor design, identification, fault finding, testing, and repair. A new working group will soon be formed to address this challenge. In the meantime, the educational resources on the AEMT website are regularly updated to provide current and valuable information.
A recent UniFrog study surveyed up to 11,000 individuals aged 11-18, revealing that climate action, equality, mental well-being, and employment opportunities are top
If you have any comments or would like to speak to me about any of the above points, please don't hesitate to contact me at thomas@theaemt.com or call 01904 674 899
Thomas Marks, the AEMT's Secretary and General Manager
MAINTENANCE-FREE COMPRESSED AIR FILTER DOES THE JOB OF THREE CONVENTIONAL FILTERS
ERIKS UK & IRELAND HAS launched a new compressed air filtration technology, Expel, which continually removes 99.9999% of water, oil emulsion fluids and solid particulates down to 1 micron.
Expel’s design means users never have to change any internal elements; they simply fit and forget. Typically, it would take three conventional compressed air filters – one each for water, oil emulsion, and solid particulates – to do the job of one Expel.
Traditional compressed air filters are only 60-80% efficient, even when operating at optimum performance levels, and can be overwhelmed with contaminants quickly as their disposable internal elements become less effective over time.
This new filter has been engineered using computational fluid dynamics and
does not require any replacement filter elements, ensuring that its performance will not fall below 99.999%.
The Expel technology does not need servicing and is virtually maintenancefree. There’s no membrane filter, no holes to become blocked and no moving parts to fail. And, although cleaning is not necessary, the Expel is fully cleanable and reusable if required.
NEW BATTERY-POWERED VIBRATION SENSOR
THE NEW VWV VIBRATION SENSOR from ifm is designed to deliver comprehensive vibration and temperature monitoring, even in hard-to-reach spots, ensuring peak machine performance and proactive maintenance.
Offering a wireless design and intelligent mesh topology for efficient data transmission, the VWV sensor provides swift integration and reliable communication, making it suitable for a wide range of industrial applications.
Key features and benefits include the choice of one (VWV001) or three (VWV002) measurement axes, wide measuring ranges for vibration (-16 to 16g) and broad vibration velocity (0 to 25mm/s), frequency ranging from 10 to 1000Hz, an ambient temperature range of -30 to 80°C, and robustness and durability with an IP68 rating.
The VWV sensor enables early detection of potential machine issues. It leverages wireless technology and a long-lasting battery, which ensures uninterrupted monitoring for a minimum of four years while reducing downtime and maximising operational efficiency.
Geared towards maintenance engineers, reliability professionals and plant managers seeking proactive and data-driven maintenance strategies to prevent potentially catastrophic failures of critical assets, the VWV sensor's standout feature is its user-friendly integration with the moneo IIoT software. This facilitates quick data analysis and visualisation
for informed decision-making. The gateway's open standard interface allows seamless data transfer to IT systems, ensuring optimal condition analysis and accelerated maintenance interventions. ow.ly/6noo50RvQrk
www.ifm.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.
AEMT calls for nominations as entry deadline approaches
Following the success of its 2023 awards programme, the Association of Electrical & Mechanical Trades (AEMT) is once again encouraging all those engaged in this industry sector to submit their award entries for the 2024 staging of the AEMT Awards.
The seventh delivery of this highly regarded awards scheme will culminate in a gala presentation ceremony, this year taking place on Thursday, November 21, at the Doubletree by Hilton Hotel in Coventry.
The AEMT Awards dinner will bring together the electrical and mechanical trades sector to celebrate business and professional excellence. Product innovation, engineering prowess, project management, skills development, diversity, and sustainability will all be acknowledged and celebrated in recognition of the achievements of individuals and companies operating across the electromechanical maintenance and repair arena.
INDUSTRY BACKING
With the support of invaluable sponsors, well-deserved acknowledgement will be given to those businesses excelling in their commercial endeavours and, in many cases, going far beyond the call of duty in ensuring the safe and efficient operation of plant and equipment within the critical manufacturing, commercial, and utility sectors.
CATEGORIES
The following nine categories make up the 2024 awards programme:
• Product of the Year – sponsored by DFA Media Group
• Project of the Year – sponsored by EMIR Software
• Service Centre of the Year –sponsored by Acorn Industrial Services
• Supplier of the Year – sponsored by Renew
• Contribution to Skills & Training Award – sponsored by Innomotics
• Rising Star Award – sponsored by TEC Electric Motors
• Diversity in Engineering Award –sponsored by Preformed Windings
• Sustainable Engineering Award –sponsored by ABB
• Special Recognition Award –sponsored by AEMT
NOMINATIONS
Entries are being sought for any company, product, application, or individual involved in the supply, installation, service, maintenance and repair of industrial machinery, 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 can nominate others that they believe merit recognition. The online entry process couldn’t be more straightforward, so anyone wishing to play their part in highlighting engineering excellence should visit the AEMT Awards website at www.aemtawards.com
CLOSING DATE FOR ENTRIES
The closing date for all entries has been set as 5.00pm on Friday, September 6,
2024, so for those wanting industry-wide recognition for a job well done, be it for product innovation or project management, for application know-how, or service and repair, they should make a note of this key date.
It is free of charge to enter the awards, but the promotional value associated with being selected as a finalist is worth many hundreds of pounds. And for those individuals and companies fortunate enough to be announced as one of the nine winners during the charged atmosphere of the gala awards dinner, the promotional benefit is even greater.
Just 30 minutes spent completing the online entry form, providing the information and details that you readily have at your disposal, could make you a winner in your industry’s awards programme. The gravitas and promotional exposure for this are both invaluable and enduring. TIMES-CIRCLE
www.aemtawards.com
Motion drives package for the Mexican tequila industry
TEQUILA IS AN EMBLEMATIC DRINK
of Mexico, with such significant cultural importance that it has become one of the most consumed alcoholic beverages worldwide. The tequila industry in Mexico is one of the largest in the agri-food sector, having generated a 5% increase in production in this sector in recent years. Tequila results from the fermentation and distillation of sugars extracted from agave cultivation.
The United Nations Educational, Scientific and Cultural Organization (UNESCO) declared the agave landscapes and the old industrial facilities of Tequila, Jalisco, as cultural heritage.
At the end of 2023, WEG, through its branch in Mexico, supplied a highly recognised company in the tequila sector with two integrated packages that include electric motors, variable frequency drives (VFDs) and gearboxes, destined for two tequila factories in the municipalities of Tequila and Atotonilco.
Each package supplied consists of 15HP W22 electric motors, WG50 gearboxes, and CFW500 variable frequency drives, which
will be used to control the speed in the agave grinding area. These components combine the quality of the electric motors, the frequency drives' reliability, and the gearboxes' robustness.
For WEG, the concept of motion drives is about having total control of the process. The main difference of this integrated solution is managing everything under the same brand, allowing perfect coupling of the
equipment, ensuring its efficient functioning and reducing operating expenses. This integrated package ensures efficiency in the process, contributing to increased operational savings.
www.weg.net
ELECTRIC MOTOR UPGRADE FOR ANGLIAN WATER SITE
THE GIBBONS TEAM WAS RECENTLY called to an Anglian Water site in Little Waltham to upgrade an old slip-ring electric motor and starter in the control panel.
Using a lifting frame with a block and tackle, the existing motor was disconnected and moved away from the area to make way for the new IE3 Gibbons 5.5kW electric motor. The current electric motor was obsolete and had failed due to a cracked casing. Repairing it would have been very costly, so it was decided that replacing the motor would be the best course of action.
To facilitate the new motor, a custommade flange adaptor was designed, manufactured, and then fitted, along with a replacement coupling to connect to the motor shaft. The engineers then took the old motor away to be recycled.
The new motor is more efficient and has a higher IP rating against dust and damp conditions, making it more suitable for the application.
Inside the starter cubicle, the slip ring resistors and obsolete control devices were removed. A new ABB ACQ580 variable-speed drive was mounted on the side of the cubicle and then integrated with the existing control philosophy. The ABB ACQ580 will now operate the ramp time of the electric motor that controls the pump, situated 20 feet below.
The Gibbons engineers overcame a slight issue regarding the power
factor connection, which required disconnecting; this was mounted behind the cubicle mounting plate, which inhibited access. The mounting plate's lower half was removed, allowing access for disconnection.
The Anglian Water team at Little Waltham now has full control of the electric motor's speed, so they can optimise the pump's control, which will allow for energy savings when necessary.
www.gibbonsgroup.co.uk
A mobile application enabling paperless service and repair
Why is Smart Site right for you?
Smart Site is easy to use on any smartphone or tablet device and requires very little training.
Smart Site reduces the waiting time of documents in transit. All job information is visible at the office as it happens.
Smart Site delivers accuracy. The app captures information as it happens, meaning there is less chance that something important is missed or recorded incorrectly.
Smart Site streamlines the administrative process ensuring that contracted and chargeable work can be completed in a timely fashion and invoiced with complete confidence.
Smart Site stores the history of an asset’s repair and service, so your engineer has all of the detail they need to do the job right first time.
See Smart Site in action!
REVITALISING POWER GENERATION
TDC PARSONS PEEBLES HAS transformed a 46-year-old induction generator into a modern powerhouse.
Originally designed in 1977 as an 11 kV, 7 MW induction generator for Foster Wheeler, the generator operated in conjunction with a power recovery train (PRT). This PRT system, consisting of a steam turbine, blower, and an expander, recovered some of the waste energy used to drive the generator. This PRT configuration continued until 1991, when a critical need arose to supply reactive power during grid outages.
To address the system’s insufficient reactive capacity and mitigate the impact of grid outages, the solution required significant modification. The existing induction generator underwent a conversion process to enable synchronous operation. While the conversion was successful, and the generator continued to operate reliably for an impressive 33 years, it suffered operational drawbacks. For instance, high operating temperatures, vibrations, and bearing issues caused the generator’s output capacity to be reduced throughout its lifespan.
In 2023, TDC Parsons Peebles was approached to provide a new generator. The goal was to replace the ageing generator with an interchangeable drop-in replacement. This new machine would address the inherited problems, offer
increased performance (11kV, 7.5MW, 8333kVA), and seamlessly integrate with the existing infrastructure. This included ensuring compatibility with the existing cabling, pipework, foundations and excitation system.
Leveraging its experience in new generator design and refurbishment, TDC Parsons Peebles’ engineering team completed a comprehensive design review. This review led to the redesign of the stator and rotor windings, an improved ventilation circuit, a redesigned shaft and base plate, and the incorporation of a new
bearing design. These changes significantly improved the generator's performance, reducing the operating temperature from over 158 to 86°C and full load vibration from 6.0 to 1.3 mm/sec (rms).
The new, like-for-like replacement generator provides increased output capacity and efficiency while minimising downtime and disruption during installation.
www.parsons-peebles.com
DISTILLERY SAVED FROM COUPLING FAILURE CATASTROPHE
WHEN A DISTILLERY FACED A critical coupling failure that threatened to halt production on a busy Saturday afternoon, ACORN's Regional Sales Manager, Phil Mclaughlin, sprang into action to rescue it from a potentially sobering situation. With their premium line at risk, the customer faced a potential £30,000 in lost revenue.
Recognising the situation's urgency, Phil knew he couldn't waste any time; he immediately identified the part and swiftly procured the vital KTR Rotex
coupling element needed to restore the distillery's operations. Despite the challenges of a weekend schedule, Phil ensured that the part was dispatched promptly to minimise downtime for the distillery. Thanks to ACORN's coupling stock holding, the crucial element reached the distillery by 7:30 pm the same day.
By acting quickly, Phil and ACORN averted what could have been a significant financial setback, saving the customer over £5,000 in lost revenue. www.acorn-ind.co.uk
Bridging the gap: How early engagement is building a brighter engineering future
The UK engineering industry faces a double challenge: a growing skills gap and an ageing workforce. However innovative approaches are emerging to bridge the gap. One initiative is the work of Primary Engineer, a UK-based non-profit founded in 2005. Its mission? To ignite a passion for engineering and technology in primary school pupils across the UK.
By fostering a love for engineering from a young age, Primary Engineer helps to lay the practical foundation for a future generation of passionate and skilled engineers, primed to make a positive impact on the world.
STARTING YOUNG
Research indicates that interest and perceptions of STEM fields are formed during primary school years and solidified by the early teens. This highlights the importance of early engagement in igniting a passion for engineering. Furthermore, the UK faces a challenge of low awareness and understanding of engineering amongst its younger generation. Figures published in 2020 by EngineeringUK found that 47% of 11 to 19 year olds knew little or nothing about what engineers do, with some learners found to possess limited definitions that framed engineering as difficult, complicated and dirty work.
Traditionally, engineers have been inspired by someone they know. But what about pupils who lack such role models? The lack of role models for children or a clear picture of what engineers do, coupled with a lack of diversity in the field, is a significant challenge. This limited understanding translates into a smaller talent pool, hindering the industry's ability to attract future engineers.
EMBEDDING ENGINEERING INTO EDUCATION
Primary Engineer brings engineering to life in classrooms across the UK with its fully-funded educational programmes, competitions, and qualifications. These activities are designed to engage both teachers and pupils in significant ways by creating meaningful connections between engineering principles and
real-world applications. Its annual competition, 'If you were an engineer, what would you do?', is a prime example. The competition encourages pupils to interview real engineers (in-person or virtually), fostering connections and sparking curiosity. Pupils then use these interviews to identify innovative solutions to real-world problems, building communication and writing skills through an annotated illustration and crafting a persuasive letter that explains their ideas. Pupils build lasting memories at regional public exhibitions and awards ceremonies where their incredible, innovative ideas are celebrated in the summer term.
SHEDDING LIGHT ON LOCAL OPPORTUNITIES
Many engineering companies operate in large, unassuming buildings, and their inner workings are a mystery to the outside world. Primary Engineer facilitates connections between these companies and schools, facilitating in-school engineering visits or even
site visits, fostering local brand awareness, and demystifying the engineering profession. This exposes pupils to a world they might not have known existed, empowers them to ask questions that truly resonate with them, and gives them a role model – after all, pupils can't be what they can't see.
This approach shatters preconceived notions about what engineering is and what engineers look like. This benefits companies by creating a talent pipeline and exposes young minds to the exciting world of engineering right on their doorstep, potentially inspiring future careers. The potential for the competition to support career aspirations is also recognised by engineers who meet pupils during their engineer interviews.
One engineer, Christina, noted: "The students I visited didn't have many engineering role models and weren't aware of the strong engineering industries in their own city. So it was really nice to help make them aware of the possibilities open to them."
INSPIRING PUPILS THROUGH EFFECTIVE ROLE MODELS
Given the wider challenges of diversity and participation in UK engineering, Primary Engineer's approach allows its educational activities to reach particular areas and communities to close inequality gaps and widen ethnicity representation, fostering a more inclusive future for engineering.
In 2023, half of the organisation's 48,052 competition entries were received from girls, highlighting the equality present within the reach and participation of the competition. Moreover, girls often receive more awards from this competition than boys, demonstrating the capacity of this project to support young girls to excel in engineering.
A learner who has participated in the project is likely to develop a stronger
understanding of engineering, which may prompt them to consider engineering educational pathways as they age.
One student who participated in the Leaders Award competition while in secondary school recalled how inspirational it was: "It really inspires you because through [the Leaders Award] we got to meet engineers, talk to them, and see people who look similar to you in aspirational roles. It just inspires you and lets you know it is possible to go down that route."
The Leaders Award competition has been designed to support substantial, cumulative change over time to build greater support for UK engineering. The competition comprises multiple components – interviews, design activities, persuasive writing, and events – with multiple points of contact between
learners and engineers. It is hoped that the positive impact of these experiences accumulates into ripples of change that have a profound impact over time and across the UK.
A BRIGHTER FUTURE AWAITS
The engineering skills gap is a complex issue, but innovative approaches like those of Primary Engineer offer a promising path forward. By igniting a passion for engineering early on, we can foster a future generation of skilled and enthusiastic engineers, ready to tackle the challenges of tomorrow. TIMES-CIRCLE
Why should engineering businesses invest in women? why shouldn't they!
WOMEN ARE DOING FANTASTIC
work in the field of engineering, and yet they still make up an unrepresentative proportion of those employed in the field. In recognition of the recent International Women in Engineering Day, and to support efforts to encourage more women into the electromechanical repair sector, the AEMT spoke to some of the inspirational women within its membership to find out why they thought businesses should invest in women and gather tips for women considering a career in engineering.
Sara Oliver, a director at Fenflow, thinks investing in women supports important organisational balance: "Every workforce needs diversity and balance. This brings different and broader perspectives and a wide variety of skills. I think without this balance, a team can become stagnant and resistant to change or to trying new ideas. Diverse teams simply perform better."
Annette Boulter, a training consultant for EMiR Software, added: "Women are smart, adaptive, and go the extra mile. Why wouldn't businesses want to invest in attracting excellent people?"
This was a view echoed by Gillian Montgomery, a winding operative at Houghton International: "Women are capable of doing these jobs, and
businesses need unique perspectives and ideas to thrive. The real question is: Why shouldn't businesses invest in women?"
Jasmine McIlroy, Health & Safety Manager at GES Group, highlighted important evidence: "Statistics have proven that companies with high levels of diversity and gender inclusion in their management teams are 25% more likely to have higher levels of profitability than those with less diverse teams.
is the attitude to learn something new."
On tips for women considering engineering careers, Annette thinks women should not be put off: "Don't buy the line that engineering is a man's world. Be what and who you want to be. Search out the positive companies to work for and put yourself in front of them."
Based on her own experience of changing careers to move into engineering, Sara pointed out the value of transferrable skills: "Over the years, I have seen an increasing number of women who have changed careers and moved into engineering roles. There are always transferable skills, and the greatest attribute
Kirstie Davies, Marketing Manager at EMiR Software, thinks anyone with an interest in the sector should give it a try: "There are many varied and interesting roles that this sector can offer. Dip in and take a look; it might just surprise you how well you will fit in."
Jasmine shared a similar view: "I always encourage young girls to pursue a career in STEM. If it's something they enjoy or are good at, they should go for it."
Finally, Corinne Roome, General Manager at Hidrostal UK, would like to see a point when we don't have to champion attracting women into engineering: "I think about it totally differently. The sooner everyone stops talking about 'women in engineering', the better. Because when they do, it will be normalised. No one talks about male nurses or male hairdressers."
Slow-speed oven motor bearing: failure detection using ultrasound
Ultrasound technology specialist, UE Systems, has used its solutions to identify bearing failure on a slow-speed oven motor, which is typically a challenging task. Renew found out more about the technology and how it helped.
Vibration analysis has long been the method of choice for bearings and other rotating equipment. More commonly, ultrasound is used in conjunction with vibration analysis to help technicians confirm the condition of mechanical assets.
Because of the versatility of ultrasound, if a facility does not have a robust vibration analysis program in place, ultrasound can be implemented to detect earlystage bearing failures, as well as other issues. If the vibration analysis is performed by an outside service provider quarterly or monthly, ultrasound can be used during the interim. This will help the facility to know the condition of some of the more critical assets prior to the service provider entering the facility; therefore, the service provider's time can be used more efficiently because the plant knows if there are any prominent problems with the assets that are being monitored by ultrasound. The service provider can then prioritise its activity based on the ultrasound findings.
Another scenario where ultrasound may be used first over vibration analysis is monitoring slow-speed bearings. Slow-speed bearing monitoring with ultrasound is easier than you might think. Because most high-end ultrasound instruments have a wide sensitivity range and frequency tuning, it is possible to listen to the bearing's acoustic quality, especially at slower speeds. In extremely slowspeed bearing applications (usually less than 25rpm), the bearing will produce little to no ultrasonic noise.
In that case, it is important to
not only listen to the sound of the bearing but, more importantly, to analyse the recorded ultrasound sound file in a spectrum analysis software, focusing on the time waveform to see if any anomalies are present. If 'crackling' or 'popping' sounds are present, then there is some indication of a deformity occurring. In bearing speeds above 25rpm, it is possible to set a baseline decibel level and trend the associated decibel level readings over time.
USING ULTRASOUND TO IDENTIFY OVEN MOTOR BEARING FAILURE
An inspection with an ultrasound instrument was carried out on a site with a newly installed oven dryer. This large drum oven was about 20m long by 5m wide. Four large motors rotated it, each of them having two large sets of bearings. These motors rotate the oven and are rotating at a speed of around 7-10rpm. This is an example of extremely slowspeed bearings, which are usually challenging to inspect.
An ultrasonic instrument was used to inspect all bearings –almost all of them presented
a smooth sound and a 0dB reading, except for one. On one of the bearings from this set, the ultrasonic instrument displayed 2dB instead of 0. Also, the sound heard from the headphones was different: it was not as smooth as in the other bearings and presented a repetitive 'knocking' sound. This gave the inspector an indication that something might have been wrong with this specific bearing.
After the results from the ultrasonic inspection, a grease sample was taken to confirm if there was any damage to the bearing – in which case, the grease sample would show metal contamination. The grease analysis results showed the presence of metal particles, confirming the damage indicated by the ultrasound instrument.
The next step was scheduling an outage to replace the bearing,
On the bearing which had been identified as damaged, part of the outer race had come away and one of the rollers had rotated by 90°.
which was in poor condition. Part of the outer race came away as it was opened. It was also noticeable that one of the rollers had moved 90°. The cage had been damaged as well.
THE METHOD
Ultrasound technology is useful when monitoring the condition of slow-speed bearings. An ultrasonic instrument/sensor can warn maintenance personnel of failure, even at extremely slow speeds, as in this case.
Bearings rotating at normal speeds can be inspected using ultrasonic technology by comparing changes in dB values. This establishes whether a bearing with a certain value above a decibel baseline needs lubrication or is already in a failure state, depending on how many decibels it is above the baseline.
However, with slow speed bearings, comparing dB levels and establishing alarms is not enough: in many situations, the difference in
the dB levels will not be significant or may even be non-existent, in which case the inspector might think there is nothing wrong with it.
For slow-speed bearings, one must rely on the sound quality and the sound pattern. For this, it is necessary to use an ultrasonic instrument with sound recording capabilities, like UE Systems'
An ultrasonic instrument or sensor can warn maintenance personnel of failure, even at extremely slow speeds.
Ultraprobe 15000, and then analyse the sound file on sound spectrum analysis software such as Spectralyzer. With this approach, maintenance professionals can simply record the sound produced by a slow-speed bearing, load the file into the software and analyse it in the Time Series view.
The spectrum analysis of this oven motor bearing showed clearly where the roller at 90° hits the crack as the knock stops briefly. Thus, the sound pattern indicated
an existing problem, being the most reliable source of information when determining the condition of a slow-speed bearing using ultrasound. On the other hand, the spectrum of a recorded sound from one of the good bearings showed a very different picture: a very uniform spectrum with almost no changes in the amplitude.
This find has saved a significant amount of money, as it was necessary to get cranes in to replace such a big bearing, a job that took up to six hours. Luckily, this was done during a planned outage, avoiding the costs of unplanned downtime. TIMES-CIRCLE
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The True Cost of Downtime 2024: A comprehensive analysis
In a new report titled 'The True Cost of Downtime 2024', Siemens has explored the financial ramifications of unplanned downtime for manufacturers. The report underscores the critical role of predictive maintenance in curbing these expenses and enhancing operational efficiency.
The in-depth report, published recently by Siemens, provides a detailed look at the escalating costs associated with downtime, driven by increasingly complex supply chains and rising energy prices, while also highlighting the significant savings potential offered by predictive maintenance (PdM) technologies.
KEY FINDINGS
Unplanned downtime is a severe financial drain for the world's largest companies. According to the report, the 500 biggest companies globally lose approximately $1.4 trillion annually due to unplanned downtime, equivalent to 11% of their total revenues. The automotive sector, in particular, faces the highest costs, with an idle production line in a major plant costing up to $2.3 million per hour. This notable increase from previous years reflects the sector's complex and interdependent supply chains.
Heavy Industry also faces substantial costs, with an hour of downtime now costing $59 million, 1.6 times higher than in 2019. In the fast moving consumer goods (FMCG) sector, costs have remained relatively stable, yet they still pose a significant financial burden. Rising energy prices have been identified as a critical factor driving the increased cost of downtime across various industries.
The report also explains how the spike in downtime costs has far outpaced inflation, particularly in the automotive and heavy industry sectors. For example, US price inflation from 2019 to 2023 was 19%, yet the cost of an hour's downtime in the automotive sector rose by 113% during the same period. This discrepancy is largely attributed to the global energy crisis, exacerbated by events such as the COVID-19 pandemic and geopolitical tensions, which have driven energy prices to unprecedented levels.
Complex supply chains in the automotive
industry mean that downtime in one part of the process can have cascading effects throughout the entire production line and supply chain. This interdependency significantly amplifies the financial impact of downtime.
THE ROLE OF PREDICTIVE MAINTENANCE
PdM has emerged as a vital strategy for mitigating the high costs of unplanned downtime. PdM involves using advanced technologies to predict equipment failures and perform maintenance at optimal times, thus preventing unexpected breakdowns and reducing the need for costly scheduled maintenance. According to the report, nearly half of the firms surveyed now have dedicated PdM teams – this is double the proportion seen in 2019.
The adoption of PdM has led to a significant reduction in downtime incidents and hours lost. On average, plants now suffer 25 monthly downtime incidents, down from 42 in 2019. The average large plant loses 27 hours per month to unplanned downtime, a significant decrease from 39 hours in 2019. This reduction has been crucial in preventing the total costs of downtime from spiralling out of control.
RECOMMENDATIONS
The report makes several headline recommendations for manufacturers to continue mitigating the financial impact of downtime.
Siemens advocates for the broader implementation of PdM technologies across all manufacturing sectors. By leveraging AI-driven machine health monitoring, companies can save millions of hours in downtime and achieve significant cost savings.
Integrating IoT, AI, and other Industry 4.0 technologies is also highlighted as essential for effective condition monitoring and predictive maintenance. These technologies
provide the rich data necessary for accurate failure prediction and maintenance planning.
Effective PdM requires comprehensive data collection from various sources, including maintenance records, operational systems, and manufacturing execution systems. Siemens also recommends that firms invest in the necessary infrastructure to gather and analyse this data effectively.
The report also highlights the unique challenges SMEs face in managing downtime costs. Siemens recommends that SMEs adopt digitalisation and PdM technologies to remain competitive and avoid unsustainable losses.
CONCLUSION
The 'True Cost of Downtime 2024' report underscores the critical need for advanced maintenance strategies and technological investments to mitigate unecessary costs. By adopting PdM and Industry 4.0 technologies, manufacturers can significantly reduce downtime incidents, enhance productivity, and achieve substantial cost savings. As the manufacturing landscape evolves, these strategies will be essential for maintaining operational efficiency and competitiveness within the sector.
AI and the future of industrial maintenance
According to Rockwell Automation’s 9th annual State of Smart Manufacturing Report, the adoption of AI tools will be surging throughout 2024 – but what impact, if any, will they have on maintenance teams? And could these tools perhaps be the key to better maintenance? Sandy D’Souza, from Rockwell’s Fiix computerised maintenance management system (CMMS) business, gives his view and looks at how barriers to adoption can be overcome.
Surveying this year’s State of Smart Manufacturing Report, it’s hard to deny that despite the many challenges facing manufacturers, a certain optimism shines through, and advanced technologies like AI are giving manufacturers hope. While AI technology is still evolving, a surprising 83% of respondents to the report anticipate using generative AI this year, propelling it to number one on the list of 2024’s top technological investments. That’s an interesting turn of events because it wasn’t long ago that most players in the space were sceptical, even a bit afraid, of AI.
THE STATE OF SMART MANUFACTURING
Many conversations about AI and machine learning tend to centre around the technical aspects of these new solutions. They are filled with narratives about their ability to parse through data or solve difficult operational challenges, but they often fail to acknowledge how the humans behind these tasks will be impacted.
In the past there has been an element of distrust around AI and an element of the unknown.
A surprising 83% of respondents to the report anticipate using generative AI this year.
But, faced with new challenges such as economic headwinds, labour shortages, skills gaps, and cybersecurity concerns, the conversation is shifting. Now, instead of focusing directly on the technology, people are asking, ‘How is AI technology ultimately going to transform and improve the lives
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of the human beings who are actually working on the plant floor?’
Naturally, this leads to questions about how AI technology can ultimately benefit maintenance teams. The team at Fiix has identified five key areas where the maintenance function can benefit.
• Finding anomalies in a sea of maintenance data: As today’s manufacturing operations grow in complexity, the amount of data generated daily grows to a scale that is simply unmanageable by humans alone. AI really shines here – digesting huge quantities of maintenance data, such as sensor data from a motor or temperature data from a PLC, and identifying the anomalies that could indicate failure.
• Increasing efficiency through automation: Much of the work that maintenance technicians perform daily is extremely valuable. Creating work orders, analysing data, and generating reports; all these tasks can now be done by AI tools, freeing up valuable technician time to focus on purely value-adding activities and making the most of scarce labour resources.
• Filling labour shortages and knowledge gaps: With the recent rise of accessible prescriptive maintenance tools, generative AI can now be trained on asset and maintenance data to produce detailed, complete, and accurate work orders. Not only does this save time, easing the pressures resulting from a shorthanded workforce, but it can go a long way towards filling in the knowledge gaps left by attrition and a rapidly changing technological landscape. Simply put, we’re at a point where AIpowered tools can increasingly complement humans in many daily maintenance tasks, serving as a team’s expert copilot.
• Improving data integrity: Like any human activity, manually gathering maintenance data and collating it into reports carries the real risk of human error. That also means the risk of
compromised decisions based on bad data. To ensure data is always of the highest integrity, an AI-powered analytics tool can automatically collect, analyse, and action data. Plus, it’s much faster to use AI than assembling these reports by hand.
• Tracking progress on operational goals: As the saying goes, you can’t improve what you don’t measure. With each closed work order, maintenance teams are adding to the wealth of intelligence that AI analytics tools can use to generate insights on important metrics such OEE and other KPIs. And this, in turn, means solid data with which to make the decisions needed to drive a maintenance program forward.
deployment off the ground.
With the emergence of AI and especially generative AI technologies, strategies like prescriptive maintenance have suddenly become highly accessible to maintenance teams – and highly effective.z
Rather than having to rely on somebody coming through with an instruction manual and asset manual, et cetera, or going on the Internet to find that information, what if you had a tool that could automatically mine some of that information?
This new generation of AI-powered maintenance solutions can be implemented in just two weeks.
TURNING AI INSPIRATION INTO AI ACTION
Of course, these are all great ideas, but they don’t mean much without effective implementation. And that means contending with change management. It’s really hard to orchestrate the change inside an organisation so you can ultimately adopt the new technology – something many maintenance teams know all too well.
When asked how teams can truly make change stick, its important to reframe the motivation behind adopting new technologies. Where I’ve seen successful change management occur really boils down to the business case behind ‘how is this technology ultimately going to transform and improve and make the life of the human beings who are actually working on the plant floor better?’
Not only does this put a justified focus on the human impact of new technologies, but when framed in that context, it tends to become much easier to get buy-in across the organisation and certainly a lot easier to get a
With this new technology, Fiix will mine historical data and present it to you so that now you can focus on the task at hand rather than doing some of that research and doing some of that grunt work. Whereas it used to take a Fortune 500-size budget and a team of data scientists, this new generation of AI-powered maintenance solutions can be implemented in just two weeks. Plus, they’re budget friendly.
As we think about the benefit of prescriptive maintenance, it really is a copilot that works alongside the people on the factory floor who are doing the maintenance and acts as a tool, as an aide to help everybody get their job done better. Among AI’s many capabilities, prescriptive maintenance might be the single most transformative for maintenance teams in the coming years. And to think, this was simply out of reach for most teams before the advent of generative AI.
Ultimately, I think where we see success is where clients have successfully articulated the human benefit of these technologies across the organisation and thus enabled the change to take effect and achieve a successful deployment and successful results. TIMES-CIRCLE
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Avoid bearing the cost of failure
Carrying out routine maintenance can be a chore, but failing to complete regular checks on essential pieces of machinery can result in unexpected downtime and lost productivity. Sulzer’s service centre in the USA, recently completed an urgent repair on a 700HP (522kW) motor caused by a failed bearing that could have been easily avoided, bringing the motor back online ahead of schedule and minimising lost production.
Amineral processing company in the USA relies on many large motors to power essential equipment such as water pumps, pulverisers and vacuum pumps. To minimise the spares inventory, they use similar motors where possible. For example, seven pieces of equipment are powered by 700HP mediumvoltage motors that are now around 20 years old. Aside from the essential spare parts, a complete motor is used to replace assets that are removed for overhauls every three or four years. However, some of the maintenance routines are a little sporadic.
Sulzer has carried out regular planned maintenance and overhauls of rotating equipment for the minerals company, including the 700HP motors, which are interchangeable between different applications. When one of the motors failed unexpectedly, it was removed from service and sent to Sulzer’s Colton service centre for inspection and repair.
When the motor was disassembled, the inspection showed that the drive-end bearing had overheated and failed, allowing the rotor to contact the stator, damaging the windings in both the stator and the rotor and the bearing cap. The motor had been overhauled by Sulzer three years previously, so all the technical details of the asset were on record. This made ordering new windings much quicker, expediting the repair process.
REPEAT FAILURE
In the meantime, the rotor and stator were stripped out before checking for any defects in the laminations. In this case, some minor machining enabled any hot spots to be removed, and the core loss tests achieved satisfactory results. At the same time, a new bearing cap was manufactured
in-house, ready for reassembly.
Gary Patton, Colton SC Manager, explained: “Under normal circumstances, the minerals company would have installed the spare motor, and production would have continued unaffected. However, in this case, the spare had recently been shipped to us for repairs following a premature bearing failure caused by a problem in the application.”
Unfortunately, in this case, the lamination stacks of the rotor and the stator could not be saved, so additional parts were required and this repair had a longer lead time. This dual outage significantly affected the production volumes of the minerals processed, which dropped by 25%. It was essential that the latest failure was repaired as quickly as possible. Once the new coils, bearings, and seals were installed, the motor was reassembled and run on Sulzer’s inhouse testbed before being returned to the customer. The expected project time was five weeks, but Sulzer reduced this by a whole week by expediting the coils and working two shifts.
Gary concluded: “On this site, we found that the vacuum pumps are located beneath another process, which means that the motor cooling ducts can become blocked with debris. Unless this is cleared regularly, the motor and bearings can start to overheat, as happened in this case. A simple maintenance process could have prevented repeated failures of these motors and saved time and money for the business.”
Industrial applications such as this need reliable equipment, but repairs need to be of high quality and delivered quickly, especially when productivity is reduced due to equipment failure.
Sulzer has suggested adding a shelter for the motors to reduce debris build-up and enable them to operate reliably between planned overhauls. Bearing temperature sensors could also alert maintenance staff to the issue before the bearing fails. TIMES-CIRCLE
Call for nominations now open...
The AEMT is once again looking to recognise and reward the people, companies, projects and services that play a crucial role in ensuring our food production, utilities, manufacturing processes, transportation and other essential services are maintained and secured.
Endorsements:
“MKE are delighted to be a part of this key annual event. The AEMTs commitment to celebrating success is a welcome entry in our calendar. This year was even more special as we were nominated for three categories and won one.”
Matt Savage MKE
“What a great evening. We were delighted to sponsor the ‘Rising Star’ category and meet the guys in person and we look forward to the 2024 awards and our continued support of the AEMT members.”
Scott Edwards TEC Motors
Thursday, November 21st 2024
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 will be 9 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, Sustainable Engineering, the Rising Star Award, and the AEMT’s Special Recognition Award. Make sure you enter now to be recognised as a leader in your industry.
www.aemtawards.com
Navigating condition monitoring challenges in hazardous areas
Employing condition monitoring in hazardous areas creates a range of challenges. Chris Callander explains how modern solutions, compliant with directives like ATEX and standards such as IECEx, make the approach more feasible and reliable in hazardous areas.
Condition monitoring is essential for maintaining the safety and efficiency of machinery in hazardous industries, including oil and gas, chemical manufacturing, and mining. These sectors operate under extreme conditions and involve significant risks, where equipment failure can have catastrophic consequences. Implementing condition monitoring solutions in such environments poses unique challenges, yet technological advancements are helping to overcome these obstacles.
CHALLENGES IN CONDITION MONITORING
Many industries operate in environments with extreme temperatures, pressures, humidity, and exposure to corrosive substances. These harsh conditions can quickly degrade monitoring equipment, necessitating frequent maintenance or replacement. For instance, in the oil and gas industry, equipment may need to withstand temperatures ranging from -40 to over 150°C and resist corrosive chemicals such as hydrogen sulphide and chlorides.
The presence of flammable, explosive, or toxic materials in hazardous areas significantly raises safety concerns for personnel and equipment. The risk of ignition or explosion necessitates the use of intrinsically safe equipment that can operate without creating sparks or heat that could trigger an explosion.
Reliable data collection is crucial for predictive maintenance and avoiding unplanned downtime. However, maintaining data integrity in such challenging environments is complex. Data accuracy and reliability in hazardous environments can be compromised by electromagnetic interference, industrial noise, and other factors.
Many hazardous industries also rely on legacy systems that may not be compatible with modern condition monitoring solutions. Integrating new technology with existing infrastructure can be both technically
challenging and costly. And ensuring seamless integration without significant downtime or operational disruption is also a major concern.
In addition, equipment in hazardous industries is often situated in remote or hard-to-reach locations, such as deep underground mines or offshore oil platforms. This makes regular monitoring and maintenance difficult, potentially delaying the identification and resolution of issues.
OVERCOMING THE CHALLENGES
Today, advances in materials science have led to the development of sensors that can withstand extreme environmental conditions. For example, sensors made from advanced ceramics or coated with
special protective layers can endure high temperatures, pressures and corrosive substances, reducing the frequency of maintenance and ensuring continuous monitoring.
Wireless technology has also been transformative for condition monitoring in hazardous areas. Wireless sensors and IoT devices eliminate the need for extensive cabling, which can be a source of sparks or electrical hazards. These systems can transmit data in real time to centralised monitoring systems, enabling continuous oversight without the need for direct human intervention.
Integrating predictive analytics and artificial intelligence (AI) into condition monitoring systems enhances data accuracy and reliability. These technologies
can process vast amounts of data to predict potential failures before they occur, reducing false alarms and ensuring timely maintenance. For example, AI algorithms can analyse vibration patterns in rotating machinery to detect early signs of wear and tear.
Edge computing brings data processing closer to the source of data collection, minimising the impact of industrial noise and electromagnetic interference. This approach ensures faster decisionmaking and more accurate condition assessments, enhancing the reliability of monitoring systems in hazardous environments.
Remote monitoring technologies, including drones, have revolutionised the inspection and maintenance of equipment in inaccessible locations. Drones equipped with sensors can safely navigate hazardous areas, providing real-time data and visual inspections without exposing personnel to risks. This is particularly useful in offshore oil rigs and deep mines.
DRIVING INNOVATION
The ATEX directive (Atmosphères Explosibles), which applies in the European Union and some other regions, and the globally recognised IECEx (International Electrotechnical Commission System for Certification to Standards Relating to Equipment for Use in Explosive Atmospheres) standard, set out the essential health and safety requirements and conformity assessment procedures for equipment intended for use in explosive atmospheres.
Both schemes mandate stringent safety requirements for equipment used in explosive atmospheres, and equipment used in defined hazardous areas must undergo rigorous testing and certification processes. They both also provide detailed guidelines on the design and installation of equipment in explosive atmospheres.
Technological innovations, driven by the need for ATEX and IECEx compliance, have enhanced the safety of condition monitoring systems by incorporating protective measures such as intrinsic safety (IS) and explosion-proof (Ex) designs.
Manufacturers of condition monitoring equipment have made significant strides in adapting their solutions to ensure safety in hazardous areas and potentially explosive atmospheres.
Intrinsically safe equipment is designed to prevent sparks and limit electrical and thermal energy to levels that cannot cause ignition. This involves using low-energy electronics, isolating circuits, and implementing energy-limiting barriers.
Explosion-proof enclosures are designed to contain any explosion that may occur within the device, preventing it from igniting the surrounding atmosphere. These enclosures are typically made from robust materials like stainless steel and are tested to withstand internal explosions.
To reduce the risk of ignition, manufacturers use non-sparking materials for components that may come into contact with explosive atmospheres. These materials are chosen for their ability to minimise friction and static electricity generation.
Sealed enclosures and hermetic sealing techniques are used to protect sensitive electronic components from exposure to hazardous environments. This prevents corrosive gases and liquids from damaging the equipment and ensures long-term reliability.
Modern condition monitoring equipment also incorporates advanced sensing technologies that are more resistant to harsh conditions. This includes the use of fibre optics for temperature and pressure monitoring, which are immune to electromagnetic interference and can operate reliably in extreme conditions. In addition, sensors are being made from advanced ceramics or coated with special protective layers so they can endure high temperatures, pressures, and corrosive substances, reducing the frequency of
maintenance and ensuring continuous monitoring.
Redundant systems and fail-safe mechanisms are also incorporated to ensure that the failure of one component does not compromise the overall safety and functionality of the monitoring system. This includes dual sensors, backup power supplies, and automated shutdown protocols.
Finally, real-time monitoring and remote diagnostics allow for continuous oversight of equipment conditions without the need for personnel to enter hazardous areas. This reduces the risk of exposure and enables quick response to potential issues.
SUMMARY
Deploying condition monitoring solutions in hazardous industries is fraught with challenges, from harsh environmental conditions to safety concerns and data reliability issues. However, technological advancements are continuously overcoming these hurdles. Robust sensors, wireless systems, predictive analytics, edge computing, remote monitoring, and interoperability standards are transforming condition monitoring into a more reliable and safer practice. Moreover, regulatory directives and standards ensure these systems meet the highest safety standards, fostering innovation and enhancing safety protocols. As technology evolves, hazardous industries can expect even more sophisticated solutions, improving both safety and operational efficiency. By embracing these innovations and adhering to stringent regulatory standards, industries can ensure the longevity and reliability of their critical machinery, ultimately safeguarding their operations and personnel. TIMES-CIRCLE
Rewinds & J. Windsor & Sons (Engineers) Ltd delivers multi-disciplinary engineering solutions that inspire confidence, improve operational efficiencies and help organisations to compete effectively.
Our services range from traditional mechanical, electronic and electrical repairs to innovative datadriven predictive maintenance and reliability strategies. We are now looking for a dynamic Electronics Sales Engineer to join our team and deliver significant growth.
THE ROLE:
As an Electronics Sales Engineer, you will be responsible for generating new business, managing existing client relationships, and driving sales growth for our premium electronics repair services. This role requires a blend of technical expertise, sales acumen, and a deep understanding of the electronics repair industry. Educated to degree level the role involves visiting existing clients, the organisation of trade fair promotions and marketing, but mainly designing and delivering a robust campaign to engage new clients with an emphasis on servomotor repairs including diagnostic feedback and calibration.
0114 256 0425 campbell.edgar@refieldservices.com www.refieldservices.com BP E-ON
• Competitive basic salary of £72,000p.a. with performance-based incentives.
• Comprehensive benefits package including fully funded quality car, health insurance and retirement plans.
• Opportunities for professional growth and development.
• A supportive and collaborative work environment
• The chance to be part of a leading company in the electronics repair industry.
HOW TO APPLY:
Interested candidates are invited to submit their resume and a cover letter detailing their relevant experience and why they are the ideal fit for this role to bernard@rjweng.com.
Join us at Rewinds & J. Windsor & Sons and contribute to our mission of delivering top-notch electronics repair services while driving substantial business growth!
The coloured dots in the listings indicate areas covered, please call or email repairers to confirm exact details.
Houghton International
SERVICES INCLUDE
• Electric motors
• Generators
• Pumps
• Gearboxes
• Condition Monitoring
• Electro-mechanical services
• Onsite testing and analysis Ex repairs - IECEx approved
We urgently need a government-led industrial policy
Writing
for Renew in the week before the 2024 general election, Make UK CEO Stephen Phipson explains why his organisation is calling on whoever is in government after the vote to ensure a modern, long-term industrial policy is announced within the first 100 days.
Manufacturing holds a vital place in the UK economy, contributing £224bn of Gross Value Added in 2023. It’s a major driver of innovation, with 43% of R&D investment stemming from the sector. Notably, it’s a significant contributor to job creation, employing 2.6 million people nationwide. Moreover, manufacturing offers solutions to pressing economic challenges like climate change and the volatility of global supply chains.
This sector is renowned for its high-skill, high-wage nature, boasting average wages 9% higher than the national average. Across the length and breadth of the country, manufacturing businesses of all shapes and sizes are leaving their mark. They’re not just factories churning out goods but are engines of local prosperity, injecting life into communities and driving economies forward. The sector’s heartlands are primarily in rural and regional areas that are often overlooked by the spotlight of London and the Southeast. These companies are the backbone of regions that are eager for growth.
But it’s not just about jobs; it’s about skill-building too. Every year, nearly 50,000 engineering and manufacturing apprenticeships are offered by UK manufacturers, nurturing the next generation of talent and keeping skills alive in communities. They’re not just places of work; they’re the heartbeats of towns, fostering a sense of belonging and opportunity. They attract investment, bring innovation, and shape the identity of the places they call home.
And they’re not stopping there.
Manufacturers have their eyes set on the horizon, aiming to ride the wave of a netzero economy and embrace cutting-edge technologies like AI and digitalisation. Their goal? Nothing short of becoming the most innovative economy on the planet. They’re not content with the status quo; they’re striving for a future where sustainability and prosperity go hand in hand.
The sector has demonstrated resilience and adaptability in recent years, setting the stage for further growth in the future. Ambitious plans aim to boost UK competitiveness by increasing manufacturing’s contribution to GDP from 10% to 15% by the end of the next decade.
Achieving this target would inject an additional £142 billion into the UK economy, fostering longterm domestic and foreign investment.
and that is why Make UK’s manifesto published ahead of the election is calling for a modern, long-term industrial policy to be announced within the first 100 days. The UK is an outlier in not having one, which is the Achilles heel of the UK economy. In particular, this strategy must embrace a skills revolution throughout the education and training system to provide future talent, as well as the upskilling and re-training of the current workforce.
In particular, this strategy must embrace a skills revolution throughout the education and training system.
By 2050, UK manufacturers aim to achieve net-zero emissions, prioritising energy efficiency and industrial innovation every step of the way. We envision a world where every factory operates without a single sheet of paper and where automation fuels productivity and progress. To achieve all of that, we need support that compares to what other countries and governments are giving their manufacturing sectors around funding, regulation and guidance.
As such, we are now at a tipping point,
Such a vision is essential given the huge changes in the policy landscape, the need to shock the UK economy out of its anaemic holding pattern and take advantage of the opportunities provided by rapidly accelerating technologies, investment in infrastructure and the move to a greener economy.
A policy framework for the economy beyond 2030 is also essential to counter the march of the US and China in green technologies in particular, as well as the need to make the UK as attractive a destination as possible for investment, given the rate at which other countries are gearing up.
If the next Government were to commit to delivering such a strategy and make it a cross Government priority then I am confident that the sector can lead the economy into the 2030s and beyond. chevron-circle-right
Excellence through expertise
Alpha Electrics is an industry-leading provider of specialist industrial electric motor and drive services, committed to ensuring your business keeps moving.
As a family-owned business run on family-based values, we are proud of the reputation and client base that we have developed over the last 30 years.
Our clients appreciate our high levels of customer service, transparency and sincere desire to always find the right solution to their needs. We are committed to excellence in everything we do and relish working in partnership with our customers.
Our Services include:
Supply New Motors & Drives
Commerical Building
Services Servo & Spindle Motor Repair
Industrial Electric Motor Rewinds
Mechanical Engineering Services
Motion Control Solutions
MEMBER
Authorised distributors for...
24,000 m 2
MORE THAN 20.000 MOTORS AVAILABLE FROM STOCK!
Motors up to 25 MW and 13.8 kV
• Low voltage slip-ring and squirrel cage motors up to 3,000 kW
• Medium voltage slip-ring and squirrel cage motors up to 15,000 kW
• Direct current motors up to 2,000 kW
• Frequency converter-proof drives
• In-house load test facility up to 13.800 V, 2.300 kVA, 120 Hz
Customized special designs
• Custom designs for special applications and operating conditions
• Optimized motor design for higher efficiency
• Mechanically and electrically interchangeable motors
