Renew Magazine - Quarter 4, 2021. Energy efficiency focus by touchwavegc

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

The journal f rom

Quarter 4 2021

FOCUS ON:

Energy efficiency

Can a repaired motor be more efficient?

Decode your motor's nameplate

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.

elcome to the latest edition of Renew magazine, the first since I took over as President of the Association of Electrical and Mechanical Trades (AEMT). I’m honoured to hold the position and determined to positively impact the association, its members, and the customers they serve during my tenure. But before I outline some of my plans, I’d like to thank my predecessor, ABB’s David Hawley. During his term of office, alongside the association’s secretariat David helped lead the organisation through what we all know was an unbelievably challenging time. Despite this, the association is much stronger today than when he took office. As President, I plan to focus on some areas I believe are essential in business. I’m passionate about the pivotal role people play in the success of any organisation. Therefore, I plan to focus on developing the way the AEMT adds value to a broader cross-section of the people within our member companies and the businesses they serve. I want to see the association support people coming into and through the sector. I’m also a believer in the value of sharing knowledge and experience and organisations working together to overcome challenges and benefit from opportunities. So I plan to explore and create opportunities for our members to come together to share best practices and explore how they can support and benefit each other. I have many other ideas and areas I wish to develop, which I will share over the coming months. In the meantime, if you’d like to share your thoughts on how we can continue the positive development of the AMET, please get in touch. You can reach me at shaun.sutton@gocentral.co.uk. Shaun Sutton, President, AEMT

NEWS 6 Industry news 10 AEMT news

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

30 Repair and optimisation of water injection pumps 32 Next maintenance in 500,000 Kilometres

12 AEMT Awards update

34 Benefit from the triangle of service 36 Understand ingress protection ratings

14 Product news 16 Project updates

Focus on Energy Efficiency

Twitter @AEMT_Updates

38 Can a repaired motor be more efficient?

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.

20 Circular economy - Don't ditch that faulty PCB

22 Decode your motor's nameplate

OPINION

Cover image: Preformed Windings

26 Thomas meets - Change is in the wind

46 Keeping the world in motion – sustainably

www.theaemt.com

40 The evolution of the plug fan

features 38

Quarter 4 2021

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

TC3231

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

DCM305E

Earth Leakage Clampmeter n n

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

AVO835

True RMS Multimeter n

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

DLRO2

MPQ1000 MPD SCAN

TC3231 DCM305E AVO835

DLRO2

Thermal Camera

2 Amp DucterTM Low Resistance Ohmmeter n

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

MPD Scan

Handheld Scanner for PD Surveying n

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

MPQ1000

Power Quality Analyzer n n n

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

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

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

AWA-IV

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

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

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

Static Motor Analyzer

AWA-IV

Static Motor Analyzer

NetEP

NETEP

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

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

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

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

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

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

The Megger Baker EXP4000 is a portable Dynamic Motor Analysis System

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

High Voltage Motor Tester

PPX

MTR105

Low resistance measurements from 1mΩ to 800Ω

PPX

Rotating Machine Tester

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

Dynamic Motor Analyzer

MTR105 n

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

EXP4000

Site Installed Dynamic Monitoring System

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

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

6 INDUSTRY NEWS

NEW APPOINTMENT FOR CEMB HOFMANN UK

SEAN BROMLEY HAS BEEN APPOINTED AS AREA Sales Manager for the east of England at CEMB Hofmann UK. He took up the role in August, joining an established team of sales, engineering and technical support experts. Sean is responsible for advising and building close working relationships with existing customers, in addition to companies looking for a new partner to resolve their balancing or vibration issues. Reporting to Managing Director Rob Jeffery, Sean will work across the company's comprehensive dynamic balancing service portfolio, including new machine sales, sub-contract balancing and support services, offering customers objective advice to ensure that they get the best possible solution to their dynamic balancing requirements. Sean will also be involved in ensuring the smooth installation and support of dynamic balancing machines. To successfully achieve this, he will work across the whole implementation process, from early requirement identification and machine specification through to machine

ordering, installation and the identification and roll-out of any relevant support services.

EXPANSION OFFERS QUARTZELEC TEAMS UP WITH AI-BASED A ONE-STOP-SHOP PREDICTIVE MAINTENANCE SPECIALIST FOR ENGINEERING SUPPLIES MOTOR REPAIR AND PROVIDER, Rotamec, has expanded its portfolio of parts and consumables for the engineering sector after joining the Troy group of industrial suppliers. The move will provide Rotamec customers with equipment from PPE to bearings at a heavily discounted rate, with the ease of purchasing through a single supplier. Troy is a UK-wide group of over 400 suppliers, providing engineering equipment including MRO products, workwear, power tools and hand tools, fasteners, and cutting tools and specialist equipment. Membership of the group will enable Rotamec to provide its customers with products from across all Troy members, in addition to providing its core service of repair and sourcing pumps, motors, gearboxes, generators and power transmission components. Commenting on the announcement, Simon Brooks, Managing Director at Rotamec, said: "We can now offer our customers all the items they could need thanks to the support of Troy and its over 500-strong supplier base." Quarter 4 2021

QUARTZELEC HAS SIGNED A partnership agreement with automated AI-based predictive maintenance solutions specialist NanoPrecise. Complementing its LIFEVIEW suite of partial discharge (PD) monitoring solutions and the popular Motion Amplification surveys, the NanoPrecise range of wireless, non-intrusive and scalable technologies will further enhance the company's market and machine monitoring presence in the global industry and infrastructure markets. NanoPrecise offers an AI + IoT based analytics approach using Machine Doctor sensors & RotationLF software that diagnoses machinehealth by recording the real-time RPM, sound, vibration, temperature, humidity, magnetic flux, and other key parameters to detect anomalies in near real-time, to predict the Remaining Useful Life (RUL) of machine components. The system empowers users/ operators to carefully manage operational decisions that may cause major damage or unplanned downtime. "Asset breakdowns can happen without warning, and the

challenge has always been to spot the signs early enough to schedule repairs," said Paul Oliver, Business Manager of Quartzelec's Aberdeen-based operations. "LIFEVIEW is a key component in reducing total cost of ownership over the lifetime of a machine and an integral element of any reliability centred maintenance (RCM) and repair strategy. By focusing on early detection solutions, our customers can cost-effectively implement preventative maintenance and avoid costly machine failures. Having the luxury of further enhancing our offering to include additional monitoring solutions that complement our PD and wider condition monitoring solutions should create a formidable, compelling, and cost-effective package of solutions."

www.theaemt.com

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

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

www.wes.uk.com

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

www.electrominst.com

8 industry News

UPGRADED BURN-OFF OVEN DOUBLES REWINDING CAPABILITIES JJ LOUGHRAN HAS RECENTLY upgraded its repair workshop burn-off oven to a new Rotary Engineering unit, designed specifically for the electric motor repair industry. With an internal volume of 10m3, the new oven will enable JJ Loughran to more than double its rewinding capability. The burn-off oven cleans motors and their parts through a process known as pyrolysis – which sees parts heated in a controlled manner to burn off the insulation, resins, paint and other contaminants but leaving the motor stator undamaged.

The high-temperature burn-off oven can operate up to 400˚C to safely burn off old insulations before a full motor rewind. A correctly controlled burnoff process eliminates damage to the stator during the repair. A water injection system regulates oven temperature if 'runaway' conditions occur, with a 450˚C ultimate safety cut out. To meet regulatory, and JJ Loughran's internal environmental standards, the burn-off oven provided includes an afterburner chamber, which operates in excess of 850˚C to convert the output from the main chamber into carbon dioxide and water vapour.

UNLOCKING VALUABLE DATA AT CARBON CAPTURE FACILITY A NEW CARBON CAPTURE PLANT IN the UK, the largest of its kind, has chosen smart sensor technology from ABB to provide remote condition monitoring on critical motors, thereby reducing the number of man-hours required on site. Tata Chemicals Europe's Winnington site has installed 11 smart sensors from ABB to enable it to identify trends in the performance and condition of a series of motors across the facility. Using the data, which is collected autonomously by the sensors, the plant can identify faults, reduce unplanned stoppages, minimise the duration of any outages, and plan maintenance tasks in

advance of them becoming critical to the ongoing operation of the site. Matthew Shepherd, Technical Manager for Tata Chemicals Europe in the UK, said: "The Smart Sensors enable remote condition monitoring of our motor-driven processes, enabling us to greatly reduce the number of manned hours on site. The data provides an ongoing trend view of vibration, temperature and bearing condition, and a host of other operational parameters, so we can react before problems arise." Due to the nature of the carbon capture process, the sensors are required

to be ATEX certified as a fault condition within the system could potentially create a hazardous environment. The installation is part of a pilot scheme, with Tata keen to move towards more data-driven production methods. "The ability to monitor trends was a key motivation for us with this project," said Matthew. "From the start, we were able to establish a baseline of what an optimal process looks like, so we will always have a benchmark. This means we can look at process efficiencies and optimisations whenever parameters are changed and monitor the effect they have on other processes at the plant."

SCOTTISH WATER DV2 FRAMEWORK PARTNERS ANNOUNCED WGM ENGINEERING LTD AND BGEN Ltd (formerly Boulting) have been awarded a MEICA Framework contract with Scottish Water for 2021-2027, with the option of an additional six years post 2027. Scottish Water is forecasting to invest one billion pounds a year, and the initial six-year period is estimated to be worth around £270m for the joint venture. Commenting on the joint venture success, Ian Mathieson, Managing Director of WGM Engineering Ltd, said: "I am delighted that as a joint venture, we have secured our position on this long-term framework. Working closely with Scottish Water, we are committed to investing in local communities and creating jobs in Quarter 4 2021

those communities throughout the period of the framework. We have aligned our ambitions to reduce carbon emissions with Scottish Water, to fully support their Beyond Net Zero Emissions ambition by 2040. Our commitment to innovation, continuous learning and improvement in the way we work, will enhance productivity, reduce cycle times and improve efficiency. "We are looking forward to working with Boulting and Scottish Water in a truly

integrated and collaborative way over the next 12 years". Robin Whitehead, Managing Director of BGEN, said: "This award is a huge accolade for our joint venture and recognition of the monumental work performed by our teams leading up to this point. I am incredibly excited to be working in partnership with WGM on this long-term contract with Scottish Water. Through this award, we will be committing to helping address a countrywide water sector skills gap and shortage, giving our existing people and new recruits the opportunity for coaching, personal development and growth, to enable everyone to achieve the very best they can" www.theaemt.com

www.brookcrompton.com

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

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

10 aemt news

UPDATE FROM THE AEMT SECRETARY Thomas Marks shares the latest news from the Association. We are into the final quarter of 2021 now, and everything is going at full steam in the office. We are pleased to be doing our first overseas training courses since the pandemic began. These are taking place in Qatar and Dubai, and we look forward to welcoming back many new and old friends to the courses. The pandemic has had the remarkable effect of zeroing in on a company’s weaknesses. For the AEMT, it was our classroom-based practical training courses. Fortunately, we were able to take these courses online, with some innovative thinking from the AEMT staff. The success of these courses has highlighted the potential for investing in online training for the future. This year, we have been working closely with York University’s Electronic Engineering department around the potential to develop software that would tangibly improve the experience of online practical learning. Amazingly, we learned that York University faced the same barriers to online practical assessments, and they suggested we apply for government funding to develop the project with them. I am delighted to announce that we were awarded funding in September, and we will soon begin developing our online learning and assessments for hands-on training with York University. We will start by launching our Ex training courses on this platform and will soon begin developing many other courses which will be of benefit to the membership. In other news, the AEMT team has enjoyed being back in the

office. It’s allowed us to work with council members on the AEMT’s direction, vision, mission, and values for the coming years. More of which will be announced soon. We firmly believe that training should be the focus of the AEMT going forward, so developing an online training platform is a very exciting path to be going down. We have now also made it easier for members to update their member profiles with us. By logging into the website, member’s can go to their company’s profile page to review, edit, update and publish their details in just a few minutes. If you can’t find the red ‘edit details’ button on your profile page, please contact Lesley at admin@aemt.co.uk, who can help you. If these details are updated by October 18th, we will be able to include these changes in the 2021/2022 Member’s Yearbook. Last but not least, I trust you have all earmarked November 18th for the AEMT Conference and Awards. We are looking forward to bringing these two seminal events back to life. During the day, we will be looking at how the relationship between industry and service centres can lead to a greener and more prosperous future, with plenty of talks, forums, workshops, display stands and networking to be enjoyed. In the evening, we can let our hair down to recognise and celebrate those who excelled in the industry at the AEMT awards ceremony. The evening’s entertainment, comedian Alfie Moore, recounts 18 years in the police service and promises a side-splitting performance for guests. If you’ve any comments or suggestions on what you would like to see from the AEMT, 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.

Forthcoming AEMT led Courses & Events COURSE TITLE

START DATE

LOCATION

Ex Theory Module 1

18 October 2021

Qatar

Ex Hands-on Module 2

20 October 2021

Qatar

Ex Hands-on Module 2R

20 October 2021

Qatar

Ex Refresher Module 3

26 October 2021

Online (SE Asia)

Ex Refresher Module 3

8 November 2021

Aberdeen

AEMT Awards 2021

18 November 2021

DoubleTree Hilton, Coventry

AEMT Conference 2021

18 November 2021

DoubleTree Hilton, Coventry

Ex Theory Module 1

22 November 2021

Dubai

Ex Hands-on Module 2

24 November 2021

Dubai

Ex Hands-on Refresher Module 2R

24 November 2021

Dubai

Ex Theory Module 1

6 December 2021

Loughborough

Ex Hands-on Module 2

8 December 2021

Loughborough

Ex Refresher Module 3

14 December 2021

Loughborough

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

All classroom-based training is scheduled subject to the COVID-19 restrictions in place at the time. Full details of the safety procedures being applied to classroom-based courses can be found on the course website. Quarter 4 2021

www.theaemt.com

Awards Update 12 NEWS

Finalists announced in 2021 AEMT awards programme Having been forced to withdraw from staging its annual awards dinner and presentation ceremony last year due to the disruption caused by the COVID-19 pandemic, the AEMT is looking forward to its return on the evening of Thursday, November 18 2021.

nitially scheduled for its regular slot in November 2020, following hugely successful events in each of the preceding three years, the Gala Awards Ceremony will return to the Doubletree by Hilton Hotel, Coventry, along with the associated AEMT Conference, which will be staged throughout the day, ahead of the evening's presentation dinner. The event will once again bring together the electrical and mechanical trades sector to celebrate business and professional excellence. Recognising and rewarding the achievements of individuals and companies operating within the repair and maintenance arena, personal endeavour, product innovation, skills training, engineering advancement and commercial acumen will be acknowledged and celebrated. Operated by the AEMT and produced by Touchwave Media, part of the team behind this magazine, the awards will again acknowledge the skill, effort and sheer dedication of the people and businesses serving this important sector. With sponsorship provided by a host of leading industry names, well deserved recognition will be given to those businesses and individuals that are excelling in their commercial endeavours.

Contribution to Skills & Training Award – sponsored by Musk Process Services • EMiR Software • Houghton International • Sreekumar Pillai, Plant Engineering

FINALISTS Following a judging process, which this year combined the remote assessment and scoring of each entry with a virtual gathering of the panel, the AEMT is delighted to announce the following 23 finalists across the seven award categories:

Rising Star Award – sponsored by FANUC UK • Juan Carlos González Villar, Kabel.Consult.Ing • Harry Channer, Bowers Electricals • Jack Rowe, Fletcher Moorland • Micheal Straw, Bowers Electricals

Product of the Year – sponsored by P&WE • 1MW High Speed Stator, ADC Electrical • IP67 Motors - Defy Flood Conditions, Menzel Motors • QualCoil H, Preformed Windings

Diversity in Engineering Award – sponsored by Preformed Windings • Central Group • Heasell Electromechanical Services

Project of the Year – sponsored by EMIR Software • Wind Turbine Generator Re-Design, GES Group • iBOT PCB Card Refurbishment, Fletcher Moorland • Promoting Major New Efficiencies and Raising Standards in the Repair of Class 66 Locomotives, Fletcher Moorland

Our sincere congratulations go to all those selected as a finalist. We look forward to announcing the seven award winners during the charged atmosphere of the presentation ceremony during the evening of Thursday, November 18. If you have not yet booked your place at this highly respected event, please visit the website and complete the online booking form. Individual places or tables of ten can be secured, with the package including reception drinks, a superb three-course meal with wine, the awards ceremony itself and excellent postawards entertainment. It is a night not to be missed. After the difficulties we have endured over the past eighteen months, it is time to re-engage, reunite, and celebrate the wonderful achievements of this important sector. For more information, visit the website www.aemtawards.com or contact the awards programme producers, Touchwave Media, by phone on 07785 290034 or email at andrew@touchwavemedia.co.uk.

Service Centre of the Year – sponsored by ABB • ADC Electrical • Cabel UK • Kirkby Lindsey Electrical • Musk Process Services - Stowmarket Team • Sulzer - Birmingham Service Centre Supplier of the Year – sponsored by Drives & Controls • Menzel Elektromotoren GmbH • Preformed Windings • Radwell International Quarter 4 2021

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

14 product News

Short and service-friendly shaft coupling WITH THE ROFLEX, KTR LAUNCHES a new DIN 740 shaft coupling, characterised by its short design and its service-friendliness. In addition to power transmission, the ATEX-approved torsionally flexible coupling compensates for misalignments and dampens torsional vibrations. The ROFLEX is available in two designs and currently in seven sizes for torques from 65 to 790Nm. The short shaft coupling features input and output shafts which can be pushed together between 3mm and 6mm, depending on the size. The torque is transmitted via elastomer packages, which at the same time compensate for misalignments and dampen shocks and

torsional vibrations. Should the elastomers fail due to extreme loads, the fail-safe coupling will continue to hold the torque. The ROFLEX is available in two types: In type N, both the pocket and the cam part consist of standard hubs. In the SH SPLIT design, the cam hub is split with the hub being specifically and mechanically separated into two halves by 'fracture cutting' or 'cracking'. The resulting fracture surfaces centre both hub halves precisely with

each other, which makes incorrect assembly almost impossible. www.ktr.com

PUMP MOTOR WITH SPECIAL FLANGE FOR CHEMICAL PLANT MENZEL ELEKTROMOTOREN CREATED AN UNUSUAL motor configuration to help out a chemical plant that needed a replacement for a failed pump motor that would be able to accommodate an existing oversized pump flange dimension. Menzel was able to provide a size 400 motor that matched the performance profile and was light enough for use in the application. It converted a stock, IM B3 type motor (foot mounting) to type IM V1 (vertical flange mounting). The driveend bearing seat was converted for the installation of a thrust bearing. Menzel also manufactured a special flange in-house and adapted it to the shaft, which could only protrude 120mm from the flange. Menzel prepared the motor for installation at the customer's site, shifting the main terminal box to the most accessible position and mounting a cable entry that could be readily adapted to the existing cable diameter on site. The motor, which is now successfully operating in the plant, has a rated output of 315 kW and a nominal voltage of 5,000V. It features

the cooling type IC 411 and an IP55 protection rating and weighs 4,900kg. www.menzel-motors.com

Variable or constant torque in a single package HP COMBI FROM LAFERT IS A two-in-one offering of a permanent magnet synchronous motor combined with a variable frequency drive. Intended both for variable torque application – typically HVAC – and for constant torque applications – such as material handling, air compressors and vacuum pumps – it promises easy configuration, increased system efficiency and up to 50% reduction in size and weight. HP Combi's key benefits are a drive pre-configuration that allows for immediate use after installation – the Quarter 4 2021

operating parameters are preloaded, so there is no need for further technical settings. It also offers advanced electronic control that allows the user to configure the drive through HP Drive Tools, a user interface app available for PC or mobile platforms, transferable with a dedicated HP Drive Stick (USB). The HP Combi is IP66/NEMA 4X rated, offering outdoor protection and for decentralised installation of the

drive near the motor, even in harsh environments. www.lafert.com 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

16 Project Updates

Planned maintenance ensures reliable electrical supply for Acute NHS hospital

WHEN AN ACUTE NHS HOSPITAL IN the Greater Manchester area recently needed to carry out planned ‘intrusive’ maintenance of its main LV switchgear, it called upon Quartzelec to carry out the task over two planned evening shifts. The building that required the maintenance is dual supplied via two ABB 1250 KVA dry resin transformers that supply two LV panels. Work was carried out over two planned evening shifts, allowing one panel per evening to be fully isolated, with all affected circuits being re-supplied via the other panel. The LV switchgear servicing, including the interrogation of all air circuit breakers, was achieved following a detailed switching program with assistance from the electrical site AP. Detailed recordings of the protective devices, ratings and settings were included, and a full report summary was issued upon completion. This included an introduction, results section, and summary of the overall condition of the switchgear. Also included as part of the works was thermographic imaging, which was captured before

isolating the supplies. All connections and torque settings were checked and inspected, and each cubicle was thoroughly cleaned. The client now has peace of mind knowing that its LV infrastructure is in good condition and remains fully compliant. “It’s not unusual to be called in by NHS Trusts at short notice to investigate and resolve electrical issues,” said Andy Taylor, Supervisor for Quartzelec’s Building Services Maintenance team who coordinated the project. “We endeavour to address issues before they cause serious risk to the hospital and regularly go that extra mile for our customers to ensure they remain operating at optimum performance and within appropriate safety parameters.” Quartzelec maintains a dedicated healthcare support team that can respond to critical issues, and all engineers are HTM

06-02 competent, plus collectively hold an array of safety and process compliance certificates needed to operate in specialist healthcare environments. www.quartzelec.com

Dry transformers enable production capacity expansion ELECTROLUX DO BRASIL S.A IS planning to expand its production capacity. For this to happen safely and effectively, the organisation has purchased two 34.5/11.9kV with 15MVA dry transformers from WEG to supply loads connected to more than ten transformers with a voltage class of 11.9kV, which are installed in the plant. One reason for specifying these transformers was their IP54 rating which makes them suitable for installation in unprotected environments, helping to

ensure low installation costs and greater ease of maintenance. Additional benefits of the transformers, which encouraged the organisation to specify the WEG products, were that they help ensure manufacturing process reliability and benefit from energy cost savings as well as power distribution consistency to avoid voltage peaks caused by the 11.9kV local network power supply. www.weg.net

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Appli cation s

Exper t Opini

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

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

18 project updates

Condition monitoring pinpoints the exact cause of gearbox vibration CONDITION-BASED MONITORING IS a proactive maintenance health check for all types of electromechanical equipment and is crucial for identifying underlying system performance issues without stopping production. Avonmouth Engineering Services (AES) provided this service to an aerospace company, Leonardo, to help investigate a loud noise generated by a lathe gearbox. The lathe is a critical item in the plant as it is the first step in the gear machining process. The cost to purchase a new machine would have exceeded £100,000 and would also have led to a loss of production caused by

downtime while a new lathe was installed. AES carried out a detailed vibration analysis on the equipment. This is a nonintrusive method that can be used to detect obscure faults such as unbalance, resonance, misalignment or bearing failure. Combining the results with the technical drawings – which outlined the number,

location and specification of the gears and bearings in the gearbox – AES was able to pinpoint that the exact cause of the excessive vibration came from a single bearing. Leonardo carried out the bearing change and have confirmed that the machine is now running without issue. www.avonmouth-es.co.uk

Speedily adapted high-voltage extruder motor WHEN LARGE MOTORS OPERATING AT HIGH OUTPUT fail, there can be long lead times for a replacement manufactured from scratch. Customised configuration of a suitable standard motor can offer an economical alternative. This was the case for a petrochemical plant operator which urgently needed to replace a failed extruder motor featuring 6000kW rated power, 10kV nominal voltage, requiring >57kNm nominal torque. Originally, the extruder was driven by a squirrel-cage machine. However, a motor with similar design parameters was not readily available on the market. Fortunately, Berlin-based Menzel Elektromotoren was able to provide a suitable three-phase slip ring motor. Its design also offered advantages for the application – driving an extruder – as it provides the required full torque from standstill. Menzel was able to procure a starter for the slip ring motor as well as implement all necessary modifications in-house. Within two weeks, the customer was able to restart the extruder system. The modular MEBSSL motor series is designed to enable flexible configuration for various applications and conditions. One of the most time-consuming jobs was fitting a bushing in

the customer's coupling hub, machining it from a diameter of 280mm to 240mm. In addition, Menzel manufactured adapter plates to adjust the shaft height from 800mm to the failed motor center height of 900mm. The replacement motor is designed with protection class IP55 and cooling type IC 611 with an air-to-air heat exchanger. www.menzel-motors.com

QUICK PUMP REPAIR HELPS KEEP ROMANCE ALIVE WEBB-ELEC QUICKLY JUMPED INTO action after it received a call from the manager of a hotel saying that they had no incoming water supply due to a failed pump, at what was an incredibly busy time – the hotel was hosting three wedding receptions during the week, which would have to be cancelled if the water supply could not be reinstated. Webb-Elec's site team attended the premises within the hour. They were able to isolate, disconnect and remove the faulty pump and took it to the workshop

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for inspection. The pump was found to be in very poor condition but was also obsolete. A replacement, which would have been the quickest option, was not possible without extensive pipework alterations. The site team informed the customer of the situation, who instructed them to carry out a repair to the pump immediately. The repair included a replacement motor, machining and sleeving of the pump shaft and mechanical seal housing

due to wear. A replacement mechanical seal was fitted and the impeller cleaned and dynamically balanced. The pump was then reassembled and tested on an in-house pump test rig. The team returned to the hotel early the following morning and re-installed the pump. They then conducted a full pump test in front of the manager who signed the job off, and happily, all the wedding receptions were able to take place. webb-elec.co.uk www.theaemt.com

20 Circular Economy

Don't ditch that faulty PCB

Estimates suggest that globally, around 60 million tonnes of waste electronic equipment are thrown away every year. As we fight the effects of global warming, growing pressure from consumers and environmental groups means this level of disposal is unacceptable. With this in mind, Matt Fletcher, Managing Director at Fletcher Moorland, dispels some myths surrounding the practice of repairing printed circuit boards and outlines some of the benefits.

hat do you see in the image above? A pile of scrap PCBs, or an opportunity to refurbish and reuse? If you see an opportunity to refurbish and reuse, great, you don't need to read any further – but I would be pleased if you do. If you see these as scrap PCBs destined for landfill, then hopefully, this is an opportunity for me to change your perspective. PCBs (Printed Circuit Boards) are in all electronic equipment the World over. They have hundreds of components soldered to them, and these components fail over time. It only takes one of these components to fail to stop a PCB from working, which can stop an entire machine or production process. Maintenance engineers can generally fault find to PCB level. Usually, the PCB is swapped out, and the machine or process can continue. It's a job well done, and the production manager is happy again. In a typical industrial process environment, this happens every day. A PCB fails, the PCB is replaced, and a new PCB is purchased. Over time, the faulty PCBs then begin to pile up, they have no value, and eventually, they end up in landfill.

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This is totally avoidable. PCBs can be repaired, refurbished and reused. I imagine a few of you are thinking, "Ok, but I don't trust PCBs that have been repaired", or "I've been told they are not repairable by the OEM", or "I've tried before, and it doesn't work". In my response, I'd explain that military, power generation and mass transport companies repair their PCBs regularly. I'd point out that OEMs want you to buy new, but that more often than not, components are readily available for most PCBs, irrespective of the OEM. And I'd ask if you had a bad experience with a repairer who either didn't have the right skills or equipment to repair your PCB. It is important to recognise that no repair company can repair everything; those who say they can might not be telling you the truth. It does take skill and the right equipment to repair PCBs properly. I mentioned earlier that it could take just one component to fail to stop a PCB from working, so fault-finding

is the most crucial skill in PCB repair. You need equipment that can test the components, such as The ABI Boardmaster. We have one that is continually in use in our repair workshop. So, would you now think twice about throwing your faulty PCBs away? If you are still not convinced, consider the following points. OEMs plan in obsolescence; quite simply, they stop making products, and they can then become very difficult to get hold of. I bet you've searched eBay and automation houses for replacement PCBs? Well, repairing your PCBs is an alternative to this. There is also the cost associated with upgrading equipment. Repairing returns a massive cost saving as opposed to upgrading equipment. But possibly most importantly, repairing PCBs means less waste and fewer resources taken from the planet. That should be reason enough in itself. TIMES-CIRCLE

“Military, power generation and mass transport companies repair their PCBs regularly.”

fletchermoorland.co.uk www.theaemt.com

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

22 Motor Nameplates

Decode your motor’s nameplate

Whether you are looking to replace or repair a motor, when talking to your supplier or service provider, it is important to give them accurate details of the motor you currently have. The most relevant information should be recorded on the motor's nameplate. To help users understand the information on their motor nameplates, Karl Metcalfe, Technical Support at the Association of Electrical and Mechanical Trades, explains what key elements mean.

o specify a replacement motor or understand the requirements of a repair or rewind, several attributes need to be established. These include information such as the size and format of a motor, its power and speed ratings, how and where it has been designed to be used, its efficiency and a range of other factors. Most motors will have a nameplate that carries this information in a format that meets standards set out by one of two bodies, the International Electrotechnical Commission (IEC) and the National Electric Manufacturers Association (NEMA). Once you understand how the information is presented, it should be

easy to read the nameplate on most motors and pass this information to your supplier or service partner. In figure 1, you will see a typical motor nameplate that meets the IEC standard. Here is what different sections represent. 1 - FRAME SIZE This indicates some of the motor's key dimensions and will usually be at the top of the nameplate as it is an important metric. Frame sizes conform to a standard that defines a motor's dimensions and outputs. The frame size is the height of the shaft's centre from the base of the motor's foot. A 315 frame, as in this example, will have a dimension from foot to shaft of 315mm.

The number will be followed by a letter, S is for a short foot, M is for a medium foot, and L is for a large foot. This letter defines the dimension between the mounting holes on the front and back feet. 2 - POWER The motor's power may be written in kilowatts (kW) or horsepower (hp). It will be written in kW on most motors, but older motors may be rated in hp. 3 - VOLTAGES Where there is more than one voltage figure listed, the delta (symbol) connection is the lowvoltage connection, while the star (symbol) configuration is for a high-voltage connection. The wiring

Figure1: A typical motor nameplate. Image courtesy of WEG. Quarter 4 2021

www.theaemt.com

> 24

24 Motor Nameplates diagram for both delta and star configurations will often also be added to the nameplate. 4 - SPEED/RPM This is the maximum speed of the motor in revolutions per minute without a load present, and this information can also tell you how many poles your motor has. A motor requires a minimum of two poles per phase and a 2-pole motor rotates fully for each polarity change. Therefore, at 50Hz, the theoretical maximum speed a 3-phase motor can run at is 3,000rpm. So, a motor labelled as having a speed around 3,000rpm will be a 2-pole motor. The reality is slightly slower in induction motors due to losses from factors such as drag and windage – referred to as slip. As rpm halves, then the number of poles will have to double. Therefore, a motor rated at around 1,500rpm (1,490rpm in our example) will be a 4-pole motor. It follows then that a rating around 1000rpm will indicate a 6-pole motor, while a motor labelled near to 750rpm will have 8-poles, and a 10-pole motor will run close to 600rpm. 5 - EFFICIENCY Efficiency is a significant factor where motors are concerned and is typically indicated by an IE number. While a lower efficiency motor can be repaired and reused, sometimes to an improved efficiency level, the Ecodesign directive governs what IE rating a new motor must have based on the application and the wider system.

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IE1 is known as standard efficiency, IE2 is high efficiency, IE3 is premium efficiency, and IE4 is super premium. There is a significant difference in efficiency between IE1 and IE4. At a power rating of around 4kW, an IE1 motor is around 80% efficient, while an IE4 motor is around 90% efficient. That represents halving the losses, which can account for a significant cost saving. If a 22kW/hr 4-pole IE1 motor which runs for around 8,000 hours per year is replaced with an IE3 equivalent, the saving could be in the region of £800 per year at an electricity cost of 15 pence per kW/h

example shows the motor can run in an ambient temperature of up to 40°C (8). The nameplate may also show what insulation class the motor has been wound to (9). The repair standard for rotating machines states that a motor can be repaired to the same or a better insulation class, so this is important information for a repair provider to have. The duty cycle may also be on the nameplate. In our example, S1 (10) stands for continuous duty and indicates that this motor has been designed to run 24/7, 365 days a year without issues – subject to scheduled maintenance. Ten duty cycle classifications cover examples such as short term use, intermittent duty and variable load. And the number after the ~ symbol (11) indicates the phase rating of the motor – either single or three. Your motors may also include other information, such as the Ex symbol, applied to motors designed for use in potentially explosive environments. These motors will need to be replaced with similarly rated motors and should only be repaired by a company with the expertise and ability to repair hazardous area Ex equipment. A list of certified repair specialists can be found on the AEMT’s Ex Register, held on the AEMT website. TIMES-CIRCLE

Your motors may also include other information, such as the Ex symbol, applied to motors designed for use in potentially explosive environments.

6 - IP RATING IP stands for ingress protection – a device's ability to stop foreign material from entering and interfering with its operation. The first of two digits after the IP represents the level of protection from solid matter and the second liquids. The first can range from 0 – no protection – to 6 – total protection from dust. The second goes from 0 – no protection from liquids – to 9 – resisting highpressure water jets. OTHER INFORMATION. Some manufacturers will include the bearing sizes on their nameplates (7). And they may include a temperature rating which in our

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.

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26 Thomas Meets

Change is in the wind Thomas Marks, General Manager of the Association of Electrical & Mechanical Trades (AEMT), spoke to James Stevens, Sales and Marketing Director of Preformed Windings, about how motor coil technology has developed over the years and how current technology is supporting the drive for increased efficiency and reliability in rotating machinery. Thomas Marks: How has the supply of formed coils changed over the years? James Stevens: Today, there's an expectation for assets to last for decades. The various quality measures required to allow for this have changed quite drastically. We are now carrying out thermal cycle and voltage endurance tests to simulate the through-life performance of the coils. To protect their products from moisture ingress, and in turn, support their longevity, OEMs have typically manufactured rotating machines using vacuum pressure impregnation or VPI technology. However, there has been some confusion in the repair market around what is better, VPI or resinrich. The OEMs use VPI, so surely, it's better? In fact, particularly in high-voltage applications, VPI isn't always the answer. If the VPI process is tried and tested and carefully controlled, it can certainly be a good choice. However, in the repair market particularly, resin-rich tends to be preferred. In high-voltage applications, it has various advantages, such as a lower void content where it matters, a lower partial discharge (PD) result and longer service life. Additionally, you can reach a point where VPI tanks are only so big, and you can only fit a certain size stator in them. Repair companies can't physically VPI a stator bigger than their tanks can accommodate, so they must turn to resin rich instead. The biggest change comes with supporting customers in creating a specification that is applicable to the repair market. Moving away from subjective requirements is also a new Quarter 4 2021

development. 'No voids to the naked eye' is quite often found in specifications for coils. Subjectively, somebody with better eyesight or better lighting could spot a void that, perhaps, others couldn't. The technology is now available so that we can have measurable metrics for the quality of a coil. We can put in measurable requirements, such as testing for a low PD number and good tan delta results. This is fundamentally what you're trying to achieve when we say, 'no voids.' Ultimately, you want a very homogenous insulation mass, with as much mica in there as possible, suspended in resin and without any voids. TM: In your view, what are the biggest challenges the repair industry is currently facing? JS: COVID-19 has made planned maintenance difficult. Where groups of people need to converge in one place, it is challenging. So unplanned maintenance has increased. Aside from the pandemic, the other challenge we're facing is an influx of lowcost and lowquality products. The supply base into the repair market hasn't necessarily always communicated what quality is and what quality means to the end-user. This is a problem because an end-user may receive tenders for repairing their equipment, and on paper, they look similar; only one is cheap, and one is more expensive. Historically, the warranty period

James Stevens, Sales and Marketing Director at Preformed Windings.

offered for the cheap and more expensive options has been very much the same. So, unfortunately, if you're an end-user looking at a solution that costs less with the same warranty period and you're not clear on what the benefits of either are, it is difficult to justify not picking the cheaper option. The solution here is to improve our

“The technology is now available so that we can have measurable metrics for the quality of a coil."

communications on the benefits of quality. These are a much longer asset life, a potentially more efficient machine when in operation, and once repaired, a better machine than it was originally out of the box. So it's nice to see magazines like Renew talk about the circular www.theaemt.com

> 28

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28 Thomas Meets

economy, the repair industry, and what these benefits are to the end-user. TM: Are there some opportunities that you're grasping for the future? JS: A large generator or motor has a considerable amount of material in it. If you can repair that asset and put it back into service at improved efficiency and quality levels, you have the best of both worlds: a long-lasting frame and asset life and modern-day efficiency. We often see brand-new motors and generators coming up for repair, particularly motors, with six to 18 months of service – it is hugely inefficient. If you expect a service life of more than two years, the repair market can improve assets that originally weren't fit for purpose. We expect one of our sets of coils to last decades, and not only that but perform far more efficiently in service. TM: What about the Internet of Things or Industry 4.0? JS: Rather than having a machine fail in service, and all the stress, Quarter 4 2021

downtime, and unplanned maintenance that comes with that, we can instead predict when assets will need repairing. This allows end-users to plan and schedule maintenance for quiet periods in production, for example. The growth in data available also allows us to learn. Partial discharge monitoring has come a considerable way in the last five to ten years. We can learn about PD, how it develops, and its effect on machine efficiency and operating conditions to develop our products. We're now working closely with organisations that carry out condition monitoring from the design stage. We're able to embed monitoring within the coils or the rewind. We're collaborating with these organisations so that we can start to predict asset life from the design stage.

Right now, we have conditioning companies, coil makers, repair companies, and end-users, all working together to collaborate, learn, and improve the product to reduce downtime and improve efficiency. TM: What is the one thing you'll be telling your customers about the repair industry? JS: There is enormous potential for equipment owners to use the repair industry to overhaul their assets and achieve exceptional efficiency, with durability, at a lower cost to replacing the equipment. The older frames tend to have more space in them, which allows you to put more insulation – and sometimes even more copper – into the coil so that you end up with a much better asset. TIMES-CIRCLE

“We expect one of our sets of coils to last decades, and not only that but perform far more efficiently in service."

www.preformedwindings.com www.theaemt.com

It’s time to re-connect, re-unite and celebrate. Table bookings now open! Endorsements: Entertainment by: Alfie Moore

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

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

Michael Limb Westin Drives

Shaun Sutton Central Group

“One of the most original and distinctive acts working today. His tales of life on the force are both hilarious and utterly convincing”.

Thursday, November 18th 2021 Doubletree by Hilton Hotel, Coventry The awards are a global celebration of business and professional excellence. They recognise the achievements of both individuals and companies manufacturing, distributing, maintaining and repairing industrial machinery such as electric motors, drives, pumps, fans, gearboxes, generators, transformers, switchgear and ancillary equipment. There are 7 awards being presented: Product of the Year, Project of the Year, Supplier of the Year, Service Centre of the Year, Contribution to Skills & Training, Diversity in Engineering, and the Rising Star Award. Make sure you book your table (or individual places) so that you can be at the industry event of the year!

Book Now: www.aemtawards.com

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Deadline: Monday, 15th November

30 Technical solutions

Repair and optimisation of water injection pumps Offshore oil fields need to optimise productivity to remain profitable, and this often means that water injection pumps are used to increase the speed of oil recovery. These high energy pumps need to deliver reliable performance from day one, so when a Norwegian offshore platform required expert support to repair two pumps, it called on Sulzer’s design and manufacturing expertise, as flow discovered.

il and gas continue to form the building blocks of our essential everyday items. As these resources become more difficult to reach, oil producers need to optimise the efficiency of their processes. The Scandinavian oil platform has operated two BB5 water injection pumps for over ten years, but they have suffered from rapid wear and high vibration. The original equipment manufacturer had delivered several upgrades, but there was little improvement in either performance or reliability. There were also long periods when there was no water injection capacity, which severely impacted oil recovery rates. To help resolve this, the operators decided to approach Sulzer for a solution. RETROFIT OF EXISTING PUMPS Initial discussions led to an offer to investigate the spare pump cartridge, which had also exhibited the same symptoms of vibration. Sulzer took the cartridge to its Stavanger Service Center and dismantled it. The engineers discovered that the main shaft had rotodynamic issues, which caused the vibrations, and that this fault had been an issue from new. To restore the water injection capability of the platform with minimal delay, Sulzer suggested, in the short term, that the cartridge should be replaced with a hybrid component. This would fit precisely into the existing barrel of the pump on the platform and enable the first pump to operate. Sulzer did not manufacture

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the pump in question, but this would pose no problems for the project because it can apply its expertise to equipment from any manufacturer. Over the next six months, the new hybrid cartridge was manufactured. Together with the onsite maintenance provider, Sulzer engineers installed and commissioned the water injection pump and returned the platform to normal operations. NEW PUMPING ASSETS In the meantime, Equinor had decided to replace both of the original water injection pumps with new assets designed and manufactured by Sulzer. Sulzer began manufacturing the new injection pumps, which would be installed during separate, planned maintenance windows. The projects were carefully coordinated to ensure the pumps were delivered on time, together with other auxiliary components, to meet the installation program set out by Equinor. Oddvar Holta, Project Manager for Sulzer, said: “The greatest challenge has been the very short delivery time on the hybrid cartridge, which would normally have taken ten months. We have managed to streamline this process and meet the objectives of our customer, getting the water injection pump up and running on time.”

ADDITIONAL ENERGY SAVINGS However, the story continues; having manufactured the new pumps to match the specifications of the original components, and after the first one had been installed, a change in site conditions prompted the decision to reduce the operational head of the new pumps to reduce energy consumption and CO2 emissions. This required the pumps to be de-staged, removing four of the original eight impellers in cartridge A and two impellers in cartridge B. The design engineers in Leeds created the necessary drawings for the transition tubes, which were manufactured at the same site. Once complete, engineers from Sulzer travelled to the platform, removed the impellers that were no longer required, and installed the new components. Pump A achieved a power saving of 2MW, which equates to 5,536 tonnes of CO2 per year. Similarly, Pump B’s power consumption was reduced by 1MW, saving 2,768 tonnes of CO2 every year. TIMES-CIRCLE www.sulzer.com www.theaemt.com

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32 Bearing protection

Next maintenance in 500,000 Kilometres Tom Nusch, Product Manager at Schunk, explains how shaft grounding systems made of carbon fibres protect against bearing damage and extend the service life of high speed and light rails trains.

t's an all too common story; suddenly, metros or trains are at a standstill due to damaged engine or transmission bearings. Such breakdowns are not only annoying but, above all, expensive. The cause is often vagrant shaft voltages that discharge in the bearings and cause lasting damage. Shaft grounding systems made of infiltrated carbon fibres can provide a remedy, reliably dissipating voltages and protecting against bearing damage. From subways to high-speed trains, we know from experience that there are many vehicles with inverter-controlled electric motors that have a problem with shaft voltages in the rail market. And the impact of this voltage is great. Our customers are not only struggling with damaged motor and gearbox bearings. In some cases, we even found that the viscosity of the lubricants had changed to such an extent that there was no lubricating effect at all. But all problems have one thing in common; they cause costly unscheduled train downtimes and high maintenance costs. But what can be done to safely dissipate vagrant shaft voltages and extend the service life of the vehicles? This is a question that Schunk has been dealing with since 2013. TWO SOLUTIONS FOR ALL REQUIREMENTS It is almost impossible to develop one standard solution. Because no two trains are the same, and the number of variants of drive units and combinations of motor and gearbox is too large. To offer our customers the best solution for their requirements, it is also necessary to take into account the demanding operating conditions under which a

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grounding solution should function reliably. These include vibration shocks of up to 100g, the shaft's alternating rotation, and influences from different media, such as water or oil. Ultimately, we developed two market-ready shaft grounding systems with carbon fibres (CFGs) suitable for railroad applications and tested following current railroad standards. The difference between the two systems lies in the type of contacting. GEAR/GEARBOX-MOUNTED CFG SYSTEM This grounding system is mounted near the gearbox, and it makes radial contact with the motor shaft with two grounded carbon fibres and dissipates the shaft voltage in this way. The shaft grounding can be tailored to any gearbox or motor and is mounted on the existing interface with little effort. MOTOR-MOUNTED CFG SYSTEM This motor-mounted unit makes contact at the centre of the axial end of the drive shaft. This contact point is already sufficient to reduce the shaft tension. The system can be fixed on any motor shield. In addition, we have supported our customers when it comes

to customised designs of shaft grounding systems. Regardless of which system customers choose, they receive a solution which dissipates vagrant shaft voltages, protects against expensive bearing damage, is resistant to strong vibrations and is insensitive to changes in the direction of rotation. The system is reliable even in the event of water or oil ingress and is generally easy to retrofit. In addition, even under the most challenging conditions, a typical maintenance interval with a CFG system is 500,000 to 600,000 vehicle kilometres. This is made possible because good electrical conductivity and favourable tribological properties make carbon a very useful material when it comes to power transmission – and thus also to shaft grounding. Because of these properties, carbon fibres and carbon brushes have become the most popular material for shaft grounding. In short, for vehicle manufacturers and transport operators who rely on the performance of their vehicles and want to extend maintenance intervals, shaft grounding systems with carbon fibres offer a reliable method of protecting transmission and engine bearings. TIMES-CIRCLE www.schunk-group.com www.theaemt.com

34 software solutions

Benefit from the triangle of service The relationship between client and repairer can be a fragile existence. Years of good service can be quickly undone by one technical issue or poor communication. Steve Ashman of EMiR Software, a leading developer of business systems for the electro-mechanical market, explains how the triangle of service helps to support positive client repairer relationships and deliver benefits to both parties.

he triangle of service consists of three key elements used by repair companies to control the repair process and maintain the client relationship. With an efficient and effective approach to all three both repair businesses and their clients can benefit. ASSET MANAGEMENT Repair companies must have clear oversight of all the assets they support for their customers, something that can be a challenge, particularly as asset registers evolve. The uptime and reliability of assets is the customers focus. In a traditional relationship, the way a service centre reacts to the demand of downtime, the commitment that they show and speed of response are all factors at the heart of great service. To achieve critical mass and suitable profitability, assets will need to be maintained in abundance. As repair centres grow, so does the administrative burden. Multiple assets across multiple sites and multiple customers means that a robust database is a minimum requirement. As industry moves towards innovative systems, designed to predict equipment inefficiency and failure, stored historical data will also have even more relevance. But what happens if you don’t record asset information in a timely fashion? The slow movement of information around a business can have surprising effects on business efficiency. It is reported that the production of inaccurate invoices, due to missing or incorrect information, is the root cause of disputed and late payments.

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In addition, simply holding data is not enough, that data needs to be available to customers. As digitalisation and Industry 4.0 gather momentum, the way repair businesses interact with their customers is changing. Analytical forecasting is playing an increasing role in the value repair businesses can deliver to their clients. However, moving away from reactive repair to a more proactive assessment of possible failure, will only be achievable if historical data and real-time sensor-based data is made available. Therefore, holding and making available accurate and timely information about a client’s assets gives the repair business the ability to build on existing services and improve the service relationship. SCHEDULING It is not uncommon for an operations team to develop its own solutions to managing and executing the daily workload. The use of the whiteboard is just one solution that is in use in many service centres for making the list of work visible to the operations team. But it does not always follow that the job schedule is visible to everyone that needs it. Handling contracts and scheduling visits are core activities in a service relationship. If everyone – internal admin, engineers, managers, and

customers – can see the status of every repair job, this can bring benefits to both sides of the client repairer relationship. Decisions that can be made instantly from up-to-the-minute information save time and improve service. A repair business’s customers and stakeholders welcome a live view of the planning schedule, as it helps to eliminate uncertainty. Situations change endlessly. In repair projects this can range from the nature of a fault to the delivery of spare parts and the availability of engineers; the whole cycle is in perpetual motion. The way a business reacts, adopts a change, and importantly communicates with the relevant stakeholders, is important. Although many changes are caused by legitimate reasons, late communication of the facts and expected outcomes can bring about a poor perception of service levels. Because of all these factors, a scheduling solution should be

The uptime and reliability of assets is the customers focus.

www.theaemt.com

Software solutions 35 a single, integrated entity, which doesn’t rely on any additional spreadsheets or whiteboards. ACCESS TO INFORMATION A connected world requires all members of a team to know what is going on, and importantly what to do next. A service and repair business is not confined to work in a single location and neither is the information that it needs. Each stage of working with the client generates important information that is critical in the process. A site engineer needs to be led by customer instruction and the scheduling team. Details of a job need to be issued to the engineer, who in turn, needs to record all aspects of the work and in today’s climate ensure legislative requirements are met. If a repair business charges its clients on a pay-as-you-go basis, the emphasis has to be on supplying its accounts team with information

to invoice as soon as possible, with accurate appraisals of the work completed. Even if the work is done under contracted terms, an accurate and reliable record should be stored and reported to the client. Many critical call outs are raised out of normal working hours. These incidents require the same amount of documentation and compliance, but this needs to be initiated by the engineer. A process is needed to ensure these visits are captured fully with critical information recorded. Companies that rely on paperwork and the manual movement of information, invite the possibility of inaccuracy and delays from a neverending and expanding collection of forms and reports. In the main, these reports are designed to meet legislation, maintain standards and hold a permanent copy of the work carried out. But if any of the paperwork is misplaced there can be serious ramifications. Now that smartphones are part of our everyday lives, they are the ideal

tool to help deal with the accurate and timely storage and access of information for the service centre and its customers. Paper trays, missing signatures and late amendments can finally become a thing of the past. CONCLUSION A service centre can improve its performance, and the service its customers receive if it focusses on three things. These are the quality and functionality of its asset register, the ability to see live scheduling information, and the use of the latest smartphone technology to capture data as it happens. Modern software offerings such as EMiR, offer an answer to all of these challenges. They can offer connected communication and integrated processing to ensure that the repairer is able to operate efficiently and effectively and deliver an enhanced service to its customers. TIMES-CIRCLE www.emirsoftware.com

Extend machine life with the N330 The N330 is our new dual channel, portable vibrometer designed to help you to identify vibration issues in the most convenient manner. The device is capable of both single and two-plane balancing as well as FFT, Smart Analysis, Vibrometer and Tachometer. Thus enabling you to best pursue a proactive, preventative maintenance routine to limit production downtime and extend the life of your machines. And all backed up by the most comprehensive support and parts service available in the UK.

For further information contact us on

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

Hazardous Areas 36 36 FEATURE

Understand ingress protection ratings Mawdsleys BER, a specialist in the repair, rewind, refurbishment and supply of electric motors, generators and pumps, looks at ingress protection (IP) ratings, what they mean and how to understand a motor's IP rating.

P or Ingress Protection refers to the degree of protection that enclosed equipment has from foreign objects and moisture. Usually found on the motor nameplate, this information is crucial when choosing an electric motor. It ensures that the enclosure can protect the motor from the environment it is operating in. IP ratings are defined in standards set by the International Electrotechnical Commission (IEC), whereas The National Electrical Manufacturers Association (NEMA) uses an enclosure description of a similar standard. The first digit of the IP rating, which goes from 0 to 6, refers to the protection the enclosure offers from solid foreign objects. The highest level of protection means that the motor is completely protected against dust. As well as motor performance, this is a safety factor that can protect against accidental contact with the motor with tools, wires or parts of the body. The second digit of the IP rating, which goes from 0 to 9, refers to the protection the enclosure offers from moisture. The highest level of protection here means that the motor is protected against highpressure and high-temperature jets of water. As well as motors, IP ratings can be used to grade the resistance of an enclosure against dust and liquids for devices such as heating units, fans and power supply cases. READING IP RATINGS An IP rating is a combination of two numbers that indicate how well protected the enclosure is

Quarter 4 2021

explosive – such as quarries, sewage treatment plants or oil rigs – a higher degree of protection will be required. Failing to take these considerations into account and specify the correct IP rating can damage a motor or even cause complete failure, or worse still, injury to personnel. Therefore regardless of the application, it is essential to ensure that the IP rating offered by a motor considers the risk of impact from liquids and solid foreign objects. TIMES-CIRCLE

against water and foreign objects. The table below lists the protection rating at each level. So, a motor with a rating of IP55 would be protected against dust and water jets. CHOOSING THE CORRECT IP RATING Equipment should protect against external influences that could negatively impact it, its users, or its environment, so the recommended IP rating of a motor will depend on these factors. In the most demanding environments, which are potentially

Equipment should protect against external influences that could negatively impact it.

www.mawdsleysber.co.uk

Solid Foreign Objects

Water

0 – No protection

1 – Protected against solid foreign objects of 50 mm and greater

1 – Protected against vertically falling drops

2 – Protected against solid foreign objects of 12,5 mm and greater

2 – Protected against vertically falling water drops when the enclosure is tilted up to 15°

3 – Protected against solid foreign objects of 2,5 mm and greater

3 – Protected against spraying water

4 – Protected against solid foreign objects of 1,0 mm and greater

4 – Protected against splashing water

5 – Dust-protected

5 – Protected against water jets

6 – Dust-tight

6 – Protected against powerful jets 7 – Protected against the effects of temporary immersion in water 8 – Protected against the effects of continuous immersion in water 9 – Protected against high pressure and temperature water jets www.theaemt.com

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

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38 Energy Efficiency

Can a repaired motor be more efficient?

Chris Callander looks at how a motor's efficiency can be improved as part of a repair or refurbishment and highlights some things you should consider.

study carried out jointly by the Association of Electrical & Mechanical Trades (AEMT) and the American Association – the Electrical Apparatus Service Association (EASA) – has shown that motor efficiency can widely be maintained when a repair is carried out to a defined set of standards. The findings of the 2019 study, which have been published in a paper titled 'The Effect of Repair/Rewinding on Motor Efficiency', established that efficiency was maintained on repairs to current machines up to IE3 efficiency. This guide has been incorporated into the latest international repair standard IEC 60034:23:2019 and the latest American ANSI/EASA standard AR100. There are, however, some circumstances under which the efficiency of a motor can actually be improved by refurbishment and rewinding. This generally applies to older, less efficient motors and the decision to repair rather than replace typically involves a broader range of factors than simply to improve efficiency. Generally, the most effective way to improve a motor's efficiency is to add more copper to its coils, as James Stephens, Sales Director at Preformed Windings, explains: "It is often possible to add more copper to a set of coils, or more specifically, increase the copper cross-sectional area. This is achieved through the very tight tolerances we can manufacture modern coils to and the ability of state-of-the-art CAD systems to optimise coil design. "This has several benefits such as reducing the coil's resistance, increasing the potential output and reducing the operating temperature of the machine, which can increase an asset's life. It is important to understand Quarter 4 2021

that adding more copper will affect other characteristics in a motor. These may require the wider system to be adapted, according to Mathis Menzel, Managing Director at Menzel Elektromotoren: "Adding more copper into a machine will affect not only efficiency but also other parameters. You should expect an increase of inrush-current – which might be in conflict with existing protective measures". INSULATION ADVANCES The ability to increase the amount of copper in a motor has been supported by advancements in insulation materials' which means that less insulation is required, and therefore space in the motors' slots becomes available. James Stephens continues: "The thickness of insulation needed for various voltage systems has significantly decreased over the years. We are often asked to optimise the design of the insulation system, and modern insulation systems can offer 15% reductions in thickness. As this is on the outside of the coil, the effect on copper cross-sectional area can be greater still. "These thinner insulations assist with heat dissipation and again can offer both an increased asset life and improved efficiency of the coils." Martin Wagner, Project Manager High Voltage Motors at Menzel Elektromotoren, points out that care is needed when comparing pre- and post-repair efficiency levels in a motor: "Efficiency should not be compared simply by looking at a motor's datasheets. Before a 2007 update of the IEC / EN 60034-2-1 standard, which defines methods of determining a rotating machine's efficiency, efficiency figures were

more generous due to how certain effects could be 'calculated out'. Efficiency levels could previously be calculated with smaller additional losses than today – a standard 0.5% of absorbed power, regardless of the motor output. "Since the 2007 update, the methods are much stricter. Now stray load losses have to be determined by a factor that reflects the motor's output, ranging from 0.5% (≤1MW) to 2.5% (≥10MW). So to avoid potentially misleading comparisons calculated from individual losses, efficiency should be measured directly at nominal load." REPAIR OR REPLACE? The decision of whether to repair or replace a motor typically involves several factors. These can include cost, the availability of a suitable replacement, system compatibility and, of course, efficiency. So, while increased efficiency is possible in certain circumstances, it isn't often the only reason to carry out a motor repair. If efficiency is one advantage you are looking for from your motor refurbishment, it may well be available, but you need to take care when calculating the actual benefits you are set to gain. TIMES-CIRCLE www.menzel-motors.com www.preformedwindings.com www.theaemt.com

Prevent Mechanical Failures in Induction Motors Master the art of vibration monitoring of induction motors with this unique guide to online fault diagnosis. 30 CASE STUDIES Vibration measurements, interpretation, remedial action, motor strip down and photographs • • •

Faults in sleeve and rolling element bearings Shaft misalignment and soft foot Resonance

• •

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Hardback | September 2020 £100 / $130 ISBN: 9781108489973 320 pages, 340 b/w illus. 64 tables

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Vibration Monitoring of Induction Motor An author with 58 years’ experience on vibration monitoring of induction motors. He is a Fellow of the IEE and a Senior Member of the IEEE.

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40 Energy Efficiency

The evolution of the plug fan Axair Fans explains how energy efficiency gains are being made in ventilation systems through the use of plug fans with integrated EC motors.

ver the past few years, there has been a fundamental shift from old scroll type fans to higher efficiency plug type fans in the air handling market. The older belt-driven or double inlet centrifugal models stood the test of time within ventilation systems due to their cost-effective nature and general simplicity, but as regulations evolved and the demand for higher efficiency within plants grew, they slowly became an unviable option as building owners demanded greater efficiency and a longer more efficient air handling unit life. The requirement for greater efficiencies, combined with advancements in technology, led to the introduction of an alternative to the double inlet – the plug fan – which started with AC motors being replaced with higher efficiency EC or brushless DC motors. The popularity of plug fans has increased over the years, proving to reduce energy consumption and CO2 emissions while also helping businesses to achieve ISO certification status and show their active reduction in energy use. You will read anywhere that the most energy-hungry component within any ventilation system is the fan, so by reducing the energy consumption within a system, building owners can make substantial savings, and shorter payback periods can be achieved. SHORTER PAYBACK PERIOD Compared to traditional double inlet fans, plug fans offer lower energy consumption and lower operating costs resulting in a much shorter payback period and increased operating efficiency. Coupled with a significant increase in both volume and pressure, plug fans quickly became the choice to overcome the energy losses inherent in the operation

Quarter 4 2021

of traditional double inlet fans and a reduction in maintenance time spent replacing drives and pulleys. According to CIBSE, the inefficiencies of these fans can be anything from 2 to 10%, definitely not insignificant. For those in the market with existing ventilation systems who looked to change to a more efficient system, the component installation was less inconvenient than the whole system replacement. The cost of refurbishing a ventilation system is currently between 35-50% less than replacing the entire system, and components can easily be installed and transported to the site without the need for cranes and building shutdowns. For those unfamiliar with the term, plug fans are direct drive fans that do not require additional belts or pulleys. They are easy to install, quiet and low maintenance. Plus, their small profile allows them to fit into smaller, tight spaces, ideal for quick retrofits. Perfect when space is at a premium in many air handling unit (AHU) designs. Modern plug fan technology fitted with high-efficiency EC motors and integrated drives can significantly increase the operating duty of both volume and pressure of the ventilation system, while also offering major reductions in operating noise and

benefitting from built-in electronics for communication, control and greater reliability. For example, the Rosenberg Generation 3 EC motor allows 40% more motor winding density creating a 30% increase in power. Many AHU manufacturers have extended the life of their systems by replacing old centrifugal fans with modern plug fans. Once installed, EC fans can be commissioned to run at fixed speeds where needed. Modulating the fan speed in response to specific time requirements or occupancy-based controls allows even further energy usage reduction. The evolution of plug fans and EC motors continue to develop in the UK fan market as international fan manufacturers invest further into research and development under constant pressure to reduce energy consumption and CO2 emissions in line with legislation.

The most energy-hungry component within any ventilation system is the fan.

www.axair-fans.co.uk www.theaemt.com

LIVERPOOL

WALLASEY

MANCHESTER

WWW.RJWENG.COM

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

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SCAN ME

Can a repaire d mot be more effic or ient?

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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42 Energy Efficiency

MODERNISED PAPER MACHINE OFFERS GREATER ENERGY EFFICIENCY MODEL GROUP DEVELOPS, PRODUCES, and supplies packaging made of solid and corrugated cardboard. At its facility in Weinfelden, Switzerland, the organisation operates two huge paper machines: almost 80m in length. Powered by dozens of electric motors, the machines operate 24-hours a day, seven days a week. The process is energy-intensive, so as the second paper machine approached the end of its service life, the company was keen to explore upgrade options that would provide a boost in energy efficiency, and so ABB was asked to help modernise the machines with energy-efficient motors and variable speed drives (VSDs). Philipp Lenhard, Technical Manager at the facility, said: "Our original variable speed drives were legacy models that suffered from a lack of spare parts, while the motors dated from 1991 and required an extensive overhaul. "We were impressed by the upgrade route proposed by ABB's experts that would enable new motors and drives to be fitted. This avoided the costs involved in overhauling the existing motors while taking advantage of government grants available for energy efficiency

improvements." The modernisation project was planned around sixday summer shutdowns in 2019 and 2020. The new equipment was delivered to site, ready for fast-track installation and commissioning. In 2019, the VSDs were replaced with the latest ABB ACS880 Multidrives. Then, in 2020, 36 electric motors were replaced with ABB IE4 motors – the most energy-efficient classification for AC induction motors. Delivery and commissioning went as planned, with paper machine two able to start up again in August 2020, quieter and more economical than before. While calculations by Model Group show that the energy-efficient motors and drives are saving up to 900,000 kWh a year, there are important additional benefits. Previously, the 2.5m wide paper web ran through the machine at some 800m/min. Now it runs at 900m/min – offering a major increase in productivity.

Furthermore, the new drive solutions will eventually allow the machine to run at 1km/min when other upgrades are carried out. The motor speed has also been reduced from 1,500 to 1,000rpm, which has made it possible to optimise or eliminate gears, significantly reducing friction. The final result is increased production speed, significant energy savings and a projected return on investment (ROI) in less than five years. bit.ly/ABBPAP

SIEMENS TO BUILD A WORLD-LEADING 2-POLE ELECTRIC MOTOR SIEMENS LARGE DRIVES Applications (LDA) has received an order from a Chinese customer to deliver a special machine with dual shaft extension. It can be operated as a motor with a power of up to 105MW and as a generator with up to 129 MVA in power generation mode. According to the company, the motor will have an efficiency of beyond 98% and will be a worldleading 2-pole electric motor. The contract also includes the delivery of a 40MW Sinamics GL150 starting frequency converter. This LCI-converter (load commutated inverter) is designed for single-motor applications with variable and constant torque characteristics. As a result of the low switching losses and the low loss thyristor technology, the efficiency of the LCI converter is extremely high and lies at 99%. The drive system will be part of an energy storage project. Energy storage technologies have been viewed as a key supporting technology for the energy revolution in China thanks to decisive Quarter 4 2021

advantages such as high capacity, low costs, high efficiency, and environmental friendliness. The plants utilising this approach operate by using motors to drive compressors, whose energy will be stored in suitable storage vessels. The stored energy can then be released to drive an expander, which drives a generator to produce electricity. The plants have a very large power rating and storage capacity, low self-discharge, and a long lifetime compared with other energy storage technologies. These attributes generally make it the most promising and cost-effective method for bulk energy storage grid services. The motor will be manufactured at the Siemens Dynamowerk plant in Berlin, Germany, which is Siemens' oldest manufacturing facility. sie.ag/3uN9LFR www.theaemt.com

Visit www.theaemt.com Call +44 (0)1904 674 899

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

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

Promoting Engineering Excellence

44 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

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 Robuschi Pumps

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

CEMB Hofmann UK Ltd

INTERNATIONAL REPAIR CENTRES SERVICES INCLUDE • Motors • Fans • Instruments • Generators • Rewinds

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

APPROVED BY SIEMENS ABB

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

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

EXCLUSIVE TO AEMT MEMBERS REACH THOUSANDS OF USERS OF ELECTROMECHANICAL EQUIPMENT WITH A LISTING IN THE REPAIR SERVICE DIRECTORY BOOK ONLINE AT WWW.BIT.LY/REPAIRDIRECTORY OR CONTACT ANDREW CASTLE ANDREW@RENEW-MAG.COM +44 (0)7785 290034

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

Pumps Motors Gearboxes Fans Servo Motors

• • • • •

Spindle Motors Inverter Drives Thermography Mechanical Rewinds

APPROVED BY Siemens

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

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

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

Inverter Drives Balancing Electrical Mechanical Rewinds

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

ADC Electrical Ltd

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

• • • • •

• 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 46 Opinion

Keeping the world in motion – sustainably Morten Wierod, President at ABB Motion believes high-efficiency motors and drives are central to the world’s invisible climate solution.

n July this year, the EU Ecodesign regulation 2019/1781 for low-voltage induction motors and variable speed drives came into effect, paving the way for millions of motordriven applications to reduce their energy consumption. Although electric motors consume about 45% of global electricity, they are often not seen while in use. The issue is that too many motor-driven systems in use are inefficient, which is why ABB is working with customers, partners, academia and governments to raise awareness of just how much energy high-efficiency motors and drives can save. Solutions available from ABB today surpass the regulatory demands that recently came into effect and those scheduled for July 2023, when the Ecodesign regulation expands further. THE INVISIBLE NETWORK AROUND US “Electric motion touches your life several times a day, even though you’re not aware of it,” explains Morten. “Motors and drives are ever-present, from ensuring that clean water reaches your home and running trains, to building, construction and the production of the food you eat. “So, all around us, and across the world, there are more than 300 million motors, drive systems and sub-systems that are installed, enabling the quality of life that we all want.” ENERGY EFFICIENCY IN A BOX “The electric motor uses and controls electromagnetic fields to create the movement to make it turn. The variable speed drive is

Quarter 4 2021

probably less well known in the general public, but I call it a box of energy efficiency. Inside the box sits power semiconductors and electronics used together with software to create the correct speeds and torque to control the motor, a much more efficient method than the previously common practice of using brakes to control the speed. “In that way, you’re able to save from 25 to 40%, even 50% of energy compared to running a motor at full speed as we would do without any speed control.” WHY THE EU ECODESIGN REGULATION IS IMPORTANT One of the key elements to achieve sustainability goals and targets in cities is energy efficiency, which can be significantly impacted by motor and drive technology.

President of ABB’s Motion business, Morten Wierod.

“I believe industrial energy efficiency has the single greatest capacity for combating the climate emergency” “I’m happy to see good progress with the energy levels of what we call IE3 being valid from July 1st 2021 and moving to IE4, which is the next level of energy efficiency in 2023. But we can do much more because new technologies are already available.” Indeed, ABB has motor and drive solutions that meet the IE5 efficiency class – the highest level of efficiency met by any design to date. “During 2020, ABB’s installed base of high-efficiency motors

and drives enabled 198 terawatthours of electricity savings, which is more than three times the total annual consumption of Switzerland. By 2023, it is estimated that the expansion of our installed base of motors and drives will help customers save an additional 78 terawatt-hours of electricity per year – more than the annual consumption of Chile. “I believe industrial energy efficiency has the single greatest capacity for combating the climate emergency. It is essentially the world’s invisible climate solution. With high-efficiency motors and drives that power most of the critical process around us, we can keep the world turning while saving energy every day.” TIMES-CIRCLE Morten Wierod’s comments were taken from the ABB Decoded podcast titled “How ABB motors and drives help keep the world sustainably in motion”, which can be accessed at bit.ly/ABBDs1e7

www.theaemt.com

ALPHA E

CTRICS E L

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

Our Services include:

Authorised distributors for...

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

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BUY ONLINE: www.alphaelectrics.com

24-7 BREAKDOWN SERVICE: 0116 276 8686

Custom Electric Drive Solutions Worldwide

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

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

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Renew Magazine - Quarter 4, 2021. Energy efficiency focus

Articles inside

Project Update

Project Update

Project Update

Project Update

Opinion

Energy efficiency

Hazardous Areas

Renew Magazine - Quarter 4, 2021. Energy efficiency focus

Benefit from the triangle of service

Energy Efficiency

Bearing protection

Project updates

Decode your motor's nameplate

Repair and optimisation of water injection pumps

AEMT Awards update

Thomas meets

Product news

Industry news

Circular economy