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

The journal f rom

Quarter 4 2020

FOCUS ON: Energy Efficiency

The benefits of understanding the repair standard

Repair or replace: The cost considerations 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.

W

elcome to the first issue of Renew, the new quarterly publication from the Association of Electrical and Mechanical Trades. Some of you will be familiar with the AEMT’s members’ magazine, the Journal. Renew has been designed as an evolution of that publication, broadening its appeal to users of rotating equipment including motors, generators, pumps and more; as well as those who supply, service and repair them. The electromechanical repair sector has a huge role to play in the circular economy, keeping resources in use for as long as possible, extracting the maximum value from them, and recycling as much as possible when a product reaches the end of its serviceable life. But the work of the repair sector can also have a significant and positive impact on energy efficiency and plant reliability – two factors driving modern industry. The AEMT believes that these three key areas – the circular economy, energy efficiency and reliability – can all be met by following the right approach. And so, Renew aims to provide a platform for those working in, and served by, the electromechanical repair sector to share best practice, new and innovative developments, opportunities for improved business performance and other valuable insights. I trust you will find the pages of this issue of interest, and we would love to hear what you think. If you have any comments or feedback, or suggestions around what you would like to see in future issues, please email our editor, Chris Callander, at chris@renew-mag.com. David Hawley, President, AEMT

NEWS 6 Industry news 10 AEMT news

AEMT St Saviours House, St Saviours Place, York. North Yorkshire. YO1 7PJ www.theaemt.com

28 The power of 3D scanning 32 Motor repair highlights flaw in original design

12 AEMT Awards update 34 The importance of winter pump maintenance

14 Product news 18 Project updates

Focus on energy efficiency 36 Improving the efficiency of HV motors and generators

Twitter @AEMT_Updates Renew is a controlled circulation journal

published quarterly on behalf of the AEMT by Touchwave Media and G and C Media. For a copy of the magazine’s terms of control and to request a copy please email circulation@renew-mag.com The content of Renew magazine does not necessarily reflect the views of the editor, publishers, or the AEMT. The publishers accept no legal responsibility for loss arising from information in this publication and do not endorse any products or processes mentioned within it. No part of this publication may be reproduced or stored in a retrieval system without the publisher’s written consent.

8

www.theaemt.com

40 Hazardous area motors are no longer exempt

updates 20 Compliance: Understanding the repair standard

42 Repair or replace: Cost considerations

24 Circular Economy: The motor efficiency survey 26 COVID: Keeping industry turning

36

OPINION

© AEMT. All rights reserved. Cover image courtesy of Sulzer

features

26

46 Repair or replace: Are you getting the right advice? Quarter 4 2020


www.brookcrompton.com

As an original innovator of electric motors, Brook Crompton offers over a century of technical and design expertise. With an extensive stock we can also modify to suit specific customer needs, with technical support from the company’s knowledgeable team readily available to ensure the correct selection of motors for any application.

Shaping the future of electric motors, Brook Crompton is focused on the development of new products that improve energy efficiency, offer lower cost of ownership throughout the motor lifetime and reduce environmental impact.

W range

Ex d range

The Brook Crompton W motor range is avaliable in aluminium (63-180) or cast iron (80-355) with outputs from 0.07 kW to 22 kW in frame sizes 63S to 355L. (56 to 587 NEMA).

Brook Crompton’s flameproof motors are designated Ex db flameproof and are designed for operation in Zone 1 hazardous areas. Outputs range from 0.37 kW to 200 kW with smaller or larger outputs on request.

Special build options: • Multi speed • Brake / brake kit friendly (63-132) • Encoder • Force ventilated (IC416) • Special shaft / special flange dims • Special paint • Special voltage • Low starting torque • Marine • Hoist / crane duty • Plus many more

Special build options: • Ex db eb IIB or IIC • Group I mining • Special shaft dimensions • Special voltage • Low starting torque • Offshore • Roller bearing • plus many more

www.brookcrompton.com


Keeping industry turning Series 10 range

Medium / high voltage

The Brook Crompton Series 10 aluminium range is a high quality standard range of electric motors with a specification suitable for most industrial applications. It covers outputs from 0.06 kW up to 900 kW in frame sizes 56 to 160 (aluminium). 80 to 450 kW (cast iron).

Brook Crompton’s range of medium and high voltage motors are available in cast-iron and fabricated steel frames, with die cast aluminium and copper bar rotors to suit the requirements of a wide range of applications and are available in outputs from 90 kW to 130 MW in induction and synchronous designs.

Stock modifications include: • B14, B34, B35 mounting options • IP56, IP65 ingress protection • Cable entry position change • Anti condensation heaters • Restamp for inverter rating • Roller bearing

Special build options: • Special shaft dimensions • Special voltage • Low starting torque • Offshore • Roller bearing • plus many more

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


6 INDUSTRY NEWS

HAYLEY 24/7 IS UK’S FIRST SKF-CERTIFIED GEARBOX REBUILDER THE BEARINGS, SEALS AND engineering solutions manufacturer, SKF, has chosen Hayley 24/7 as its first certified gearbox rebuilder for the UK, at its sites in Dudley and King’s Lynn. To gain accreditation, a set of stringent criteria had to be met. Hayley 24/7 staff have also upskilled in root cause failure analysis and condition monitoring as part of the program. The teams at both locations will now benefit from access to the latest product innovations, the highest quality tools and equipment, and the specialist expertise of SKF. At the same time, regular audits will be conducted to ensure that strict quality standards are being met with every job. As a result of the certification, the mechanical engineering specialist’s customers will be able to enjoy benefits, such as lower cost of ownership,

Gary Quinlan, Regional Director, Hayley Group (East Anglia) (left) with Mark Brady, Managing Director, Hayley 24/7.

reduced maintenance costs, decreased operational downtime, and both an enhanced level of mechanical reliability and overall productivity. Mark Brady, Managing Director at Hayley 24/7, said: “We are delighted to

become the UK’s first certified gearbox rebuilder for SKF. This will further raise the bar of our gearbox diagnosis and repair standards, subsequently delivering longer life and reliable gearbox assets for our clients.”

WILO JOINS GLOBAL SUSTAINABILITY INITIATIVE THE WILO GROUP HAS BEEN selected to participate in the global sustainability and climate protection initiative called ‘50 Sustainability & Climate Leaders’ of the United Nations and Bloomberg. The participating companies will act on the basis of the 17 sustainability goals of the United Nations. Commenting on the announcement, Oliver Hermes, President & CEO of the Wilo Group, said: “We are proud and happy to be

part of this initiative. The Wilo Group is committed to achieving better living standards worldwide and improving the efficiency of water management systems in the face of climate change.” As part of the initiative, the participating companies will make an important contribution to the debate on current issues such as environmental and climate protection or social justice. At the same time, they will digitally present the results of

their own sustainable actions in short documentaries. “We take a clear position on issues such as climate protection, energy and resource efficiency as well as digital transformation. Together with our global network partners, we drive future-oriented climate-friendly solutions and proactively promote dialogue with politics, business and NGOs. Corporate political responsibility as a part of sustainable action is a living practice for us,” added Oliver.

Construction of Sulzer’s service centre on track WORK ON SULZER’S NEW STATEof-the-art service centre in Birmingham, UK, is continuing to schedule. As planned, the building is now watertight, and attention is turning to the internal construction of the workshop area and the offices. Customers can expect the new facility to be open towards the end of autumn 2020, and in the meantime, the existing service centre will continue to work at full capacity. Located in the prestigious Birmingham Business Park, Sulzer’s new service centre is rapidly taking shape with the main building shell in place and sealed. While the construction continues, plans for moving all the staff and their tools and equipment are being finalised to avoid any interruption in service to customers. A great deal of planning has gone Quarter 4 2020

into developing the most efficient workflows for each area of the service centre. Together, they will deliver a wide range of capabilities, all using lean manufacturing techniques, to ensure all maintenance and repair projects are optimised. Chris Powles, Head of Electro Mechanical Services – EMEA at Sulzer, commented: “This new facility will be an engineering centre of excellence using lean manufacturing principles to ensure an enhanced customer experience. The

improved working environment and more efficient processes will benefit our employees as well as our customers, who will have an uninterrupted, highlevel service throughout the transition to the new site.” www.theaemt.com


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

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8 industry News

HOUGHTON INTERNATIONAL SIGNS AS BAKER HUGHES CHANNEL PARTNER BAKER HUGHES HAS APPOINTED Houghton International as its latest Channel Partner, focusing on API 610 centrifugal pumps in the UK and Ireland. It’s a comprehensive agreement covering overhauls, repairs, parts, replacements, and more with the proven advantages of Baker Hughes’ OEM service processes and technologies. The partnership agreed with Houghton International isn’t just about repairs and regular maintenance, it’s about injecting new technologies into old machines. Some of the 150+ API 610 pumps operating in the region have been in service for 30-40 years, so the manufacturer’s ongoing knowledge and technology sharing with Houghton International will help improve pump efficiency and reduce energy consumption. The two companies will work together to use their combined knowledge and experience to ensure that the installed base of pumps remains fit for purpose, modifying the design and upgrading the components accordingly to improve

efficiency, save energy and extend the mean time between failure (MTBF). As an authorised Chanel Partner, Houghton International will also be able to support the specification and installation of new Baker Hughes pumps across a range of sectors. Commenting on the appointment, Michael Mitten, Houghton International CEO, Michael Mitten. CEO of Houghton International, in upstream and downstream added: “We are delighted to have the opportunity to work with Baker Hughes processes, Baker Hughes pumps are known for exceptional performance to support the ongoing operation in extreme conditions, and we look and performance improvement of its installed base of centrifugal pumps in forward to supporting customers in the UK and Ireland. continuing to operate these pumps for many years to come.” “With decades of proven experience

LEICESTER ENGINEERING FIRM MARKS NEW FACES JOIN THE RIDGWAY TEAM 30 YEARS IN BUSINESS RIDGWAY MACHINES, A manufacturer of precision taping and winding machines for the electrical and energy industries, has welcomed no less than six new specialists to its team. Paul Heggs has joined the company’s production team as Production Manager and Neil Chesters as Installation & Commissioning Engineer. Paul will be using his experience to manage Ridgway’s team of mechanical fitters and engineers to meet production deadlines. Neil is joining to support Ridgway’s customers all over the world, both remotely and on-site. Two new mechanical fitters are also joining to bolster Ridgway’s team, and support in machine builds. The company has also appointed Paul Kirk as Quality Manager. Paul understands Ridgway’s customer needs and requirements and will be further developing effective quality control processes. While Ashley Sinclair has joined the company, bringing design engineering experience and innovative new ideas. Ashley will be working on new product designs to provide the best solutions for Ridgway’s Customers. Quarter 4 2020

THE OWNERS OF A LEICESTERElectrics, said: “We are constantly evolving based industrial electric motor service and seeking ways to change, improve and company, Alpha Electrics, says a develop our services in a drive to become ‘commitment to excellence’ has helped more specialist and maintain our position it reach 30 years in business, with the as experts in this field. That is why we are firm having recently made significant now planning for the next phase of the investments, including doubling the size of business. We started by revisiting what has its premises. got us to where we are now and have then The Patel family started Alpha Electrics used these values to help devise a strategy in 1990, and the company is now planning to further grow the business.”. for the next 30 years by investing in the business and setting out plans for growth. The company specialises in the repair, maintenance and service of industrial electric motors, working across sectors including construction, aerospace, precession engineering, food, packaging, automotive, retail and more. Hem Patel, Senior Sales Alpha Electrics’ company director Rajesh Patel (left) and Engineer at Alpha Hem Patel, Senior Sales Engineer www.theaemt.com


- Are you frustrated with unplanned downtime? - Wish you could prevent failures? Well you can with Meerkat!

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10 aemt news

MEMBER PROFILES AND THE AEMT YEARBOOK

AEMT Secretary, Thomas Marks, shares the latest news from the Association.

AS YOU WILL APPRECIATE, THIS HAS BEEN A challenging year for everyone, and the AEMT is not immune to the effects of COVID-19. At our AGM, we announced that the Association had been affected by the pandemic, but we have a robust strategy in place to ensure we see through the coming months. While we maintain as much of the AEMT’s support and delivery as we can, a lack of resources means we will not be able to produce our annual yellow yearbook, which as you can appreciate, takes a great deal of work to produce. The next edition of the AEMT Yearbook will be published in Autumn 2021. In the meantime, full and up to date details of all AEMT members are available online at www.theaemt.com/Members-Search. There you can identify repairers and suppliers by location, services provided, certificates held and other key factors. And of course, you will find details of many members within the pages of this magazine, including the repair service directory on page 45. One event that the pandemic could not derail was the annual AEMT golf day, which went ahead at the Forest of Arden golf club on a gloriously sunny

day in mid-September. Sponsored by EMiR Software, the teams made up of Association members, and their guests enjoyed the challenging Arden course before gathering for a socially distanced prize giving back at the club. I am also delighted to report that membership of the AEMT has continued to grow, with six companies recognising the value of joining the association since our last publication – the final issue of the Journal. We have two new associate members. The first is the specialist manufacturer of pumps and pumping systems for the water supply and air conditioning sectors, Wilo UK. Also signing up as an associate member is Northern Ireland-based sheet metal fabricator, JMS Metaltec. Three new international members have joined our ranks. Iberica Electrical is a South African specialist in marine and industrial repairs based in Cape Town. Kazakhstan based KTR (KazTurboRemont) provides a full range of services, from design to commissioning, to the oil and gas, energy, chemical and mining industries. And PT Mega Prakarsa Engineering provides a range of maintenance and repair services for motors and generators across its native Indonesia. Then in the UK, new full member, Hoss Engineering, offers repair and refurbishment of electric motors, pumps, cooling towers, air handling units, extract fans and also supplies of new equipment, including new pressurisation units and booster sets, from its Chelmsford site. I want to welcome all our new members and of course, to thank our existing members for their continued support, especially in this challenging period.

Forthcoming AEMT led Courses on Hazardous Area Equipment Repair, Overhaul and Reclamation MODULE

COURSE TITLE

START DATE

END DATE

LOCATION

1

Ex Theory

02 November 2020

03 November 2020

Online GMT +4

2

Ex Hands-on

04 November 2020

06 November 2020

Online GMT +4

2R

Ex Hands-on (and Refresher)

04 November 2020

06 November 2020

Online GMT +4

1

Ex Theory

16 November 2020

17 November 2020

Aberdeen

2

Ex Hands-on

18 November 2020

19 November 2020

Aberdeen

3

Ex Refresher

16 November 2020

17 November 2020

Aberdeen

2R

Ex Hands-on (and Refresher)

18 November 2020

19 November 2020

Aberdeen

1

Ex Theory

30 November 2020

01 December 2020

York

2

Ex Hands-on

02 December 2020

03 December 2020

York

3

Ex Refresher

08 December 2020

09 December 2020

York

For more information or to book any of the couses listed please visit www.ex-repair.com The AEMT is continually monitoring COVID-19 to ensure all classroom-based training remains safe. Full details of the safety procedures being applied to classroom-based courses can be found on the course website. Quarter 4 2020

www.theaemt.com


QUALITY. SERVICE. SPEED YOUR NO. 1 COIL PROVIDER

With over 50 years experience delivering high quality, short lead time coils, Preformed Windings are leading suppliers of coils for high voltage motors and generators as well as traction motors. Our bespoke solutions use the latest technologies and materials to maximise the quality delivered to end users, repairers and OEMS worldwide. Our high quality and short lead times ensure minimised downtime and maximised operational cost efficiency for our valued customers. We offer the highest quality backed by 24/7 technical support and the shortest lead times in the industry. “Preformed coils are the highest quality produced. I have tried other manufacturers of High Voltage coils. No one can compare to the speed, performance, and quality of Preformed coils. Every part of my experience with the Preformed team has been top shelf.” - Kiemle Hankins

Product range Diamond coils • Armature coils • 400V - 18kV • Winding kits • DC/AC traction coils • Rotor bars • Resin rich, VPI & all major • conductor & insulation types Preformed Windings offers more than 45 years experience in delivering coilshop@preformedwindings.com high quality coils for traction motors, high voltage motors and generators.

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Using the latest technologies and the best materials, we can create bespoke, cost effective solutions for end users, repairers and OEMs anywhere in the world We are highly experienced in working within short lead times, thereby minimisin any downtime for our customers.


12 awards update

AEMT AWARDS DINNER: FURTHER POSTPONEMENT ANNOUNCED Acknowledging the ongoing challenges brought about by COVID-19, and the possible effect this might have on the awards entry process, coupled with the Government’s recent extension to the restrictions, the AEMT Council has decided to postpone its Gala Awards Dinner until November next year.

O

riginally scheduled for its regular November timeline in 2020, the Awards Ceremony was quite rightly moved to a new date in April 2021. However, given the situation, and the continued uncertainty caused by both the pandemic and the resulting constraints, the event will now take place on the evening of Thursday 18th November 2021. The Doubletree by Hilton Hotel in Coventry will again play host to this special evening, as it will for the associated AEMT Conference which will be staged during the day, with the move heralding a return to the usual end of year timing and location. This, the fourth staging of the AEMT Gala Awards Dinner, will once again bring together the entire electrical and mechanical trades sector in a celebration of business and professional excellence. Recognising and rewarding the achievements of both individuals and companies operating within the electrical & mechanical maintenance and repair sector, personal endeavour, product innovation, skills training, engineering advancement and commercial acumen will once again be acknowledged and celebrated. INDUSTRY WIDE ENGAGEMENT Operated by the Association of Electrical and Mechanical Trades (AEMT) and produced by Touchwave Media, the awards will acknowledge the skill, effort and sheer dedication of the people and businesses serving this important sector of industry. With sponsorship provided by a host of leading industry names, which to date has included ABB, Avonmore Electrical, Axflow, Drives & Controls, EMIR Software, Fanuc UK, Fletcher Moorland, Menzel, Musk Process Services, Plant & Works Engineering, Sulzer, TEC Motors and WEG UK, well deserved industrywide recognition will be given to those

Quarter 4 2020

businesses who are excelling in their commercial endeavours. These traits have been increasingly evident throughout the pandemic, with many companies going far beyond the call of duty, to ensure the safe and efficient operation of plant and equipment within our critical sectors. AWARD CATEGORIES The following seven categories make up the 2020/21 awards programme: • Product of the Year • Project of the Year • Service Centre of the Year • Supplier of the Year • Contribution to Skills & Training Award • Rising Star Award • Lifetime Achievement Award CALL FOR NOMINATIONS Entries are being sought for any company, product, application or individual involved in the supply, installation, service, maintenance and repair of industrial machinery technology such as electric motors, drives, pumps, fans, gearboxes, generators, transformers, switchgear and ancillary equipment. Individuals can put forward entries for themselves and their own company, or they can nominate others that they know merit recognition. The online entry process couldn’t be easier, so anyone wishing to play their part in highlighting engineering

excellence should visit the AEMT Awards website – www.aemtawards. com. CLOSING DATE FOR ENTRIES Given the new date for the presentation ceremony, the closing date for all entries has been extended to 5.00pm on Friday 10th September 2021, so for those wanting industry-wide recognition for a job well done, be it for product innovation or project management, for application know-how, or service and repair, they should make a note of this date. It is free of charge to enter the awards, but the promotional value associated with being selected as a finalist is worth many hundreds of pounds. And for those individuals and companies fortunate enough to be announced as one of the seven winners during the charged atmosphere of the gala awards dinner, the promotional benefit is even greater. So, what have you got to lose? Just 20 minutes spent completing the online entry form, providing the information and details that you have at your disposal and which presents and supports your business and professional endeavours, could make you a winner in your industry’s awards programme; the gravitas and promotional exposure for which is both valuable and enduring. TIMES-CIRCLE www.aemtawards.com www.theaemt.com


Coil Manufacturing Winding & Taping

Ridgway Machines manufactures a full range of Coil Manufacturing Equipment, including Rotor Winders, Loop Winders and ancillary equipment such as Capstan Tension Units, Winding Beams and Drum Stands. Ridgway Machines also manufacture a range of BCT Coil Taping Machines designed for the fast, precision application of tape insulation systems to a wide variety of components – including motor and generator stator coils and bars.

Loop Winders

Rotor Winders

Band Tension Units

BCT Coil Taping Machines

Straighten Strip and Cut Machine

Drum Stands

Leicester, UK

+44 (0) 116 289 9199

sales@ridgwayeng.com www.ridgwayeng.com


14 product news

RIB COOLED INDUCTION MOTOR IS READY FOR DUTY ABB’S RIB COOLED HIGH VOLTAGE motor is available from stock for immediate delivery to the UK. The motor provides high power density for compact installations, offering more power per kilogram when compared to conventional motors. This often allows operators to use a motor one frame size smaller than conventional products require, making optimal use of available space and providing suitability for retrofit applications. Stock frame sizes range from 315 to 450 with ratings of 200 to 1400kW. Both direct-online (DOL) and variable speed drive (VSD) variants are available for use in hazardous and safe areas. Rib cooling provides superior air flow for internal cooling, reducing the risk of overheating and unpredicted failures. The motor’s rigid, weight-optimised frame is engineered to minimise vibration, and it is provided with an ABB Ability Smart Sensor as standard at no extra cost. The smart sensor is the next step in digitising motor applications, turning mechanical equipment like

motors, gearing, bearings and pumps into IoT-ready smart devices that can provide near real-time feedback on equipment performance, condition and efficiency. The sensor fits directly to the motor’s chassis and can be installed and configured within a matter of minutes. Once installed, it measures parameters

such as temperature, acoustics, vibration, energy consumption and magnetic field straight from the surface of the motor, and transmits it via the cloud to a dashboard from which it can be analysed, facilitating remote monitoring and predictive maintenance. www.abb.com

CONNECTED MOTORS DELIVER HIGH EFFICIENCY LEVELS NIDEC LEROY-SOMER HAS LAUNCHED Dyneo+, a range of super premium efficiency permanent magnetassisted synchronous reluctance motors. Combining the performance of synchronous permanent magnet technology with the easy set-up of induction motors, the motors have been designed to meet the most stringent requirements of industrial applications while offering them even more options using digitalisation. Nidec Leroy-Somer has developed the range to incorporate all the benefits of induction and synchronous permanent magnet technologies, and in addition to offer significant advances in

Quarter 4 2020

terms of smart drive solutions. With an energy efficiency level above IE5, reaching the highest efficiency levels of IEC 60034-30-2 and NEMA Super Premium/ Ultra-Premium, Dyneo+ makes it possible to achieve substantial energy savings in real use on cycle at variable speed and load. As a consequence, the range is said to achieve the lowest total cost of ownership on the market. The motor range has been developed alongside the Powerdrive F300 and the new Powerdrive MD Smart variable speed drives. Designed to optimise the

Dyneo+ motor performance, this last generation of high power variable speed drives is fitted with a new HMI and a secured Bluetooth connection to enrich the user experience and fully benefit from the features of the new Systemiz application. Systemiz is a unique interactive application which provides a wide variety of digitalised services, to facilitate the exchange of information between the systems and trigger the subsequent actions. In addition to instantaneous access to all the product literature, the application enables direct access to motor parameters for easy and intuitive drive setting by simply scanning a QR code on the nameplate. acim.nidec.com/motors/leroy-somer www.theaemt.com


The UK’s First - SKF Certified Gearbox Rebuilder

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0845 30 40 247 Castle Mill Works, Birmingham New Road, Dudley, West Midlands. DY1 4DA


16 product News

NEW SYNCHRONOUS GENERATOR MORE ECONOMICAL THAN REPAIR MENZEL GREAT BRITAIN LTD HAS supplied a synchronous generator with a power rating of 11,380 kVA to Westfield Power Station in Scotland. The plant operated by the Independent Power Producer (IPP) Melton Renewable Energy UK Ltd had suffered a failure of its existing generator. Purchasing the replacement generator, which was delivered in only two weeks, was significantly more costeffective than a lengthy repair, as the IPP may incur revenue losses when the power supply is interrupted. It was fortuitous that a synchronous generator of suitable rating and performance class was readily available on the market, as this application and configuration are very rare, and such generators are usually manufactured with long lead times. Menzel Great Britain is a subsidiary of German motor manufacturer Menzel Elektromotoren, which maintains a very extensive inventory and is a specialist in customised adaptations at short notice and which was therefore well prepared to answer this urgent request. A steam turbine powers the generator. It operates at 11kV supply voltage and weighs more than 35 tons. Menzel completed the various customer-specific interface modifications in the short time available. Preparing the shaft to match coupling interfaces was particularly complex, since it had to be shortened, machined for a smaller diameter, and the appropriate flange had to be weld-fitted and subjected to an ultrasound check, which ensured that the modification was sound. To match site requirements, Menzel also changed the cooling type of the replacement generator from IC 01 open-circuit ventilated to IC 81W air-water heat exchanger, building an adapter frame and mounting a suitable twin element heat exchanger from existing stock.

Westfield Power Station, which was commissioned in 2000, is the only biomass power plant in Scotland fuelled by poultry litter. It is a key partner to the region’s agricultural industry both for disposing of a highvolume waste product and as a supplier of power and fertiliser – the nutrientrich ash produced is a precious natural alternative to artificial fertilisers. The 9.8MW biomass steam power plant also stands out technologically as it is one of a limited few in the world utilising fluidised bed technology. The CO2 savings compared to gas-fired power plants are considerable. In another short lead time project, Menzel Great Britain’s parent company, Menzel Elektromotoren, has Menzel’s synchronous generator. customised a motor for a compressor drive operated by Tata Steel, shipping it within just (cooling type IC 611). Menzel staff at two weeks. A motor failure had stalled the Berlin plant shortened the motor the booster air compressor, which is shaft, milled the shaft end, and produced integral to one of the corporation’s Indian intermediate plates to adjust the fixing steelworks, providing oxygen necessary dimensions to the existing installation for steel production. Thanks to its modular site. The 2-pole motor was designed with warehousing strategy, Menzel was able to sleeve bearings with two-wedge bearing speedily configure a squirrel-cage motor shells to avoid any critical speed in the to meet the customer’s specifications. vicinity of the operating point of 2,987rpm. The MEBKSL-type motor was electrically The motor is also designed for demanding and mechanically adapted to enable conditions with ambient temperatures installation and commissioning by the up to 50°C and humidity up to 95%. It customer without further modifications of features a tropicalised motor winding in the motor or the site. temperature class “F” and the increased The motor, with an operating voltage protection class IP55. of 6,600V and a rated power of 3,200kW was fitted with an air-to-air heat exchanger www.menzel-motors.com

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Wilson Fans, Pumps & Motor Group Generating Solutions Since 1951 @Wilson Fans, Pumps & Motors Group

@WilsonGroup1951

@WilsonGroup1951

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Supply

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After Care

Unrivalled attention to customer requirements. Generating solutions derived by us based on the requirements set by you.

Completed by our experienced expert engineers at our workshop.

Complete and extensive stock of Fans, Pumps, Motors and Inverters and other equipment. Also, a large network of suppliers offering short delivery times.

Installed by our fully trained, accredited expert engineers to get the very best from your system.

Service and maintenance for all newly installed equipment and existing installations via Wilsons 30+ Point Plan.

Fans | Pumps | Electric Motors | Inverters | Control Gears Soft Starts | Rewinds | Energy Management | Sump Pits | Refrigeration Motors & Spares Head Office: Zone D Willow Lane Mitcham Surrey CR4 4NA Email: sales@wilsonelectric.co.uk Phone: 0207 228 3343 Website: www.wilsonelectric.co.uk


18 project updates

PROOF THAT VIBRATION MONITORING MAKES SENSE WHEN ENGINEERS ON A NORTH SEA platform reported that an 800kW Ex de certified induction motor was exhibiting high vibration levels Quartzelec’s Aberdeen service centre was approached to investigate and undertake any necessary repairs on an urgent basis before the issue led to a major machine failure. High vibrations in rotating electrical machines can indicate issues with operational performance which will impact machine availability so, with the 800KW production critical motor displaying increased vibration levels, Quartzelec advised that it was quickly removed from operation and sent to

Aberdeen workshop for investigation. The motor was stripped and inspected to determine the repairs needed. All repairs were then completed within an agreed timeframe, and it was then immediately returned to the platform. Commenting on the project, Paul Oliver, Quartzelec’s business unit manager in Aberdeen, said: “We had successfully repaired the sister machine on the North Sea platform two years earlier after catastrophic bearing failure. On that machine, the bearing failure also led to further damage and a full rotor and stator rewind was required. Whilst the first motor repair was costly to the

customer in terms of financial outlay and the resulting lead times, following our recommendations, they incorporated ongoing vibration monitoring which helped them spot problems developing before the failure occurred. This resulted in them saving considerable time and money; whilst maintaining a safe working environment without impacting output. “When budgets are tight, condition monitoring can sometimes be sacrificed, but this is a perfect case which proves that investing in the correct condition monitoring system makes perfect business sense,” concluded Paul. www.quartzelec.com

In-situ machining of a traction motor EARLIER THIS YEAR MERSEN POWER TRANSFER Technologies UK, working with Mersen Benelux, started the in-situ machining of more than 90 brushed MA set DC motors at the customer depot. The MA Set commutators had started to show signs of wear and tear after many years of service, with some motors flashing over and failing on the Class 455 locomotives, causing train availability and reliability issues. Mersen deployed its Motor Maintenance and Services (MMS) team, in very strange times due to the ongoing pandemic, and started the machining of the DC commutators to return them to a nearly new state. The project should be completed by the end of this year. www.mersen.co.uk

CAUSING A STIR ENGINEERS AT WESTIN DRIVES came up with an innovative solution when they were presented with a paintstirring machine that was only able to run at one speed. Fraser Lynch, Technical Manager at Westin Drives, explained that the machine’s owners needed to diversify their paint offering, but the bespoke, single-phase agitator was not up to the job. A cost-effective solution was needed to enable them to upgrade the unit so it could run at variable speeds to reduce over-agitation of certain paints and to increase it for others. Quarter 4 2020

Because single-phase motors have limited and expensive variable speed drive controls, a progressive output three-phase motor and single to threephase IP66 inverter from Invertek was offered as a suitable engineering solution. Because it was still perfectly serviceable, the existing gearbox was retained. The customer was delighted with this neat and effective solution and was able to adapt to present and future requirements with only 24 hours of downtime. www.westindrives.com www.theaemt.com


project updates 19

MINIMISING DOWNTIME IN AN EGG GRADING FACILITY IT IS A FACT OF LIFE THAT THE MORE specialised your equipment, the harder it is to repair or replace parts in the event of a failure. In the food industry, unexpected downtimes can be costly, which is why an egg grading facility turned to Rotamec – an electro-mechanical engineering service provider for engineered equipment – to deliver repairs and source spares. The grading facility assesses each egg that reaches its processing lines from partnered farms before packaging. By checking for any imperfection with specialist equipment, grading ensures every egg is in optimum condition before it is packaged and delivered to customers. Reducing downtime through the use of responsive maintenance was very important to this facility. Darryl Beecham, business development executive at Rotamec, takes up the story: “We have to react quickly to minimise downtime. For example, the customer required a double-sided open length timing belt to keep a conveyor operational after a failure of the OEM part. With the cost of downtime on this machine being around £3,000 an hour, lead time was all-important. In this case, the maintenance team decided to order

www.theaemt.com

two parts, one from us and one from the OEM, to maximise its chances of getting the machine back up and running the same day. “We were able to deliver the belt within two hours, while the OEM took six hours. Our belt was quickly installed, and the OEM item was added to spares. All in all, we managed to save this customer around £12,000 in downtime costs.” The egg grading facility operates varied motors and gearboxes. Reliable supply of a wide range of standard parts from a single supplier is important to help keep equipment running. Thanks to existing warehouse stock and in-house distribution capabilities, Rotamec can deliver standard parts quickly – typically the same day if required. Further, its inhouse machining capabilities mean that bespoke items such as shafts in various bore sizes can be easily produced too. Rotamec can offer 24-hour turnarounds on motors and gearboxes, so despite different configurations and equipment throughout the site, it can still offer reduced repair and sourcing lead times. This customer does present some specific challenges, as Darryl explains: “One repair job required us to source specialist foam material that cushions

the eggs during grading. The egg comes through to a sensor, where it taps against the foam, which detects any hairline cracks as part of the quality control process. Improper foam will crack the egg, so only an exact solution will do. The grading facility required replacement foam for the machine, but the OEM lead time was going to take too long, so we were approached. It was a bit different from the mechanical issues we typically deal with, but we managed to source the foam within the required timeframe.” Both the grading facility and Rotamec understand that reducing downtime is one thing, but preventing it is another. This is why engineers from both businesses are building redundancy into maintenance and repair operations. By undertaking asset inspections and identifying ‘showstoppers’ – equipment that risks overall uptime if it fails – the engineers are prioritising maintenance to focus on the most critical assets. Rotamec has also enacted a policy of ordering spares from relevant OEMs during each repair, ensuring maintenance work is backed by a growing spares inventory. rotamec.com

Quarter 4 2020


FEATURE 20 Compliance

Take time to understand the repair standard The thought of reading through lengthy standards documentation strikes fear into many! But Karl Metcalfe believes there are several ways that users of electric motors can benefit from having an understanding of the BS EN IEC 60034-23 repair standard.

T

he repair standard, BS EN IEC 60034-23, establishes the benchmark for repairing rotating equipment; maintaining efficiency levels, high standards of quality control and improving efficiency in associated pieces of equipment. Before the standard existed, eco-design – in terms of rotating equipment – had mainly focused on energy efficiency. Now, with reference to the circular economy, attention has turned to reducing material consumption as well. Customers who understand the core principles of the standard are better equipped to choose the correct repairer for their needs. AEMT repair members cover a vast range of repairs and services and could work with equipment from national power stations through to local farms. There will be users that have no interest in this standard, and they will be happy to use anyone to repair their motor, but as awareness of the standard grows, and the focus on motor efficiency widens, an end-user familiar with the standard can ask a repairer more indepth questions around what they can offer. There are four key aspects of the standard that motor users should be particularly aware of. They are the circular economy, efficiency, root cause analysis and reporting. THE CIRCULAR ECONOMY The circular economy and the environment are both written into the standard, promoting environmental good practise and responsible recycling. The circular economy reflects what the repair industry has been doing for over 100 years; repair reuse and recycle. Unfortunately, in recent years the proportion of motors being repaired has significantly reduced due to repair costs going up and the increased availability of lower-priced motors.

Every project has a cut-off point when replacement becomes more appropriate than repair. However, making that decision purely on cost may miss other important benefits. The standard states that: “The repair or refurbishment of energy-efficient machines ensures the most efficient use of the world’s dwindling resources. When repairing or maintaining a typical 110kW machine with new bearings, the effective life is doubled, and 99% of the original machine is maintained. Plus, the old bearings, making up 1% of the machine, are recycled as highquality green steel scrap. If the machine is rewound, 90.5% of the machine is reused during refurbishment. The same weight of materials used during a rewind is returned as high-quality green copper and steel scrap. The only items not reused or recycled during a repair are the varnish, insulation, paint and grease, representing just 0.9% by weight of the materials present in a typical 110kW machine.” On this basis, when a repair is a close price match to a replacement, maybe the cost of the environment should be considered too. The circular economy is gaining pace in popularity, the younger generation is making these topics a top priority when choosing employment, and within a few years, those individuals could be deciding which repairer to use.

“Customers who understand the core principles of the standard are better equipped to choose the correct repairer.”

> 22

Figure1: Efficiency by power rating across four motor classes. Quarter 4 2020

www.theaemt.com


AMC has run business on Repair and Maintenance Service for Motor, Generator,Hydro-Generator, Hydro-Turbine, Rotating Machinery, Ex Equipment and Pump for more than 25 years. AMC also provides service for dynamic balance, modification, repair & rebuilding and manufacture of spare part which is equivalent to original equipment manufacturer (OEM). AMC is also well-known as capable Onsite Service Provider which consists of removal, installation, alignment, spare part replacement and etc.

ASIA MOTOR SERVICE CENTER CO.,LTD. 98/4 MOO 6, T.Suanphigthai, A.Muangpathumthani, Pathumthani 12000 (THAILAND) Tel.: +66 2 831 0700-90 www.AMC.co.th E-Mail amc@amc.co.th


22 COMPLIANCE EFFICIENCY As you would expect, the standard promotes the provision of the best efficiency option when repairing a motor, including deciding between whether to repair or replace. As you can see from Figure 1, across the four classes, there is little difference in efficiency on high-end kW motors. Typically, from 110kW upwards, except for IE1, motors are over 95% efficient. But take a look at midrange motors, around 3kW to 30kW, and the potential for improvements in those motors is clear to see. A survey conducted by ABB found that in 2016 20% of motors in use were IE1, 40% were IE2, 30% were IE3, and only 1% were IE4. So, the potential savings for the user could be considerable if replacing IE1 motors with IE3 or IE4 equivalents. On the other hand, if a customer has an IE3 or IE4 motor and a repair is required, by following best practice and the criteria of the repair standard, the efficiency class of the motor can normally be retained even when a rewind is required. This is borne out by a study originally conducted by the AMT and EASA in 2003 and revisited in 2019, which showed that rewinding a motor does not necessarily mean a loss in efficiency. The standard’s reference to maintaining efficiency includes checks and tests which need to be carried out, plus aspects such as controlling the heat used to remove windings, which should not exceed 370°C to protect the interlaminar insulation and the efficiency of the core. It also references copy winding techniques, keeping the winding overhang the same or less and the mean length turn as close to original as possible. While correct grease methods are also covered to make sure their repairer uses the same type of grease the customer uses as part of their maintenance. By choosing a repair that works to the standard, the end-user can be confident that these important points are all picked up, and by appreciating what is involved, they can ask the right questions and understand the decisions and findings they are presented with. ROOT CAUSE ANALYSIS The standard promotes the identification and communication of the root cause of any failure, identifying the signs such as colouration patterns on the windings, contaminates, traces of moisture, bearing housing wear or bearing failure. These findings can be relayed back to the customer, so they are made aware of what possibly caused the failure and what they should check before returning the motor to service. An end-user may have no idea they have a water pipe leaking above the motor, or that a seized gearbox has caused the motor to burnout, a contact has failed in the panel or the drive belts are too tight. To the end-user, the motor has failed, and they want it back quickly, but without understanding the cause of the failure, unnecessary future disruption is a real risk. With the current focus on plant reliability and reducing downtime, anything that helps minimise these risks is a real benefit to the end-user. Quarter 4 2020

REPORTING Reporting is an important area and is designed to support both the repair and the customer. The standard calls for the use of digital cameras to record key information about the item under repair. It says: “Digital photographs provide an accurate record of how the machine was received. This also provides a visual record of any significant component defects found and provides evidence to the user of the remedial work required. All findings should be recorded to ensure that a list of remedial action undertaken is available for the final report.” Photographic evidence of the repair process, from receipt to dispatch, gives clear evidence of how the motor arrived and how it left the repair facility. A scope of works is also required. Essentially an expanded quote, a scope of works will include information such as a detailed visual inspection, the root cause analysis and the proposed scheme of work. And in a final report, the repairer should collate all documentation relating to the repair. This will include a record of parts used and the work carried out, plus details of any machine work, balance check reports and tests that have been performed, with the results. The report should also state what tests and checks have not been done, for instance, if no core flux test was performed, or no load or vibration tests were recorded. This comprehensive level of information enables the end-user to keep a record of the service. If the motor is worked on elsewhere in the future, this information can be supplied to the new repairer, while any repairer working to the standard will keep a record of test results, data, faults and information for at least three years.

“The standard promotes the identification and communication of the root cause of any failure.”

CONCLUSION There are several benefits of working with, and understanding, a repairer working to BS EN IEC 60034-23. But, as the concept of circular economy gains greater popularity, companies that embrace the standard will be able to promote their active participation. This has the potential to highlight the professionalism of both the repairer and the company selecting the repairer. It also demonstrates their collective commitment to reducing waste and minimising the consumption of resources. TIMES-CIRCLE Karl Metcalfe, provides technical support on behalf of the AEMT www.theaemt.com


24 Circular economy

The effect of repairs on motor efficiency

The drive to embrace the circular economy – maximise resource use and recycle wherever possible – falls directly in line with the work of the repair sector. However, where motors are concerned, this has to balance with requirements for energy efficiency. To confirm that the two aims can work in parallel, the AEMT and EASA have again used independent testing facilities to confirm that higher efficiency IE3 units are unaffected by a repair that uses good practice procedures.

E

lectric motors place a huge demand on electrical supplies throughout the world, and most countries have now introduced regulations for the minimum efficiency levels of new motors. Legislation in Europe and Internationally continues to improve the efficiency of the overall motor population. ESTABLISHING PROCEDURES An original study in 1998 by the Association of Electrical and Mechanical Trades (AEMT) and the UK Government established the first Good Practice Guide, under the DETR Best Practice Programme, using 40 smaller motors of around 5.5kW. In 2003 a very comprehensive joint study using 23 large motors was completed by AEMT and the Electrical Apparatus Service Association (EASA) in America. Considerable time was spent determining the parameters of the investigation as well as the procedures and testing facilities that would be used. As part of this process, options such as multiple rewinds and round-robin testing were included in that study. As these did not affect those results, they were not included in the latest 2019 tests. The results of that study were published as ‘The Effect of Repair/Rewinding on Motor Efficiency’. It established that efficiency was maintained on repairs to current machines up to IE3 efficiency. To enable comparisons, the ten premium efficiency or IE3 motors under evaluation had similar characteristics to those in the 2003 tests. The power ratings ranged from 30kW to 75kW with half being IEC and half NEMA designs. They had totally enclosed fan-cooled enclosures, covered both 50Hz and 60Hz supplies with 2-pole and 4-pole models. The repair procedures that were published in the Good Practice Guide to Maintain Motor Efficiency in 2003 were followed for each motor. This guide has now been incorporated into the latest international repair standard IEC 60034:23:2019, and the latest American ANSI/EASA standard AR100. As per the previous 2003 study the IEEE 112B test standard was used. The international IEC 60034-2-1 test standard is now harmonised with the IEEE 112B standard so that the results of the latest study comply with both standards. THE TEST AND REPAIR PROCESS All the efficiency testing was performed using the eddy current dynamometer test stand shown in Figure 1. Each motor was initially operated at rated load until steady-state temperature conditions were established

Quarter 4 2020

and then load tested per IEEE 112B. All stators were burned out with a controlled part temperature limit of 370°C. Other specific controls applied to stators included control of core cleaning methods and rewind details such as turns/coil, mean length of turn, and conductor cross-section. Each motor was then rewound, reassembled Figure1, Eddy current dynamometer test stand. and transported back to the test lab and tested using the same equipment as before. In all cases, core losses were measured before burnout and after coil removal using a commercial core loss tester at the motor service centre. To minimise performance changes due to factors other than normal rewind procedures, bearings were not replaced, lubricant was not changed, and rotors were not balanced. ANALYSING RESULTS The test results from the ten motors showed no significant change in efficiency compared to figures taken before the rewind, which mirror the results from 2003. On average there was a decrease in efficiency of just 0.1%, as this is well within the range of the standard calibration test accuracy of +/- 0.2%, it effectively means that there was no efficiency change beyond that which would normally be expected during testing. The main conclusion that can be drawn from these results is that by using the latest international repair standards to repair a motor, the efficiency of the machine will be maintained within the tolerances that it was originally manufactured to. TIMES-CIRCLE

“By using the latest international repair standards to repair a motor, the efficiency of the machine will be maintained.”

For more information on the effects of repairs and rewinding in motor efficiency, download the full study at www.theaemt.com/technical www.theaemt.com


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26 business as usual

keeping industry turning, and customers safe Renew finds out how AEMT members have adapted in recent months to ensure it remains ‘business as usual’ for their servicing and repair offerings.

W

hen it comes to keeping things moving during the pandemic the service and repair sector has had a huge role to play, and AEMT members have responded well to the challenge, with many quickly posting their pandemic response on their web sites to reassure customers of the precautions being taken, in line with changing government guidance. Coming into contact with others is a necessary day-to-day event and is mostly unavoidable for those offering servicing and repair capabilities. MKE Engineering Group, for example, has many external contacts coming to their facilities. In keeping with the necessary precautions for human contact, MKE has been asking pertinent questions of all external suppliers, contractors and customers before they visit. All external contacts are also being asked only to visit the company’s facilities if it essential to do so, to help minimise risk. When it comes to working on-site, MKE says it will do its best to maintain its high level of service and response and is keeping its customers up to date with any likelihood of change. When Renew spoke to Matt Fletcher, Managing Director at Fletcher Moorland, he quickly pointed out that it is definately business as usual. He said: “As a 24-hour electronic and electro-mechanical maintenance engineering specialist we have always operated a round the clock service, and we have continued to do so throughout the pandemic to ensure that we meet the needs of our customers. We have found that some customers – for example, those in the food and packaging food, healthcare, pharmaceutical sectors – have been busier than ever. “Of course, we are ensuring that we continue to adhere to changing government guidance. We have had to change some shift patterns – to spread the work more evenly throughout 24-hours, which allows our employees to maintain social distancing and many of our office staff have been able to work from home. Even though we have brought in different working patterns during the pandemic, because so much of our business is reactive, if a Quarter 4 2020

customer tells us they have had a breakdown we still need to be on hand to fix it quickly.” Fletcher Moorland is ensuring that all collections and deliveries are now undertaken in a contact-free way. “Our team has been offered advice and training on how to ensure safe handling and staff have been issued with all the necessary PPE. We even made our own masks using a 3D printer – and were pleased to be able to share these with local schools and businesses,” said Matt. He went on to point out the importance of keeping the lines of communication open with customers to ensure everyone understands what the requirements are for repair teams going onto sites. “We have found that the safety briefings and paperwork needed when entering a site has increased and of course more PPE is now required at many sites. We are still doing the same job that we have always done, but now our teams need to take different

“We have always operated a round the clock service, and we have continued to do so throughout the pandemic.”

www.theaemt.com


business as usual 27 precautions to ensure everyone stays safe,” continued Matt. According to Matt, there is no one-size-fits-all set of instructions. Different industries and different sites will have different requirements. “While we have seen a drop in business from some industry sectors that we service, we have also seen an increase in business from other sectors, and we have worked hard throughout the pandemic to let the industries we service know that we are still there for them – I believe that marketing is a very important tool and it has helped us benefit from an upswing of inbound sales with new companies asking for our help – some companies are working with reduced staffing levels so need help with their traditionally in-house maintenance tasks. We have surprised many customers, as often we are able to handle a repair or undertake maintenance more quickly than their own in-house team, who always have lots of other things to keep them busy. Indeed, we have recently had to recruit new employees to meet growing demand and are still actively looking for more staff.” Giles Lloyd, Director of Sales and Marketing at Wilson Electric, has also experienced a mixed bag of changes in demand during the pandemic. He pointed out that reacting quickly to the emerging situation was vital to ensure staff safety. He said: “We organised a series of internal meetings to discuss how we would approach the pandemic and we provided our engineers with a kit bag containing

LIVERPOOL

WALLASEY

all the PPE needed to keep them safe. Every project we undertake requires a risk assessment, so it made sense to add a COVID-19 section to this. “We found that many jobs previously scheduled to take place out of normal working hours in commercial buildings were brought forward by facilities companies when it became apparent that office buildings would no longer be full,” continued Giles. “This allowed us to undertake more of these projects in normal hours.” Giles went on to say that the company has also seen increased demand for its services from many hospital and healthcare customers and has been asked to undertake work that, pre-COVID, would have been handled by in-house staff. Conversely, in the commercial sector, the company has found that in-house maintenance staff are now able to handle more of their own maintenance tasks and this has resulted in an increase in our supply only of goods service. In conclusion, AEMT members are still there for their customers, and during these difficult times, it remains, as much as is possible, business as usual. TIMES-CIRCLE

“Reacting quickly to the emerging situation was vital to ensure staff safety.”

MANCHESTER

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28 3D scanning

The power of 3D scanning Houghton International explains how advances in 3D scanning capabilities have brought a range of benefits to the electro-mechanical repair sector – especially when coupled with modern machining and 3D printing technologies.

I

n recent years there have been significant advances in computer-aided design software along with 3D laser scanning and printing capabilities. Not only have these advances helped bring 3D technologies to a wider market, they have also resulted in improved reliability, accuracy and speed. Today, 3D scanners can produce models to within microns – one-thousandth of a millimetre – collecting data from millions of points to produce a highly accurate digital file. For example, the Hexagon Absolute Arm has the capability to collect data down to just a few microns, which, for context, is smaller than a single red blood cell. This level of resolution means it is simple to capture slight variations on complex surfaces within a relatively short time. At Houghton International, services can range from the overhaul of century-old equipment to cutting edge R&D projects, such as new product development for leading-edge drive solutions. For this wide range of operations, the use of a 3D laser scanner enables rapid and accurate measurement and digitisation, freeing up valuable labour hours. 3D scanning technology can be utilised for the scanning of various parts from motors, pumps and other electrical rotating machinery. These parts often have complex geometry, the measurement of which can be time-consuming and less accurate when using traditional methods.

Quarter 4 2020

Just one example of where this technology proves especially useful is in the measurement of pump volutes, which, due to their curvature, are difficult to measure accurately. The irregular curve is difficult to accurately represent through more traditional measuring techniques. However, through a combination of laser and hard probes, accurate representations of complex threedimensional shapes, planes and curves, both internal and external, can be captured. This means equipment can be reverseengineered when no drawings or component details are available. From here, the product can be, for example, CNC machined or 3D printed. It can also be modified or reverse engineered using CAD software, enabling performance improvements and the manufacture of obsolete or long lead time parts. This leads to savings in cost and time when manufacturing replacement parts and allows effective repairs to be performed more quickly as a result. This is advantageous as speed is

“Equipment can be reverse-engineered when no drawings or component details are available.”

www.theaemt.com


3D scanning 29 often a key priority as machine downtime can be highly detrimental to a customer’s business performance. In one instance, the Houghton International engineering team utilised a 3D scanner during the repair of a boiler feed pump that had been operating in a power station. The engineers used the detailed scan of the split casing pump to produce a 3D model and accurately measure the worn ring bores, machined split faces and NDE bearing cap flange. Engineering drawings were produced from the data so that a specification could be produced for weld repairs, machining the casings and manufacturing new components such as the missing NDE bearing cap. The high level of accuracy of the repairs and manufactured components also increased the pump’s efficiency and both the cost and lead time were reduced by manufacturing components in-house. A digital model can also be used for quality assurance purposes, enabling in-depth inspection before manufacture. 3D models can be inspected in minute detail and compared to original drawings and specifications or other CAD data. Faults can be identified and examined, and changes can be trialled before they are made to the actual machine. Both digital models and physical prototypes are also used for customer communications. For example, engineers may be identifying a fault on a pump or making changes for improved efficiency or reliability. An accurate, three-dimensional model or a physical prototype of the pump can make it easier to visualise these. If new components are to be manufactured,

a scale model can be used to demonstrate before beginning full production. One important strength of these technologies is that they can be integrated with other key CAD software. For example, in the process of high voltage coil manufacturing, data can be used in conjunction with Houghton International’s AutoCoil software to produce a highly accurate 3D coil shape or core mock-up. This can then be used to determine fit and clearances confidently, before commencing with coil manufacture. Hodi Mirafsari, Engineering Director at Houghton International, commented: “3D scanners offer a combination of speed, accuracy and large fields of view. This makes the process of capturing data more efficient and offers flexibility into the quality control process. Combined with our 3D printing capabilities, these technologies are helping us to constantly add value for our customer base, reduce lead times and drive innovation.” As 3D scanning and printing technology continues to develop and become increasingly integrated with existing CAD design capabilities, its role in electromechanical engineering will only continue to grow. TIMES-CIRCLE

“3D scanners offer a combination of speed, accuracy and large fields of view.”

houghton-international.com

UK

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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.

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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.

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

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

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

n

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

n

The Megger Baker EXP4000 is a portable Dynamic Motor Analysis System

n

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

High Voltage Motor Tester

PPX

MTR105

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Low resistance measurements from 1mΩ to 800Ω

PPX

Rotating Machine Tester

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

n

Dynamic Motor Analyzer

MTR105 n

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

EXP4000

EXP4000

Site Installed Dynamic Monitoring System

n

n

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

n

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


32 offshore

Motor repair highlights flaw in original design Sulzer explains how it solved cooling issues which had been identified when an offshore gas compressor motor was being rebuilt to improve its reliability.

H

igh pressure gas compressors are vital pieces of equipment that reduce the volume of a gas before it is transferred to shore from a floating production storage and offloading (FPSO) vessel. The owner of one such unit off the coast of Ghana called Sulzer in to carry out an inspection, which uncovered a long-term defect that needed to be resolved. Initially, the original equipment manufacturer (OEM) was contacted and asked to undertake a repair of the motor. A repair of the connections was completed, but as soon as the motor was restarted, it immediately failed. At this point the OEM suggested that an offshore rewind would not be possible, and the platform operator did not think the motor could be removed for an onshore repair. Sulzer’s Regional Sales Director in Ghana is in regular contact with the operators of the FPSO. Although they are well-acquainted with Sulzer’s expertise in pump design, manufacturing and maintenance, other areas of the company’s knowledge had remained unexplored. During one particular meeting, the issue with the highpressure gas compressor motor was raised and Sulzer offered to investigate. Working on offshore vessels, especially those involved in the oil and gas industry, requires specialised training to ensure everyone’s safety. Fortunately, Sulzer has a number of suitably qualified engineers, and some of these were dispatched to the FPSO to carry out an initial inspection. Testing of the windings found very low insulation resistance readings and various discussions were held to determine the best course of action. The motor would need to be dismantled to locate the problem and Sulzer’s initial suggestion was a complete rewind, performed onboard the vessel. FINDING THE BEST SOLUTION Once Sulzer’s engineers had the motor separated into its component parts, they discovered that it would be possible to remove the motor from its operating position and transport it to an onshore location. This presented a number of advantages to the repair project, not least the ability to carry out a full-load test on the motor once it had been repaired. It transpired that the gas compressor had been modified to increase its output and this had required additional power from the motor. In fact, rather than operating at 8.5MW, the motor was being required to supply 9.3MW, so the ability to deliver full-load testing as part of the project would offer very good confidence levels in the future reliability of the motor. Meanwhile, once the decision to complete the rewind onshore had been made, Sulzer’s field service engineers took all the necessary measurements of the windings and sent the information to the Falkirk Service Centre in

Quarter 4 2020

Scotland. The coil data was verified and issued to the Birmingham Service Centre in the UK, which has a 24hour high voltage (HV) coil manufacturing facility. At the same time, the motor was air-freighted to Falkirk, where the rewind would be completed. Marc Stuart, Service Centre Manager in Falkirk, explained: “In these applications, speed of response is very important; downtime on such vital pieces of equipment can run into millions of dollars. We fully expected to complete this project within the 45 days that had been agreed with the customer and we worked round-theclock to get the stator rewound and the motor reassembled.” The new windings, designed and manufactured in Birmingham, have increased the copper content by 1.82% by using the latest in insulation material technology, which has improved since the original coils were manufactured. Even this modest increase will have an impact on efficiency and the operating temperatures of the coils.

“Rather than operating at 8.5MW, the motor was being required to supply 9.3MW.”

PROFESSIONAL COOPERATION For projects of this size, Sulzer works with ATB Laurence Scott, which is also an OEM for high voltage motors, and has one of the largest motor test beds in the UK. This facility was used to carry out a full-load test, which was witnessed by Sulzer and staff from the FPSO. Since the motor had been in operation for almost ten years, no significant issues were expected. However, during the full-load test, a cooling issue with the original design was identified where air flows www.theaemt.com


offshore 33 were unbalanced, with the non-drive end receiving air at 13 meters/second, while the drive end air flow was negligible. At this point, an investigation was instigated and the delivery time for the motor was suspended until a suitable solution could be found. Design engineers from Sulzer held extensive discussions with ATB Laurence Scott and the customer to work out the options for a robust and reliable solution. The process of making alterations to an original design must be carefully considered, especially when they are located at the centre of a motor rotating at 1,800rpm and operating in a potentially explosive atmosphere.

returned to the FPSO and completed the installation and commissioning of the motor, which continues to operate reliably. Having established the quality and reliability of the work completed by Sulzer, the customer is now looking to have similar work completed on an additional five motors, which potentially have the same design flaw. TIMES-CIRCLE www.sulzer.com

IMPLEMENTING IMPROVEMENTS Following a comprehensive design process that ensured the new parts could withstand the stresses of normal operation, and they could be easily installed, the manufacturing process got under way. Once complete, the new parts were installed and the full-load test repeated; this time with no anomalies and well-balanced air flows. The motor was returned to Falkirk, where it was dismantled and packaged for airfreight back to Ghana. Sulzerâ&#x20AC;&#x2122;s field service team

Is Your Business Thriving

Post-Lockdown? Take a look at this guide designed to help electro-mechanical businesses conquer new challenges


34 pump maintenance

The importance of winter pump maintenance John Drew explains the common causes of failure in heating pumps and busts some of the myths surrounding winter maintenance.

K

eeping heating systems operating reliably in the winter is essential for any facility manager, whether they are responsible for an industrial processing plant or a hospital. However, as heating is a seasonal application it’s not uncommon for heating pumps to lie stationary throughout the summer, only to present reliability issues when they are turned back on as temperatures drop. Understanding the common causes of failure is the first step in preventing breakdowns, which is why it is important to be proactive with any winter maintenance schedule. TYPICAL FAILURE MODES Mention the words ‘winter maintenance’ and people automatically imagine stoic engineers facing arctic conditions as they bring a frozen pump back to life. The truth, however, is a little less dramatic; adverse or extreme conditions cause very few failures. While freezing temperatures and bad weather can have a debilitating effect on equipment, the main risk to heating pumps in the winter is how they are treated during the summer months. The majority of failures that we are called out to at this time of year are a result of the heating pump being switched off for months on end. Leaving a pump standing idle can cause a host of issues that will only present themselves when it comes time to turn them on. If the pump has been left standing with water in the system for six months, then corrosion can form within the internals of the pump. Where corrosive liquids are involved, this corrosion could extend to the impeller. Indications that the pump has been damaged will only be apparent when it is next turned on, when you may notice excessive noise or a drop off in performance. Pumps also feature a mechanical seal which is finely machined. If water gets trapped between the shaft and the seal, this can also result in corrosion – with the potential to spread to other associated components that also may need subsequent replacement. Most of the calls Rotamec receives at the start of winter with regards to failed heating pumps are issues arising from incorrect maintenance practices during the summer months. By introducing a heating system treatment programme, it is possible to minimise corrosion during long periods of standing to ensure that equipment is ready to start, first time, when it’s needed. TRY TO AVOID EMERGENCY REPAIRS Recent experience demonstrates the issues that can be caused when a heating pump is left standing for too long. Following the first cold snap of winter, Rotamec was contacted by a medical facility in Bristol which had experienced a heating pump failure. Time was of the essence, as without adequate heating, an entire department would be taken out of action, which would have affected the healthcare service. We were able to

Quarter 4 2020

diagnose the fault and affect a repair within a day, which ensured the department could stay open and keep treating patients. The primary learning point with this scenario is that if the damage is only identified when heating is required, then it will result in an emergency repair. Issues are further exacerbated if any redundancy pumps have also suffered similar damage due to inactivity. Failed heating systems can bring manufacturing facilities to a halt or force the closure of public and commercial buildings. The urgency of the repair will also typically necessitate higher costs as resources are stretched and lead times must be kept to a minimum. Taking a preventative approach is the best solution in terms of value and uptime. Preventative maintenance schedules will, in most cases, keep the pumps and ancillary components in a good state of repair and ready for operation in winter. Of course, all mechanical parts eventually fail, but by identifying damage while the system is not in regular use, it is possible to include repairs as part of any planned maintenance schedule. This same approach is equally as valid for pumps that run cooling systems during the summer months. A proactive winter service schedule should be followed to make sure they are ready when the warmer weather eventually arrives. To ensure the smooth running of pumps throughout the year, facility managers need to employ a preventative maintenance strategy. This can ensure that pumps can be periodically run and checked for issues well in advance of seasonal duty requirements to ensure reliability. TIMES-CIRCLE

“Leaving a pump standing can cause a host of issues.”

John Drew is Site Services Manager at Rotamec. rotamec.com www.theaemt.com


More than a standard overhaul as standard With over 35 years’ experience, we offer a high quality monitoring, maintenance, repair and life

extension service for all electrical rotating equipment:

• Multi service offering covering all electro mechanical assets, from low voltage motor and pump overhauls to major 50MW rewinds

• Fully equipped, industry accredited facility with up to 40 tonne cranage, 13m working height and 135,000sqft space

• Experienced team of multi-skilled electro mechanical engineers • 24/7 emergency repair service, 365 days a year

• Certified site services team

• In-house high voltage coil manufacturing facility

Electric Motors

Pumps

24 HOUR EMERGENCY REPAIR SERVICE: 07860 440 295

E: info@houghton-international.com T: +44 (0)191 234 3000 W: www.houghton-international.com

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Quarter 4 2020

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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

Generators

Gearboxes

High Voltage Coils


36 energy Efficiency

Improving the efficiency of HV motors and generators Demand for replacement HV coils, to help improve the efficiency and operational life of HV motors and generators, is increasing. James Stevens explains what needs to be considered when designing and manufacturing diamond coils to meet these demands.

T

he discussion around repairing or replacing High Voltage (HV) motors and generators has been on-going for many years. This is an in-depth subject, often influenced by factors such as whether a machine is known to be faulty, the end-user can plan an outage for repair or replacement of the machine(s), or whether the existing machine has particularly low efficiency, or if the machine is operating continuously making an efficiency-based ROI realistic amongst many other factors. As the industry strives to gain a clear understanding of the effect of repair vs replacement, the full carbon footprint of each option, and contribution to the circular economy should certainly be included in the overall picture. Much like the debate about whether running a ten-year-old car with reduced efficiency is a better environmental prospect than purchasing a new car and absorbing the carbon footprint of manufacturing and transporting it. In calculating this comparison, it is key to consider the efficiency of old vs new, as well as the carbon footprint of manufacturing vs repair. There is an option to improve the efficiency of HV motors and generators when repairing, and this subject is one that would benefit from further research. As a manufacturer of diamond coils, Preformed Windings is often approached by repair companies, whether OEMâ&#x20AC;&#x2122;s or independent repair facilities, to supply coils to rewind HV motors and generators. This repair ethos is typically driven by factors such as; the end-user has this machine on a frame and does not want to redesign to suit a new layout, or integration of equipment down or upstream of the machine in question. The lead time of a new machine could be longer than that of a repair to their existing equipment. New equipment could be perceived to be less durable as the material content may be reduced. Regardless of the reason, there are key steps that can be taken to improve the operational efficiency of the equipment being repaired along with contributing to the circular economy, and we are seeing increased

Quarter 4 2020

demand from the industry for HV coils that both improve efficiency and offer a longer life. It takes experience and knowledge to understand the influencing or limiting factors, therefore often coil manufacturers in the repair market supply like for like replacement coils, 2 rather than optimising designs to improve machine characteristics at little or no extra cost. There have been studies showing that typically the largest loss component of three-phase AC equipment is I2R losses. An effective way to reduce I2R losses in a diamond coil is to reduce the resistance of the coil, which can be done by reducing the length of the conductors or increasing the crosssectional area (CSA).

â&#x20AC;&#x153;There have been studies showing that typically the largest loss component of threephase AC equipment is I R losses.â&#x20AC;?

> 38

www.theaemt.com


38 energy Efficiency point during the installation of the coils. This is where experience and best practices become particularly important. EDDY CURRENTS Eddy currents in the slot are caused by cross-slot leakage flux introducing a potential difference in voltage between the top and bottom of conductors and across the slot. This can be minimised by effective design of the conductor stack, laminating the conductors with conductor insulation and turn insulation. Another effective way of reducing the eddy current losses is to put a transposition or roebel in the coil. Preformed Windings often manufactures coils with transpositions in, while redesigning the conductor stack to take advantage of increased CSAâ&#x20AC;&#x2122;s, using state of the art manufacturing facilities including a conductor pay-off that rotates through the axis of the copper allowing for in-line turn taping and transposing at the looping stage. Our ability to design in and apply dedicated turn insulation allows us to manufacture coils suitable for variable frequency drives further enhancing efficiency

â&#x20AC;&#x153;The careful design and manufacture of high-quality diamond coils are critical to improving the efficiency of HV machines.â&#x20AC;?

COIL GEOMETRY When repairing a machine, the geometry of an HV coil is influenced by the voltage, power and speed of the machine, as well as the limitations of the existing core dimensions such as slot width, height and length, support ring location, and baffle location. The height and width of the slot ultimately limit the overall cross-sectional dimensions of a coil in the slot portion, along with manufacturing tolerance and slot packing. HV machines tend to have a long service life if well maintained, and since the time of original manufacture, advances in insulation material technology often allow for a reduction in insulation thickness while maintaining or even improving the dielectric properties, in turn, allowing improved efficiency and lengthening service life. As manufacturing technologies improve and R&D is carried out, the tolerances to which we manufacture coils are improved, allowing for conductors with a larger CSA to be used, resulting in reduced I2R losses. As the slot length is generally fixed, there is limited opportunity to reduce the conductor length by reducing coil length as it usually involves altering the endwinding geometry, which is critical. Experience when redesigning the endwinding is key as reducing the overhang length can make winding of the coils more difficult as well as effecting machine operating conditions. If the overhang length of the coil is reduced, it affects the space between coils which is important to the effective cooling of the machine. The operating temperature of the machine directly affects the life of the insulation, and therefore careful consideration should be made when designing the overhang portion of the coil. Additionally, reducing the overhang length may introduce smaller radiuses at the point where the slot portion joins the end winding, which is a stress concentration Quarter 4 2020

PARTIAL DISCHARGE A subject that is becoming more prevalent in the repair industry is partial discharge (PD). PD is small electrical discharges occurring in localised areas in coils between two electrodes typically occurring in voids within the coil. Typically, in Resin Rich (RR) coils it is caused by poor manufacturing, while in Vacuum Pressure Impregnated (VPI) coils, it can be poor process control during the vacuum process. PD accelerates the breakdown of insulation and shortens the life of the coil while also reducing efficiency. Manufacturing control during the production of RR coils is critical to ensure a homogenous insulation stack, and through R&D Preformed Windings is at the forefront in the development and supply of low PD coils, supplying coils with under 100Pc (Qm value at 8.8kV) in response to an increase in specifications calling for low void content and low PD. The careful design and manufacture of high-quality diamond coils are critical to improving the efficiency of HV machines and keeping assets in service for longer. Although coils from various manufacturers may look similar from the outside, it is important to design the conductor stack carefully and implement quality manufacturing processes to reduce the various losses highlighted as well as reduce the number, and size of voids, which in turn increases the life of coils and the efficiency of the machine. HV coil losses can be significantly reduced, and we would welcome further collaboration and whole-industry research into efficiency gains and the circular economy related to the repair of HV machines. TIMES-CIRCLE James Stevens is Global Sales and Marketing Director at Preformed Windings. www.preformedwindings.com www.theaemt.com


Coiltech International Coil&Winding Exhibition Pordenone / Italy 23-24 September 2020

Ulm / Germany 17-18 March 2021

marcogarofalo.net

Two Exhibitions in the center of the market Leading companies of the Coil Winding Industry

Free entrance and free parking for registered visitors

Coiltech exhibitors offer the complete product range of the Coil&Winding Industry.Talk to suppliers and get updated twice a year to stay ahead of the market.

Go to www.visitcoiltech.com to sign up and: • download your free entrance ticket, • download the free parking voucher, • book a hotel room at discounted rates, • book the shuttle service.

Visitor Breakdown The #1 conference in the Coil & winding sector WMC

At the World Magnetic Conference, developers from industry and academia present their latest innovations and current research to make electrical machines and their production more efficient.

Topics In cooperation with:

University of L’Aquila Dept. of Industrial and Information Engineering and Economics

T1 T2 T3 T4 T5 T6 T7 T8

E-mobility Advanced integrated powertrains for electric vehicles Electric motor industries Special electrical machines and actuators Measurements and testing of electric machines Materials Manufacturing technologies Software

33.88%

Head of production Product and quality management

24.38% 13.02%

R&D Purchasing and sourcing staff

19.53%

President/CEO/Vice president

9.28% 15.65%

Owner/co-owner Other top management

1.80% 12.88%

Sales and marketing Other staff

3.74%

Source: information obtained by the Coiltech visitor marketing team on the base of personal phone interviews or encounters with visitors of Coiltech, and other research.

At the show

Machinery and materials for transformers and motors production

Floor plan always available online

Coiltech is the only Coil Winding exhibition that qualifies for UFI Approval.

Coiltech staff does its best to make all relevant information available on their website, however, they are always glad to give personal support on the phone or via email. Do not hesitate to contact them: +39 02 87 23 40 50 or coiltech@quickfairs.net.


40 ENERGY EFFICIENCY

Hazardous area motors are no longer exempt Strict regulations are synonymous with hazardous environments. Despite this, changes to legislation can still cause disruption. Marek Lukaszczyk explains the changing regulations for hazardous area motors and how the new energy efficiency requirements could provide significant financial gain.

E

urope has over eight billion electric motors in use, consuming approximately 63% of the electricity generated across the continent. Until recently, some of these motors, including those designed for hazardous areas, were exempt from energy efficiency regulations – but these regulations are about to change. The latest regulation changes will include a wider scope of motors, and for the first time, variable speed drives are included to achieve a higher efficiency standard, starting from July 2021. The Minimum Energy Performance Standard (MEPS) was introduced in 2009 by the EU Commission Regulation EC 640/2009. The regulation required motors of 0.75-375kW to reach international standards set by the International Electrotechnical Commission (IEC) for single-speed three-phase motors. IE1 describes standard efficiency, IE2 is high efficiency, and IE3 is used for motors with premium levels of efficiency. Updates to the legislation in 2016 specified that electric motors require an energy efficiency class of at least IE3, or IE2 class if the motor is used with a variable speed drive (VSD). The regulation, bolstered by improved design and materials for electric motors, brought about huge improvements to the energy consumption related to motor use. Unsurprisingly, the electric motor market rapidly reflected the shift in regulation and transitioned to more efficient motors. IE1 and below, which represented 80% of European market share in 2009, held onto just 17% of market share by 2016. During the same period, IE3 premium class motors rose from 0% to 29% of the market share – good news for the planet and cost savings for the end-user. The design of electric motors has seen improvements to maximise on energy-saving opportunities. Now, the European Commission’s (EC) ecodesign committee has approved a new, stricter version of the ecodesign requirements, which take effect from July 1, 2021. Previously, the scope of the regulations only covered three-phase motors ranging from 0.75kW to 375kW, leaving motors outside this power range excluded. From 2021, this will no longer be the case. The impending regulation requires all-new 2-, 4-, 6- and 8-pole motors in the power range of 0.75-1000kW to meet IE3 efficiency class. The previous legislation allowed for an IE2 motor to be used provided a VSD controlled it, but this will no longer be valid. Sizes from 0.12-0.75 kW will need to meet IE2 class. Special purpose motors, such as explosion-proof or flame-proof motors were exempt from the previous

Quarter 4 2020

regulation, out of precaution for the higher-risk environments they were used in. From July 2021, new ATEX motors entering the supply chain must be rated IE3 or higher, with increased safety motors Ex eb being the exception. These motors will need to meet at least the IE2 efficiency level by 2023. Energy-efficient motors for hazardous environments have been available for decades, but with no obligation to implement high levels of energy efficiency in hazardous environments, some businesses opted for low-efficiency motors, possibly due to the cheaper upfront costs. In energy-intensive industries, such as chemical, pharmaceutical or oil and gas, thousands of motors often operate 24-hours a day. Even a slight improvement in efficiency, extrapolated over the sheer volume of motors and hours of operation, will benefit the businesses’ bottom line. Energy costs for electric motors account for 95 to 97% of total life cycle costs, depending on the application. Investment in energy-efficiency drives and motors, even if it’s not through choice, usually provides a very short return on investment. Take the IE3 W22Xd series of explosion-proof motors from WEG for example. The lower operating costs of these induction motors can reduce costs by 20 to 40% compared with conventional approaches. TIMES-CIRCLE

“The latest regulation changes will include a wider scope of motors, and for the first time, variable speed drives are included.”

Marek Lukaszczyk is the European and Middle East Marketing Manager at WEG. www.weg.net www.theaemt.com


Wire Electric Supplies Limited

ice, v r e er S , Bett ality u Q er Bett ces. i r P er Bett

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• • • •

Nomex® & Nomex® Laminates Low & High Voltage Cables Electrical Sleevings Copper Wire

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42 energy efficiency

REPAIR OR REPLACE: COST CONSIDERATIONS Choosing whether to repair or replace an old motor is not always a straightforward decision. Rob Wood explores some of the factors that can determine which of the two options is the right one for your motor.

I

n general, a well-maintained electric motor is extremely reliable and can give you many years of service. However, motors are not indestructible, and poor maintenance or misuse can see them break down. When this happens, you have two options: either repair the old motor or replace it with a new one. It is a tricky decision at the best of times, and if getting people and equipment on-site is a challenge in the current circumstances, then you need to know that you’re spending wisely. Upgrading a motor to a new high-efficiency model can pay off in additional energy savings; however, repairing the old one could still be the best decision depending on the circumstances. Thankfully this decision can be made easier by making some simple calculations, considering your motor’s operating hours and costs. Bear in mind that no two applications are the same, so any decision for a given motor should be taken on its own merits. RUNNING HOURS Firstly, consider the motor’s running hours. If a motor runs for less than 2,000 hours per year, then the energy savings gained from installing a new motor are unlikely to justify its purchase cost. In this case, such a motor could be a good candidate for a high-quality repair or rewind. However, if the motor runs for more than 2,000 hours a year, then this introduces upgrading as a potential option. UPFRONT COST Secondly, compare the cost of repair against that of replacement. Typically, if the option to repair is around 60% or more of a replacement motor, then this makes the replacement a more viable option. If a replacement motor will be difficult to source or has high installation costs, then clearly this will need to be factored in as well. TOTAL COST OF OWNERSHIP Finally, calculate the motor’s total overall running costs. This looks at the costs of purchasing, plus running (i.e., energy use), plus not running in terms of annual maintenance. The cost of not running is based upon process downtime and can be significant. For example, if we assume that a motor is offline for 30 minutes in a given year and that application downtime costs £150,000 per hour, and then apply this over a 20-year lifetime, this gives you a total cost of not running of £1,500,000. As this example illustrates, the initial purchase cost is but a fraction of the overall lifetime cost of running or not running a motor, which is why it’s important to consider the lifetime costs carefully, and not just the upfront costs of a replacement or rewind. In addition, a new motor may have a higher purchase cost than a repair, but the running costs will be lower due to its superior energy efficiency, and it should be less likely to break down, meaning a lower cost of not running.

Quarter 4 2020

REDUCING YOUR TOTAL COST OF OWNERSHIP One way to significantly drive down both the cost of running and of not running is to digitalise your motor. Smart sensors are devices which attach, without hard wiring, to the motor’s frame and measure parameters such as temperature, vibration and energy consumption straight from the motor, providing near real-time feedback on operation and condition. Data is transmitted via the cloud to a dashboard or can be viewed locally on a smart device such as a mobile phone or tablet from which it can be analysed, providing a window through which your motor can be monitored and optimised. This opens vast new possibilities for remote monitoring and predictive maintenance, allowing potential faults to be identified and mitigated long before they develop into failures, while parameters can be tweaked to improve efficiency. This can significantly reduce both the cost of running and the cost of not running over the motor’s lifetime. Moreover, by using smart sensors to prevent your motor from failing in the first place, you can sidestep the repair or replacement debate altogether. TIMES-CIRCLE

“One way to significantly drive down both the cost of running and of not running is to digitalise your motor.”

Rob Wood is Local Division Manager, Motors & Generators, at ABB new.abb.com www.theaemt.com


To give special thanks and recognition to the repair and service centres underpinning our health service, infrastructure and manufacturing sectors throughout the COVID-19 crisis, we have decided to postpone the awards until November 2021.

New date for the diary... 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 6 categories to choose from including: Product of the Year, Project of the Year, Supplier of the Year, Service Centre of the Year, Contribution to Skills & Training and the Rising Star Award. Make sure you enter now to be recognised as a leader in your industry.

Endorsements:

“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

Enter Now: www.aemtawards.com

...with thanks to previous sponsors:

Deadline: Fri, 10th September 2021


Visit www.theaemt.com Call +44 (0)1904 674 897

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.

Quarter 4 2020

Promoting Engineering Excellence www.theaemt.com


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 07785290034 envelope andrew@renew-mag.com

APPROVED BY ABB


FEATURE 46 Opinion

repair or replace: are you getting the right advice? Matt Fletcher gives his perspective on the age old question; whether it is better to repair or replace an electric motor. He suggests that the answer you get may well depend on who you ask.

I

don’t know who first asked the question ‘should I repair my electric motor, or should I replace it?’, but I do know that, around the world, this question is asked every day. And the answer? Well, the answer you will get depends on who you ask. And, if you are responsible for getting your plant back up and running again, the answer might not be in your best interests either. Just consider this for a moment. You ask two people that same question. One is your local electric motor rewinder, and the other is an electric motor stockist. I’m fairly sure that you will get a different opinion from each of them. The rewinder might want to keep the workshop team busy, so they will be likely to suggest the motor is repaired, the motor stockist probably works on commission, so they will want the sale. So, it’s back to you to choose. So, who is right? Well, I’m in no position to tell you what is best for your business, but I can offer you some things to consider and some questions to ask, to help you to make your own opinion. It could be said that it’s too late to ask whether a motor should be repaired or replaced when it has failed. In many facilities, this question should be asked proactively in readiness for when the motor needs to be removed from service. It could be as simple as recognising that the motor is an older, less efficient type of motor and that a new IE3 or higher motor would be a better option. There are those of us in the industry who can survey your installed plant, then offer suggestions based on running costs and motor availability to help you make a decision proactively. The most usual scenario is a reactive one though, when you have a failure and you are considering your options. This is where I believe productivity should drive your decision. If production output is critical and there is a new motor available to you quickly, then that is probably your best option. I’m sure there will be rewind companies reeling in horror at this. Our industry’s reputation is built on providing quick turnrounds with us working through the night to get a motor rewound and back into service as quickly as possible. That is all well and good, and as an industry we’ll continue to do this; however production demands should always come first. But if you have a spare motor available or you can live with downtime, the ‘repair or replace’ Quarter 4 2020

question still needs to be answered. This is where a conversation with your repairer is valuable. If your motor is old and a replacement is offered because ‘it’ll be more efficient’, ask to see the running cost comparisons to make your own decision. Every repair company should be able to offer you this. There are also times when the failure mode of a motor causes it too much damage; then it really is better to replace. We can all perform miracles, but sometimes the recycling bin is the best place. Let’s look at the most common scenario. When a motor needs a rewind, I wouldn’t automatically look to replace it. If it’s already an IE2 or IE3 motor, then a rewind carried out in line with the ISO6003423 repair standard will bring that motor back to a ‘zero hour’ rebuild. It can be as good as new. I would always offer a repair price and a replacement price. A cost-based decision about whether to repair or replace can then be made. But then we have to watch out for the purchasing department, who with little engineering input might say that if the repair is a certain percentage of new, then they won’t repair. Why is this though? If you are getting a repair that is as good as new, with the same guarantee as new, and for less money, then why not repair? When someone suggests to you that either a repair or a replacement motor is better for you, ask them why. You’ll hopefully get a reasoned technical, and cost-based answer, if not you’ll soon figure out who’s interests are best being served. And in the interest of full disclosure, my business has an active interest in repairing motors, and selling new motors as an ABB value provider. I believe that companies which offer repairs and stock replacement motors will give you the best impartial advice on whether to repair or replace your electric motors when they fail. TIMES-CIRCLE

“When someone suggests to you that either a repair or a replacement motor is better for you, ask them why.”

Matt Fletcher is the Managing Director of Fletcher Moorland Ltd. 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.

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