Renew Magazine - Quarter 2, 2021. Condition monitoring and predictive maintenance focus

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

The journal f rom

Quarter 2 2021

FOCUS ON:

Condition monitoring & predictive maintenance

Protecting motor bearings from electrical damage Is your stored electric motor really ready for operation?

Industry News

Innovations

Applications

Expert Opinion

Re-Conditioned Motors       

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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        

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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.

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

A

fter some 45 years of involvement with the AEMT, including 20 as the Association’s Secretariat, 19 on the Council and two terms as President, Tim Marks is taking a well-earned retirement to spend more time with his growing family.

Much has changed in the electromechanical repair sector and the industries it serves over the years Tim has been involved. So, Tim sat down with our Editor to talk about how he first became involved with the AEMT, what the industry looked like at the time, how it has evolved in the intervening years and what the future may hold. On behalf of the Association, and I’m sure the rest of the repair sector, I’d like to thank Tim for his many years of valuable service and wish him a long and happy retirement.

Elsewhere in this issue, we look at predictive maintenance and condition monitoring. With the ever-increasing pressure to minimise unplanned downtime juxtaposed with an ongoing drive to keep maintenance costs low, this is an important topic, and one that I am sure is set to grow in significance over the coming years. That view is reflected by Amazon’s recent move into the space, which we cover in this issue, alongside articles looking at the benefits that condition monitoring can bring.

This is just a taste of what we have in this our third issue of Renew – our biggest yet. Thank you all again for your continued support, and please, keep your feedback and ideas coming; you can email our Editor, Chris, at chris@renew-mag.com.

David Hawley, President, AEMT

NEWS 6 Industry news

10 AEMT news

28 The times they are a changin’

14 AEMT Awards update

38 Is your stored motor ready for operation?

34 Putting motors through their paces

16 Product news 42 Protecting motor bearings from

electrical damage

18 Project updates

Focus on condition monitoring and predictive maintenance

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

Cover image courtesy of Fletcher Moorland Ltd.

www.theaemt.com

features

44 Keeping a sharp eye on critical systems 46 The positive impact of condition monitoring

16

Regulars 22 Compliance - Taking compliance seriously 24 Circular economy - Innovative

recycling technology 26 Energy efficiency - Adopt high

efficiency motors to combat

climate change

44

OPINION 50 Amazon bets on condition monitoring Quarter 2 2021

Megger Electrical Test and Measuring Equipment For over 130 years, Megger has been the premier provider of portable test and measuring instruments for electrical power applications. Although Megger is best known for its world-famous range of insulation testers, we can assist your acceptance, commissioning and maintenance testing for predictive, diagnostic or routine purposes.

By working closely with electrical utilities, standards bodies and technical institutions, Megger contributes to the dependability and advancement of the electrical supply industry.

TC3231

n

n

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

DCM305E

Earth Leakage Clampmeter n n

n

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

AVO835

True RMS Multimeter n

n

n

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

DLRO2

n

MPQ1000 MPD SCAN

TC3231 DCM305E AVO835

DLRO2

Thermal Camera

2 Amp DucterTM Low Resistance Ohmmeter n

n

n

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

MPD Scan

Handheld Scanner for PD Surveying n

n

n

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

MPQ1000

Power Quality Analyzer n n n

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

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

Megger Baker Electric Motor Analyzers The Baker Instruments family of electric motor analyzers provides a comprehensive suite of tests which characterize the health of your motors and generators.

These testers are valuable in industrial settings for predictive maintenance, and in motor repair/rewind shops for troubleshooting and QA.

DX

AWA-IV

n

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

n

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

n

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

Static Motor Analyzer

AWA-IV

DX

Static Motor Analyzer

NetEP

NETEP

n

n

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

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

n

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

n

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

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

n

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

n

The Megger Baker EXP4000 is a portable Dynamic Motor Analysis System

n

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

High Voltage Motor Tester

PPX

MTR105

n

Low resistance measurements from 1mΩ to 800Ω

PPX

Rotating Machine Tester

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

n

Dynamic Motor Analyzer

MTR105 n

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

EXP4000

EXP4000

Site Installed Dynamic Monitoring System

n

n

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

n

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

6 INDUSTRY NEWS

FLETCHER MOORLAND PLANTS 1500 TREES IN CARBON OFFSET INITIATIVE AS IT CELEBRATES ITS 75TH ANNIVERSARY, industrial repair specialist Fletcher Moorland has launched an initiative designed to offset its carbon production by planting a tree for every repair the company carries out.

The project has been introduced in partnership with Bristol-based Ecologi, an organisation that works with individuals and businesses to plant trees and deliver climate crisis solutions.

For every order that Fletcher Moorland receives, the company has pledged to plant a tree with Ecologi’s help.

“For every motor or inverter repaired and every pump refurbished, each time we sell a motor, balance a fan or fix a PSU, we plant a tree. Whatever the order, no matter how big or small, we plant a tree,” explained Matt Fletcher, MD at Fletcher Moorland.

In the two months since the initiative began, the company has funded the planting of over 1500 trees, offsetting the equivalent of more than 111 tonnes of carbon dioxide. To put that into context, that is the same amount produced by 85 long haul flights or more than 275,000 miles driven in an average car.

“Clearly, the environmental benefit this opportunity is having is amazing, but it has also given the team here a real boost, knowing they are a climate-positive workforce,” added Matt.

ERIKS announces flagship fulfilment centre SPECIALISED INDUSTRIAL SERVICES provider, ERIKS, has announced a multimillion-pound investment programme in a major new UK headquarters and fulfilment centre in Oldbury in the West Midlands.

Due to open in the summer of 2021, the new fulfilment centre is between two major motorway junctions on the M5, providing excellent transport links, and covers over 11,000m², with extensive warehouse facilities, loading bays and office space. This will dramatically increase ERIKS’ capability and capacity to fulfil far more deliveries than ever before, with greater accuracy, speed and efficiency for all customers. The new building has already been constructed and is now in the process of fitting out, in readiness for its opening later this summer.

Once complete, the new fulfilment centre will incorporate advanced storage solutions working with the latest warehouse management technology controlling automated vertical picking systems, rapid transit conveyors and integrated vision and weighing equipment. The company’s goal is to reach consistent 100% pick accuracy, Quarter 2 2021

with full traceability, to ensure that every customer order, no matter how complex, is fulfilled precisely in the shortest possible time.

The new fully computerised systems will also enable ERIKS to give customers far greater visibility of all orders, from sale through to delivery, while creating a dynamic new digital platform on which the company can develop new customer service options for the future.

ERIKS’ CEO for the UK and Ireland, David Gillies, explains: “This is an

exciting development for our customers, and a huge endorsement by our parent company in our team and the ongoing success of our business. We recently celebrated our 80th year as a major industrial services provider and are excited to be embarking on the next phase of our development. The new fulfilment centre will become our primary hub and headquarters in the UK & Ireland, enabling ERIKS to set the standard in quality, accuracy and value of service provided to all our customers.” www.theaemt.com

— New Ecodesign regulations: July 1, 2021 Are you ready for IE3 and beyond?

Many ABB motors have been Ecodesign-compliant for years: • IE3 since 2008 • IE4 since 2012 • IE5 since 2020 (SynRM) Including additional motor types: • Hazardous Area ‘Ex’ motors • TEAO motors • Motors for 60 Hz networks

Committed to the future of efficiency Not because we have to – but because we choose to To find out more visit: www.abb.co.uk/energy

8 industry News

WEG TO SUPPLY TRANSFORMERS TO NEW AIRPORT IN MEXICO MOTOR, DRIVE AND GEARBOX manufacturer, WEG, has announced a contract to supply 241 transformers to the International Airport Felipe Ángeles, in the state of Mexico. The WEG equipment is significant in the construction of the General Felipe Ángeles International Airport, which aims to reduce the high saturation of the current Mexico City International Airport.

The project, which will be partially operating in the first quarter of 2021, will allow 20 million passengers per year to travel through the airport. The project also includes the expansion of the existing runway along with the addition of a new runway.

To support the project, WEG will supply 241 transformers, including 49 dry transformers from 300 to 3150kVA, 168 pedestal transformers from 30 to 2500kVA, 21 dielectric varnish dry transformers from 30 to 300kVA and three power transformers from 60MVA 230kV.

Manufactured at the WEG Mexico plant, the transformers are designed for an operating altitude of 2,500 m above sea level.

“WEG power transformers are designed to guarantee high performance on the most diverse applications for all market segments,” explained Marek

Lukaszczyk, European & Middle East marketing manager at WEG. “We also offer a wide range of dry-type transformers, in voltage classes up to 36.2kV, having over 20 years of experience in the manufacture of such products with consolidated technology for all applications.”

EDWIN JAMES GROUP ALIGNS BRANDS TO SUPPORT GROWTH EDWIN JAMES GROUP IS SUPPORTING its growth plans with the alignment of its brands. Jex Process Services will become EJ Musk Process Services, and Korrie Technical Services will align with the EJ Parker Technical Services brand.

The move comes as the Group rolls-out its expansion plans with its biggest ever investment in training and technology across the UK. Both businesses will continue to deliver engineering services with a more defined offer to the market. No job losses will occur as a result of the integration. The operational teams and people remain unchanged, with a focus on providing a quality service to customers.

Commenting on the growth plans, Christopher Kehoe, chief operating officer of Edwin James Group, said: “It is important that we define our position in the market and the integration of our brands creates a platform to accelerate our growth. A clear focus on engineering excellence in both process

Quarter 2 2021

and technical services is driving our business forward. Customers will benefit from the strength of our combined capabilities and a clearer offer. We are investing in technology and our people to ensure we continue to provide industry-leading service.”

Musk works in partnership with companies to improve their

manufacturing capability and competitive advantage. Parker offers clients a complete package of technical services for the built environment.

Bringing the companies together under two business units aims to deliver better customer service through joint engineering and manufacturing expertise.

www.theaemt.com

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

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

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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

10 aemt news

UPDATE FROM THE AEMT SECRETARY

Thomas Marks shares the latest news from the Association.

IT FEELS GREAT TO HAVE LAST YEAR BEHIND US, AND with plenty of promise for the year ahead; Spring is in the air!

We successfully moved office in February to the AEMT’s new headquarters at Tower House, York. For the full address, please refer to the contents page of this magazine. A new telephone system means members should be finding it easier to get hold of us while we continue working from home.

We’re excited to be launching a series of webinars hosted by our technical support representative, Karl Metcalf – our Bitesize Guides to Electric Motors. The target audience for these are new recruits, office staff and members’ customers who could benefit from understanding more about the trade. These webinars are free of charge to members and are proving to be very popular. Karl has worked in the rewind industry since 1987 and is excited to share his broad and deep knowledge of the subject. We also have a free of charge

workshop raising awareness on Ex equipment on the 21st May. We encourage all ex repair shops to invite their customers to the workshop so we can raise awareness on this critical topic.

We have been playing catchup this year on the Ex courses, as we provide refresher courses to all those who missed out last year. Many of our online courses have now sold out, and we are working on releasing some new dates soon. Feedback for the online courses has been really positive, and we now know this is definitely something to take forward beyond the pandemic.

I look forward to sharing progress on our online training offering in due course. Right now we are working on a booking system so that course bookings can be made via our website, and paid for by card, which we hope to release this summer.

I’m also pleased to say we completed the membership outreach project in February and have launched the new member profiles on the AEMT website. If you are a member and haven’t already checked your profile page for accuracies, please do so and let us know if you want to make any further changes.

If you’ve any comments or suggestions on what you would like to see from the AEMT, please don’t hesitate to contact us, one of the council or the President. You can email us at admin@aemt.co.uk or call +44 (0)1904 674899.

Forthcoming AEMT led Courses COURSE TITLE

START DATE

END DATE

LOCATION

Ex Theory Module 1

19 April 2021

20 April 2021

Loughborough

Ex Hands-on Module 2

21 April 2021

22 April 2021

Loughborough

Ex Refresher Module 3

27 April 2021

28 April 2021

Loughborough

Bitesize: Identifying a Motor

30 April 2021

Online (UK)

Bitesize: Dismantling & Fault Finding

07 May 2021

Online (UK)

Ex Refresher Module 3

11 May 2021

13 May 2021

Online (SE Asia)

Ex Refresher Module 3

18 May 2021

19 May 2021

York

Ex Awareness Workshop

21 May 2021

Online (UK)

Bitesize: Following the Repair Standard

28 May 2021

Online (UK)

Bitesize: An Introduction to Rewinding

04 June 2021

Online (UK)

Ex Refresher Module 3

08 June 2021

09 June 2021

Aberdeen

Ex Refresher Module 3

15 June 2021

17 June 2021

Online (Gulf)

Bitesize: An Introduction to Assembling & Testing

18 June 2021

Ex Theory Module 1

21 June 2021

22 June 2021

Kuala Lumpur

Ex Refresher Module 2R

23 June 2021

24 June 2021

Kuala Lumpur

Ex Hands-on Module 2

23 June 2021

24 June 2021

Kuala Lumpur

Online (UK)

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

All classroom-based training is scheduled subject to the COVID-19 restrictions in place at the time.

Full details of the safety procedures being applied to classroom-based courses can be found on the course website.

Quarter 2 2021

www.theaemt.com

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

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Transforming for a Digital "New Normal"

12 Skills

ONLINE EX TRAINING HITS THE MARK The challenges of COVID-19 are affecting every business, and where possible, some aspects have been transferred to an online setting. Professional training remains as important as ever, and the AEMT has developed online courses that enable delegates to complete training on Ex-rated equipment to acquire or renew certification.

A

ll staff involved in the repair, overhaul or reclamation of Ex equipment, such as motors, pumps or gearboxes, should be properly trained for these tasks and periodically this training needs to be refreshed. Of course, some aspects of the training requires handson practice, and participants will be expected to accomplish a practical test as well.

Depending on their role in the organisation, staff need to understand the correct procedures and practices for the repair of explosion-protected equipment. This is essential to ensure the original certifications are maintained as well as compliance with legal and health and safety requirements.

To ensure continued professional development in these challenging times, the AEMT offers managers and staff involved directly in the repair and maintenance of equipment used in zoned areas ATEX training courses recognised by the IECEx. Online courses are modular, allowing delegates to select the most appropriate courses for their needs.

Module 1 covers the basics of Ex including, zones, categories, protection concepts, markings, standards and certificates. Module 2 is the hands-on course, which focuses on the repair, overhaul and reclamation of Ex equipment using BS EN IEC 60079-19 as the guideline. The module takes delegates through measuring and calculating an Ex’d machine’s enclosure, good practice for repairers and end-users. Module 3 is a refresher course for those that require a three-year assessment to update their current certification.

The practical aspect of the training is very important, and AEMT trainers have developed the online course to deliver practical training and the required assessment. For example, delegates can watch a demonstration video that shows, step-bystep, how to determine an Ex’d machine’s volume.

They can then practice the procedures in their own time until they feel confident enough to take the assessment.

Throughout the training courses, delegates have full interaction with the trainer, and are assessed on their progress with multiple-choice questions.

The final assessment is a one-on-one format with coaching from the lecturer on any areas of difficulty.

Feedback on these training courses has been very positive. “The online AEMT Ex Training is the best Quarter 2 2021

A delegate from Chupun Industrial Services Co. Ltd, Thailand on the online Ex practical hands-on course.

course I have participated in since I started working in 1991,” commented Ramiro Pinto, EFACEC. Kevin Price of WEG added: “I found it to be very interesting and worthwhile. Also, it was great for me that the course was online. I understand that due to COVID restrictions, we had to do an online course, but I see no reason why this course could not be made permanent.”

Meanwhile, Carl Barnes from Hayley 247 explained: “I thoroughly enjoyed the course. I felt that both instructors demonstrated in-depth knowledge and were helpful with any questions we had. I was a little anxious about the course being online but was very impressed with the level of teaching, and I came away from the four days feeling well prepared to repair ATEX units. All in all, I would highly recommend the course!” TIMES-CIRCLE

“I understand that due to COVID restrictions, we had to do an online course, but I see no reason why this course could not be made permanent.”

www.ex-repair.com/overview www.theaemt.com

14 Awards Update

Recognising and rewarding excellence once again Having been forced to withdraw from staging its annual awards dinner and presentation ceremony last year, due to the ongoing fallout from the COVID-19 pandemic, the AEMT is eagerly anticipating its return later this year.

I

nitially scheduled for its regular slot in November 2020, following hugely successful events in each of the preceding three years, the Gala Awards Ceremony will now take place on the evening of Thursday 18th November 2021, at the Doubletree

by Hilton Hotel, Coventry. The associated AEMT Conference will also move to this new dateline and will be staged throughout the day, before the presentation dinner in the evening. More information on the conference, its programme and its speakers will be available shortly.

The 2021 AEMT Gala Awards Dinner will once again bring together the 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 repair and maintenance arena, personal endeavour, product innovation, skills training, engineering advancement and commercial acumen will be acknowledged and celebrated.

HIGH PROFILE SUPPORT Operated by the AEMT and produced by Touchwave Media, part of the team behind renew magazine, the awards will again 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, including ABB, Drives & Controls, EMIR Software, Fanuc UK, Menzel Motors, Musk Process Services, Plant & Works Engineering, and Wilson Fans, Pumps & Motors Group, well deserved industrywide recognition will be given to those businesses and individuals that are excelling in their commercial endeavours.

SEVEN CATEGORIES The following seven categories make up the 2020/21 awards programme: • Product of the Year – sponsored by P&WE • Project of the Year – sponsored by EMIR Software • Service Centre of the Year – sponsored by ABB • Supplier of the Year – sponsored by Drives & Controls • Contribution to Skills & Training Award – sponsored by Musk Process Services • Rising Star Award – sponsored by FANUC UK • Lifetime Achievement Award – sponsored by AEMT

Quarter 2 2021

NOMINATIONS Entries are now being sought for any company, product, application, or individual involved in the supply, installation, service, maintenance and repair of industrial machinery technology such as electric motors, drives, pumps, fans, gearboxes, generators, transformers, switchgear, and ancillary equipment.

Individuals can put forward entries for themselves and their own company or nominate others that they know merit recognition. The entry process could not be more straightforward, so anyone wishing to play their part in highlighting engineering excellence should visit the AEMT Awards website – www.aemtawards.com – and complete the simple online entry form.

ENTRY DEADLINE The closing date for all entries has been set for 5.00 pm 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 key date.

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

Your Asset Care Partners Working with us to ensure the care of your assets means having an experienced team on hand to help you meet your manufacturing targets cost-effectively.

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16 product News

Portable dual-channel vibrometer A NEW DUAL-CHANNEL, PORTABLE balancing vibrometer and machine analyser is now available from CEMB Hofmann UK. The N330 handheld instrument is designed to enable engineers to conveniently identify vibration issues and pursue a proactive, preventative maintenance routine to limit production downtime and extend the life of their machines.

Applicable across multiple sectors and applications, the N330 should be intuitive to use and allows engineers to identify any vibration issues quickly onsite. While in use, the N330 displays the vibration values, and a menu button provides the option to save

over 1,000 readings, thanks to 14.8GB of memory that can be expanded to 128GB. The device is capable of both single and two-plane balancing as well as FFT, Smart Analysis, Vibrometer and Tachometer.

Rob Jeffery, Managing Director at CEMB Hofmann UK, commented: “With the N330, in addition to preventing costly repairs, engineers will also be able to prolong the life of machines through preventative maintenance and with our UK-based

service team we can respond quickly to any calls for assistance.” www.cembhofmann.co.uk

ASYNCHRONOUS GENERATOR WITH SPECIAL SHAFT MENZEL ELEKTROMOTOREN HAS built an asynchronous generator with a special shaft and a special flange for operation on a Pelton wheel in a Scandinavian hydroelectric power plant.

The large radial forces acting on the shaft end in this application had damaged the existing generator to the extent that it was a total write-off. The customer required a more robust shaft construction to avoid such damage in the future. In addition, the new generator had to be identical to the old one and have the

same electrical parameters.

Menzel’s subsidiary Franz Wölfer Elektromaschinenfabrik designed and

manufactured a shaft made of 42CrMo4 high-tensile strength special steel, reinforced on the turbine side. Menzel quickly prepared a verified offer and completed the generator within two and a half weeks. A prefabricated threephase asynchronous generator met the requirements of the application. Menzel also designed and manufactured a new bearing shield for the reinforced shaft and bearing. www.menzel-motors.com

New products to showcase at virtual Hannover Messe ON ITS VIRTUAL EXHIBITION STAND at the Hannover Messe Digital Edition, which launches on April 12, 2021, Baumüller is presenting several new products.

New DS2+ synchronous motors add higher speed options to the existing series of high-performance main drives.

Maximum speeds up to 5,000rpm and nominal speeds up to 4,500rpm are now possible in sizes 100 and 132. The new models are particularly suited to applications such as injection casting machines, or for printing, forming and textile machines.

Another addition is the option of oil cooling for all synchronous servo motors and synchronous main drives in sizes 45-200. This development means that mechanical engineers can now cool motors efficiently with hydraulic oil. Compared with air-cooled motors, Quarter 2 2021

the power density of the oil-cooled motors is considerably higher, so motors with smaller dimensions can be used. The motors can also be more costeffective since a recooling unit is no longer needed.

The DSD2-100 servo motor series has also been updated and made longer for improved dynamics. This significantly expands the torque and power spectrum. Therefore, in high torque applications, it is no longer necessary to choose a larger size, which would have a negative effect on the dynamics. With the new, longer

DSD2-100 series, Baumüller is abe to offer peak torques of up to 400 Nm. www.baumueller.com www.theaemt.com

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ONE

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18 project updates

REPLACING AN OBSOLETE GEARBOX AND MOTOR DRIVE A 35-YEAR-OLD FOOT-MOUNTED gearbox and stand-alone motor had been working continuously to power the infeed conveyor of a de-barking process.

The original manufacturer was no longer trading, and the gearbox and motor details pointed to ASEA, who was also no longer trading (they are now the A in ABB).

Having decided that the gearbox and motor had finally reached the end of their useful lives, the company called on Avonmore Electrical for help and advice.

An Avonmore engineer attended the site and took some dimensions. By measuring the drive drum and working out the linear speed, it was possible to determine the required output speed and calculate the gearbox’s transmission ratio. The customer advised the conveyor was just short of 100m in

length with a 15° incline and was subject to heavy shock loading, anything up to 20 stop/starts per hour and the conveyor needed to be able to start under a full load of 40,000kg.

Avonmore Electrical calculated the generated output torque from the old unit. Utilising the information provided by the customer, it was possible to estimate the torque needed to drive the conveyor – there was also a secondary 1in triplex drive providing additional torque through another reduction. The base torque value came in at 21,000Nm. The next step was to calculate service factors. Due to the heavy shock loading and the stop/starts, a high service factor would be desirable due to the wood processing industry’s nature – a service factor of 3.0 or above was therefore decided upon.

The motor chosen was an ABB 90kW

4-pole with IE3 efficiency. There was no need for increased capacity on the motor bearings as the direct-coupled drive meant there were no external axial forces on the motor.

A backstop was also added as a safety precaution to ensure the inclined conveyor does not back drive in the event of a power failure. The gearbox was modified to meet the application requirements and fitted with spherical roller bearings to cope with the extreme forces exerted on the output shaft.

The triplex chain drive means there are some high axial forces on the low-speed shaft bearings and also the stop/starts, with the conveyor starting fully loaded meaning the need for increasing the capacity of the bearings was a must. www.avonmore-electrical.com

OVERHAUL OF TWO 90KW CENTRIFUGAL FANS JJ LOUGHRAN WAS ASKED BY A LOCAL POWER station to assess two 90Kw centrifugal fans. The company’s electrical engineering team attended the site and checked the motors’ insulation resistance, and found that the values recorded were below nominal levels, which would not allow the motors to operate safely.

The extract fans could not be repaired on site, so an engineering team was immediately dispatched to mechanically disconnect both fans from the ductwork, crane them out of position and send them to JJ Loughran’s engineering workshop for an overhaul. Due to the power station’s critical nature, initial inspection and removal were carried out on the same day.

Once in the workshop, the motors were dismantled into individual parts, and each unit was electrically inspected. The mechanical dimensions on the front and back end caps were checked to ensure the values were within machine tolerances.

All individual parts were cleaned, rotors and extract fan blades were dynamically balanced, and the bearings were replaced.

The motors were then reassembled and tested before the units were delivered back to the site and were mechanically and electrically reinstalled, run and tested.

JJ Loughran made a recommendation that 230VAC heaters be fitted into the motor windings. Because the fans do not run constantly, these heaters would be energised when the motor is not in use, ensuring dampness or condensation buildup does not occur within the stators. www.jjloughran.com Quarter 2 2021

www.theaemt.com

20 project updates

TURBO GENERATOR PACKAGES FOR BIOMASS THERMOPOWER PLANTS WEG IS SUPPLYING OXE ENERGIA WITH FOUR COMPLETE sets of turbo generators – including logistics, assembly and commissioning services – for use in four biomass thermopower plants located in the northern state of Roraima in Brazil.

The contract includes the installation of four reaction and condensation turbines, with two CT model back-side installation uncontrolled outlets, together with four 12.5MVA, 13.8kV, 1,800rpm, 60Hz three-phase synchronous generators, plus the protection and monitoring electrical panels.

Due to be installed in two different locations, the power plants will each have an individual installed generating capacity of 11.5MW and will use reforested wood chips as biomass.

Delivery of the equipment was set to take place in the

first quarter of 2021, with the forecast for the operation and commercialisation of energy by June. weg.net

COMPRESSOR MOTOR RUSH JOB SECURES OXYGEN SUPPLY WORKING UNDER HIGH PRESSURE, Menzel Elektromotoren was able to complete two much-needed compressor motors and deliver them in just two weeks at the turn of the year.

An order, which came from Bangladesh, was to ensure the supply of medical oxygen, which had an added urgency during the current pandemic.

A Spanish gas manufacturer needed to replace a failed motor quickly to minimise production downtime and revenue loss.

Menzel was able to provide highvoltage motors with outputs of 3000kW and 5200kW and coolers from stock. All the necessary interface modifications were carried out in-house in the short time available, including the conversion from air-to-air to air-towater cooling, machining the shaft end, installing a support and flange for an oil pump, converting the terminal boxes, and boring new foot holes.

Special technical expertise was required to secure the oxygen supply even in the event of grid fluctuations; Menzel’s technical department and the start-up transformer manufacturer

together calculated the ramp-up to ensure that the new motor was compatible with the existing starter. www.menzel-motors.com

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r new FOR THE MAINT

ENANC E, REPAIR

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EMENT OF ROTATI

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Quarter 2 2021

FOCUS ON:

Condition mo nitoring & predictive ma intenance

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22 Compliance

Taking compliance seriously Engineering compliance needs to be the number one priority to keep staff safe and to avoid heavy penalties. Renew finds out from Musk Process Services how external compliance specialists can help lighten the load.

J

ust three examples of the penalties handed out last year to UK manufacturers for failure to comply with British engineering safety standards and regulations were £20,000 for breaching PUWER regulations; £400,000 for not complying with DSEAR; and another £100,000 for PUWER breaches.

The potential fines for non-compliance are unlimited, and in the most severe cases, can also include a custodial sentence for company directors. It does beg the question, why, 18 years after the introduction of the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) and 28years since the Provision and Use of Work Equipment Regulations (PUWER) came into effect, are we still seeing frequent examples of dangerous compliance failures in the manufacturing industry?

A NUMBER ONE PRIORITY Chris Wood, Head of Engineering Compliance at Musk Process Services, believes that engineering compliance should not just be an expenditure enforced retrospectively. Instead, he argues that it should be the number one priority for every organisation, no matter how big or small. “It’s all about keeping employees safe,” he said. “Unfortunately, as with wider health and safety issues, it’s often seen as boring, inconvenient and isn’t prioritised, until an accident happens, someone gets seriously injured, has their quality of life affected or in the worst-case scenario, loses their life. Then suddenly, the company will start looking into compliance. But it should be the other way around. Compliance may not be exciting, but there is a very good reason why it is required by law, and that is to keep people safe.”

How, then, can engineering compliance regulations be more effectively handled by manufacturers? Chris believes that engaging external engineering compliance specialists could offer an easy, safe and convenient way for many manufacturers to ensure they meet British safety standards, avoid fines and keep their workforce safe.

Most businesses have their own Health & Safety (H&S) manager or teams in charge of keeping the workplace in line with UK safety regulations.

However, where equipment, machinery or the working environment is found to be non-compliant, even if they identify an issue, these H&S professionals often lack the specialist engineering knowledge required to design and implement the upgrade or solution to rectify the noncompliance and bring it up to standard. This is where the knowledge of an engineering compliance specialist can be helpful.

“The Musk Process Services design team, for example, includes electrical, mechanical and software

Quarter 2 2021

designers who are all trained in engineering compliance,” said Chris. “This means that a PUWER assessment, for example, detailing the non-compliant equipment in a plant, our design team is able to identify how to make that equipment compliant, then design the necessary upgrade, then oversee its correct installation.”

In addition to day-to-day standard operating procedures, it is also important to ensure the workplace is safe for maintenance teams. “At one brewery client, a lot of the upgrades we have installed recently have been to improve the safety of maintenance engineers.

For example, installing interlocks to prevent machinery from running when someone is inside it, and creating improved pipework schematics for easier identification and maintenance,” said Chris.

Another reason businesses may be tempted to avoid their compliance responsibilities is that they fear any upgrade work may impact production or cause delays and downtime. But this does not have to be the case.

“Take, for example, a major UK food manufacturer, for which we carry out remedial actions highlighted in the PUWER risk assessment. For 2019 there were over 2,800 tasks assigned, all of which were successfully carried out without impacting production or interfering with the client’s engineers and normal working patterns. This was achieved by taking a partnership approach to the upgrades and scheduling them to avoid any disruption, just as regular outsourced maintenance is planned to avoid unnecessary downtime on production equipment,” added Chris. TIMES-CIRCLE www.edwinjamesgroup.co.uk www.theaemt.com

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

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

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

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24 Circular Economy

Innovative recycling technology supports a circular economy Engineers at the University of Sheffield’s Advanced Manufacturing Research Centre (AMRC) have used their simulation capabilities to support a metal processing business in developing an automated scrap sorting technology that can contribute to a circular economy and help preserve the planet.

B

ased in Dinnington, Sheffield, Advanced Alloys processes significant quantities of aerospace scrap, which is currently sorted manually.

It is difficult to determine the grade and composition of the different materials, and currently, rare elements found in aerospace alloys, which are hard to identify, are not sorted. This results in high-value elements being amalgamated in lower value materials, such as stainless variants.

Advanced Alloys worked with the AMRC, part of the High Value Manufacturing (HVM) Catapult network of research centres, to explore improvements and automation of identifying and sorting rare earth metals for reuse. The project was paid for using HVM Catapult funds as part of a commitment to support smaller and medium-sized businesses.

A team of engineers from the AMRC’s Factory 2050 facility worked with Advanced Alloys to suggest technologies that could be used within the automated process. These included the use of cameras, robotics, conveyors, inscribing technology and high-speed X-ray fluorescence. The AMRC also provided support with understanding the costs and benefits associated with each specific technology.

Stephen Hall, Managing Director of Advanced Alloys, said that while the events of 2020 have meant temporarily pushing the pause button on the project, the company hopes to restart in 2021. “In a way, the pause might not have been a bad thing,” said Stephen. “The suggestions we had from the AMRC took us to the edge of what is currently possible, and further refinement of image analysis software, in particular, would help us get to where we want to be. Robotics is excellent at identifying pieces and components of a regular size and shape, but we’re often looking at irregular shapes, sharp edges, and an array of different sizes.

“We’re pushing at the limits of technology here. The strength of the AMRC is in adapting developments at the cutting edge of new technology into the workplace, and it is inspirational to see.”

Dr Phil Yates of the AMRC said the work undertaken for Advanced Alloys was fascinating and the type of project where you realise you’re working on something important.

Dr Yates added: “There is already a lot of automation across the industry in manufacturing and assembly.

Where there’s much less automation is in recycling.

Quarter 2 2021

It’s more challenging to find ways to automate the identification and sorting of scrap materials. So, this was an excellent project for the AMRC. We like doing the awkward stuff, the stuff that taxes our brains and uses our skills.

“We put together simulations of several methods for identifying and cleaning different scrap metals, some of which are very expensive and can also be dangerous so that these elements could be separated out from the rest of the scrap and recycled for use again.

“This is about supporting a fantastic local business, but ultimately, when it comes to keeping these rare earth elements in use, it’s also about developing technology that can contribute to a circular economy, to design out waste and keep materials in use, and help preserve the planet.”

Stephen added: “Working with the AMRC opened our eyes to what is possible. I’d say to any business considering working with the AMRC, this is a way you can access new technology, understand what’s available and how it might apply practically to your work. We often expect innovative technology to be costprohibitive and out of our reach, but the AMRC bridges that divide between normal manufacturing businesses and advanced engineering developments.” TIMES-CIRCLE

“The machines’ energy efficiency stayed within the rated band of efficiency after repair.”

www.amrc.co.uk www.theaemt.com

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26 Energy Efficiency

adopt high-efficiency motors and drives to combat climate change A whitepaper published by ABB reveals the potential for significant energy efficiency improvements in industry and infrastructure enabled by the latest high-efficiency motors and variable speed drives. Based on the findings, the company is calling on governments and industry to accelerate adoption of the technology to help combat climate change.

A

ccording to the International Energy Agency (IEA), industry accounts for 37% of global energy use and some 30% of global energy is consumed in buildings.

While mostly hidden from public view, electric motors – and the variable speed drives which optimise their operation – are embedded in almost every built environment. They power a vast range of applications fundamental to our modern way of life, from industrial pumps, fans and conveyors for manufacturing and propulsion systems for transportation to compressors for electrical appliances and heating, ventilation and air conditioning systems in buildings.

Motor and drive technologies have seen exceptionally rapid advancement in the past decade, with today’s innovative designs delivering remarkable energy efficiencies. However, a significant number of industrial electric motor-driven systems in operation today – in the region of 300 million globally – are inefficient or consume much more power than required, resulting in monumental energy wastage.

Independent research estimates that if these systems were replaced with optimised, high-efficiency equipment, the gains to be realised could reduce global electricity consumption by up to 10%. In turn, this would account for more than 40% of the reduction in greenhouse gas emissions needed to meet the 2040 climate goals established by the Paris Agreement.

“Industrial energy efficiency, more than any other challenge, has the single greatest capacity for combatting the climate emergency. It is essentially the world’s invisible climate solution,” said Morten Wierod, President of ABB Motion.

Considerable steps have already been taken to support the uptake of electric vehicles and renewable energy sources. ABB believes it is time to do the same for an industrial technology that will deliver even greater benefits for the environment and the global economy.

“The importance of transitioning industries and infrastructure to these highly energy efficient drives and motors, to play their part in a more sustainable society, cannot be overstated,” continued Morten. “With 45% of the world’s electricity used to power electric motors in buildings and industrial applications, investment in upgrading them will yield outsized rewards in terms of efficiency.”

ABB frequently assesses the net impact of its own installed high efficiency motors and drives on global Quarter 2 2021

energy efficiency. In 2020, it enabled 198 terawatt-hours of electricity — savings – more than half of the Achieving th e UK’s annual consumption. By 2023, Paris Agreem ent Th e vit al it is estimated that ABB motors role of high-efficienc y motors and drives will enable customers and drives in reducing en globally to save an additional 78 ergy consum ption terawatt-hours of electricity per year, almost as much as the annual consumption of Belgium, Finland or the Philippines and more than the total annual consumption of Chile.

Regulatory policies are among the main drivers of industrial investment in energy efficiency around the globe.

While the European Union will be implementing its Ecodesign Regulation (EU 2019/1781) this year, which sets out stringent new requirements for an expanding range of energy efficient motors, many countries have yet to take action.

To take advantage of the tremendous opportunities afforded by energy efficient drives and motors to reduce greenhouse gas emissions, ABB says all stakeholders have a critical role to play. Public decision makers and government regulators need to incentivise their rapid adoption. Businesses, cities, and countries need to be aware of both the cost savings and environmental advantages, and be willing to make the investment.

While investors need to reallocate capital towards companies better prepared to address the climate risk.

“While our role at ABB is to always provide the most efficient technologies, products and services to our customers, and continue to innovate for ever greater efficiency, that in itself is not enough. All stakeholders need to work together to bring about a holistic transformation in how we use energy. By acting and innovating together, we can keep critical services up and running while saving energy and combatting climate change”, concluded Morten.

ABB’s white paper ‘Achieving the Paris Agreement: The Vital Role of High-Efficiency Motors and Drives in Reducing Energy Consumption’ can be downloaded at: W H I T E PA P ER

bit.ly/ABBPAWP www.theaemt.com

28 An evolving industry

The Times they are a changin’ As he prepares to start his retirement and enjoy more time with his family, Tim Marks, who has spent 20 years as the Association for Electrical and Mechanical Trades’ Secretariat, reflects on how the repair sector has changed and looks at what the future holds.

L

ike many people, Tim Marks came into the industrial equipment repair industry by chance, as he explained: “Back in 1945, my father started a Lucas agency in York and North Yorkshire. There were few foreign cars or tractors at that time, and Lucas had a virtual monopoly on vehicle electrics.

“We also had a small rewind company. It was a Brook Crompton authorised repairer and sold its motors if a repair could not be done in time. And so, I quickly learnt to love the smell of a burnt-out motor.

“Then, when my father passed away while I was in my late 20s, I took over the running of these companies.”

In around 1975, the rewind company in York joined the Association for Electrical and Mechanical Trades (AEMT), and Tim was encouraged to attend the organisation’s Associates Display and AGM. Suddenly, he realised there was much more to the industry than he had suspected.

“In what seemed like no time at all, I found myself on the Association’s council in 1982,” Tim continued. “Then, by 1989, I became President, a position I held for two years, and then again for a year in 1996.” For many years the Association had been fortunate to have a very professional Secretary in Tony Harman, until his retirement in 1991. Then three other secretaries held the role over the following years, all for relatively short terms.

“When in 2001 the AEMT was once again looking for another Secretary, and having been on the council almost continuously since 1982, I suggested that I may be able to carry out the role if it only took up two days per week,” added Tim.

Tim’s offer was accepted, but the AEMT seemed to become more and more of a full-time job. So he stepped back from his other interests to give the Association his full attention.

AN EVER-CHANGING INDUSTRY When Tim first got involved with the industry, there were many small motor repair shops with very elementary repair equipment: pegboard for formers, a few selfmade ovens, large cans of not very clean grease, no bearing heaters, hammers and chisels to get the windings out, and even the occasional bonfire to loosen difficult windings.

And in those businesses, there was often a large queue of motors on the floor waiting to be wound.

But it became clear, through ‘state of the industry’ surveys the Association carried out in the 80s, that the sector was changing, and there were too many rewind companies fishing a smaller and smaller pond.

Heavy industry was being affected by political and economic influences, meaning the overall number of industrial motors was reducing. Plus, where in previous years cheaper labour and the relatively high cost of motors had seen most companies want to repair their machines, an influx of low-price motors from countries such as China reduced prices and what could be rewound economically.

“I quickly learnt to love the smell of a burnt-out motor.”

> 30

Tim Marks speaking at the inagural AEMT Awards

Quarter 2 2021

www.theaemt.com

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

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30 An evolving industry As a result, over the following years, the number of workshop staff in many rewind and repair companies shrank, and sales of energy-efficient motors and drives increased, needing more people in sales roles.

The electric motor became a commodity identified by a part number, and bearing companies began selling motors with very little knowledge about them or why the previous machine had failed.

Today far greater attention is being paid to ensuring motors do not break down, employing condition monitoring, predictive and preventative maintenance techniques. The Association’s members began supporting their customers by ensuring that unplanned failures were minimised.

As a result, the workforce has evolved once again and now needs to be of a higher quality than ever. Many businesses have an electronics department repairing and fitting drives. A growing number also have teams that carry out maintenance and condition monitoring and the removal and refitting of machines. As motors were increasingly sent for repair with a pump, the industry began to repair pumps and gearboxes as well as the motors. While, of course, the sector also began to carry out inspections and repairs of hazardous area machines When North Sea oil was discovered, there was a significant problem that the oil companies were experiencing with the repair of hazardous area machines. The manufacturers were insisting that these machines could only be maintained and serviced by the manufacturer. So the oil companies asked the AEMT and BEAMA, the UK trade association for manufacturers and providers of energy infrastructure technologies and systems, to find a solution so that the repair industry could repair Ex rated equipment without compromising safety and conforming to the original certification. To meet this request, in 1984, the original AEMT BEAMA Code of Practice was published. Then in 1993, this was adopted word-for-word as the International Standard IEC 60079 19 – which covered the repair, overhaul and reclamation of electrical machinery for use in explosive atmospheres – positioning the AEMT as a global authority for this standard.

SHAPING THE INDUSTRY In the 1990’s the AEMT carried out another series of projects. The first was to prove that burn out ovens could help strip motors without any adverse effects on the machine’s rated efficiency. Having confirmed this assumption, the Association produced the first research-backed good practice guide for repair companies to follow. “This first project looked at smaller machines,” explained Tim. “As more repairs were being carried out on larger machines, the AEMT invited EASA (the American Electrical Apparatus Service Association) to join us on a similar project with larger machines. This proved that motors repaired using the resulting AEMT/ EASA Code of Practice maintained their original rated performance and energy efficiency.”

Several years later, the AEMT also chaired and organised the total rewrite of the IEC Technical Quarter 2 2021

A Brook Motors advertisement from 1946, shortly after Tim’s father had opened the rewind business Tim would later go on to run.

(Image courtesy of Grace’s Guide - www.gracesguide.co.uk)

Specification for repairing rotating machines. This major rewrite of BS EN IEC 60034 23 was upgraded to an International and European standard when it was published in 2019 and incorporated all the lessons learnt from the above projects.

Thanks, in part, to the reputation the Association was gaining internationally, it has grown quite considerably.

Up until 2004, the Association had just a handful of international members. However, with the growing use of the internet and emails, it became far easier for the Association to help international companies, as well as those based in the UK. This led to a rapid growth of AEMT members, particularly in the Gulf and South-East Asia regions.

The AEMT also began offering courses in these locations. This development meant that the major companies in the oil and chemical sectors knew that the service companies they were using had staff trained to the required international standards.

“I am pleased to say that, with its involvement in shaping the standards used globally by the motor repair

> 32

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32 An evolving industry industry, and through the training it was able to give those undertaking the work, the AEMT has grown to become recognised worldwide,” continued Tim. THE ROLE OF THE INDUSTRY TODAY When Tim became involved with the AEMT, electric motors were often left to run in hot, damp, dusty and dirty environments. But much has changed today. Yes, some of the older heavy industries could still be improved, however, the modern factory can now be clean enough to eat off the floor; just look at Maclaren’s facility.

Typically, the only wearing parts of a motor are the bearings. In a modern, clean, air conditioned factory and with modern switchgear, there is no reason why bearings in an energy-efficient motor shouldn’t last 20,000 hours if they are properly maintained and changed before they fail. If the rest of the device is also properly maintained, the machine’s potential life can readily be made to exceed 100,000 hours.

This evolution of the technology has seen the repair industry turn full circle since the early years of Tim’s involvement.

Today, the world uses an ever-larger number of electric machines – motors, generators, alternators, transformers, chargers, and batteries. Because of this, the demand for copper and aluminium is going to be immense.

The repair industry supports the aspirations of a circular economy and is ideally positioned to make the best use of the world’s limited resources. Rewind companies recycle the copper and aluminium they remove as part of a repair or replacement as the highest quality scrap.

As materials become scarcer, as the demand for more and more green energy grows, and industry and transport are electrified, the demand for companies to carry out remanufacturing of energy-efficient electric motors, pumps, fans and generators is going to grow.

“This is an amazing environmental advantage that the repair industry has to offer,” added Tim. “It ensures the best use of limited resources at a time when awareness of how a circular economy can preserve the world’s copper and aluminium for future generations is growing. Currently, these elements could run out within a lifetime. Thankfully, the repair industry is at the forefront of delivering that circular economy.”

Perhaps a lot of the machines will be exchanged and repaired by manufacturers, but many will decide that repair and maintenance is not their core business, creating an opportunity for repair businesses with the right expertise.

In what looks set to be yet another major evolution for the repair sector, the significance of the AEMT and its members looks to be as high as it has ever been.

But Tim offered a cautionary observation: “Making the most of these opportunities requires major investment – in both facilities and skills. It will also require a determination to find ways of repairing the machines of the future. I truly hope that many of the AEMT’s members grasp some of the huge market potential and demand for remanufactured and repaired drive motors, wind turbines and other emerging technologies.”

So much has changed in the repair industry in the 20 years since Tim became Secretary. It is clear that his work has had a significant impact on the Association, the members it serves and the industry they all support. With so much opportunity facing the sector in the coming years, he leaves it on an extremely sound footing, ready to reap the rewards of the future. TIMES-CIRCLE

“There is an amazing environmental advantage that the repair industry has to offer.”

Tim Marks with representatives from AEMT member, Asia Motor Service Center Co. during a visit to Thailand Quarter 2 2021

www.theaemt.com

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34 Motor Testing

Putting motors through their paces Mathis Menzel, CEO of Menzel Elektromotoren, discusses load testing and temperature rise testing of large electric motors and entire drive systems. He looks at the benefits of different test methods and how testing can contribute to efficient commissioning and operation.

M

otor testing might be required for a variety of reasons. In the first instance, it offers a way to verify data.

Motor manufacturers can identify limitations, weaknesses, and performance reserves of products. Notified Bodies use test services because they need to verify data independently, while motor users can check whether their motor or drive system meets their specifications. In addition, testing can also be used for troubleshooting and for parameterisation.

For motor manufacturers, testing is generally the most appropriate way to see ‘how far can we go’ and which solutions are possible. For example, during type testing, it might be questioned whether a motor designed for continuous operation at a certain rated output can also drive another application with a slightly smaller load, with intermittent operation, and if so, what cooling periods are required? Or, might different or more powerful cooling solve a performance issue? Testbed operation offers a safe setting for load and no-load runs. Drive systems can be tested even with extreme parameters, such as severe short-term overloads, voltage drops, or various duty cycles or other non-standard situations during operation.

Load testing creates a very broad database about the tested equipment, and this can be very useful to answer questions at any later stage when the equipment is in the field. For example, the mechanical output is ensured with tested efficiency points, and so the mechanical input for the driven machine is also ensured.

DATA QUALITY Conventional tests with a direct coupled load usually just show that the motor works properly on load. The efficiency values from such a setup will be guesswork. Menzel uses a slightly more sophisticated setup that allows calibrated measurements and produces high-quality information on the actual efficiency ratios. The exact input current is measured with current and voltage transformers. A torque measurement shaft installed between the motor and load measures the generated torque. Losses and efficiencies are calculated from the difference between the (electrical) input power and the (mechanical) output power. With the tested motor and the load generator operated in a closedloop, this setup only consumes power for startup and any energy loss. Therefore, supply lines do not have to be over-dimensioned, and energy-saving tests

> 36

The manufacturer’s digital offer includes live streaming of motor tests to customers and a virtual tour of the test field on the website.

Quarter 2 2021

www.theaemt.com

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

UK

Part of the

Frank & Dvorak

Group of Companies

IE1/IE2/IE3 230/110V Single Phase Exd(e) Zone 2 & 22 CSA/UL Metric DOL & Star Delta Starters Slide Rails & Bases

Universal Inverters High Output Two Speed MV & High Voltage Nema Marine Motors

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

Universal Motors UK Ltd – Unit E2, Meltham Mills, Holmfirth, HD9 4AR 01484 660 222 enquiries@universalmotors-group.co.uk www.universalmotors-group.co.uk

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

36 Motor Testing

Berlin-based Menzel Elektromotoren operates two in-house load test fields for large industrial motors

can be performed over hours and hours. This setup also allows for precise simulation of the application load profile to determine the motor’s performance at individual load points.

COUPLED OR UNCOUPLED During normal operation, the motor’s thermal behaviour is continuously monitored via temperature probes in the motor windings and on the bearings.

These also provide some orientation during temperature rise testing. However, the only relevant reading is the winding resistance, which is measured in a de-energised state after the heat run to determine the final temperature. In addition to direct coupled heat runs, dual frequency testing according to IEEE / IEC 60034-29 is another way to determine a motor’s thermal capacity. This is a viable alternative if direct coupled testing is impossible or not economical. This once common procedure is still being used in the US and Asia but is little known in Europe today. The test specimen is operated at no load; two supply voltages with different frequencies are induced. These different frequencies are adjusted so that the motor’s rotational speed oscillates. The current input can be varied, allowing for a heat run at rated voltage, rated current, and rated speed. The motor’s temperature rise is within safe margins – at a maximum 6% higher than at regular load.

Since dual frequency testing requires no coupling to a load machine, vertical machines and machines with special shaft ends can be tested without modifications. This test method offers energysaving benefits because only the energy losses must be covered as active power. However, it is used exclusively for determining thermal characteristics and does not provide information on efficiency. As an added advantage, test fields that do not have the facilities to test high-output machines at load can Quarter 2 2021

instead perform dual frequency testing if they have the necessary know-how.

SYSTEM TESTS WITH ADDED VALUE If components that have been tested and proven individually are combined into a drive system, whole new problems can arise.

Comprehensive system tests are used to detect and resolve potential interface problems between individual components ahead of commissioning. This simplifies planning and reduces waiting times for end-users.

Over the years, Menzel has noted that the demand for entire drive systems tests has dramatically increased.

For example, there is a high demand for testing configurations with a transformer, variable frequency drive (VFD) and motor. Load testing is a means to verify system efficiency at different load points, but it can also be used to set the VFD parameters so that all settings and startup are completed before shipping. This enables true plug-and-play solutions, which helps keep downtimes to a minimum.

To be able to perform a system check, it takes more than just having standard test facilities: there must also be sufficient space to securely place and operate all components, flexible measuring equipment – to measure efficiency on any component of the system – and, most importantly, personnel with the necessary experience to ensure a safe setup that will provide accurate data. TIMES-CIRCLE

Over the years, Menzel has noted that the demand for entire drive systems tests has dramatically increased.

www.menzel-motors.com/motor-test-field 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

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+44 (0) 116 289 9199

sales@ridgwayeng.com www.ridgwayeng.com

38 Motor storage

Is your stored electric motor really ready for operation?

Suzanne Gill gathers advice from AEMT members to help ensure that electric motors stored as spares are still up for the challenge when they are finally called into operational service.

B

ecause electric motors are a crucial element of so many commercial and industrial operations, it is standard practice to store working spares on site to ensure fast response times in the event of a motor failure.

For this reason, it pays to make sure that any stored motors remain operation-ready, and this requires correct management and regular servicing. Unfortunately, this is commonly overlooked, with many operations not putting enough emphasis on the correct management and servicing of stored motors.

Matt Fletcher, Managing Director at Fletcher Moorland, emphasises the importance of ensuring that the shafts of stored motors are rotated at regular intervals. If the shafts are not turned, the bearing balls will start to wear at the point they rest on the bearing raceway. When the motor is finally put into operation, the bearings will likely fail very quickly. “Turning the shaft regularly while it is out of operation helps to minimise wear on any one point of the bearings, prolonging their life,” said Matt.

"While most people acknowledge that this is necessary, we find that in practice, very few put it into action as no one person is tasked with the job.” Matt’s advice is that motor shafts

Quarter 2 2021

get a dozen or so full turns every month, using the keyway as an indicator that this is being done. For example, in January, the keyway is left pointing upwards, in February, it is left pointing to the left, etc., giving a clear visual indication that the task has been undertaken.

Matt also highlights the importance of making this task someone’s responsibility as part of a maintenance schedule.

Matt also advises that motors be kept clean while in storage. Often when the motor is not being powered, dust can enter via the cable glands. “I have also seen motors, after long periods of storage, blowing alarming amounts of dust and grime out of their channels when powered up.”

Another area to consider is the shelf life of the grease in the bearings. “I wouldn’t advise leaving a motor with sealed bearings on the shelf for more than two years, as the grease inside the bearing will separate and so will not do a great job when it starts turning again,” said Matt. “If you are storing a motor with regreasable bearings, it is advisable to regrease them once every year or two. This can help prolong bearing life and will ensure that the motor is fit for service when needed.”

> 40 www.theaemt.com

40 Motor storage WHAT’S INSIDE MATTERS While a motor coming out of storage may look in good condition on the outside, it is important that while it is being stored, the inside of the motor is also kept in good condition.

Peter Hardy, Business Manager – lubricant and fluid control condition monitoring, at Socotec, offers some advice. “It is important to store motors in a dry environment because moisture, dampness or being open to the elements will result in moisture getting into the motor and speeding up the oil oxidation process.”

Peter advises that before putting the motor into storage, it is good to first drain the oil, flush it through, and replace it with fresh oil. Oil in operational motors helps ensure that any debris or particles are held in suspension while the motor is running. But, once stationery, any debris held by the oil will sink to the bottom of the motor sump. Then, when the motor is finally started up again, all the debris will be quickly pulled through the motor.

“Filling the motor with the right quantity of clean oil, and ensuring that it is sealed correctly, will slow down the oil oxidisation process,” said Peter. “But, over time, all oil will oxidise as it will react with any moisture and air inside the motor. Unless you are storing the motor in a temperature and humidity controlled environment, the motor will be subject to temperature fluctuations which causes the seals

to expand and contract, allowing moisture into the motor, forming condensation – which degrades the oil.” Peter advises periodically checking the oil – once or twice a year – to make sure it remains fit for purpose. “Because all oil will degrade over time, it is also advisable to check the oil before starting the motor after a long period of inactivity,” he said.

Matt makes one last but very important point – don’t let anyone steal parts from stored motors! “I have seen this happen too many times,” he said. “In my experience, the parts most often missing from stored motors are terminal box lids and fan cowls. While it is often only the intention to ‘borrow’ the parts, to replace a broken part on an operational motor, more often than not, the part never does get replaced, which means that the spare motor will no longer be operation-ready.”

In conclusion, if kept in the right environment and properly maintained, motors with regreasable bearings can be safely stored for many years without encountering any problem when they are finally put into operation. TIMES-CIRCLE

Before putting the motor into storage, it is good to first drain the oil, flush it through, and replace it with fresh oil.

TOP TIPS FOR PROTECTING MOTORS IN STORAGE GES Group has put together some useful information to help ensure electric motors stay in good condition.

Short-term storage: Protect the motor from the elements, vibration, and extreme heat. Indoor storage is preferred. If storing outdoors, wrap the motor loosely with a rain-proof tarp but leave a space around the bottom for airflow. If wrapped tightly, condensation will build up inside the motor from the heat of the sun and lack of ventilation.

Long-term storage: Store indoors in a clean and dry environment, with minimal to no vibration. Consider ‘floating’ the motor on a vibration-absorbing material. Store the motor vertically if it is to be used vertically; store it horizontally if it is to be used horizontally.

Prevent infestation of small animals such as mice or birds, which can damage the winding insulation. Prevent insect infestation by wrapping the motor loosely and covering all openings.

Coat the exposed surface areas to prevent rust and corrosion.

Apply a rust inhibitor throughout the storage life of the motor.

This will need to be cleaned and removed prior to placing the motor in service.

Frequent shaft rotation is necessary to prevent false brinelling (damage to bearings caused by fretting) and to redistribute lubricant. Rotate shafts on smaller motors a minimum of once per month. Rotate shafts on larger motors a minimum of once per week.

On grease-lubed motors: Fill the bearing cavities completely for long-term storage. If moisture collects in the grease, drain and Quarter 2 2021

replace it. If the grease hardens, dismantle the motor, remove the grease, and repack the bearing cavities with new grease.

On oil-lubed motors: Add just enough oil that contains rust and corrosion inhibitors to cover the bearings but not so full that it overflows the stand tube or the labyrinth seal.

Windings must maintain a temperature of 10°C to 20°C above ambient temperatures to prevent degradation of the winding insulation.

Take a baseline insulation resistance (IR) measurement before storing the motor, then a second measurement before installing the motor. Any decrease in the measurement can be addressed prior to installation, saving time and costs.

Take a baseline polarization index (PI) of form coil windings prior to storage then again before installation. The PI should be taken once each year the motor is in storage.

To prevent a chemical reaction in DC machines, some synchronous machines, and wound rotor machines, lift the brushes away from the commutator and/or slip rings. To prevent weakening the springs, place them in a relaxed position, if possible.

Out of storage and into service: Before moving the motor, measure the insulation resistance (IR) with a megohmmeter.

Remove dust, dirt, and old grease, and drain if it is an oil-lubed motor.

After installation, record vibration levels, and evaluate the spectra on motors with rolling element bearings for any signs of bearing fault frequencies. Perform a vibration analysis during start-up. Document uncoupled baseline vibration levels. 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

42 Bearing protection

Protecting motor bearings from electrical damage Martin Deiss, European Sales Manager at Electro Static Technology, discusses a cost-effective solution to protect motor bearings from electrical damage.

A

ll manufacturers of three-phase AC motors will offer motor product lines that are suitable for operation on variablefrequency drives (VFDs).

Precision RPM and torque control of motors using VFDs enable energy cost savings of at least 30%. However, VFDs are not without their problems and, when used to control AC motors, they can induce unwanted shaft voltages. Without adequate protection, these voltages can result in premature bearing failure and thus motor failure.

While the National Electrical Manufacturers Association (NEMA) and other institutions have identified this problem in motors, and it is recommended that motors are equipped with effective bearing protection, the most frequent cause of bearing failure is still electric current passage. Inverter duty motors include insulation designed to meet the latest standards to protect the windings, but the bearings are often neglected. For an AC motor to be truly suitable for VFD operation, it should have long-term bearing protection. Usually, this is not given sufficient consideration and leads to expensive downtime due to motor failure.

ELECTRICAL BEARING PROTECTION A reliable and cost-effective way to minimise electrical bearing damage and increase the reliability of VFDcontrolled motors and systems is the use of an AEGIS Bearing Protection Ring – combined with an insulated bearing for motors larger than 75-100kW. In contrast to traditionally used shaft grounding technology offered by spring energised carbon brush, AEGIS Bearing Protection Rings offer a more efficient solution for avoiding high-frequency bearing currents.

The bearing protection rings consist of conductive microfibres, which are secured in the channel. Scalable to any shaft diameter, the fibres surround the motor’s shaft offering a lowimpedance path from the shaft to frame and then to ground, to divert damaging currents. Because the microfibres work with little or no contact with the shaft, they are not subject to wear, unlike conventional carbon brushes.

RISK OF MOTOR DAMAGE Damage to windings and bearings can result from the repetitive and extremely fast impulses produced by modern VFDs in motors. This phenomenon is Quarter 2 2021

described in terms of harmonic content, parasitic capacitance, capacitive coupling, electrostatic charge and common-mode voltage. Regardless of the name, high voltage peaks and fast clock times can cause untold damage.

If the load impedance is greater than the line impedance, current is reflected back to the VFD, and voltage spikes occur in the motor connection, which can be twice as high as the intermediate circuit voltage.

The damage caused by VFD-induced currents is often overlooked until it is too late to save the motor.

Electrical discharges can damage bearings that normally have a mirror-smooth bearing surface.

Without protection, shaft voltages pass through the bearings and cause undesirable electrical discharges. Spark erosion damages the bearing surfaces and leads to premature failure of the bearing or motor. Within a short time, the bearing surface is strewn with microscopic scale melt craters, giving it a frosted appearance. Over time, a corrugation (washboard-like surface) forms, resulting in increased bearing noise and vibrations.

When using insulated bearings, the damaging current will find a different path to ground, usually through connected units such as the gearbox, pump, tachometer or encoder. This, in turn, will damage the bearings of these devices.

When using insulated bearings, the damaging current will find a different path to ground.

www.theaemt.com

Bearing ProtectionFEATURE 43

Oscilloscope voltage profile of bearing without shaft grounding (left) compared to bearing with AEGIS Bearing Protection Ring (right).

PROOF OF EFFECTIVENESS The effectiveness of AEGIS Bearing Protection Rings can be quantified by measuring the shaft voltage using an oscilloscope. Without shaft grounding, the voltage profile exhibits high voltage peaks and steep discharge edges. After applying the bearing protection ring, a virtually flat line appears.

The Bearing Protection Rings have already proven their value in over two million installations worldwide, and today motor manufacturers use factory-installed bearing protection rings as standard, or as options, for certain motor series. This ensures that the

LIVERPOOL

WALLASEY

operation of the VFD will have no detrimental effect on the motor.

CONCLUSION To operate an electric motor by a VFD without issues, it is not sufficient to rely exclusively on the manufacturer’s statements. Insulation is designed according to the latest standards, but manufacturers often do not pay attention to effective shaft grounding, which protects the bearings against harmful highfrequency VFD currents. AEGIS Bearing Protection Rings can provide a proven and effective solution. TIMES-CIRCLE www.est-aegis.com

MANCHESTER

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WWW.RJWENG.COM

44 Condition Monitoring

Keeping a sharp eye on critical systems Renew spoke to Matt Fletcher, Managing Director of Fletcher Moorland, to find out how Meerkat, his company’s wireless condition monitoring system, is saving time and money for a facilities management company.

C

ompleted in 2018, the London-based commercial skyscraper, the Scalpel, is 190m high and comprises 38 floors.

Naturally, the facilities management (FM) company looking after the building is keen to ensure its tenants are comfortable. A complex HVAC system manages the interior environment, and this must remain operational 100% of the time, with all efforts made to avoid system failures or breakdowns.

In other buildings managed by the FM company, there is a planned maintenance programme designed to ensure system parts and components are checked, and where necessary replaced, before there is any chance of failure. But the company recognised that a condition-based maintenance approach would be more effective – not only from a cost perspective but also from the quality of the building’s environment. With maintenance staff only required when a need was identified, they could be freed up for other work. Plus, components costs could be reduced with parts replaced less frequently, only when they demonstrated a reduction in performance.

It was the Meerkat solution from Fletcher Moorland that the FM company chose for its building, as the company’s Managing Director, Matt Fletcher, explained: “With the project out to tender, we were approached by the building’s facilities team who had heard about Meerkat and were keen to find out about the system.

“Many condition monitoring systems are highly complex, and it can require a deep understanding of vibration analysis to use them properly. We intentionally designed Meerkat to be very simple from a user’s point of view. We took a demo system to the site and left it online for a few weeks so the facilities company could get a feel for it. They loved it, and it was indeed the simplicity that won us the contract.”

The system installed at the Scalpel has 158 sensors, or points – sensing vibration, temperature, and where needed, speed output from the inverter drives. Some assets have more than one sensor attached; for example, a large pump may need two sensors on the pump itself and two on the motor. How this is set up is where the expertise of the installation team comes into play. Fletcher Moorland’s installation team are vibration analysis

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certified and use a combination of their experience, and the parameters set out in ISO 10816 to establish how best to monitor each of the assets.

“While self-installation, plug-and-play systems are available, understanding where to place the sensors will make a huge difference to the performance of the monitoring system,” continued Matt.

SIMPLIFIED CONNECTIVITY One of the advantages of the Meerkat system is that it is wireless. In the Scalpel, there is a plant room in the basement and one on the top floor. This would require vast amounts of cable – challenging to route through the building and adding to the project cost.

Each point is connected to a network node powered by a battery that lasts on average two years. All the

A FLEXIBLE SOLUTION In an automotive manufacturer’s paint plant, the paint would build up on the ventilation system’s fan impellers, sending them out of balance.

To avoid this leading to motor failure and unplanned downtime, the manufacturer needed maintenance teams to regularly inspect the fans.

As well as the time it took the maintenance team, this also caused a degree of disruption to production.

A Meerkat system was designed and installed at the site, monitoring the fan’s vibration. With the maintenance team only needing to get involved when an alarm is triggered by the system detecting a threshold breach, significant maintenance hours have been saved, resulting in reduced production downtime. www.theaemt.com

Condition Monitoring 45 nodes are then meshed together over a wireless network sending data to a central gateway in the building. The data from each point is given an identifier and date stamp before being sent off-site to the cloud over a mobile GSM network. This approach allows the system to be installed anywhere without interfering with existing infrastructure The Meerkat software takes the data, and after a baseline is established, thresholds are set. Ongoing data is then monitored, and if any of the thresholds are breached, an alarm can be triggered.

“This is another advantage of the Meerkat system,” Matt added. “There is no requirement for someone to monitor the data graphs physically. If the thresholds are exceeded, an email or text message is sent to alert the relevant user.”

This is another area where the software working behind the scenes is intuitive which makes the enduser’s involvement in the system relatively simple.

While the vibration and temperature sensors monitor direct conditions on the assets, Meerkat can also cater for speed fluctuations with sensors on the inverters, which can help identify where changes in the thresholds might be needed. If, for example, the speed of a fan drops, the vibration threshold is reduced. Simply setting a static temperature or vibration level to trigger an alarm could cause false alarms or lead to issues being missed.

When an alarm is triggered, the data history can then be studied to see what patterns have emerged, helping to establish what may have happened. A steady change over time could indicate gradual wear, while a more sudden change would suggest some form of failure. For example, in a brickworks also employing a Meerkat system, the vibration data from one asset shot up suddenly. When the team went to inspect the kiln extractor fan, they discovered that one of its brackets had fractured. It was quickly re-secured but had the fan failed, the kiln would have been compromised and its entire output ruined.

In terms of the impact Meerkat is having at the Scalpel, it is relatively early days. However, the maintenance team’s hours have already been reduced, as have replacement component costs.

And an unexpected benefit has been discovered.

Through the ongoing monitoring of some of the system’s pumps, the potential to make savings in energy use has been identified – something which would have otherwise gone unnoticed. TIMES-CIRCLE

“If the thresholds are exceeded, an email or text message is sent to alert the relevant user.”

fletchermoorland.co.uk

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

And all backed up by the most comprehensive support and parts service available in the UK.

For further information contact us on

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

46 Condition Monitoring

The positive impact of condition monitoring

When rotating equipment like pumps and motors are running smoothly, it is easy to overlook common maintenance tasks and justify that it is not worth the time to regularly inspect and replace parts. Houghton International explains why it is vital to ensure that such equipment has a programme of maintenance.

B

y adopting a maintenance programme for a critical pump, a business can prevent costly downtime and improve performance. A good maintenance programme will help identify a problem in its infancy, allowing users to put a plan in place to carry out repairs during a shutdown period. It also lets users maintain pumping capacity to ensure a pump is running as efficiently as possible and reduce future costs by prolonging its life.

Routine preventative maintenance practices should include the monitoring of bearing temperature, vibration, bearing lubrication, amps (power) readings, suction and delivery pressures. By comparing them to the test and commissioning data, users can set a predetermined level of internal wear, which is acceptable to the process and the pump, to use as the basis of a maintenance plan. It is also worth noting that during an annual assessment of a pump’s performance, any changes in the benchmarks can be recorded and used to determine the level of maintenance that may be required to get a pump back to operating at its Best Efficiency Point (BEP).

When planning the maintenance of a pump as part of a predictive maintenance programme, it is worth considering condition monitoring. Condition monitoring is performed to highlight a pump's decreasing performance, as opposed to undertaking maintenance at predefined scheduled intervals. It is a maintenance approach that monitors the actual condition of a pump to decide what maintenance needs to be carried out on specific pump components when a set level is reached.

Another benefit of adopting this maintenance approach is that it is performed while a pump is running, which reduces the disruption to normal operations and reduces the cost of pump failures, increasing reliability and minimising the overall time spent on maintenance compared to a reactive approach. Also, this method will identify when the pump is running left of the BEP and therefore running less efficiently.

Another advantage of ongoing condition monitoring is that data readings can be digitally stored, reducing the need for manual input.

Techniques such as vibration analysis can help detect many serious problems at an early stage, allowing maintenance engineers to undertake remedial work at a time that suits. All rotating electromechanical equipment exhibits a varying degree of vibration, but by utilising a vibration sensor, you can detect how excessive the Quarter 2 2021

vibration is.

Vibration can be measured in three basic quantities: displacement, velocity, and acceleration and should be measured when the pump is at its normal steady-state operating condition.

It is a non-intrusive, fast response, preventative maintenance solution, designed to locate a potential problem and rectify it before it causes further damage to the machinery.

Laser alignment is another key part of the overall condition monitoring process and gives users a firm printed report, which is unchangeable. As with vibration analysis, laser alignment detects the smallest deviations in the shaft to provide an accurate warning of possible breakdowns.

Oil and lubrication analysis, on the other hand, is one of the easiest and most effective condition monitoring methods. Trending particle counts can be an early sign of bearing and seal wear long before vibration analysis can be effective.

There are, however, a few points to consider when planning to implement condition-based monitoring as part of your maintenance programme. The initial investment cost of the measuring equipment and sensors, as well as the subsequent installation, needs to be taken into consideration and even then, particularly on older equipment, users might have to make modifications to allow monitoring equipment to be retrofitted correctly. There is also the time and money investment in up-skilling maintenance staff to ensure that they can use the condition-based monitoring equipment correctly and safely.

All things considered, the benefits of adopting a predictive maintenance system such as conditionbased monitoring have become well accepted and can help prevent costly downtimes, ensure pump efficiency and reduce costs. TIMES-CIRCLE www.houghton-international.com www.theaemt.com

N

EW D ATES Conference • Workshops • Exhibition • Awards Programme A NNO

2021

6th & 7th October • Harrogate • Yorkshire • UK

UNCE

IT IS NOW TIME TO SUBMIT A PAPER For 20 years, the Hazardex Conference & Exhibition has been the global platform for sharing key industry information and topical discussion on process safety-related topics.

With the unprecedented COVID-19 pandemic causing many of us to work remotely, preventing the usual networking opportunities from taking place, Hazardex 2021 will be an ideal occasion for the industry to once again come together and make up for the lost months of crucial knowledge sharing and networking.

The Call for Papers for Hazardex 2021 is now open and we are seeking submissions from contributors with experience and knowledge of the process safety and high hazard sectors.

Submissions must be non-commercial and could be in the form of research, industry developments, lessons learnt from near-misses, investigation findings, good practice for industry, or case studies, to name just a few of the formats we are looking for.

The 2021 event will include a comprehensive conference for all those concerned with hazardous area operations, personnel, and environmental safety systems.

COVID-19 regulations and UK Government guidelines will be observed & enforced as required at the time of the event.

Visit the website for how to submit a paper: www.hazardex-event.co.uk

Media Partners

Contact us for 2021 participation information now!

Email: hazardex@imlgroup.co.uk Tel: +44 (0)1732 359990 www.hazardex-event.co.uk www.hazardexonthenet.net

Supporting Organisations

D

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

R.E. Field Services Ltd • • • • •

Balancing Condition Monitoring Marine Repairs Mechanical Rewinds

APPROVED BY

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

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

• • • • •

Gearboxes Laser Alignment Condition Monitoring Marine Repairs Thermography

• • • • •

APPROVED BY BP E-ON SSE INTERGEN VEOLIA VIRADOR

Vibration Electrical Mechanical Generators Rewinds

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

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

SERVICES INCLUDE • • • • •

Spindle Motors Inverter Drives Electrical Mechanical Rewinds

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

Fyfe Wilson Ltd APPROVED BY NIDEC SIEMENS MAVILOR BOSCH TECMOTORS SCHNEIDER

Arfon Engineering SERVICES INCLUDE • Laser Alignment • Pumps • Condition Monitoring • Motors • Marine Repairs • Gearboxes • Thermography • Fans • Switchgear • Inverter Drives 0151 334 6808 (Wirral) 01286 675 853 (Caernarfon) sales@arfonrewinds.com www.arfonrewinds.com

APPROVED BY

WEG Motors Wilo Pumps NORD Geared Motors Dertec Geared Motors Hoyer Motors Elmo Rietschle Robuschi Pumps

ADYARD ABU DHABI LLC

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

• • • • •

Transformers Balancing Machining Fabrication Rewinds

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

CEMB Hofmann UK Ltd

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

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

APPROVED BY SIEMENS ABB

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

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

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

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Quarter 2 2021

FOCUS ON:

Condition mo nitoring & predictive ma intenance

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Protecting mo tor from electrica bearings l damage Is your stored electric mot really ready or for operatio n?

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FEATURE 49 49 repair service directory Neu-Servo Repairs SERVICES INCLUDE • • • • •

Pumps Motors Gearboxes Fans Servo Motors

• • • • •

Spindle Motors Inverter Drives Thermography Mechanical Rewinds

APPROVED BY Siemens

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

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

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

Inverter Drives Balancing Electrical Mechanical Rewinds

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

ADC Electrical Ltd

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

• • • • •

• Condition Monitoring

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

APPROVED BY Baker Hughes

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

• • • • •

Condition Monitoring Marine Repairs Mechanical Rewinds Ex Hazardous Area

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

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

Mechanica Utilities Ltd

Fletcher Moorland Ltd

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

• • • • •

Marine Repairs Vibration Electrical Mechanical Generators

APPROVED BY

SPP Pumps Belzona Coatings Hydromarque Pumps Brown Europe Gearboxes

SERVICES INCLUDE • • • • •

Pumps Motors Gearboxes Fans Laser Alignment

• • • • •

Servo Motors Inverter Drives Condition Monitoring Rewinds Ex Motor Repair

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

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

Rotamec Engineering Solutions

Invincible Electrical Eng Co

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

SERVICES INCLUDE • • • • •

Marine Repairs Electrical Mechanical Generators Rewinds

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

APPROVED BY Lowara Grundfos Motovario Lenze TEC NIDEC Marelli

• • • • •

Pumps Motors Gearboxes Fans Spindle Motors

• • • •

Inverter Drives Electrical Mechanical Rewinds

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

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

APPROVED BY ABB

FEATURE 50 Opinion

Amazon bets on condition monitoring Late in 2020, Amazon announced the launch of Monitron, an end-to-end machine monitoring system powered by its AWS infrastructure. Blake Griffin, Market Analyst at research specialist, Interact Analysis, believes this move demonstrates the increased importance that condition monitoring will play in the future.

O

n December 1st, 2020, Amazon announced a suite of new AWS machine learning services.

To many, this announcement appeared to be Amazon’s launching off point towards being a major supplier of predictive maintenance solutions.

However, this announcement follows a long history of Amazon carving out its capabilities in industrial digitalisation. Since its 2018 release of AWS IoT Sitewise – a service that enables its users to gather and organise asset-health related data housed in repositories such as a historian – Amazon has consistently added to its industrial digitalisation offering. Now, the company has a highly competitive solution with one capability unique to Amazon.

In some ways, Amazon’s announcement of its new suite of machine learning services represents a rounding out of a predictive maintenance offering rather than a jumping off point. When manufacturers are looking at implementing predictive maintenance into their facilities, they ask these fundamental questions: Which assets do I have visibility into already, and how can I leverage this data? Which assets do I not have visibility into, and what can I do to change that?

The announcement of AWS IoT Sitewise was Amazon’s solution to the first question. Many manufacturers in process industries generate large amounts of data from the devices controlling their machines. AWS IoT Sitewise was developed so manufacturers could more effectively utilise this data for condition monitoring/predictive maintenance purposes.

Strategically, this was a logical first move. Amazon already had a wealth of analytical tools it could deploy to make use of data housed in a historian; the only thing needed was a mechanism for gathering and organising that data to be analysed.

Fast forward to Amazon’s recent announcement, and we see the company moving to provide a solution to question two. Assets that are often cited as being ‘offline’ from a condition data perspective are the mechanical portions of a motor-driven system, i.e. induction motors, gearboxes, bearings blocks, etc. These components are numerous throughout factory floors, and their failure can represent a significant loss of production. The industry has responded to this need by offering smart sensors, a wireless-enabled sensor that can be connected to the side of a motor to gathering data on vibration and

Quarter 2 2021

temperature behaviour. When combined with machine learning algorithms, these two data points can quickly illuminate what kind of stress motor components are facing and alert its users to problems ahead of failure.

One of the services announced in late 2020 has been coined Amazon Monitron. The solution utilises smart sensors and gateways produced by Amazon to offer up data on the health of motor system equipment, effectively solving the problem of gathering data on assets not being monitored via historian data. This solution is in direct competition with more familiar predictive maintenance providers. In our view, the announcement of Monitron means Amazon now has a solution that fully addresses the needs of manufacturers looking to invest in predictive maintenance as part of a broader industrial digitalisation initiative.

Every platform offered by the major providers of predictive maintenance is built on cloud storage technology offered largely by either AWS or Microsoft Azure. The full development of Amazon’s industrial digitalisation offering represents the first time a supplier can provide both the cloud storage and analytic capabilities under one entity.

It is difficult to foresee what impact this will have on the partnerships AWS has in place with current industrial digitalisation providers. However, what is easy to see are the numerous advantages Amazon will have in potentially winning the business of those investing in industrial digitalisation for the first time. If customers are looking to utilise the cloud for their industrial digitalisation initiatives, Amazon will represent the fewest number of touchpoints between customer and supplier during the sales process.

Additionally, many manufacturers may already be using AWS for cloud storage but have yet to invest in further industrial digitalisation technology. In these scenarios, Amazon would already have a foot in the door, which would yield them an advantage when the time comes for users to begin evaluating providers of digitalisation.

At the very least, this announcement should be taken as a signpost of future growth within an already fast-growing predictive maintenance market. Amazon does not enter markets that are expected to appreciate modestly; it enters markets whose opportunity could one day be worth billions of dollars. www.interactanalysis.com www.theaemt.com

ALPHA E

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