Renew Magazine - Quarter 3, 2021. Hazardous areas focus

Page 1


The journal f rom

Quarter 3 2021


Hazardous areas

Are you documenting Ex repairs? Don't neglect your generator Industry News



Expert Opinion

Re-Conditioned Motors       

Cage up to 1mw Ex Stock Slip-Ring up to 500kw Ex Stock D C Motors High Tension Motors 3.3Kv Geared Motors Two Speed Motors Vibrator Motors New Motors

  

Cage up to 400kw Ex Stock Slip-Ring up to 315kw Ex Stock Geared Motors and Vibrators

Large Stocks of Electric Motor Spares Both Current and Obsolete Including:Brook Crompton Series 7 Steel Motor Spares Brook Crompton Series 6 Cast Iron Motor Spares        

Fan Covers Terminal Box Assemblies Endshields Bearing Covers Slip-Ring Assemblies Brushgear Carbon Brushes Cooling Fans Variable Speed Drive Specialist

Schneider Altivar Range of Variable Speed Drives from 0.18kw to 315kw available Ex—Stock

87 Kingstown Broadway, Kingstown Industrial Estate Carlisle, Cumbria, CA3 0HA Tel : 01228 552000 Fax : 01228 552001 E-Mail:

CONTENTS 3 Editor Chris Callander +44 (0)1732 671123 Contributing Editor Suzanne Gill Publisher Andrew Castle +44 (0)7785 290034 Accounts Touchwave Media Ltd Production G and C Media Ltd

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


he Association’s AGM, on 24 June, marked the end of my two-year period as President of the AEMT. As I prepared for the event, I dusted off the chains of office and considered that aside from the AGM two years ago, it was only the second time I had worn them; the other was the 2019 conference and awards. The challenges faced by all our members have not escaped the AEMT. We have needed to find solutions to the issue of maintaining credible courses in an online world. Face-to-face meetings have been cancelled, and Teams and Zoom have become a daily reality. I am proud of how we have responded to this. Many lessons have been learned, and many sleepless nights suffered; however, I feel that the Association is now better placed to manage the new normal. I want to thank all of the AEMT staff, fellow officers and council members for the way they have responded to these challenges. I would also like to thank outgoing council members Graham Brooker and Matt Fletcher. The impact these two gentlemen have made cannot be easily measured. They will certainly be missed. I would also like to thank the Secretariat, under the lead of Thomas Marks, and I would single out Karl Metcalfe for the excellent work done over the last year in the most difficult of circumstances. Now to the future and the new president. Shaun Sutton and I have worked very closely over this last year. I have little doubt that his experience, leadership skills, energy and team spirit will drive us into the post-pandemic era, and I wish him the very best. David Hawley, President, AEMT

NEWS 6 Industry news 10 AEMT news

30 Q&A - Bearing protection

12 AEMT Awards update

36 Don't neglect your generator

14 Product news

38 Challenges for bearings in mining and quarrying environments

32 Coil manufacture

18 Project updates

Focus on Hazardous Areas

Twitter @AEMT_Updates

44 Are you documenting Ex repairs?

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 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.

46 Vibration monitoring could have saved thousands of pounds


Regulars 22 Compliance - WRAS approved adhesives 24 Circular economy - How the repair sector is driving it forward 28 Energy efficiency - Regulation changes affecting transformers



OPINION 50 We must support Diversity in Engineering Quarter 3 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.




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


Earth Leakage Clampmeter n n


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


True RMS Multimeter n



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




TC3231 DCM305E AVO835


Thermal Camera

2 Amp DucterTM Low Resistance Ohmmeter n



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

MPD Scan

Handheld Scanner for PD Surveying n



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


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




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


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


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

Static Motor Analyzer



Static Motor Analyzer





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

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


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


Voltage (measures ac 10 mV up to 1000 V; dc 0 to 1000 V; TRMS), Frequency (15Hz to 400Hz), Phase Rotation n 800-752-8272


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


The Megger Baker EXP4000 is a portable Dynamic Motor Analysis System


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

High Voltage Motor Tester




Low resistance measurements from 1mΩ to 800Ω


Rotating Machine Tester

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


Dynamic Motor Analyzer

MTR105 n

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



Site Installed Dynamic Monitoring System



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


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


MUSK PROCESS SERVICES UNDERTAKES UPGRADE FOR LALLEMAND ANIMAL NUTRITION LALLEMAND ANIMAL NUTRITION, A YEAST AND bacteria producer, has chosen EJ Musk Process Services to undertake a £2,000,000 expansion of its Malvern site. The investment will see the installation of new larger capacity fermentation vessels to increase production capacity, as Jonathan Wiffen, Operations Director at Lallemand Animal Nutrition, explains: "This investment and the improvements at our Malvern production site will help us to meet the growing demand for our products. The team at Musk showed a real understanding of the project, and with their other group companies, they were able to provide us with a full solution, from planning and design right through to manufacturing and implementation." Musk, part of the Edwin James Group, is delivering the turnkey project from design to installation with fabrication handled via the Musk workshop in Swadlincote. Commenting on the project, Charlie Price, Operations Director at Musk Process Services, said: "We are working in partnership with Lallemand to deliver a turnkey project that will expand capacity at this key production site in the

Charlie Price, Operations Director at Musk Process Services.

Malverns. It underlines the integration of services across the Edwin James Group to deliver everything from project design to fabrication and installation."

LAKERS EXPANDS INTO UK WITH ACQUISITION LAKERS AS, A NORWEGIAN company specialising in the service, sales and hire of pumps, has expanded into the UK market with the acquisition of Pump Supplies Ltd. Pump Supplies owns and operates a hire fleet of electric submersible pumps and accessories, including pipework, spares, and accessories for a wide range of industry sectors and applications. Established 39 years ago by Andrew John, Managing Director, in Port Talbot, the business has grown significantly to include a further four strategically located depots in Gloucester, Winsford, Bodmin and Wexford. Commenting on the acquisition, Andrew said: "This is a great coming together of two businesses who will mutually benefit from the deal. It stabilises a mature business that is well regarded in its marketplace and provides a strong platform for the company's future development. It Quarter 3 2021

Andrew John, Managing Director at Pump Supplies.

provides Lakers with a gateway for its plans to expand further in the UK. "There will be no significant or material change to the running or organisation of the business in the near future. It's business as usual with the

existing management team, including myself remaining in place with arm's length support from the Lakers team in Oslo. We'll continue to provide the same support and service levels going forward."

Industry NEWS 7

SIEMENS AND SCHAEFFLER COOPERATE ON INTELLIGENT DIAGNOSTICS FOR DRIVES A COOPERATIVE AGREEMENT between Siemens and Schaeffler, on intelligent diagnostics for drive systems, sees Siemens combine its Sidrive IQ IIoT platform with Schaeffler’s experience in designing, manufacturing, and servicing bearings. Sidrive IQ integrates a number of functionalities into one solution and augments drive systems with AIbased analytics and digital content. For the end-user, this gives the ability to make better decisions when it comes to operation and maintenance measures for drive systems. Bearings experience all the loads and stresses that occur in the electric motor, so bearing diagnostics provides a crucial


RIDGWAY MACHINES, A DESIGNER and supplier of precision taping and winding machines for the electrical and energy industries, has moved its office and production facility to new premises in Leicester to accommodate an increase in business. The new premises also allows for future growth as the business continues to thrive despite the pandemic. A new Reinforced Thermoplastic Pipe development line is currently being installed at the new site to allow customers to have reinforced pipe samples made for testing.

indicator of the overall condition and reliability of a motor. The integration of Schaeffler’s analysis service for automated bearing diagnostics into Sidrive IQ makes it possible to determine the bearing condition with greater certainty and precision. With the help of well-founded insights and specific information, operators can quickly determine whether the drive system can continue to operate or whether, in the event of impending damage, the bearing needs to be replaced at the next maintenance interval or if it should be replaced immediately. This reduces the effort and cost of maintenance and most importantly it helps prevent unplanned downtime.

BETTER HEALTH AT WORK AWARD RECOGNISES HOUGHTON INTERNATIONAL HOUGHTON INTERNATIONAL HAS been awarded the Better Health at Work Bronze Award in recognition of several initiatives delivered to promote health and wellbeing in the workplace. The award, endorsed and supported by Public Health England, requires businesses to demonstrate how they are working to deliver advice and support to employees spanning a range of health and wellbeing issues, including mental and physical health, healthy eating and kicking bad habits. Judged by a representative from the Better Health At Work scheme, the award requires organisations to create and present an Award Portfolio, which is then judged against set criteria. Based on feedback from employees and backed by the HR department and management team, Better Health Advocates from across the business helped develop and deliver a series of health & wellbeing campaigns. Commenting on the award, Craig Hutton, Operations Director at Houghton International, said: "It's fantastic to have

completed the Better Health at Work Bronze Award scheme, and I commend everyone across the business for their efforts in working towards this achievement. This isn't just about a title or certificate – the wellbeing of our employees is of the highest importance, and completing this award has helped us explore new ways of creating meaningful improvements. "We're proud of the support we have in place for employees, including Mental Health First Aiders, annual health checks, a holiday buy & sell scheme and flexible working, and an Employee Assistance Programme, which provides access to a range of support covering work, family, life, health and money as well as services such as on-demand GP appointments. However, we recognise that we can always do more. "Achieving the bronze award has laid a great foundation for us to build on, and we will now work towards achieving the silver standard as we continue to work with the Better Health Advocates and employees across the business to improve health and wellbeing." Quarter 3 2021

8 industry News

DI-SPARK INVESTS IN HORIZONTAL BALANCER FROM CEMB HOFMANN UK DI-SPARK OPERATES AROUND THE clock, manufacturing aerospace components, including parts and subassemblies. The company has recently invested in a ZBT02 horizontal dynamic balancing machine from CEMB Hofmann UK, which has enabled it to dynamically balance its products and subassemblies in-house, offering a more complete service to customers – from design drawings through to delivery. Currently, this includes impeller and inducer components, parts and subassemblies, although the company has plans to expand its offering across its entire product range and additionally offer sub-contract balancing services. Commenting on the investment, Rob Severne, CAD/CAM Engineer at Di-Spark, said: "CEMB Hofmann offered to testbalance some of our parts before we committed to purchasing the machine, and the results were impressive. This added value service is what made them stand out, and delivering proof of concept gave us peace of mind and confidence that we were investing in the right machine for our application." Installation and calibration of the

new machine were completed by CEMB Hofmann UK in May 2021, and the company delivered training to Di-Spark at this time. "The engineer was incredibly helpful and informed," continued Rob. "He delivered the training in a practical way that ensured we had the knowledge to do what we needed to without

overcomplicating things. This was key to a successful implementation, and we are already seeing the benefits in the form of additional work from our customers." By offering a balancing service inhouse, rather than having to subcontract the work, Di-Spark can save its customers money, and the additional provision has been well received.

ECONOMY 2030 INQUIRY: NOW IS THE TIME TO ACT ACCORDING TO TOM BOUCHIER, Managing Director at FANUC UK, the newly-launched Economy 2030 Inquiry represents a major opportunity to generate the biggest economic policy change in a generation and could finally hold the key to unleashing British productivity, "The past 15 years have witnessed some of the most uncertain economic periods in our history. While recovery has often followed a fall, we cannot ignore the comparatively lethargic rate of productivity versus many of our continental and international peers," he said. "The newly-launched Economy 2030 Inquiry rightly flags the significant macro issues facing British industry, such as post-COVID recovery, Brexit Quarter 3 2021

and the Net Zero transition. However, perhaps its most alarming message is the danger of facing up to these challenges without a significant change in mindset." Tom believes that automation is fundamental to unlocking the UK's productivity puzzle, and that the attitudes outlined in the report – namely far too little technological change and the persistent worry linked to the changing nature of work – have long been two of the biggest barriers to implementation, along with talent attraction and retention, and funding. "I very much welcome the report's acknowledgement over the need to reconcile the two, as we simply cannot be more productive without further

automation. However, as a society, we need to de-fear automation and change the narrative around what it actually means. For me, the key point is that automation is designed to replace roles, not jobs. When properly executed, it provides an opportunity to upskill an existing workforce, and make their working environment safer, more ergonomic and – I would hope – more rewarding. "Ultimately, I hope the Economy 2030 Inquiry will succeed in engaging policymakers over the coming months and years, and lead to a tangible change in approach that will unleash British productivity on a scale as yet unseen. The time to act is now, or we risk falling even further behind."

10 aemt news

UPDATE FROM THE AEMT SECRETARY Thomas Marks shares the latest news from the Association. WHILE WRITING THIS UPDATE, WE ARE WRAPPING UP the organisation of our 76th AGM, which will have taken place by the time you read this – on 24 June at Silverstone. We committed to hosting the AGM at a venue this year instead of the online alternative we have all been saturated by in the last year! It feels wonderful to be out and about again, albeit with restrictions still in place until mid-July. At the AGM, we will have welcomed our new honorary President, Shaun Sutton of Central Group, Merseyside. After four years with an associate at the helm, it will be refreshing to have a full member back in the chair. Dave Hawley of ABB chose an extraordinary year to be President, but it has not stopped him from pushing the AEMT in a positive direction for the future, and he leaves a strong legacy for Shaun to pick up on. We will publish more on this after the AGM. Now we are halfway through 2021 and 15 months into the pandemic, it is a relief to see the AEMT’s books looking much

stronger compared to this time last year. The online training courses led by Karl Metcalfe have been an enormous success. Not only that, but we have also completed six dedicated seminars introducing our industry: The Bitesize guide to Electric Motors. The series focused on identifying a motor, dismantling and fault finding, following the repair standard, introducing rewinding, and an introduction to assembly and testing. The full course will soon be available on the AEMT website, exclusively for members. Looking forward, I trust you are all thinking hard about your nominations for the AEMT Awards! They return this year on the 18 November. Make sure your nominations are submitted by Friday, 10 September. As a critical sector, the service/repair industry was needed to keep our infrastructure running, as we all huddled indoors away from the pesky virus. We look forward to judging the entries this year and hearing of these experiences. We have also introduced a new category for Diversity in Engineering, awarded to any organisation, company, individual or team that has delivered a specific scheme, project, or initiative, or can demonstrate inclusive participation in their everyday behaviour that significantly contributes to the enhancement of equality, diversity, and inclusion at work. If you’ve any comments or suggestions on what you would like to see from the AEMT, please don’t hesitate to contact us, one of the council members or the President. You can email me at or call +44 (0)1904 674 899.

AEMT AND BPMA SIGN MUTUAL CO-OPERATION AGREEMENT THE ASSOCIATION OF ELECTRICAL AND Mechanical Trades (AEMT) and the British Pump Manufacturers’ Association (BPMA) and have announced the recent signing of a Mutual Co-operation Agreement. The agreement covers a range of collaborative ideas and opportunities, primarily geared around the development of improved skills and enhanced technology understanding across the industrial and engineering arena. It will allow both parties to explore additional content to strengthen their existing range of training courses. Working on possible compliance and legislative related issues and other factors within the repair and maintenance of pumps and motors will also form a key part of the arrangement. Commenting on the agreement, Dave Dave Hawley, AEMT President (left) and Richard Harden, BPMA President, Hawley, AEMT President said: “There sign a Mutual Co-operation Agreement are clear synergies between our two organisations, including some cross-over of membership, and so I am thrilled to have this agreement engineering arena for many years and have developed vast in place and excited by the potential activities that the experience in their respective disciplines. But by forging closer collaboration could deliver.” links and a more collaborative approach to certain activities, Echoing this viewpoint, Richard Harden, BPMA President we can better harvest that expertise for mutual benefit and added: “Our two associations, have been serving the reward.” Quarter 3 2021

Forthcoming AEMT led Courses & Events COURSE TITLE



Ex Training Course Module 1

19 July 2021


Ex Training Course Module 2

21 July 2021


Ex Refresher Module 3

10 August 2021


Ex Training Course Module 1

23 August 2021

Aberdeen (near capacity)

Ex Training Course Module 2

25 August 2021

Aberdeen (near capacity)

Ex Refresher Module 3

07 September 2021

Online (Gulf)

Ex Theory Module 1

13 September 2021


Ex Hands-on Module 2

15 September 2021


AEMT Golf Day

17 September 2021

Forest of Arden (near capacity)

Ex Refresher Module 3

21 September 2021


Ex Refresher Module 3

12 October 2021


Ex Theory Module 1

18 October 2021


Ex Hands-on Module 2

20 October 2021


Ex Refresher Module 3

26 October 2021

Online (SE Asia)

Ex Refresher Module 3

08 November 2021


AEMT Awards 2021

18 November 2021

DoubleTree Hilton, Coventry

AEMT Conference 2021

18 November 2021

DoubleTree Hilton, Coventry

For more information or to book any of the couses listed please visit

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.

— 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:

12 Awards Update

AEMT Awards adds Diversity in Engineering category After an extraordinary 18 months, the AEMT Awards programme will this year give special recognition to all those who have underpinned our health service, infrastructure, and manufacturing sectors throughout the COVID-19 crisis. Additionally, a new category is being introduced – Diversity in Engineering.


he Diversity in Engineering Award will be presented to an organisation, company, individual or team that has delivered a specific scheme, project, or initiative, or can demonstrate inclusive participation in their everyday behaviour that significantly contributes to the enhancement of equality, diversity, and inclusion at work. The recipient will exemplify a healthy commitment to encouraging, promoting, or creating a workplace culture in which employees and colleagues feel valued, respected, and accepted. Sponsored by Preformed Windings, a global manufacturer of coils and a trusted partner to OEM’s and rewind shops around the world, this new category has been developed in conjunction with Croner – the AEMT’s HR partner – and supports the commitment to fostering an open and inclusive engineering environment which promotes equality of opportunity and values diversity. Commenting on the support given to this new category, James Stevens, Global Sales & Marketing Director at Preformed Windings, said: “We are delighted to support this year’s AEMT Awards, and particularly the recognition and celebration of diversity across the engineering arena in which we operate. We pride ourselves on our approach to diversity and are delighted to be able to play our part in encouraging, heralding, and rewarding others for their commitment to this important aspect of career development.” Postponed from its original date in November 2020, the next Gala Awards Ceremony will now take place on the evening of Thursday 18th November 2021, at the Doubletree by Hilton Hotel, Coventry. The associated Conference will also move to this new date. With the introduction of the Diversity in Engineering award, eight categories make up the 2020/21 awards programme. CATEGORIES • 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 • Diversity in Engineering Award – sponsored by Preformed Windings • Lifetime Achievement Award – sponsored by AEMT

Quarter 3 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 they believe merit recognition. The entry process could not be easier, so anyone wishing to play their part in highlighting engineering excellence should visit the AEMT Awards website – – 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 hundreds of pounds. And for those individuals and companies fortunate enough to be announced as one of the eight winners during the presentation ceremony, the kudos and promotional benefit are even greater.

14 product News

NEW MOTORS EXTEND SERVO DRIVE SYSTEM RANGE SIEMENS IS ADDING NEW SERVO motors to its Sinamics S210 singlecable servo drive system. All motors of the servo system are connected via a single cable that combines power wires, encoder signal and brake in one line. Aimed specifically for use in the pharmaceutical and food industries, the Simotics S-1FS2 is a motor version with a stainless-steel housing and a protection rating of IP67/IP69, and high-resolution 22-bit absolute multiturn encoders. The servo motor meets all hygienic conditions and can be used for mixing and stirring, air conditioning and ventilating, dosing and filling, as well as conveying, packaging and storing a wide variety of end products in the food and beverage sector and in the pharmaceutical industry. The Simotics S-1FK2 servo planetary gearmotors complement the Sinamics S210 drive system. They are used when high cycle rates need to be achieved with a lightweight and low-inertia gear design, or when inertia matching is required to move heavy loads precisely.

The motors are ready mounted and as a unit are available in a range of gear ratios and sizes. Thermal dimensioning is achieved via the digital twin in the Totally Integrated Automation (TIA) Selection Tool. Finally, with the Simotics S-1FT2, Siemens is launching a servo motor that offers a range of different options for

the Sinamics S210 servo drive system. For example, encoders with a resolution of up to 26 bits improve system accuracy, and the IP67 protection rating and various motor coatings make the solution suitable for use in harsh environments.

PARTIAL DISCHARGE SENSOR ADDED TO CONDITION MONITORING SUITE THE LIFEVIEW CONDITION monitoring solution from Quartzteq, part of the Quartelec Group, offers a flexible and modular approach to evaluating the health of rotating electrical assets. Offering both online and offline monitoring options, with an assortment of sensors and modules that measure multiple parameters, the range has been enhanced further with the QRC40 sensor ATEX, IECEx and UKCA certified, for partial discharge monitoring. For high voltage machines in an Ex environment, where typical terminations are HV power cables and bushings and where partial discharge monitoring is a fundamental requirement – the LIFEVIEW sensor of choice would be the QRC Rogowski Coil.

Quarter 3 2021

Quartzteq’s QRC85 Rogowski Coil was developed to fit on machines with Euromold Terminals or around a cable with diameters of up to 85mm and to measure Partial Discharge from motor or generator windings. The new QRC40 sensor has been introduced to fit around smaller cables – with a diameter of up to 40mm. Designed for continuous use, up to 2000 A rms on the primary supply side, the QRC40 and the QRC85 both acquire the high current pulses generated by Partial Discharge from high voltage rotating machines. Each comprises two wound coils potted into aluminium casings with the casings being secured together to create a full circle enabling them to be installed around in-situ high voltage power cables and bushing, including Euromold connectors. As well as being ATEX and IECEx certified for

use in hazardous areas, both sensors have also received UKCA Certification in line with regulations post-Brexit.

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

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

Contact us at: T: +44 (0)1484 557200 E:

16 product News

Operations management solution updated CLOUD-BASED OPERATIONS management software solution, simPRO, has seen several updates introduced in quarter two of 2021. One of these is a new feature to enhance communication with employees that includes pop-ups for new tasks. The team behind simPRO has introduced pop-ups as an extra way to capture the office-based team’s attention. In the initial release, pop-ups can notify an employee that they have been assigned to a new task. A small pop up will appear at the bottom of the screen and can either be dismissed or clicked on to navigate to the new task. The pop up will automatically clear from the screen after five seconds. A new icon displaying the number of unread pop-ups has also been added to the top navigation bar as a further prompt. This will stay visible for seven days or until the employee reads or dismisses them. A further update to the software

solution gives users an easy way to adjust what times have been clocked on and off. Sometimes errors are made, especially by staff busy out in the field, which means data in simPRO may not reflect the actual hours worked by staff. Selected staff in the office can now easily edit the clock on and off times of other employees simply by viewing the hours and adjusting the times. Having the ability to edit this means that data in simPRO is even more accurate, allowing you to ensure labour reporting is aligned with the hours each staff member is truly working. Further updates released recently allow users to design forms for jobs,

Frank & Dvorak

Group of Companies

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assets and job cards that better meet their businesses’ needs, complete Square payments faster using prepopulated address details and view more information about their Reverse Tax Charge reports (UK).

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

MAHLE IS DEVELOPING A NEW KIND OF magnet-free electric traction motor that does not require rare earth elements. This makes production more environmentally compatible and also offers advantages in terms of cost and resource security. A feature of the new motor is the inductive – and therefore contactless – power transmission which enables the motor to operate wear-free at high speeds. The efficiency is said to be above 95% at almost all operating points. This development is also easily scalable, so it can be used in anything from subcompacts through to commercial vehicles. The new electric motor is characterised by a high degree of durability, because the necessary transmission of electrical currents between the rotating and stationary parts inside the motor takes place without contact and is therefore wear-free. This makes the engine maintenancefree and suitable for a wide range of applications. During its development, MAHLE has used a simulation process in which various motor designs are adjusted along different parameters until an optimum is found. It is an approach that is significantly faster and cheaper than conventional processes.

Quarter 3 2021

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







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Completed by our experienced expert engineers at our workshop.

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

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

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

18 project updates

ADMIN FUNCTIONS ADDED TO BUSINESS MANAGEMENT SOFTWARE SOLUTION THE TASK CENTRE EXTENSION of the EMiR software solution from Solutions In IT has been adopted by Alpha Electrics. EMiR is an integrated business management system designed for the electro-mechanical industry. Alpha Electrics is a diverse repair and maintenance company specialising in motor and servo rewinds and repair, engineering services, the production of control systems and a wide range of building management services. The company first installed EMiR software in 2012 as part of a drive to formalise the way that work was handled. In 2020, as part of Alpha's continual development programme, Hem Patel, director at Alpha Electrics, approved the purchase of EMiR Task Centre to take communications to a new level. Task Centre is a Business Process Management (BPM) tool that uses the live data in the EMiR system to send messages and alerts about the state

of play to essential stakeholders in the business. Task Centre offers an Amazonstyle delivery capability to each aspect of business processing by punctuating completed operations with automated messages. Task Centre is a configurable asset in the EMiR system and comes with 15 pre-built alerts already in operation by EMiR users. Phase one of the Alpha Electrics installation included 'Despatch Notification' – when a job is finished, the customer gets an email to tell them when they are receiving the item and by what delivery method, resulting in a significant reduction in the number of customer phone calls asking for information. It also included 'Chasing Supplier Delays' – items on order with a supplier that do not arrive on their specified date are automatically emailed requesting clarification. "An item that isn't urgent can

become critical to an operation if this isn't kept in check," said Hem. The automated email from Task Centre puts the supplier on the spot without further delay. Another useful feature is 'Overdue Quotes', which chases the client for answers or updates on outstanding quotes – a labour-intensive role for the salesperson. Although further calls may be made to the client, the automation of the quote statement is a gentle reminder of what needs to be decided. Finally, the 'Booking in Report' function ensures that at 6.00 am every morning, Task Centre compiles a report for company managers to show all of the work booked in the previous day, offering an instant appraisal of the additional workload and ensures that items that have arrived in the workshop are not missed.

Engine room fan refurbishment MAWDSLEYS BER RECENTLY secured a contract to refurbish engine room fans to support the Royal Fleet Auxiliary (RFA) Cluster Team responsible for engineering and management support to RFA Mounts Bay, RFA Lyme Bay, RFA Cardigan Bay, RFA Argus and HMS Scott. When one of the ships was in dock for scheduled maintenance, one of the tasks on the list was a complete refurbishment of the 24in axial flow engine room fans, and Mawdsleys was called in to help with this task. Boasting a fully-equipped workshop and in-house expertise, the company won the contract thanks to its competitive pricing and ability to provide a quick turnaround for the fan refurbishment project. The axial flow fans were collected from the ship. Once delivered to the workshop, Mawdsleys' engineers set about cleaning, degreasing, shot blasting and dynamically balancing the fans before they were

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reassembled with a 45kw overhauled motor. Electrical checks were then carried out to assess performance and ensure the fans would run optimally and safely once back on board the ship.

Finally, the assets were painted in light admiralty grey before being transported back to the ship for refitting into the vessel, on time and within budget.

Project Updates 19

URGENT MOTOR OVERHAUL TO A TIGHT SCHEDULE DURING THE RUN-UP TO CHRISTMAS 2020, a scheduled maintenance inspection by the in-house team at an industrial gas manufacturing plant in South Wales identified a worryingly low insulation resistance (IR) on one phase of a critical 11kV compressor motor. Quartzelec was called and could attend, at very short notice on Christmas Eve, to assess the situation and endeavour to rectify the problem. Upon inspection, heaters were placed around the motor to quickly improve the IR – this resulted in only marginal improvement. Following consultation, the decision was made that Quartzelec would remove and undertake a major overhaul on the 1188kW Parsons Peebles compressor motor, whose duty helps provide a range of critical gases to major industries and medical facilities across the UK. "Having agreed on the plan of action with the customer, we returned early in January to remove the 16 tonne motor for a detailed inspection and overhaul in our workshop," explained Simon O'Leary, Swansea Business Unit manager for Quartzelec. "An issue with the overhead

on-site crane and position of the motor saw us bring in additional specialist lifting equipment to avoid delay, enabling us to get the motor back to our workshop to commence stripping it down." Working extended hours and weekends, the first task for the Quartzelec engineering team was to dismantle the motor before steam cleaning the stator windings. It was then placed in a temperature-controlled oven to help improve the IR. New insulated cable clamps were manufactured and replacement 11kV heat shrink fitted to all cables. The motor was then

transported to Quartzelec's Rugby facility, where a full Baker Test and Partial Discharge tests were carried out to quantify and record the IR improvements achieved before it was finally transported back to the site and reinstalled. Quartzelec was able to keep to an agreed tight schedule for the project of under a month in a bid to minimise downtime at the plant and at a fraction of the time and cost of having a new motor specified and commissioned.

Helping to prepare for an electric vehicle boom Bowers Electricals is proud to have been part of the largest EV charging hub based in the North of England. Monks Cross Park & Ride Electric Vehicles (EV) charging hub in York is set to be finished and in use by July. It will include rapid chargers, a solar canopy, and battery storage. The UK Government intends that the sale of new petrol and diesel vehicles will cease by 2030, and the sale of hybrids will end by 2035. The Monk's Cross Park & Ride hub is one of two being built in York to help this movement. Both sites support modern EVs with larger battery capacities, containing four Ultra-Rapid (150kW) and four Rapid (50kW) chargers. Working with Evo Energy, who is leading the project, Bowers installed a 1500kVA, 11000/415V, Dyn11, KNAN, Tier 2 transformer, finished in a custom pearl green colour. Associated with energy efficiency, the green coloured transformer aims to complement the move towards a green transport infrastructure.

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20 project updates

ELECTRIC MOTORS FOR BRAZIL’S LARGEST OIL AND GAS PRODUCTION PLATFORM WEG is supplying around 40 MV electric motors, with rated outputs of up to 13,400 kW; over 100 LV electric motors; and five MV variable speed drives (three of which have an 11,723 kW rated output), to drive machinery at the Bacalhau oilfield, which is said to be the largest oil and gas platform in Brazil. With the first oil production scheduled between 2023/2024, the new platform is expected to have a production capacity of 220,000 barrels of oil per day and 15 million m³ per day of natural gas.

Driving ammonia compressors for an innovative heating solution TWO LOW VOLTAGE MOTORS and low harmonic variable speed drives (VSDs) from ABB have been specified to drive the compressors for a new heating system which is set to transform the way homes, businesses and public buildings in Clydebank, Scotland are heated. The District Heating Network is the first high temperature (80°C) water source heat pump (WSHP) system in the UK. The system works by extracting water from the River Clyde to generate heat for buildings on the Queens Quay. The two 2.65 MW WSHPs have been designed, manufactured and installed by Star Refrigeration in Glasgow and are part of the company's Neatpump range. The renewable energy heat pump extracts heat from the river's water by compressing the ammonia refrigerant in a high-efficiency screw compressor. ABB's motors and drives are used to power the ammonia compressors, each rated at 836 kW. Applying variable speed control makes it possible to increase screw compressor capacity by overspeeding up to 60 Hz. The compression process raises the water's temperature before releasing the heat via a heat exchanger to a district heating loop at up to 80°C. Pumping water through a network of underground pipes provides heating for several hundred homes and businesses in the area. Dave Pearson, Group Sustainable

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Development Director for Star Refrigeration, said: "Harnessing heat from a river is easy. We simply utilise the thermodynamic principles used in fridges but with a focus on the heat produced. The hard work comes from doing this with the minimal amount of energy input from the electric motors. "ABB supported our analysis of dozens of data points to ensure we had the maximum flexibility, control and efficiency. This will be even more important when we modulate electricity demand to help balance the grid; offloading in times of under generation and increasing demand to reduce the

amount of wasted generation known as curtailment." Most usefully, the VSDs reduce the starting current. Low harmonic VSDs were chosen to minimise harmonic interference on the mains supply. The VSDs exceed the requirements of EN 61000-3-12 and IEEE519 and offer genuine unity power factor with no compensation needed, thereby avoiding reactive power penalties. In addition, the standalone design of the VSD gives it a small footprint, minimising space requirements in the control panel.






22 Compliance

Testing the water with WRAS-approved adhesives Jon Whitehouse, Director, Industrial MRO and Safety at ERIKS, looks at the regulations surrounding the use of threadlockers and sealants on products and systems used in the supply or storage of water for domestic purposes.


trict rules and regulations surround the use of adhesives such as threadlockers and sealants for products that are likely to convey or regulate public drinking water. Failure to check that an adhesive complies with the necessary standards can lead to disastrous consequences. Health, costs, and brand reputation are on the line. So, our advice is to check carefully before making a purchase. The Water Regulations Advisory Scheme (WRAS) is a conformance mark that demonstrates that an item complies with the high standards outlined by UK water regulations. In short, no material or substance that causes, or is likely to cause, water contamination shall be used in the construction, installation, renewal, repair or replacement of any water fitting that conveys or receives water supplied for domestic purposes. To make it clear, that includes drinking, bathing, washing or cooking. Only materials which have satisfied the requirements of BS 692:2000 Parts 1 and 2 shall receive WRAS Material Approval, with anything from pipes, fittings, valves, pumps, taps, showers, washing machines and dishwasher, to coffee machines, boilers and toilets needing to comply. THE CHALLENGE Non-metallic materials, such as threadlocking adhesives and sealants, are today commonplace in various products and assemblies for domestic water supplies. However, some non-metallic materials can affect the odour, flavour or colour of water, with further potential issues such as the release of soluble organic chemicals or the promotion of micro-organisms a cause for concern. BS 6920:2000 – ‘Suitability of non-metallic products for use in contact with water intended for human consumption with regard to their effect on the quality of water’ – outlines the test methods and criteria observed by WRAS when assessing non-metallic materials. The tests in BS 6920 reproduce the typical conditions that a material might meet during its service life in contact with wholesome water. Receiving WRAS approval declares that the product is of suitable quality and standard to avoid water contamination and minimise waste, but only if applied correctly. TESTING, TESTING, TESTING So, now we’re guessing you want to know what the tests involve? Well, odour and flavour testing are fairly

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self-explanatory. A panel of experts assess the taste and smell against a control of tap water. Colour is examined using a colour spectrum, while turbidity (a measure of the degree to which the water loses its transparency) is tested using a turbidimeter, with predetermined pass/fail criteria applying to both instances. Microbial testing reveals if a product will promote any significant growth of aerobic micro-organisms. MDOD (mean dissolved oxygen difference) then determines the pass or fail criteria over the duration of the test, which typically takes 7-10 weeks. The removal of oxygen from the test system occurs as aerobic organisms increase, with comparisons drawn between this loss and the control system. MDOD is the mean value from samples taken at different stages of the testing process, with final evaluation concluding in a pass or fail. Cytotoxicity testing is also required, with a typical duration of seven days. Throughout this period, the analysis team will look for a cytotoxic response or, in other words, determine whether a product shows any toxicity levels to humans.

“Receiving WRAS approval declares that the product is of suitable quality and standard to avoid water contamination.”

Compliance 23 DON’T LET QUALITY CORRODE AWAY When it comes to drinking water, protection against corrosion over a product’s lifecycle is the prerequisite for avoiding contamination. Taking this stance, many of the latest WRAS-approved threadlocking adhesives are designed with patented cure chemistry that optimises performance on anti-corrosion, zinc-flake coated fasteners, and passive substrates such as stainless steel and zinc dichromate. Zinc-flake coated fasteners are today becoming a common choice over zinc-plated and chromedbased alternatives, as they are more resistant to corrosion, safer to manufacture, and do not carry the risk of hydrogen embrittlement. The newest WRASapproved adhesives can also lock and seal brass fittings in drinking water applications. Quality is key here. It’s that simple. Inferior adhesives can become brittle after the curing process, resulting in the seal breaking or fracturing if the plumber accidentally drops the fitting or throws it into a storage box. In addition to WRAS approval, a successful adhesive for this particular application will absorb shock after curing, providing a durable resultant bond, and be supplied hazard label free.

However, we should make you aware that not all products brandish the logo as it is not a requirement. To be certain, it is advisable to check the approval directory on the WRAS website or even ask the manufacturer, merchant, or retailer. Remember, you can never be too sure. In conclusion, there should be no compromise on safety when it comes to drinking water applications. That really is the bottom line. By choosing the LOCTITE range of WRAS-approved threadlockers and sealants, you can rest assured that optimum safety has been considered for both plumbers and consumers. TIMES-CIRCLE

STAMP OF APPROVAL Once approved, selected adhesives and sealants can carry the ‘WRAS Approved’ logo on their packaging.

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

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24 Circular Economy

Do you consider the circular economy when making repair or replace decisions? Matt Fletcher, Managing Director of Fletcher Moorland, explains how the motor repair sector is supporting the drive towards a circular economy.


t's a pretty simple scenario; let's say you have a 160kW motor that's failed. You are either going to send it for repair or replace it. Does the circular economy (or, put more simply - recycling) play a part in your decision? We recently carried out an exercise to see how much of a motor was recyclable. The results were quite surprising, really. The 160 kW motor, based on weight, was over 99% recyclable. Would that make you think again about repair versus replacement? Just concentrating on the electric motor we repaired (or perhaps I should say 'recycled'?), it was sent to us for a repair, the windings had blown, and new bearings were required – a pretty straightforward service. We decided to judge the recyclability of the motor based on weight; this was the easiest variable to measure in our workshops. Before our eager engineers got their hands on the motor, it was weighed at 876kg. Pretty quickly, and because we were all interested to see the results, the motor was stripped down, the bearings were removed, and it was washed and weighed. The windings were burnt-out, removed and weighed. Now I know there will be those of you who have been told that a rewind reduces a motor's efficiency. But, providing critical steps are followed, it does not. This has been proven by a joint EASA and AEMT study, which was updated last year. Without going into the individual weights of the

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stator core, rotor, windings, bearings, pins, washers etc., the total weight of the parts we were either reusing or being sent for recycling was 869kg. So only 7kg was going to waste! I'm going to say with a degree of confidence here that repairing electric motors is a process that's over 99% recyclable. In 2015 the European Commission produced a communication to the European Parliament titled 'Closing the Loop - an EU action plan for the Circular Economy', the first paragraph says: "The transition to a more circular economy, where the value of products, materials and resources is maintained in the economy for as long as possible, and the generation of waste minimised, is an essential contribution to the EU's efforts to develop a sustainable, low carbon, resource-efficient and competitive economy". The electric motor repair process fits in pretty well with that statement; my company and other repair companies are, and have been for a very long time, a crucial part of the circular economy. I'm just wondering whether an age-old process of making-do-and-mending has just been given a new name? TIMES-CIRCLE

“Repairing electric motors is a process that's over 99% recyclable.”

Coil Manufacturing Winding & Taping

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

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26 Circular Economy

Improving standards for the sustainability of electric motors Thomas Marks, AEMT General Manager, highlights the importance of looking at all the options when an electric motor needs to be repaired.


he international focus on minimising our carbon footprint aims to reduce the effects of global warming and stabilise weather patterns. At the same time, there is a realisation that we need to improve our sustainability and preserve the world's resources for the next generation and beyond. For those operating in industrial sectors, there is an opportunity to contribute to these efforts by looking at the most effective solution for motor repairs. Many service centres for electric motors belong to the Association of Electrical and Mechanical Trades (AEMT), which encourages members to assess and deliver the most appropriate repair or replacement of a motor. This ensures that customers have the opportunity to reduce their energy usage by upgrading to a more efficient option, or repair the asset using the latest international standards and extend the service life of the motor cost-effectively. IMPROVED PERFORMANCE Making the best choice relies on having all the relevant information for a specific situation. The decision to replace a motor with one of a higher efficiency classification is usually governed by the initial cost against the additional savings made during its service life. Depending on the application, upgrading from an IE2 to an IE3 motor may not be justified by the improvements in efficiency. However, some operators have concerns about the efficiency of a repaired motor compared to the original factory built specification. These questions were answered by a recent study carried out jointly by the AEMT and the Electrical Apparatus Service Association (EASA) in the USA. It concluded that the energy efficiency of a motor is retained after a repair that follows international standards and guides of good practice. Furthermore, the repair or remanufacturing of a motor effectively doubles the machine's service life, especially in modern, clean environments. The reliability of the motor is similarly extended, and in many cases they will carry the same warranty period as a new machine. For those with specialist environments that require repairs to hazardous area motors, suitably qualified and certified repair centres will follow

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Image courtesy of Houghton International

international standards (IEC 60079 19) to ensure the continued safety of the intrinsic protection concepts. It is worth noting that only suitably trained staff should undertake such repairs; otherwise, the asset record for the motor may be compromised and, with it, the assurances of the manufacturer's design. CIRCULAR ECONOMY The decision to repair a motor rather than replacing it is not only a cost-effective solution, but it also minimises the resources that need to be used. This is summarised in IEC 60034 23, the international standard for rotating electrical machine: repair, overhaul and reclamation. It highlights that replacing the bearings in a 110kW machine effectively doubles the asset's life while retaining 99% of the original machine. Furthermore, the old bearings can be recycled as high quality 'green' steel scrap. For a refurbishment that involves a motor rewind, 90.5% of the motor is reused, and those parts that are replaced consist mainly of high-grade copper and steel scrap that can be recycled. In fact, just 0.9% by weight of the original machine, made up of varnish, grease, insulation and paint, will not be reused or recycled. In every case, maintenance and repair centres that are members of AEMT will always consider all the options for each case and ensure that the operator is aware of both the financial and environmental costs. With all the available information, it is the responsibility of those working with electric motors to decide on the best course of action. TIMES-CIRCLE




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


28 Energy efficiency

Regulation changes affect allowable transformer losses Changes to the Ecodesign regulations, which come into force this year, affect a wide range of energy-related products. As well as increased efficiency requirements placed on new DC motors, the changes affect the acceptable levels of losses in transformers. Michael Bowers, CEO of transformer supplier Bowers Electricals, outlines what the changes mean for the supply of new transformers and the impact the changes will have on carbon emissions.


he 2021 update to the EU Ecodesign regulation was published in October 2019. The new regulation tightens the requirements for load-losses and no load-losses on energy-related products. It is in place to improve energy efficiency, environmental compatibility and to reduce CO2 emissions. And among the areas updated, it made amendments to Regulation 548/2014 on transformer losses. The European Commission estimates that 2.9% of all energy generated across the 27 EU countries (EU27) and the UK is wasted through transformer losses. In a survey led by the EU, it was discovered that the EU27 transformer industry produces annual losses of up to 93.4TWh. To address this, the strict design regulation aims to reduce energy losses of distribution transformers and hopes to save on average 16TWh annually, which equates to 3.7Mt CO2 from being emitted into the atmosphere. To put this in perspective, the revised directive will enable transformer users to save the equivalent of the electricity consumed in a country the size of Belgium*. The revised regulation comes into force on Thursday, July 1, 2021, and can be read at The regulation applies to transformers placed into service in the UK and EU. With a few exceptions, the regulation affects small, medium, and large transformers with a minimum power rating of 1 kVA which are used in 50 Hz electricity transmission and distribution networks or for industrial applications. In essence, the regulation means that any new transformers purchased must be up to the Tier 2 standard. That said, suppliers can still deliver and install Tier 1 transformers if they were available on the market before July 1, 2021. Some manufacturers, including Bowers Electricals, have a limited supply of Tier 1 transformers that they can still sell; however, there should be no further work done to them.

A New Tier 2 1500kVA Transformer supplied by Bowers Electricals to client EVO Energy

The potential reduction in carbon emissions is a clear benefit of this regulation change, but there are other savings to be made. For example, by installing a new 2021 spec Tier 2 transformer from Bowers Electricals, savings of up to £12,753 per annum can be made when comparing the running costs to a pre-2015 standard CRGO Transformer. So, over the course of a unit’s typical 25-year lifespan, there are significant cost benefits as well. TIMES-CIRCLE

“The revised directive will enable transformer users to save the equivalent of the electricity consumed in a country the size of Belgium.”

Quarter 3 2021 *2.9% of the energy generated across EU27 and the UK equals 93Twh, which is enough to power Belgium for a year (based on 2019 figures of 90.3 TWh from

30 Technical solutions


In this issue of Renew, Martin Deiss, Sales Manager Europe & Middle East at Electro Static Technology, answers readers questions about motor bearing protection.

Question: Variable frequency drives can operate at different carrier frequencies. What is the best frequency to use to avoid electrical bearing damage? Martin Deiss: The carrier frequency determines how often the drive switches on and off. You typically use high carrier frequency to avoid audible noise. Basically, the carrier frequency causes the motor to vibrate (make sound). The higher the frequency, the less you can hear the resulting sound. But the higher the carrier frequency, the more often the drive switches the phase voltage on and off. Every time a phase switches, there is a pulse of common mode current. This common mode current causes destructive rotor ground current and high frequency circulating current in larger motors. So high carrier frequency can increase electrical bearing damage. But that doesn’t mean low carrier frequency prevents damage. The carrier frequency doesn’t affect the common mode voltage so much. It’s the common mode voltage that capacitively couples from the motor stator to the rotor to produce shaft voltage. This is the biggest problem in small, well-grounded motors. Changing the carrier frequency doesn’t affect the level of the shaft voltage (only how frequently it changes). If the shaft voltage gets high enough, it will arc through the bearing, regardless of the frequency. So the short answer is: There is no ideal carrier frequency that will prevent damage. Some people say that lower frequency reduces damage, but we’ve never seen a case where a user reduced the frequency, and the problem went away. What you need is good shaft grounding like an AEGIS ring and good motor grounding or motor-load bonding with a high-frequency grounding strap. These will dissipate shaft voltage, and stop it from arcing through the bearing, and prevent rotor ground current. If the motor is over 100 hp/75 kW, you should also have one insulated bearing to interrupt high frequency circulating current. Beyond that, you can set the carrier frequency to be high enough not to make too much noise. Question: What is the influence of motor speed on bearing current magnitude? Martin Deiss: We haven’t seen that speed is a major

factor. It plays in, but it’s not the biggest player in the field. If a motor system is going to have a problem, it will have it whether it runs at 1500 rpm or 3000 rpm. It might be a matter of having a bearing failure in five months instead of six. Question: What size of peak-to-peak shaft voltage should we be worried about? Martin Deiss: There’s no hard and fast answer, unfortunately. We usually say 10V peak-peak. But we’ve seen situations with only 2V peak-peak, but about 100,000 discharges per second. This was in an MRI cooling system. It wreaked havoc on their system after six months. But this is exceptional; normally, 2V peakpeak is fine. In a motor without shaft grounding, you sometimes see low amplitude shaft voltage discharge. This seems to be because the grease is contaminated with metal and carbon particles that make it more conductive. So there’s still arcing going on, but it happens at a lower voltage. Damage accumulates, but because the voltage is low, it accrues slowly at this stage. We like to see shaft voltage under one volt peak. But every system is different. We have seen systems with 40-60V peak-peak, and adding an AEGIS ring only brings it down to 2V. That’s a win. The energy in a bearing discharge grows with shaft voltage squared, so that’s a massive reduction of potentially damaging energy. If you can eliminate most of the shaft voltage, that’s almost always enough. TIMES-CIRCLE

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32 Coil Design

Reducing partial discharge in diamond coils Preformed Windings, a specialist manufacturer of coils for motors and transformers, explains some of the key factors which go into manufacturing diamond coils which minimise the occurrence of partial discharge and offer longer asset life.


here is a growing awareness in the motor and generator repair industry that partial discharge (PD) levels play a significant role in the life expectancy of MV/HV assets. PD is defined as an electrical discharge occurring between two conducting electrodes without completely bridging the gap. It can significantly reduce asset life due to the energy caused by such discharges deteriorating insulation. The risk of PD occurring is increased considerably above 6kV, and therefore careful consideration should be given when designing and manufacturing components for these machines. Diamond coils should be designed with low PD in mind as this is an effective indicator of the quality and integrity of a coil’s insulation and, therefore, its life expectancy. Preformed Windings, based in Sheffield, UK, has been a thought leader in the manufacture of high-quality diamond coils for over 50 years and is very fortunate to work with leading OEM’s and independent repair facilities across the globe in industries such as hydro, nuclear and oil and gas. In these industries and many others, it is critical to have machines operating reliably even as is often the case, they are expected to last significantly longer than the original design life of the machine. Due to its global presence along with close relationships with the Association of Electrical and Mechanical Trades (AEMT), The Electrical Apparatus

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Service Association (EASA), leading insulation manufacturers, repair facilities and PD monitoring companies, Preformed Windings has been approached by several leading OEM’s to carry out significant R&D projects over the past few years, with a focus on reducing PD levels in windings. This research and development has allowed Preformed Windings to assist end-users and repair companies alike to clearly define specifications that reduce PD levels in assets providing the benefit of reduced maintenance costs and long-term reliability.

“Reducing voids or cavities in diamond coils significantly improves PD results.”

PARTIAL DISCHARGE IN COILS There are many quality control considerations when designing and manufacturing diamond coils, but for this introduction, the focus is on the reduction or elimination of voids within coils. Reducing voids or cavities in diamond coils significantly improves PD results. Strictly controlled manufacturing processes allow for significant reduction, or even elimination, of the voids typically found in locations such as between conductors and the mainwall or turn insulation, within the mainwall insulation itself, or between the coils and the stator.

> 34

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34 Coil Design Voids within coils can be eliminated or significantly reduced if they are manufactured with precision and using high-quality materials. Also, attention needs to be paid to proper fitting, and an initial design with a long service life in mind, to avoid voids being introduced during operation from issues such as insulation delaminating due to thermal or electrical stresses. High quality manufacturing of coils, a trusted repair company and extensive testing such as waveform, corona camera, thermal cycle, voltage endurance and tan delta then all become key. MANUFACTURING CONSIDERATIONS When manufacturing diamond coils with low PD levels in mind, sourcing only the highest quality materials is always the starting point, along with the correct handling and storage of materials. Careful consideration should then be made at every stage of coil design and manufacture. For example, due to insulation tape being applied under tension, it is vital to ensure that all conductors are parallel to avoid introducing voids between the conductors and the insulation. Therefore, from the first manufacturing stage, which is looping, careful control of back tension of the copper, lay of the conductors, and careful application of turn tape is critical. “We are often asked why we apply turn tape in-house and why we do not apply mainwall insulation while the coil is a loop rather than after we have shaped the coil. The reason is simply that we want to control the overlap of the insulation very carefully and avoid introducing voids. If the mainwall insulation is applied before shaping, then at every bend the overlap of the insulation is reduced on the outside face of the bend and on the inside, there is a tendency for the insulation to ripple under compression. In high-stress areas, such as the first bend at the end of the slot portions, this would result in undesirable void content and PD levels,” said Martyn Widdowson, Technical Manager at Preformed Windings. Another key part of high-quality resin-rich coil manufacture is the final pressing stage, where the insulation and resin are pressed into a homogenous mass using the careful application of pressure and heat. Carrying out this final press stage in a factory environment allows extremely tight tolerances and exceptionally low PD results to be achieved. Les Guthrie, Production Manager at Preformed Windings, explained: “A common question is how long should the final pressing take,? Many coil manufacturers simply press for a standard time for all coils regardless of coil size, number of layers of insulation or thermal mass. Additionally, manufacturers often make the mistake of inserting coils into the press while the press is at curing temperature, which causes the surface to cure very quickly and without allowing air bubbles to escape. Unfortunately, there is no simple answer to this question as to achieve the lowest PD levels, trials of the pressing process must be carried out to ensure that the temperature of the resin is consistent and correct throughout the coil allowing for the correct viscosity to be achieved, and the excess resin to flow from the coil Quarter 3 2021

without removing valuable insulation and introducing air bubbles.” The careful application of high-quality insulation and the subsequent careful shaping and pressing processes ensures that the insulation is void and ripple-free and is less susceptible to delamination. Without this approach, the voids, ripples and delamination would rapidly reduce the life of coils as identified through an extensive thermal cycle and voltage endurance testing with PD testing before and after. Danny Fox, Managing Director at Preformed Windings, said: “It is our experience that carefully manufactured low PD coils can not only survive the rigours of the thermal cycle and voltage endurance testing but also then pass all standard electrical tests while still returning results mirroring a brand-new coil.”

“A key part of highquality resin-rich coil manufacture is the final pressing stage.”

THE FUTURE Currently, there is a hunger in the HV repair market for low PD coils, but there is a lack of clear specification or guide to best practices. For this reason, Preformed Windings continues to work with well-respected partners to carry out extensive R&D activity related to reducing PD in coils and rewound stators. James Stevens, Global Sales and Marketing Director at Preformed Windings, said: “Preformed Windings is well positioned and willing to help end-users and repair companies alike to raise the expectation of service life in rotating electrical machinery by sharing knowledge and expertise. We have successfully developed low PD coils that have been extensively tested both internally and independently, exceeding industry standard tests such as thermal cycle and voltage endurance many times. As a result, it is now possible to have much longer warranties such as five or ten years with confidence that the machines will run consistently and efficiently.” TIMES-CIRCLE

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Are you docu menting Ex repairs?

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

Don't neglect your generat or Indu stry New


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36 Generator maintenance

Don't neglect your generator Generators can often be called on at short notice, so it is essential that they remain fully operational. Singapore-based Maintech Engineering Services highlights six signs that warn a generator may need a repair or maintenance to ensure it is ready when needed.


egular maintenance is key to ensuring that electric generators run smoothly and remain operational whenever a power outage occurs. In addition, generator maintenance also prevents fuel issues, saves money for the long-term, lengthens equipment lifespan and boosts a generator’s efficiency. So, it is paramount to keep generators in good working condition – for streamlining operations in the workplace and improving the bottom line. To do this it is important to conduct frequent inspections to spot any warning signs that show if a generator needs servicing. Let’s look at the six signs you should look out for that may indicate the need to conduct an electric generator repair. FLUID LEAKAGE Fluid leakage is one of the easiest signs to spot. If you notice any fluid leaking during routine inspection, schedule an engineer to take a look as soon as possible. Fuel leakage can lead to increased fuel consumption which results in a higher fuel cost. If it is a coolant leak, there may be a risk of the generator overheating after prolonged operation. INCREASED FUEL CONSUMPTION If you notice that your generator is not performing up to the recommended level provided by the manufacturer, it may be due to an increase in fuel consumption. However, keep in mind that fuel leakage may not be the only cause of high fuel usage. Therefore, you may wish to have an expert access the situation and check for further issues. SLOW STARTING If you notice your generator is slow to start whenever it is powered on, it could be a sign of more severe problems. The slow start could be due to a lack of use, especially if this is the backup generator, and therefore may be a non-issue. However, if the primary generator is giving you problems, that means it is time to give your engineer a call. DAMAGED OR FAULTY PARTS It is crucial to look out for any damaged or faulty components when conducting an inspection. A generator that is situated outdoors is subjected to weather conditions that can damage the machine’s components. There is also an increased risk of the machine parts being damaged when directly exposed to sunlight for a prolonged period. Look out for any damaged copper windings that may indicate the need for a generator rewind. In addition, any frayed wires have to be replaced, and the loose nuts and

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bolts have to be tightened up. If you spot any damaged components, it is advisable to call an expert to take a look before activating the generator. STRANGE SOUNDS It can be hard to distinguish unexpected noises from the regular sounds emitting from a generator. Pay attention to specific audio cues, such as metal-on-metal sounds, loud banging noises or a sputtering engine that may indicate problems with your generator. INCREASED GAS EMISSION It is normal for a few puffs of smoke to be produced when activating a generator, and they should soon dissipate. However, the generator may have an underlying issue if the smoke does not clear up after a few minutes. If the generator emits excessive smoke or the smoke produced is black, you should turn it off immediately and have your engineer inspect it. Blow-by gas can be emitted when a generator is active. Blow-by occurs when there is a leakage of the combustion gas between the engine’s piston ring and the cylinder wall into the engine’s crankcase. It is not possible to have a perfect seal between the piston ring and the cylinder wall. As a result, this leakage is bound to occur. However, it is still advisable to measure the blow-by gas emitted from a generator regularly. Increased emission of this gas could be a sign of faulty components that need replacing. It is advisable to schedule regular inspections on a generator to prevent more significant issues down the line. Your engineer will be able to conduct a generator overhaul and detect any problems that need fixing immediately. Performing regular maintenance gives added security and ensures that you are less likely to encounter a faulty generator. TIMES-CIRCLE

A global leader in coil manufacturing for over 50 years Providing superior quality, high voltage coils with the lowest Partial Discharge levels and best Tan Delta Results in the industry. As an independent coil manufacturer we are a trusted partner to the largest OEM’s and rewind shops around the world.

E: | T: +44 (0) 114 248 4391 AW_PW_Half_Page_Ad.indd 1

21/05/2021 15:50

Machines for all applications Our ZB750 is a horizontal machine for the dynamic balancing of rotors up to 1,100 kgs. It can be supplied with dual drive - a cardan shaft drive and a belt drive with manual or pneumatic tensioning. The machine allows the balancing of rotors at a wide range of speeds and is supplied with B9 or B11 instrumentation. And all backed up by the most comprehensive support and parts service available in the UK. So whatever your balancing requirement we’ve got you covered. For further information contact us on T: 0161 872 3123 or E:

38 Harsh Environments

Challenges for bearings in mining and quarrying environments Steve Onions, of Haley Bearing Solutions, looks at some of the key challenges faced by bearings in the mining and quarrying sector and outlines some of the options which can help to overcome them.


earings that operate within the challenging environment of the mining and quarrying sector have to function effectively in a world that is vastly different from the highly sanitised conditions of the food processing and manufacturing industries. Along with other key components, in these harsh working conditions, bearings have to face numerous challenges associated with their (mostly) outdoor locations, the nature of the materials being handled, and the high production demands of an industry that measures daily output in thousands of tonnes. With this in mind, careful bearing selection is vital to ensure that they meet specific needs and are robust enough to withstand whatever is thrown at them, and help to keep vital high-volume production running. Let’s explore four key challenges faced by bearings operating in these environments. CONTAMINATION Due to the outdoor nature of mining and quarrying operations, critical machinery and components, including bearings, are exposed to the elements 24/7/365. This creates a suboptimal environment for effective performance and reliability, as bearings are often at the mercy of whatever the

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weather throws at them, including heavy and persistent rainfall. Conditions both during and after rainfall are a key concern for engineers, with effective sealing solutions on spherical and housed bearings proving to be popular solutions. Products such as the SKF Triple Barrier solution and RHP Self-Lube Triple Lip Seals are on the market to help keep contamination of both liquids and solid particles out of bearings, prolonging their service life as a result. Another external contamination threat that bearings are subjected to in these applications is the high levels of dirt and dust that are ever-present. Sand, dirt, and dust particles, biproducts of mining and quarrying activity, can result in excessive abrasion, capable of creating misalignment and ultimately reducing service life. Larger particles of grit and chippings can also cause pitting and bruising (dents) if they progress into bearing enclosures, resulting in premature spalling and failure. NTN-SNR ULTAGE KIZEI spherical roller bearings have been specifically developed to withstand extremely challenging applications. The bearing’s unique metallic shield design creates an armour against solid contamination and offers a robust and durable solution.

> 40

Giving special thanks and recognition to the repair and service centres underpinning our health services and infrastructure during the pandemic

Call for nominations now open... Endorsements:

“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

Thursday, November 18th 2021 Doubletree by Hilton Hotel, Coventry The awards are a global celebration of business and professional excellence. They recognise the achievements of both individuals and companies manufacturing, distributing, maintaining and repairing industrial machinery such as electric motors, drives, pumps, fans, gearboxes, generators, transformers, switchgear and ancillary equipment. There are 7 categories to choose from including: Product of the Year, Project of the Year, Supplier of the Year, Service Centre of the Year, Diversity in Engineering, Contribution to Skills & Training and the Rising Star Award. Make sure you enter now to be recognised as a leader in your industry.

Enter Now:

2021 Partners:

Deadline: Fri, 10th Sept 2021

40 Harsh Environments HEAVY LOADS The nature of the product excavated from mines and quarries means that bearings will need to deal with very heavy and variable loads. Take, for example, the critical application of bearings within conveyors used to transport high volumes of material across long distances. These conveyors are intrinsic to the operation, and the bearings within them must be robust enough to withstand the loads involved. Any length of downtime affecting these critical applications can harm production and revenue, with the costs quickly mounting. NSKHPS (high-performance standard) spherical roller bearings have a dynamic load rating of up to 20% higher than conventional spherical roller bearings, making them an ideal choice for applications where a heavy load capacity is required. Available with a steel or brass cage for standard or large-sized bearings, respectively, they are also suitably strong for demanding applications. VIBRATION Perhaps the most challenging applications for bearings operating in the aggregates industry are vibrating screens (sometimes called shaker screens). These machines are usually substantial in size and vibrate continuously to move products along a length, separating materials such as solids from liquids and dividing them by size along the way. The non-stop and vigorous vibration that bearings are in contact with here is regarded as a dynamic force that can inflict damage and impact bearing performance. Bearings selected for use in vibrating screens must have a high load and speed rating, strong misalignment capabilities, and generate minimal friction to operate smoothly. FAG special spherical roller bearings with Durotect coating are a specially designed solution for vibratory machinery applications. These bearings can withstand the severe stresses involved in vibrating screens, whilst the Durotect hard chromium coating

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helps to prevent the common issue of fretting corrosion between bore and shaft. DIFFICULT ACCESS AND MAINTENANCE Bearing locations within mining and quarrying applications have a reputation for being some of the most difficult to access and, as a result, to carry out maintenance on. This is because they are often in trapped or enclosed parts of the machinery that themselves are not the easiest to gain access to. As the demands on continuous production are so strong in the industry, the amount of downtime required to complete any maintenance needs to be kept to an absolute minimum. The SKF Cooper split spherical roller bearing offers a solution that reduces the meantime to repair (MTTR) by 70%. With no need to dismount the drive coupling or the cantilevered drive when replacing the bearing, productivity is improved with less downtime needed. Maintenance engineers’ exposure to potential accidents and injuries is also reduced as a result. It is evident that bearings operating in machinery such as conveyors, vibrating screens, and crushers in the polluted and exposed environments of the aggregates industry, face a range of challenges. Therefore, settings like mines and quarries are some of the most inhospitable for bearings and most other engineering components, such as transmission products and motors. Hayley Bearing Solutions work in partnership with world-leading bearing manufacturers to support our customers and deliver solutions. TIMES-CIRCLE

Settings like mines and quarries are some of the most inhospitable for bearings.

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

+44 (0) 1952 208 730

42 Traction Motors

Traction motor repair for hybrid bus operator When a London bus operator needed to identify a partner to repair and overhaul the motors and gearboxes of its fleet of hybrid buses, it turned to the electromechanical repair specialist,Houghton International, as Renew found out.


he London bus operator runs a TB08 hybrid diesel-electric fleet of buses, all fitted with traction motors featuring hermetic and oil cooling integrated gearboxes. However, with no repair and maintenance partner appointed, the operating company’s only option for failed traction motors was to replace them with entirely new motors, sourced from America, with a significant lead time and cost, guided by the OEM. Because of this, the operating company set out to find a competitive alternative with a shorter lead time to repair and extend the life of the existing motors. Building on Houghton International’s experience, a research and development project was carried out to develop a repair and overhaul specification. This process included a complete 3D scan of the motor to produce a comprehensive 3D CAD model. This was documented in detail to report back to the operating company and Transport for London (TfL) to provide a detailed working specification for all future requirements. Houghton International is experienced in repair, maintenance and overhaul of a wide range of electromechanical assets, and this meant that the operating company had the added assurance of sending the motor and gearbox to one service provider where they could be overhauled together. The repair specialist drew on prior knowledge and expertise to develop an overhaul procedure for the motor and gearbox with replacement parts reverse engineered where required. After an initial inspection, it was established that the motor required a rewind. Houghton International’s engineering team is experienced in working with rare types of coil and bespoke winding procedures. An unusual style of hollow copper, designed to run coolant through the windings, was used in the motor’s coils. Specialist tooling was manufactured, and the Houghton International purchasing team engaged with its extensive international supply chain to source and import the required copper. The coils were reverse engineered, designed and manufactured in-house, working closely with the winding team to ensure optimum coil fit and windability for a high-quality rewind. The units were tested in line with the operating company and TfL’s requirements, including pressure

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testing to identify any potential coolant or oil leaks, to give the customer added peace of mind before the motor and gearbox unit was returned to service. The Houghton International team developed a bespoke repair and overhaul specification for the TB08 traction motor and gearbox. All steps of the process were documented to provide a detailed working specification for future work and reported back to the operating company. This provided the operator with a cost- and time-effective alternative to sourcing new motors when existing ones fail, significantly reducing lead times and avoiding an overreliance on the OEM. All at a reduced cost compared to the price of new. Houghton International is experienced in delivering volume contracts and ad-hoc casualty repairs, mobilising quickly to carry out emergency repairs with quick turnaround times whilst following an established process to ensure quality and consistency. Houghton International is now well equipped with the necessary data and specifications to meet the operating company’s needs for ongoing support for electromechanical assets on its fleet of hybrid buses. TIMES-CIRCLE

Hollow copper, designed to run coolant through the windings, was used in the motor’s coils.

Visit Call +44 (0)1904 674 897

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

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

Promoting Engineering Excellence

Hazardous Areas 44 44 FEATURE

Are you documenting Ex repairs? Wherever there are gaseous atmospheres and dust, there is the potential for explosions with disastrous results. It is easy to see why legislation relating to hazardous areas and ensuring it is followed is important. When repairing electromechanical equipment used in hazardous areas, correct documentation is key to demonstrating compliance, and in turn, safety, as Karl Metcalfe, Technical Support at the AEMT, explains.


he responsibility for ensuring compliance and safety in hazardous environments sits squarely with the user of the equipment.This means that if you commission the repair of Ex rated equipment, the responsibility for ensuring the repair maintains the equipment’s compliance with the ATEX directive is yours. The AEMT Ex Register is a list of AEMT members who have met the requirements to be listed as an Ex registered member with the expertise and ability to repair hazardous area Ex equipment, but ensuring they do is the user’s responsibility. The situation can be likened to repairing a car. A garage will fix it, but you are still responsible for that car being roadworthy when you drive it afterwards. The garage will give you a piece of paperwork to say what has been done, and you will keep that piece of paper as a record of that work. Looking after Ex equipment is relatively similar, if somewhat more involved. The Ex repair standard (BS EN IEC 60079-19:2019), which has been developed to ensure the safe repair, maintenance and overhaul of equipment used in hazardous areas, states that: “The user is the organisation or person which is the owner, or operator, of the equipment, and they are primarily responsible for repairing it; not the equipment manufacturer or repairer”. It also says: “The user should consider whether sufficient facilities and competencies are available to undertake the repair or overhaul of such equipment by the user or whether it should be contracted to specialist repair and overhaul service providers”. In situations where equipment is to be repaired by a specialist service provider, the standard goes on to state that: “The user has to ascertain that the service facility concerned can demonstrate compliance with the relevant stipulations of this document [the standard] and any regulatory requirements”. If you don’t ask the repairer for evidence that their practices and the work they have carried out meet required standards, they do not have to give that to you. But it

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remains your responsibility that the item you have had repaired is still safe for use. If an incident happens, you will have to explain why you have fitted a piece of equipment in a hazardous environment without knowing the specification of that piece of equipment. In addition, it is the user’s responsibility to be aware of any relevant legislation regarding periodic inspection and verification to ensure equipment remains fit for purpose. Plus, the user should be aware that sufficient information must be provided to third-party service facilities and installers to meet occupational health and safety obligations. DOCUMENTATION To meet these requirements, the user and repairer should work together, and the documentation of all stages of a repair is essential. The service facility needs to assess the equipment’s status and agree on the expected status of the equipment after repair and the scope of work with the user. This should be done in writing so that if there is a problem at a later date, there is a paper trail to evidence the circumstances – something which can protect both the user and the repairer. The service facility should also ask the user to provide all necessary information and data related to the equipment being

repaired, including previous repairs, overhauls, or modifications. To do this, the user must gather and keep this information when previous repairs have been carried out. After a repair, the user should be given written details of all the faults detected, full details of the repair or overhaul, a list of replaced or reclaimed parts, plus the results of all checks and tests. And this information should be in sufficient detail to be useful to the next repairer. In addition, a copy of the user contract or order, along with a comparison of the results against the criteria that have been used to determine compliance, and a recapitulation of the marking applied should also be kept. The repair standard says that the service facility must keep all documentation, including any drawings, electrical and mechanical measurements and readings, and all agreements in writing between the user and repairer for ten years. The equipment user should do so as well. A repairer listed on the AEMT Ex repair register will have been assessed as meeting the requirements needed to repair hazardous area Ex equipment, so this is an excellent place to start when a repair is required. But any end-users needing guidance on safely repairing Ex equipment can also contact the AEMT directly. TIMES-CIRCLE

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

Faults in sleeve and rolling element bearings Shaft misalignment and soft foot Resonance Problems caused by magnetic forces Problems in induction motors supplied from inverters

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


Vibration Monitoring of Induction Motors An author with 58 years’ experience on vibration monitoring of induction motors. He is a Fellow of the IEE and a Senior Member of the IEEE. Use code IMEC0721 for 20% discount Read one sample industrial case study. Reviews, Endorsements & More

45582.indd 2

24/02/2021 15:12

46 Hazardous Areas

Vibration monitoring could have saved thousands

Engineering service provider Quartzelec, a specialist in the offshore sector, explains how it repaired a critical motor fan on a floating production storage and offloading vessel and how, with preventative maintenance in place, the issue may never have occurred.


espite the floating production storage and offloading (FPSO) vessel being just three years old, it had already experienced several equipment issues, with one significant failure related to the fan unit of a critical Ex de induction motor drive. When Quartzelec was approached to investigate the issue, it helped rectify the immediate problem and identified and addressed the root cause, as well as suggesting a potential solution that could minimise the likelihood of similar issues occurring in the future. Quartzelec’s initial inspections of the 67kW 690V Ex de, cage induction motor identified substantial damage, including failure of the DE and NDE bearings, multiple ATEX defects, a melted cooling fan due to bearing failure, core damage to the stator and rotor, plus significant winding damage. The immediate solution was to secure and fit an identical direct replacement machine; sourced and reinstated into the casing by Quartzelec, with the new unit fully balanced and tested. For most suppliers, that would have been the end of the project, but the Quartzelec team was eager to identify the root cause of the problem. “Having been able to install an operational replacement machine, we quickly established that a lack of regular maintenance had caused the previous failure. This was brought about by the motor greasing points being impossible to reach when the machine was in service,” explained Seoras Shaw, Project Manager at Quartzelec Aberdeen. “Rather than accepting that this failure could reoccur with the newly installed duplicate motor, we worked with both the client and the OEM to identify a viable solution. Accessible greasing facilities have now been installed on the unit to allow the bearings to be maintained as part of the regular maintenance schedule, and this should significantly increase the operational life of the machine and reduce future risk of failure.”

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Despite being less than three years old, the failed machine was beyond salvaging. However, had a condition monitoring programme been implemented from the outset, such extensive damage and the resulting replacement and downtime costs could have been limited or even totally avoided. Quartzelec has developed preventative maintenance solutions and offers both ongoing and scheduled condition monitoring along with a vibration monitoring service, all of which can help identify potential issues as, or even before, they develop. Remedial maintenance can then be scheduled before a failure occurs. In this instance, the fan unit was critical to plant operations with its failure causing operational issues for the client and almost three months without a functioning unit. “As identified by our expert engineers, the root cause of failure is often overlooked, but it is critical when offering a repair solution to prolong machine lifespan and ensure longevity,” added Paul Oliver, Quartzelec Aberdeen’s Business Unit Manager. “In this instance, we could have realistically saved around £17,000, which the client had to spend on a new machine, and eliminated all the associated costs and additional equipment downtime. “Quartzelec's simple to implement vibration monitoring service would have identified the initial, first stage bearing defects as they happened. Appropriate action would have cost around £4,000 for replacement components and the time required for the replacement, which could have been done as part of a scheduled maintenance programme in under a couple of weeks.” TIMES-CIRCLE

"In this instance, we could have realistically saved around £17,000."


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


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


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:

Media Partners

Contact us for 2021 participation information now! Email: Tel: +44 (0)1732 359990

Supporting Organisations


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


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

+44 (0)282 565 6406

• • • • •

Gearboxes Laser Alignment Condition Monitoring Marine Repairs Thermography

• • • • •


Vibration Electrical Mechanical Generators Rewinds

0114 256 0425

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


Spindle Motors Inverter Drives Electrical Mechanical Rewinds

0191 519 3344


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)


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



• • • • •

Transformers Balancing Machining Fabrication Rewinds

01279 653333

CEMB Hofmann UK Ltd

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

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


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

0161 872 3122


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The journa l f rom

Quarter 3 2021


Hazardous are

To continue to receive your free copy of Renew, in print or online, register at: Stay up to date with the latest products, technical insights, news and innovations, for everyone responsible for maintaining the safe and efficient operation of electrical and mechanical plant and equipment.




Are you docum

enting Ex repairs?

Don't neglect your generat or Indus try News

Innov ations

Appli cation s

Exper t Opini


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

Pumps Motors Gearboxes Fans Servo Motors

• • • • •

Spindle Motors Inverter Drives Thermography Mechanical Rewinds


01527 575888

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

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

0191 4165222

Mechanica Utilities Ltd

Fletcher Moorland Ltd

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

• • • • •

Marine Repairs Vibration Electrical Mechanical Generators


SPP Pumps Belzona Coatings Hydromarque Pumps Brown Europe Gearboxes


Pumps Motors Gearboxes Fans Laser Alignment

• • • • •

Servo Motors Inverter Drives Condition Monitoring Rewinds Ex Motor Repair

01304 206690

01782 411021

Rotamec Engineering Solutions

Invincible Electrical Eng Co

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


Marine Repairs Electrical Mechanical Generators Rewinds

01934 743165

APPROVED BY Lowara Grundfos Motovario Lenze TEC NIDEC Marelli

• • • • •

Pumps Motors Gearboxes Fans Spindle Motors

• • • •

Inverter Drives Electrical Mechanical Rewinds

01384 261307

To feature in the Repair Service Directory, contact Andrew Castle: PHONE +44 (0)7785 290034 envelope


FEATURE 50 Opinion

We must support Diversity in Engineering Following International Women in Engineering Day in June – an initiative supported by many AEMT members – Thomas Marks, Secretary & General Manager at the AEMT, looks at what else needs to be done to improve diversity in engineering.


espite a heavy focus being placed on encouraging greater inclusivity in the workplace and levelling the gender pay gap over recent decades, diversity in engineering remains stubbornly poor. I know this from personal experience, because whenever we look to recruit new Council Members, there appear to be very few women in any leadership roles within the AEMT membership. Sadly, this does seem to echo the wider industry norm, whereby women, black, Asian, and minority ethnic groups are underrepresented in a broad range of technical disciplines. And this problem is, of course, further compounded by the fact that there is an overall shortfall of engineers and technicians with the required core skills, creating a desperate need for new talent. However, diversity is about far more than simply recruiting female staff members or those from the BAME community; it is about creating a mix of different backgrounds, cultures, and ways of thinking. And there are clear business benefits to be gained as well. For example, encouraging workers from more diverse areas of society will give an increased choice of skilled workers. A breadth of backgrounds, cultures, and experiences also offer wider scope for problem-solving and creative thinking, while customer service can be improved when staff from a broad range of backgrounds better understand the needs of end-users. And, of course, a more inclusive work culture will lead to increased productivity. At the AEMT, we are focused on improving this situation among our membership. One way we are trying to make a difference is by encouraging member companies to become involved with organisations and initiatives supporting diversity in the STEM sector. One example is the WISE Campaign; an initiative focused on making a sustainable difference to gender balance in STEM roles. The Royal Academy of Engineering is also heavily focused on diversity and has several initiatives crossing industry and academia. We have also introduced a new category to the annual AEMT awards – Diversity in Engineering. This new award will be presented to an organisation, company, individual or team that has delivered a scheme, project, or initiative that significantly contributes to the enhancement of equality, diversity, and inclusion in their place of work. We hope that

Quarter 3 2021

the introduction of this award not only recognises existing activity but also helps to draw attention to, and drive a focus on, diversity among the AEMT membership. But creating an environment conducive to developing a diverse workforce does require the talent to be available. And this is where a large part of the challenge lies – encouraging our young people into engineering. This is an ongoing problem for a number of reasons. There is a lack of role models in engineering, and daughters particularly get little support from their parents to encourage them into engineering. And then looking at diversity more widely, cultural differences may mean engineering is not recognised as a path to success. Again, there are initiatives designed to encourage and support young people on a path towards an engineering career. One such project, Primary (and Secondary) Engineer works with young people from early years settings through to further education and supports the students and the educators. It does this with significant support from and involvement with industry. While not specifically focused on diversity, its activities are entirely inclusive and aim to encourage engineers from all cultures and backgrounds. So it is clear that there is much activity aimed at driving diversity in engineering, but more needs to be done. And if the engineering community is to benefit from a young, inclusive workforce coming through, then it is incumbent on all of us to do what we can in support. Indeed if you have any specific initiatives designed to improve and encourage diversity within your business or have come across them elsewhere, we’d love to hear about them. Please email details to our editor, Chris Callander, at TIMES-CIRCLE

“If the engineering community is to benefit from a young, inclusive workforce coming through, then it is incumbent on all of us to do what we can in support.”



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