Renew Magazine - Quarter 3, 2023. Hazardous Areas focus

r new

FOCUS ON: Hazardous Areas

Gearbox considerations for hazardous environments

Brook Crompton

IP23 Cast Iron

Range from 18.5kw 710kw in

frame sizes 160 to 355

In Stock

New Motors

TT Electric

Full range of High Quality DC Motors from 1kw to 2000kw IP23 IP55.

In Stock

Re-Conditioned Motors

• Cage up to 1mw Ex Stock

• Slip-Ring up to 500kw Ex Stock

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

• D C Motors

• High Tension Motors 3.3Kv

• Geared Motors

• Two Speed Motors

• Vibrator Motors

Variable Speed Drive Specialist

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

Editor Chris Callander chris@renew-mag.com

+44 (0)1732 671123

Contributing Editor Suzanne Gill suzanne@renew-mag.com

Publisher Andrew Castle andrew@renew-mag.com

+44 (0)7785 290034

Accounts

Touchwave Media Ltd accounts@renew-mag.com

Production G and C Media Ltd production@renew-mag.com

Founded in 1945, the Association of Electrical and Mechanical Trades is an International Association representing companies in the electrical and mechanical service and repair industry.

This is the last time I will be introducing an issue of Renew magazine as President of the AEMT. At our Association AGM in June, with my fixed term of office at a close, I passed the baton over to James Stevens of Preformed Windings, as he takes on the President's role for the next two years.

I have thoroughly enjoyed my time as President and the opportunity to contribute to shaping the ongoing direction of our Association. A key area of focus for me during my time in office has been the people within our membership. And by that, I mean all the people working within our member organisation. I believe in collaboration and the power of sharing knowledge and experience, and I hope as I leave my position, the Association has grown in those vital areas and our membership has benefited as a result.

I want to thank all the council members for their support over the last couple of years and hope that as we move forward, we continue to attract and secure such enthusiastic and dedicated people within the organisation.

I would like to also thank my predecessor, David Hawley, for all his hard work and support in the run-up to my taking over and as past President during my tenure.

I would, however, particularly like to thank the AEMT team, Thomas, Karl, Rebecca and Lesley, for all their incredible work in the day-to-day running of the Association.

I am confident that the AEMT will remain in good hands as James Stevens takes over the Presidency, and I am excited to see what the future holds for the Association and, of course, its members. We must never forget those members carry out incredibly important work each and every day, and it is a privilege for the Association to support them.

Renew is a controlled circulation journal published quarterly on behalf of the AEMT by Touchwave Media and G and C Media. For a copy of the magazine’s terms of control and to request a copy please email circulation@renew-mag.com

The content of Renew magazine does not necessarily reflect the views of the editor, publishers, or the AEMT. The publishers accept no legal responsibility for loss arising from information in this publication and do not endorse any products or processes mentioned within it. No part of this publication may be reproduced or stored in a retrieval system without the publisher’s written consent.

© AEMT. All rights reserved.

Shaun Sutton, (past) President, AEMT

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.

DLRO2

2 Amp DucterTM Low Resistance Ohmmeter

n New “difference meter” for quick data comparisons

n Safely tests the resistance of inductive loads at 1A

n <600 V active protection against inadvertent live connections without blowing a fuse

MPQ1000

Power Quality Analyzer

n Automatic CT recognition

n Onboard data analysis

n 1000 V ac and 1000 V dc range

DCM305E

Earth Leakage Clampmeter

n 0.001 mA resolution

n Up to 100 Amp range for standard ac current measurements

n Low pass filter to aid stability of readings

MPD Scan

Handheld Scanner for PD Surveying

n Fast verification of partial discharge activity in MV and HV plants

n Universal application range due to a wide variety of sensors

n Integrated camera and QR code scanner

AVO835

True RMS Multimeter

n High/low sensitivity live circuit detection

n Phase sequence measurement for 3 phase circuit and motor testing

n 10 MΩ and 10 kΩ input impedance switching

PD and Tan delta testing, PD online monitoring

Partial Discharge and Tan delta testing is together with Static testing complementing the standard FAT and on site testing procedure of the insulation status for critical HV motors and generators.

The ICMflex system can perform PD and Tan delta testing in one simultaneous test sequence with one common test report. It is a compact and portable all in one unit suitable for on site, as well as workshop testing. Portable AC Hipot solutions are available too.

The ICMmonitor system is an approved solution for online Partial Discharge monitoring on HV rotating machines and it can come as a portable unit for temporary monitoring/ spot testing, or as a permanently installed monitoring cabinet with remote access and alarming.

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.

Automated Diagnostic Test Equipment

n Asset-centric approach promotes turnkey testing for operators

n Separating Asset from Installation provides greater insight into asset service needs and issues

n PowerDB Dashboard secure cloud-based analysis software

n Choice of Manual, Automatic, or Sequence testing

n Screen-level context sensitive help

n Adaptable search capability

n Asset management tools

NetEP

Site Installed Dynamic Monitoring System

n Permanently installed, fully automated machine system monitoring solution which evaluates each component of the electromechanical system and identifies electrical and environmental factors that will accelerate insulation degradation

n The system continuously acquires health and performance data on up to 32 electric motors and the rotating machine systems they operate

MTR105

Rotating Machine Tester

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

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

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

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

Dynamic Motor Analyzer

n The Megger Baker EXP4000 is a portable Dynamic Motor Analysis System

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

PPX

High Voltage Motor Tester

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

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

ENGINEERING FIRM INVESTS IN BALANCING CAPABILITY

A HEAVY ENGINEERING COMPANY based in the North East of England, specialising in component machining for the defence, renewable power, nuclear and marine industries, has invested in a ZB4500 horizontal balancing machine from CEMB Hofmann UK.

Due to approved supplier status with defence contracts and a world-leading mechanical power transmission brand, the company experienced increased demand for balancing manufactured and refurbished rotor components for heavyduty industrial projects.

The new machine will now be used to balance medium to large rotors and can deal with components of up to 6,000kg and with a diameter of up to 1,580mm.

With one of the largest machining capabilities in the UK, the ZB4500 will play a vital role in delivering the company’s service offering and is further proof of its commitment to continual investment in the latest technologies.

CEMB Hofmann UK has recently supplied, installed and commissioned the machine and undertaken comprehensive user training. Ongoing support will be delivered in the form of an annual service of the machine, undertaking on-site fault diagnosis as required, plus supplying and installing genuine spare parts.

The customer decided to take the dynamic balancing capability in-house to meet increasing demand for its services, although previously used CEMB Hofmann UK’s sub-contract balancing service, which will still be available to solve any capacity or capability challenges should they arise.

RENEWABLE DIESEL PLANT OPTS FOR SULZER PUMPS

A CANADIAN OIL producer is undertaking a project to use local canola (rapeseed) oil to create renewable diesel on an industrial scale. At the heart of the plant will be a number of precision pumps from Sulzer that have been designed to handle challenging process conditions. The expected outcome of the initiative is a reduction in carbon emissions by three million tonnes annually, equivalent to cutting the number of vehicles on the road by 650,000.

The anticipated output of the facility is more than one

billion litres of net zero diesel per year that can be used to power vehicles, trains and industrial boilers. The proposed expansion of the existing refinery is expected to be complete by March 2024.

In all, Sulzer will supply 26 pumps. Two MSD (BB3) models will be responsible for the highpressure and high-temperature naphtha feed application, a central part of the catalytic process to break down the canola oil. Two BBT-D recycle pumps, and a number of

OHH and PRE process pumps will be delivered with a Duplex stainless steel construction to ensure extended service in challenging conditions.

EA APPROVAL FOR LITHIUM-ION BATTERY RECYCLING PLANT

Technology Minerals, a UK company focused on creating a sustainable circular economy for battery metals, has announced that its battery recycling business, Recyclus Group, has received final clearance from the Environment Agency (EA) to commence full operations at its lithium-ion (Li-ion) battery recycling plant in Wolverhampton, West Midlands. Recyclus has also been awarded Approved Battery Treatment Operator ABT status by the EA, allowing it to commence recycling operations immediately, with on-site treatment and processing of spent Li-ion batteries.

The EA permit allows Recyclus a daily storage limit of 140 m³ (c.100 tonnes) and to process up to 22,000 tonnes of Li-ion batteries per annum. It is expected that 8,300 tonnes will be processed in the first year, utilising a single shift pattern of labour during the standard working week. The approval from the EA for the Wolverhampton plant is a significant milestone for Recyclus, making it the first industrial-scale plant in the UK with the capability to recycle Li-ion batteries.

Recyclus owns the IP for both the process and the plant, which is designed to

process most Li-ion battery types. Recyclus will manufacture all plants, including those designed specifically for OEM clients, here in the UK. Recyclus aims to increase the UK processing capability to c.50,000 tonnes per annum by constructing five more Li-ion recycling plants.

BIS Research's latest study, Black Mass Recycling Market - A Global and Regional Analysis, states the global market for black mass, produced from the recycling process and containing critical battery metals that can be sold back into the battery supply chain, is projected to reach $53 bn by 2031.

ABB COMPLETES ACQUISITION OF SIEMENS LOW VOLTAGE NEMA MOTOR BUSINESS

ABB HAS COMPLETED ITS ACQUISITION OF THE Siemens low voltage NEMA motor business. The transaction was originally announced on August 11, 2022, and the financial terms of the transaction were not disclosed. The business employs around 600 people and generated revenues of approximately $63 million in 2021.

The acquisition of this business is part of ABB’s Motion business area’s profitable growth strategy. It strengthens ABB’s position as a leading industrial NEMA motor manufacturer, and provides an even stronger platform from which ABB can better serve its global customers.

The line of horizontal and vertical induction severe duty and general purpose motors will be re-branded as ABB and reintroduced to the market during the second quarter of 2023.

The global NEMA motor industry, roughly $2.7 billion in size, comprises industrial electric motors primarily used within North America. NEMA motors are essential components used to run equipment in industries such as food and beverage, oil and gas, mining & aggregate, and water & wastewater and in applications like those which move air, liquids, and units.

ERIKS LAUNCHES APP FOR DIGITAL REPLENISHMENT

ERIKS UK HAS launched an app that enables its customers to digitally replenish their stores, ensuring they experience fast, efficient and reliable next-day delivery with full digital traceability.

For applications at the point of use or open industrial stores, the app is specifically to help ERIKS’ customers replenish their stocks. It’s a simple tool that allows users to create their own QR/bar codes, scan QR/bar codes, select the right quantities of product they wish to order and complete an order in the ERIKS webshop. The QR codes generated can be affixed on a customer’s racking, boxes or wherever their machine is, and their process is then fully integrated into the ERIKS webshop.

The app also allows people to search for products, set up a favourites list, and build a shopping cart – much as most people do when using Amazon or other web shops. As with those, it’s simple to check out, and a full order history is available. An important feature of the app, given the supply chain difficulties that most industrial businesses have experienced in the last few years, is that lead times for products are shown when searching and products are picked, dispatched and delivered in 24 hours to most of the UK.

FIVE-POINT PLAN TO COMBAT SUPPLY CHAIN STRESS

RECENT FINDINGS BY THE CHARTERED Institute of Procurement & Supply (CIPS), found that the downturn in UK manufacturing accelerated at the end of 2022. Moreover, the rate of decline was among the steepest during the past 14 years.

Companies reported that recent output had been scaled back due to declining intakes of new work and disruption caused by stretched supply chains and material shortages.

Long lead times prove to be a huge challenge for businesses attempting to source genuine parts for equipment and machinery. That’s why Obso Global has launched a new guide, which outlines five simple steps operators can take to help

source and stock new and refurbished parts for production, helping to mitigate the risk of unplanned downtime and maintain productivity.

Available to download from bit.ly/ObsoPlan, the five-point plan guides operators through the key steps to take to reduce the impact long lead times are having on businesses. It includes guidance on the importance of an operational strategy for parts procurement, developing contingency plans or using a third-party provider for bonded stock holding.

The plan has been compiled using insight from Obso’s experienced technical team, which has helped many customers across the world combat the stresses of ongoing supply shortages and parts availability.

The supplier of hard-to-find and obsolete automation spare parts also plans to launch a series of blog articles discussing – from personal experience – how longer lead times and rising costs have affected the business over the past few years and what steps the team has taken to overcome this.

EXCLUSIVE UK DISTRIBUTORSHIP DEAL FOR HYBRID BALL BEARINGS

BEARINGS FIRM, BEARINGS & DRIVES Ltd (BDL) has become the sole UK distributor of CeramicSpeed Insulate ball bearings, strengthening their offering and introducing to the UK market the latest technology in operational efficiency, allowing UK customers day-to-day direct access to these products from their warehousing facilities.

Constantly focused on technological development and innovation,

CeramicSpeed is a dedicated supplier of hybrid ball bearings. With a strong presence in the European market, the company is rapidly becoming the industry’s most trusted supplier of advanced bearing solutions.

CeramicSpeed Insulate ball bearings are custom-made for electrical motors and are a guarantee against damage caused by stray currents.

Steve Bacon, Sales Director at Bearings & Drives, explained the significance of the supply arrangements for UK industry: “We are thrilled to become the UK distributor for such a ground-breaking product. The demand for stronger, more durable and longerlasting bearings for electrical motors is on the rise – and in many applications, conventional steel balls in motor bearings simply can’t compare.

“When we reviewed CeramicSpeed Insulate in action in Denmark, we saw the immediate benefits we can bring to our manufacturing clients here in the UK. Taking, for example, how the product range brought significant efficiencies to a leading Danish dairy products manufacturer. The manufacturer faced sizeable issues with the durability of the steel bearings they were using in a specific motor. The products manufactured by the dairy contain many small particles that penetrate the bearings, subsequently reducing bearing life. Along with high bearing temperatures, this led to many control shutdowns and became detrimental to efficient operation.”

CeramicSpeed Insulate bearings are non-conductive as the ceramic balls in the bearing have a resistivity of 15kV per mm. The Insulate series is said by BDL to be the best defence against damage caused by stray currents. In addition to being protected

from the passage of electrical currents, the operating temperature in hybrid bearings is approximately 10-20°C lower than conventional bearings. By using these, the Danish dairy has reduced the bearing temperature by 15ºC, increasing lubricant life and decreasing production shutdown considerably. The CeramicSpeed bearings, with their higher resistance towards corrosion and contamination, increased the life of the bearings by 400%.

Why is Smart Site right for you?

Smart Site is easy to use on any smartphone or tablet device and requires very little training.

Smart Site reduces the waiting time of documents in transit. All job information is visible at the office as it happens.

Smart Site delivers accuracy. The app captures information as it happens, meaning there is less chance that something important is missed or recorded incorrectly.

Smart Site streamlines the administrative process ensuring that contracted and chargeable work can be completed in a timely fashion and invoiced with complete confidence.

Smart Site stores the history of an asset’s repair and service, so your engineer has all of the detail they need to do the job right first time.

See Smart Site in action!

5 Steps to Service Success

UPDATE FROM THE AEMT SECRETARY

THE DAWN OF 2023 MARKED A DISTINCT PARADIGM shift that few could have predicted. As we waved farewell to the previous year, whispers of a technological innovation known as ChatGPT by OpenAI began circulating in the halls of social media. Now, in retrospect, it seems we may have underestimated the transformative potential of this revolutionary software.

As we now stand on the threshold of a new era, we're collectively striving to comprehend the true essence of artificial intelligence (AI) and its myriad applications within our commercial operations. A recent LinkedIn poll shed light on the fact that many of us are still in the early exploratory phase, cautiously navigating the uncharted territories of this game-changing technology. And this is exactly where the indispensable role of a trade association comes into play.

We're eagerly anticipating the collaborative journey ahead as our community pools their collective experiences, learning together to harness the power of AI. Despite the prediction that it will take years for firms to fully adopt and integrate this technology, early adopters are set to reap unprecedented benefits.

An illuminating study by MIT underscores this point: daily business activities like crafting emails, drafting sales proposals, or creating social media posts were completed 37% faster when aided by AI, with a marked 20% increase in overall effectiveness. Additionally, the study noted increased levels of job satisfaction upon completion of tasks.

Consider this food for thought: if you choose to overlook this technology, you risk your competitors surging ahead, leaving you trailing in their wake, struggling to compete with their speed and efficiency.

Annual general meetings provide a mirror, reflecting back on the accomplishments and the progress we have made in the preceding year. As we look back on our recent AGM in June, the reflection is heartening. Despite being a lean team, we've shown the ability to be agile and responsive to our members' evolving needs, consistently

exceeding our own expectations.

2022 was indeed a landmark year for the AEMT, laying the cornerstone for our ambitious five-year growth plan. Our strategy revolved around creating value and fostering growth for our members, appealing to businesses poised to transcend boundaries. Our vision to establish an online academy dedicated to professionalising repair, overhaul and reclamation of hazardous area rotating electrical equipment came to fruition within just one year – a feat we initially anticipated would take double that time.

However, we weren't blind to the financial pressure that escalating costs were placing on businesses and employees. Rising energy prices, increasing grocery bills, and soaring living costs called for a decisive response, leading to the creation of AEMT Advantage – an exclusive membership portal offering cost-saving benefits to our members.

As we welcome our new President, Mr James Stevens of Preformed Windings, we're infused with a renewed sense of excitement. His global experience and expertise in business growth, coupled with his tenure with the AEMT since 2019, positions him perfectly to steer the ship. I eagerly look forward to collaborating with him to unlock the potential of our international membership, thereby infusing UK businesses with fresh perspectives and insights.

Oh, and in case you were wondering, this article was written with the help of AI!

GUIDE HELPS MOTOR USERS CUT COSTS AND REDUCE ENVIRONMENTAL IMPACT

THE ASSOCIATION OF ELECTRICAL AND MECHANICAL Trades (AEMT) has published a new guide designed to help users calculate their industrial motors' total cost of ownership (TCO). With a focus on assisting organisations to reduce costs and improve their motors' environmental impact, the free guide can be downloaded from the AEMT website.

Despite a slight improvement in recent weeks, today's energy prices are more than double the pre-2021 historic average, and forecasts suggest they will remain so for some years to come. As a result, the lifetime cost of running an electric motor is an increasing focus for many users. However, we are still some way from a motor's TCO becoming a standard factor in most purchasing decisions.

The purchase price of a typical industrial motor can be just 2% of its lifetime cost. So, to help end-users benefit from a greater focus on a motor's TCO, the AEMT's new guide outlines the variables which need to be considered when calculating the overall cost and offers recommendations for how it can be reduced. Areas covered in the guide include using variable speed drives, higher efficiency motors and improving motor reliability.

Commenting on the AEMT's new guide for industrial motor users, Thomas Marks, the AEMT's Secretary and General Manager,

said: "Our members are experts in advising motor users on the most efficient and effective solutions for their applications and we want to highlight the positive impact users can have on their bottom lines and the environment."

According to research from the World Energy Council, electric motordriven systems are estimated to account for almost 50% of all global electricity consumption. Alongside the potential for significant financial savings, if that consumption dropped by just 10%, that could reduce the global demand for electricity generation by 1,425TWh, equivalent to the total amount of electricity used by India, the world's third largest consumer.

Focusing on a motor-driven system's TCO can help realise these benefits, and this new guide from the AEMT has been designed to support the process.

bit.ly/AEMT_TCO

Wire Electric Supplies Ltd

Committee to support AEMT members with equality, Diversity and inclusion

With support from its members, the Association of Electrical and Mechanical Trades (AEMT) has launched a committee which aims to drive, support and promote equality, diversity and inclusion within the electromechanical sector.

In the UK, the engineering sector has a long-standing history of being less diverse than the general population.

Research from EngineeringUK shows that 16.5% of those working in engineering are female compared to 51% of the workingage population, while 9% are from minority ethnic backgrounds compared to 12% of the population, and 9% declare they have a disability or impairment as compared with the average of 14%. At a time when the engineering sector faces a widespread skills shortage, a focus on equality, diversity and inclusion (EDI) offers a broader talent pool to help meet the sector’s recruitment needs.

Research also demonstrates that increased workforce diversity improves innovation, creativity, productivity, resilience and market insight. A study carried out by McKinsey has shown that companies in the top quartile for racial/ethnic diversity were 30% more likely to have financial returns above their national industry median, while those in the top quartile for gender diversity were 15% more likely to have increased financial returns.

The business case for EDI in engineering is undoubtedly there, but many organisations in the sector are unsure of how they can improve their position or, indeed, what support and resources are available to them.

The AEMT’s new group aims to help its member companies to develop their approach to EDI within their organisations and reap the available rewards. This work will include identifying and sharing best practices, signposting members to resources and initiatives to support them on their journey, and raising awareness of the benefits a focus on EDI can deliver. The group will also work to encourage individuals from diverse backgrounds and experiences, and those with wide-ranging needs, to explore careers in the electromechanical repair sector by promoting the opportunities available in the industry and highlighting the way EDI is supported.

The new AEMT committee was formed by a group of Association members with

experience promoting and supporting EDI within their businesses. Members of the committee include representatives from Houghton International, ABB, ADC Electrical, Bedford Pumps, EMiR Software, Fenflow, Hidrostal, Mid Kent Electrical and Primary Engineer.

Commenting on the new group, Kirstie Davies, Marketing Manager at EMiR Software, said: “The electromechanical sector is facing a skills shortage as young and diverse individuals are not choosing to enter the sector. I believe we will benefit significantly from promoting and actively engaging in diversity and inclusion, as companies that celebrate diversity and inclusion are seen as more progressive and attractive to customers, employees and investors.

Lucy Ogden, Marketing Manager at Hidrostal (GB) Ltd, added: “We strive to make our engineering workforce diverse, equitable and inclusive. At 25%, our proportion of female staff is well above the UK average, plus we have diverse role models, particularly within our leadership team, who show our staff that there are no limits to their progression within our organisation.

“Employing a diverse workforce benefits our business in many ways. It extends our skill set and provides us with a wider range of perspectives, plus it increases our productivity by enabling us to blend our experiences and learn from each other. Ultimately, our employees are happier.”

Eleanor McIntosh, Marketing Manager at Houghton International, explained how her company works to embed an EDI focus

across the business: “With support from a well-established HR team Houghton International embeds effective policies and procedures, health and wellbeing support, a strong internal culture and set of core values throughout recruitment, training and apprenticeships, staff retention, development, performance management, and business operations.

“Within our workforce there is the representation of ages from 16 to 60+, giving us the benefit of decades of experience alongside innovative young minds and fresh perspectives.

“In a traditionally male-dominated industry, the number of women within the business has increased steadily. With many women within the business routed into significant career development and progression.”

One of the group’s first actions was to sign the Association up as a supporting partner of EngineeringUK’s Tomorrow’s Engineers Code, a community of over 250 organisations working toward common goals to increase the diversity and the number of young people entering engineering careers. This move sees the Association commit to actively participating in the Code’s community, contributing where applicable and sharing knowledge/good practice. TIMES-CIRCLE

www.brookcrompton.com

Keeping industry turning every second... every day...every year

With over 110 years of technical and design expertise, Brook Crompton offers leading edge energy efficient electric motors across global markets. As the original innovator in electric motor development, Brook Crompton are trusted to power limitless industrial processes and its robust motor design drives fans, pumps, compressors, conveyors and more.

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

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

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

New generation of NEMA motor offers high energy efficiency and reliability

ABB HAS DEVELOPED THE NEW generation AMI 5800 NEMA modular induction motor to offer exceptional energy efficiency and reliability in demanding applications such as pumps, compressors, fans, extruders, conveyors and crushers. Rated for a power output of up to 1750HP, the AMI 5800 offers the capability for a high degree of modularity and customisation to suit both new-build and upgrade projects in a wide range of industries, including chemical oil and gas, conventional power generation, mining and cement, and metals. The motor opens up new options for UK OEMs looking to export customers in North America.

The AMI 5800 motor is a true NEMA design that builds on ABB’s technology leadership in the North American market to meet both electrical performance requirements and mechanical mounting standards. A key feature is a high-strength welded steel frame typically found only in motors with larger frame sizes. This

lowers stress on the motor while mitigating vibrations and resonance to ensure reliable operation in harsh conditions with a design life of 25 years or 20,000 starts.

A further important advantage of the AMI 5800 is a shorter bearing-to-bearing span compared with previous models. This innovative feature improves performance at high speeds and enables the motor to be used as a simple drop-in replacement to upgrade existing equipment.

According to ABB’s Stephen Clabburn, UK Sales Manager, Large Motors & Generators: “We have engineered the AMI 5800 motor to meet customer requirements for high energy efficiency and reliability, as well as sustainable manufacture and use. Its modular design, in terms of cooling methods, bearings, shaft extensions and terminal boxes, also provides the flexibility to match the North American installed base. This makes the AMI 5800 ideally suited for upgrading existing installations and next-generation designs, no matter

how harsh the environment is. From a UK perspective, for UK OEMs exporting to the North American market, ABB can now support you locally with this new generation of NEMA designs that build on our already extensive NEMA range.”

new.abb.com/uk

LIGHTWEIGHT, HIGH-EFFICIENCY AND HIGH-RELIABILITY MOTOR FOR HAPS

SOFTBANK AND NIDEC HAVE JOINTLY developed a lightweight, high-efficiency, and high-reliability axial flux-type motor for High Altitude Platform Stations (HAPS). This newly developed motor also meets the specifications required for Sunglider, the unmanned aircraft system (UAS) developed by HAPSMobile, a subsidiary of SoftBank. The jointly developed motor boasts lightweight, high efficiency and high performance that enable UAS for HAPS to endure long flight times solely on solar power and high thermal dissipation that keeps them performing stably in the

stratosphere’s hypobaric environment. In addition, with the use of the magnetic circuit design technology, which Nidec has

long nurtured in its small precision motor development, together with an optimised magnet arrangement to maximise magnetic field strength, a special design that encapsulates magnets in a rotor to improve reliability, and a unique, patentsapplied motor assembly method for better performance, the HAPS motor has achieved a torque density of 12.5Nm/kg, despite its low weight.

www.nidec.com

PUMP MOTOR FOR THERMAL POWER STATION

MENZEL ELEKTROMOTOREN HAS manufactured a motor with a special flange for a condensate extraction pump in a combined heat and power plant. The original motor, which was over 30 years old, had to be matched precisely in all mechanical and electrical interfaces.

Works included the manufacture of a flange with special dimensions for vertical installation and repositioning

of the main terminal box. The energy supply company, already a customer of Menzel Italy, awarded the order because Menzel could fully confirm all technical requirements.

Menzel’s MEBKGR series comprises high-voltage squirrel cage motors with a good price-performance ratio. For the current application, the manufacturer designed a 4-pole motor with size 500,

6000V nominal voltage, 1100kW nominal output, protection class IP55 and cooling type IC 411 (fin cooling with external fan). Menzel took the motor all the way through to commissioning, which was carried out to the customer’s satisfaction.

www.menzel-motors.com

Awards entry deadline is approaching fast

Time is running out to prepare and submit nominations for the 2023 AEMT Awards Programme. With the final entry date set as 5.00pm on Friday, 8 September, the AEMT again looks forward to recognising and rewarding excellence across the electrical and mechanical repair sector.

Building on its past successes, the sixth outing of this sector-specific awards scheme will culminate in a gala presentation ceremony to be held on the evening of Thursday, 23 November, at the Doubletree by Hilton Hotel in Coventry.

This venue will also play host to the supporting AEMT Conference taking place throughout the day. The full programme is currently being finalised, but its focus will again be on providing AEMT members with help and guidance on a range of topics of primary interest to the development of their businesses. Staff recruitment, development and retention, the adoption of smart technologies, the commercial value associated with circular economy and sustainability initiatives, and the support networks that can be accessed by those operating in the sector will all be featured. The speakers will share their knowledge and expertise in a series of talks and presentations specifically designed to be of tangible value and relevance to all those companies operating across the engineering service and maintenance arena.

INDUSTRY-WIDE ENGAGEMENT

Operated by the AEMT and produced by Touchwave Media, the awards programme will again acknowledge the skill, effort, and dedication of the people and businesses serving this important industry sector. With sponsorship provided by a host of leading industry names, including ABB, DFA Media Group (publisher of Drives & Controls and Plant & Works Engineering magazines), EMIR Software, TEC Electric Motors, Megger, Sulzer, Menzel, and Preformed Windings, well deserved industry-wide recognition will be given to those businesses which are excelling in their commercial endeavours.

AWARD CATEGORIES

The seven categories that make up the 2023 awards programme are:

• Product of the Year – sponsored by DFA Media Group

• Project of the Year – sponsored by EMIR Software

• Service Centre of the Year – sponsored by ABB

• Supplier of the Year – sponsored by Megger

• Contribution to Skills & Training Award – Sulzer

• Rising Star Award – sponsored by TEC Electric Motors

• Diversity in Engineering Award –sponsored by Preformed Windings

• Lifetime Achievement Award –sponsored by AEMT

CALL FOR NOMINATIONS

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

own company or nominate others that they believe merit recognition. The online entry process is quite straightforward, and anyone wishing to play their part in highlighting engineering excellence should visit the AEMT Awards website at www.aemtawards.com.

CLOSING DATE

The closing date for all entries is 5.00pm on Friday, 8 September 2023, so those wanting industry-wide recognition for a job well done, be it for product innovation or project management, application knowledge, or service and repair, should be making a note of this key date.

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

www.aemtawards.com

TWO-SPEED SHIP MOTOR FOR POSITIONING

MENZEL ELEKTROMOTOREN HAS manufactured a ship motor with two separate windings for different speeds. The motor was commissioned by a petroleum company and is to drive an azimuth thruster. The type MEBKSW630-8/10 three-phase squirrelcage motor is certified by Lloyd's Register.

The modular series, which features IP55 ingress protection and IC 81W cooling (air-to-water heat exchanger) by default, enables flexible, costefficient customisation while at the same time offering a tested and proven design. The ship motor was constructed for vertical mounting. The customer attached great importance to smooth commissioning through interchangeability with the previous motor.

At a nominal voltage of 6000V, the 8- and 10-pole rotor windings are designed for nominal outputs of 2000kW and 800kW and speeds of 895rpm and 713rpm, respectively. The size 500 squirrel-cage motor weighs

12.5 tons. The motor series is also characterised by high power density, high efficiency, high overload capacity and high-durability bearing designs. Menzel also offers explosion-proof motor designs and motors with higher

PUMP REFURBISHMENT FOR COLCHESTER ZOO

THE GIBBONS ENGINEERING maintenance team recently attended Colchester Zoo to remove a pump from the sea lion enclosure which was due for its annual inspection and refurbishment.

The Sea Lion enclosure is home to the Zoo’s Patagonian Sea Lions and holds a whopping 500,000 gallons of water. It is the longest straight underwater tunnel in Europe at 24m long, with 10cm thick glass inside the tunnel.

The Gibbons engineers took up the challenge of removing the 55Kw pump so it could be assessed at the Gibbons workshop. Upon arrival, the engineers were met by Colchester Zoo’s Estate Team engineer, who granted access to the plant room. Once inside, the team got to work by electrically isolating the pump and shutting off the water valves. Once the water valves had been shut off, the wet end fixing bolts were loosened so the pump could be drained of any excess water.

After the pump had been drained,

the motor was unbolted and lifted out of the way using the lifting frame. The coupling was then removed and placed to one side so that the pump could also be lifted by the lifting frame and

safely placed onto a pallet along with the motor. Both the pump and motor were then taken back to the Gibbons workshop for inspection.

A replacement pump and motor were then lifted back into position and bolted down with the coupling fitted to both shafts. The motor was then laser aligned to make sure that the new equipment worked to its highest efficiency, and the engineers ran a series of tests to ensure the process ran smoothly and to check for any possible leaks.

The freshly removed pump and motor were delivered to the workshop engineers at Gibbons, who carried out a full refurbishment of both, including new seals and bearings. Tests were then carried out to make sure the equipment ran smoothly, ready for use back at the Sea Lion enclosure.

IP protection classes for marine and petrochemical applications.

The motor manufactured by Menzel Elektromotoren can drive a ship's azimuth thruster at two different speeds, thanks to two separate windings.

FULL OVERHAUL FOR AMMONIA COMPRESSOR MOTOR

THE TEAM AT BOWERS ELECTRICALS has recently carried out a full overhaul of a 160kW, 2 Pole, IP23, drip-proof motor, one of three motors that run an ammonia compressor used in a food processing factory at a UK supplier of frozen chicken and turkey meat.

The IP23 rating and the drip-proof enclosure allow for ventilation whilst providing protection from objects greater than 12mm and falling water or dirt entering the motor.

The motor was rewound by one of the company’s engineers before going through its stove and varnish procedure. The motor was fully dipped in Bowers’ varnish tank, soaked for 30 minutes

and then lifted and drained. It was then put in the oven overnight at 150ºC. The varnish makes it stronger electrically and mechanically, stopping any movement of wires and insulation.

The end shield also had some mechanical repairs with the bearing housing relined due to wear from mechanical damage.

The final stages of the overhaul saw the motor cleaned, painted, and then reassembled with new bearings before undergoing a full test.

BREATHING NEW LIFE INTO A DC MOTOR

WEBB ELEC RECENTLY OVERHAULED and rebuilt a 287kw ABB DC motor for one of its metal processing customers. DC motors are the main workhorse for steel and metal-producing companies, where they often drive a drawbench which pulls the steel or metal that is being processed. These types of shunt wound DC motors are useful for this application as they provide constant torque and variable speed. The ABB DC motor overhaul was needed as, over time, carbon dust from the brushes builds up inside the motor along with other debris that, in a worstcase scenario, can cause the winding insulation to fail. The bearings in these motors also have to be replaced at the correct intervals taking into account the L10 bearing life.

Following dismantling and a full cleaning cycle of all the components, the motor underwent a Baker and surge test to the armature, field and interpole windings. This enabled the Webb Elec engineers to check the integrity of the winding insulation both to earth and between each individual conductor. The resistance of all the coils within the individual winding circuits was then measured, and the motor passed all of these static tests.

Following the tests, the motor components were stoved, and all windings were re-impregnated with anti-tracking varnish. The armature then went through to the company’s

balancing department, where it was dynamically balanced to ensure efficient and smooth running and to maximise the bearing life. The bearing journals and housings were then checked for wear, and replacement bearings were fitted. The commutator was machined, undercut and polished to ensure the brushes had a smooth and even brushtrack which reduces wear and heat generation and keeps the machine running efficiently. The brushgear was then fully overhauled with new carbon

brushes fitted.

Finally, the force ventilation blower was serviced and rebuilt with a new motor being fitted, and after assembly, the coupling was re-greased and refitted. The motor then underwent an extensive run test with the brushes being correctly bedded in before being painted and returned to the customer.

It's everyone's loss if we cannot think differently

An increased focus on equality, diversity and inclusion can support the recruitment challenges faced by many businesses in the engineering sector. But there are other clear ways that the approach can benefit a business. Highlighting a personal example, David Bernie, Branch Manager at Mid Kent Electrical and member of the Association of Electrical and Mechanical Trades’ newly formed Equality, Diversity and Inclusion committee, reflects on a missed opportunity.

In a job interview, you say you are there to grow, to learn more about your subject. You do not speak the whole truth; that you are prepared to settle for the amount of money you are offered for the opportunity to work hard. Some of us know what we want to do early in our school years. Others will retire wondering what happened. Survival is the primary reason. If you love your work, that is a bonus. Maybe this is the same for love? Does this person mean everything, or do we need someone to help us with the mortgage? How about exercise? Do you really love running, or do you want to gorge yourself after a marathon guilt-free?

Diversity? Now that is a tricky one. We want to be accepted above all else. Let me tell you a story about a friend who did not get the acceptance he needed. This is a lesson about diversity and its vital role in life.

I saw it coming, and I could do nothing.

When you spot the ending in a film, you get a glimpse. You cannot quite verbalise it yet, but you feel something. I knew I had not heard from him in a while, but I had not realised how long. I will not say something banal like I knew what was on that text, but whenever I receive an oddly timed communication, I think the worst. This time I was right. I remember when I met him at school, his appearance was striking; I had not seen anybody like him before. He acted differently, too, caring, thoughtful, almost too much, especially for someone in his early teens. His father arrived in this country with nothing and in one generation had built a successful business that was set up for the healing

and caring of others. After numerous interview rejections, my friend was forced to join the family company and was now instrumental in its operation. Our group of friends had a broad skill set in finance, law, humanities, and business. It was his dream that we would rally together for a greater cause, funded by his family profits.

This never materialised.

Whilst his plan was far from complete, there was a glimmer of potential. A green shoot we should have nurtured and not eradicated from the pavement cracks. If only we had been

more patient, more invested, asked more questions. I lament the negativity we responded to him with. His despair grew. Being unable to channel his resources into something greater meant he resorted to random acts of kindness. He passed out dressing gowns from an upmarket department store to the homeless. He reduced the rent on one of the properties he owned by 90% based on nothing but a sob story. He cleared out the gift shop at the Houses of Parliament to give to schoolchildren.

I missed him one morning, so I drove over to his house. The door opened and

I felt the air. A cold draft hit the back of my throat. I had never felt so thirsty. I realised my foot was over the threshold. He would have to slam the door to move it.

Why are you here?

Because I'm worried about you.

I'm fine.

I don't believe you; for a man with so many phones, you don't do much texting.

What do you want?

To see you.

I'm fine.

His hair and beard were a powdered mane. A white crust meandered across his oversized shirt. A trouser pocket hung out on one side.

'You wanna watch some telly or something?' I asked.

'How's Jane?' He obviously ignored my question

'She's great. Can I come in?'

I stepped back just in time as he slammed the door in my face. Stunned, I paused and looked around. Monthsold weeds had invaded the driveway. Mature dandelions fountained out of the swaying lawn. A rusted washing line leaned against the splintered fence. I wandered to the front of the house. A heavy net curtain dominated the bay window. I could tell the lights were off.

My greatest regret is that I did not push my way into the house when I had the chance.

Isolation and distance followed. We were not allowed in his house. When we finally did gain access, we had to wade through knee-high piles of fast food wrappers. The sink was black. Dotted around the room were spoils of his business success. High-value electronics, aged liquor, and the latest fad item, peppered among the chaos. It was not until afterwards that we discovered the scale of his outgoings. His attempts to right the world in his own way. Clearing out bookshops to gift to schools or dozens of sim cards to hand to strangers who needed them. Close to the end, he showed me one of his most prized possessions, a second edition of the Origin of Species, thousands of pounds worth of book. Ironically Charles Darwin did not have many believers until he was gone either.

The business world needed this individual. He modernised and streamlined an already successful business. He found efficiencies where

they looked as though they did not exist. His sharpened focus allowed him to achieve his business deliverables at a breathtaking rate. Yet instead, he was ignored, allowed to retreat into himself, his potential and talents wasted. Yes, he ran his business alone, but he would have thrived in an organisational environment. He would have complemented any team, and instead, he worked in isolation – to the detriment of those in the business world who would have benefited from his neurodiversity. There are many others like my friend that employers reject before they even start.

I often reflect on what could have been. He used his intellect to encourage and include others, not outmanoeuvre them. His warmth was real and not a bright façade to lure a mark to their undoing like a corporate moth. His fascination with technology and invention drove his business forward; the wheel of change did not get stuck in the mud. His subordinates were made to feel like a part of a whole rather than a necessary expense. The final thing he did was run their payroll before he closed his laptop for the last time.

If we do not look for people with varied experiences, we cut ourselves off from valuable resources and valuable insights. Had the world accepted my friend's neurodiversity, he would have been a great organisational asset. My friend cut himself off from us and we are weaker for it. His diverse mind was not valued and supported. People with atypical intellectual approaches would now be described as 'neuro diverse', and as the award-winning investigative reporter and author Steve Silberman states in his book NeuroTribes, which documents the origins and history of autism from a neurodiversity viewpoint, "[Businesses are] moving on from the notion of employing people with cognitive disability as a form of charity to realising that it can be good business". He goes on to observe the following: "They're realising that they can

think in ways neuro-typical people can't, can identify problems invisible to neurotypical employees and suggest solutions outside of the box."

During WWII, Percy Spencer was working on an energy source for radar equipment. He was unsuccessful in that pursuit, but he did manage to melt the chocolate bar in his pocket. Thus, he ushered in the era of the microwave. Whilst this may be a light-hearted allegory for the romantic side of invention and discovery, it originates from a different time in our history. The demands on the engineering world will continue to increase, companies want results, and we need to rise to this challenge by casting further out into the talent pool and embracing those who think differently.

My friend was not appreciated when he was around. Maybe we were too quick to judge. Maybe he needed to leave us to make us understand. Years passed. His peer group, my friends, are closer than ever; even our children are close. Every year we hold a charity event in celebration of our time together and donate to those who still experience the anguish my friend once harboured. His influence still reaches into the future he never experienced to motivate and encourage others.

I did not know about neurodiversity. My friends did not know about neurodiversity. Most organisations did not know about neurodiversity. Contrary to conventional thought, those who think and act differently do not have water in the fuel tank; rather they are a precious metal. Rare and hard to extract, but once mined, they are critical to any operation. Do we want to diversify our organisations because we think we should or because it is a convincing value proposition and a savvy business decision?

You decide. TIMES-CIRCLE

www.mke.co.uk

"If we do not look for people with varied experiences, we cut ourselves off from valuable resources and insights."

Generators: Increasing output and extending life

James

Stevens

,

Global Sales

and

Marketing Director

of

Preformed Windings,

explains how HV Diamond coil specification and design can tackle the challenges presented by an ageing and constrained installed base of hydro generation infrastructure.

Our passion for achieving a net zero future relies heavily on renewable energy sources. With hydro energy representing the largest renewable energy source, and a requirement to increase hydro output by 3% annually to achieve this goal, according to the International Energy Agency, it is critical to maintain and increase hydro generation levels. However, over the past five years, less than half of the required increase in output has been achieved.

The average age of hydro generators in established markets such as North America and Europe exceeds 40 years old, which is of serviceable age, presenting a significant risk to the installed base of hydro generation. In addition, the opportunity to build new hydro facilities in these regions is limited by suitable locations that haven’t already been utilised and the investment required to build them, which is made challenging by legislation and economic pressures.

So it is difficult to build new hydro infrastructure in North America and Europe, and the existing fleet requires refurbishment and modernisation, yet there is a desire to increase the amount of energy being generated by hydro. While the expectation in the industry is for high-quality formed windings that last for decades. Therefore, a favourable solution provides a highquality and reliable refurbishment while an opportunity is present to utilise the existing assets to increase their output.

Preformed Windings has identified this challenge and opportunity in the market and, due to its independent status as purely a product manufacturer, is well-positioned to collaborate with the industry to carry out research and development related specifically to high-voltage windings. This R&D, made up of over 25,000 hours over the past three years and in collaboration with leading OEMs and insulation manufacturers, has resulted in significant steps forward in winding technology.

The hydro industry is already benefiting from this. For example, Project Holter, which was voted a finalist at the prestigious AEMT

awards, resulted in a modernisation program at the Holter dam in Montana, USA, which upgraded the output of its six generators by 42%, resulting in enough renewable energy to power 16,500 additional homes and businesses in the surrounding area. This example – involving a redesign of the turbines and generator core – highlights the opportunity across the industry, and when compared to developing new hydro facilities, this approach is also exceptionally costeffective.

James Stevens, Global Sales and Marketing Director at Preformed Windings, commented: “We are dedicated to a sustainable future and excited to collaborate with leading organisations and end-users in the industry to answer a specific and solvable problem; how do we modernise this ageing fleet and capitalise on the huge untapped potential of additional hydropower generation from existing assets using a circular economy approach.”

Due to the age of much of the installed base, significant output gains are often achievable without major redesign activities beyond the windings. For example, the principle of increasing the output of generators centres around increased output and improved efficiency, both of which can be achieved by utilising the available slot space in the core of the generator more effectively, capitalising

on advances in insulation technology and cutting-edge manufacturing techniques to increase the number of turns and crosssectional area of the copper. Optimising the design of the coil geometry and achieving exceptionally tight tolerances can offer benefits such as reduced mean-turn-length of the coils and uniform windings. When coupled with coil specifications that offer previously unheard-of levels of tan delta and partial discharge levels, the result is a refurbishment of the generator designed to last, and with increased performance.

While huge opportunities for the development of the existing hydro installed base, and many other industries, such as nuclear power generation, have been identified, Preformed Windings is dedicated to continuing its investment in thought leadership. In 2023 approximately £2.5m is being invested by the company to develop quality-led manufacturing processes and carry out R&D while increasing the capacity of its manufacturing facility to satisfy the global demand for high-quality windings. The company welcomes the opportunity for collaboration to push the boundaries of what is achievable when refurbishing machines. TIMES-CIRCLE www.preformedwindings.com

Improving drive reliability in harsh environments

Renew discovered how a replacement variable speed drive from TEC Electric Motors, installed in an extreme operating environment, has reduced downtime and repair frequency for a metal recycling company.

As a result of extreme conditions, Cleveland Electrical Co, a platinum distributor and stockist for TEC Electric Motors, found it was replacing two variable speed drives every six months at its customer European Metal Recycling’s (EMR) Liverpool site.

The drives were controlling the speed of motors powering cyclone fans, which were extracting metal dust from the atmosphere after vehicle parts were crushed and transported on a conveyor system. It was a challenging environment, even inside the panel where the VSDs were mounted, that was taking its toll.

In addition to the problems caused by the airborne particles, the VSDs were experiencing periodic nuisance trips due to low voltage dips caused by the power demand of the crusher’s motors.

When the cyclone fans were not operating, the crushing and transport operations had to stop due to the contamination of metal particles in the air.

It was becoming increasingly difficult to find replacements for, or repair the original VSDs, so Mike Bamford from Cleveland Electrical contacted TEC Motors to see if the company could offer a solution.

The team at TEC proposed using its TDI350 inverter fitted with input chokes to reduce the supply current harmonics. The TDI350 is an IP 20 VSD rated for high and low torque applications and has inbuilt serial communication, dual 4-20ma and 0-10V input. The drive is made for harsh environments, which makes it ideal for the application.

The 355KW inverters were also available ex-stock, minimising the project lead time, with the time taken to install and configure the new devices also kept to a minimum.

Mike Bamford of Cleveland Electrical Co explained: “We had the fans up and

running within one day of TEC supplying its TDI350 inverters. Once installed on site, they were programmed and commissioned by drive technicians from TEC Motors. As a result, downtime for EMR was kept to a minimum.”

MULTIPLE OPTIONS

The TDI350 range of inverters offers a range of functions that allow TEC to meet customer requests. With the option to change input cards, various communication options are available, including PROFINET, PROFIBUS, Industrial Ethernet, Ethercat, Modbus, CANopen, and closed-loop vector control. Thanks to dedicated software, the TDI range can be directly connected to a laptop or computer station, offering monitoring, programming, fault reports and the simulation of various applications.

The replacement VSDs have been running without fault for over eight months – longer than the typical mean time between failure for the models they replaced.

Mike continued: “During the eight months since installation, the drives have been continually monitored without any reasons for concern. We will continue to monitor the drives over the next three to four months to see a 12-month result.

“The drives seem to be ideally suited to the harsh environment on our customer’s site, and we would not hesitate to install the TEC TDI350 drive on future installations.” TIMES-CIRCLE

Tackle machine vibration and improve reliability

Wear and tear, unbalance, looseness and misalignment are the most commonly found vibration issues in machines. Timely detection of vibration can help avoid downtime and enhance the lifespan of machines. Machine reliability specialist, Reliability Maintenance Solutions, explains how precision balancing and alignment practices help minimise forces acting on a machine’s bearings and shaft seals, resulting in the improved reliability of these key components.

When looking at the causes of vibration problems, it is always necessary to distinguish between normal operations and emerging issues. Vibration can be symptomatic of a problem, or it can be the cause of a problem. There are times when the machine isn't physically vibrating, and there is a problem. In general, most systems are designed to avoid vibration as opposed to creating it. (Excluding shakers and screens, of course.)

COMMON VIBRATION PROBLEMS

Vibrating machinery, left unchecked, can speed up the deterioration rate of parts or cause damage to the system that may require key components of a machine to be replaced. There are quite a few reasons why machinery may start vibrating; here are the four most common causes.

WEAR

When rotating components like roller or ball bearings, gears, or drive belts start to show signs of wear, the machine vibration patterns and levels change, mostly increasing in vibration.

For example, if a roller bearing race becomes pitted, the bearing rollers generate impacting and frictional vibration. This occurs as the rolling elements travel over the section of the pitted race. Other examples of wear causing vibration include a drive belt

breaking down or a heavily worn or chipped gear tooth.

These both generate a different increase and pattern change in the vibration signature.

UNBALANCE

If a rotating component has what is known as a heavy spot, this can cause machine vibration, which increases exponentially with speed. Unbalance occurs when the shafts' geometric and mass centrelines do not coincide. The reason for this is because the heavy spot will force the mass centreline off the

geometric centreline.

Unbalance can be caused by a few different things, such as:

• Maintenance issues: missing balance weights or dirty or deformed fan blades.

• Manufacturing defects, including casting flaws or machining errors.

The effects of an unbalance will become more significant as a machine's speed increases. The biggest concern with unbalance is that it can cause unnecessary vibration and drastically reduce the operational life of bearings.

If a roller bearing race becomes pitted, the bearing rollers generate impacting and frictional vibration.

LOOSENESS

Looseness can be rotating or mechanically generated.

There are three types of mechanical looseness to consider: Rotating looseness, structural looseness (foundation flexibility) and non-rotating looseness. Rotating looseness can occur due to wear in a bearing.

The problem with looseness is that, irrespective of what caused it, looseness can cause damage such as fatigue and wear in equipment mounts and further bearing wear. It can become very dangerous and destructive if a vibrating component is either loosely attached to its mounts or has loose bearings.

MISALIGNMENT/ SHAFT RUNOUT

A common cause of vibration is when the machine shafts are out of line. Misalignment is the root cause of many machine breakdowns, bearing failures, and damaged seals, shafts and couplings. It is widely believed that over 50% of machine failures are due to misalignment.

Misalignment does not have a single cause but can be a combination of reasons. It can happen:

• By developing over time (wear)

• During the assembly process

• Not considering thermal expansion during the alignment process

• Not being reassembled properly after maintenance

• Because of shifting components (structural issues)

Not practising precision alignment will cause premature wear and tear of components, increase unscheduled downtime and increase maintenance costs due to unexpected repairs or the replacement of parts.

As we have already mentioned, machine vibration can create time-consuming and expensive problems. For example, vibration consumes excess power, forces equipment to be taken out of service for unscheduled downtime, and expedites machine wear, increasing overall asset life costs.

There are also secondary safety issues to consider, as well as

reduced operational uptime.

Measuring and analysing vibration can give asset owners an indication of a machine's health condition and hence reliability. When this data is analysed correctly it can help with preventive and reactive maintenance actions.

It can improve preventive maintenance by enabling the maintenance team to stay ahead of potential problems. It can help with corrective maintenance to ensure that everything which needs repairing – or replacing – is done the first time so there are no unpleasant surprises later on.

Technicians need to understand the difference between abnormal and normal vibration in machine components. With this understanding and the right tools, a technician can reliably, effectively, and quickly find vibration-related issues and then determine whether or not the component(s) can be repaired, serviced, or if they need to be replaced.

CORRECTIVE METHODS

When it comes to machine vibration problems, the good news is that practically all issues can be corrected in place. That is, of course, provided the vibration-related issues are found early enough.

There are a few ways to treat vibration problems correctly; these include:

1. Precision balancing.

2. Bearing replacement.

3. Identifying any additional bad parts and having them sourced and then replaced.

4. Precision alignment.

5. Precision lubrication. That is, ensuring the correct lubricant is in the correct volume at the right time.

6. Dissemble, inspect visually, clean,

and then reassemble. This can help to fix some of the more elusive problems. However, be aware of introducing new defects due to human error on intrusive maintenance like this.

7. Stiffening and mass loading to reduce measured vibration. This should lower motion; however, it will increase local stresses on the bearings if the cause of the machine vibration is not eliminated and this will cause bearings to wear at a faster rate.

On a final note, some machines do have excessive vibration. In these cases, where the machine function is still being fulfilled, and there is no deterioration, it may not be worth doing anything as long as the machine is carrying out its primary function with no apparent anomalies.

If the vibration amplitude is stable, then, in most cases, it's safe for the machine to continue operating. The advantage of this is that it will avoid additional downtime and the unnecessary cost of repairs. As long as you monitor and assess your machinery with vibration analysis, you should be able to plan, operate your machines for longer with less wear and tear, and reduce the risk of machine failure. TIMES-CIRCLE

Machine vibration can create time-consuming and expensive problems.

Call for nominations now open...

Giving special thanks and recognition to the people, companies, projects and services that play a crucial role in ensuring our food production, utilities, manufacturing processes, transportation and other essential services are maintained and secured.

Endorsements:

“The AEMT Awards is one of the highlights in the industry calendar, and ABB is delighted to have sponsored the ‘Service Centre of the Year’ Category since 2018. I’d like to thank the organisers and offer my congratulations to all finalists and winners on the night.”

Rob Wood ABB, UK

“We were delighted to win the Diversity in Engineering category. The AEMT Awards are a fantastic opportunity to network and share best practice within our industry. It’s great to see so many businesses driving innovation and advancement.”

Eleanor McIntosh Houghton International

Thursday, November 23rd 2023 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.

2023 Partners:

Connected reliability drives efficiency and productivity

With support from Fluke Reliability, Jack Daniel’s cooperage is supporting its barrel manufacturing with predictive maintenance, as Renew found out.

The Jack Daniel Cooperage, where barrels or casks are made, creates barrels for Jack Daniel’s and other brands within Brown-Forman, producing thousands per week.

Such a facility requires a well-trained team to track and analyse maintenance needs to increase productivity and ensure a smooth production process.

Martin Nelson, a maintenance and engineering manager at Jack Daniel Cooperage, and his team of repair and preventative maintenance technicians are responsible for just that. Nelson and his team use the eMaint computerised maintenance management system (CMMS) software and two types of vibration sensors from Fluke Reliability to keep the facility up and running.

The Jack Daniel Cooperage team can automatically generate work orders when their equipment exceeds temperature and vibration thresholds by connecting condition monitoring sensors with the maintenance software. As a result, they have improved their preventative maintenance (PM) and moved into predictive maintenance.

While the whiskey is made with Jack Daniel’s time-honoured and time-consuming process, the cooperage uses state-of-the-art technology to make its barrels. “The number one cost that goes into a whiskey is the barrel,” Martin Nelson explained.

To meet Jack Daniel’s exacting standards, Martin’s team needed to test and prove the value of various prototypes of custom barrel-making equipment for different parts of the process. In addition to the machinery used to make the barrels themselves, the cooperage has an extensive dust collection system which needed to be taken into account. All of it requires strong attention to detail and a firm commitment to an asset management strategy.

WORKING WITH A CMMS

Every technician on the team is now using eMaint. The features they rely on most are work orders and inventory management. They have customised PMs to include

pictures with captions explaining what needs to be done.

“I have several PM reports that autogenerate to me and give me the status of open PMs, overdue PMs, and PM completion percentage, which is huge,” Martin added. “We are slated to have 100% PM completion every week.”

The work order system in eMaint has been a crucial tool for the cooperage in helping to plan and prioritise the work that gets done. “One of the nice things about eMaint is I can differentiate work orders,” Martin continued. “I segregate all the project stuff out versus what’s going on in real time.”

Martin uses several different categories of work orders, including RCCA (root cause and corrective action), safety work, corrective maintenance, TPM (total productive maintenance), and emergency maintenance. Identifying what’s most urgent, for example, or what will require specialised parts or labour, helps the team ensure they have the resources they need when and where they need them.

ENHANCING THE BENEFITS

In addition to using eMaint, the cooperage also uses two types of vibration monitoring sensors from Fluke Reliability. The sensors and software work together to keep the maintenance team updated on how the equipment is operating. “I like the way that it does the reporting and auto-generates the work orders when it’s out of its threshold –over the temperature or vibration,” Martin went on to say.

VibGuard vibration sensors offer advanced alarm tools to monitor for specific failures. They collect several different types of data. The cooperage also uses other Fluke vibration sensors. Maintenance teams can advance their connected reliability journey with access to real-time machine health data in their CMMS. Connected reliability is about centralising data from different systems and tools to make it readily accessible and actionable. Pairing sensors and software makes a more holistic approach possible, where teams can plan rather than just react.

Approximately 31 staves – narrow lengths of wood – go into making each barrel. The staves are precisely shaped on all sides with the cooperage’s specialised equipment. Thousands of barrel staves are processed each shift.

Due to this, the cooperage now also uses vibration sensors on the gearboxes, blowers, bearings, and motors which are part of the dust collection system to ensure a holistic maintenance strategy.

LOOKING TO THE FUTURE

With a focus on continuous improvement and connected reliability utilising Fluke Reliability’s solutions, the Jack Daniel’s cooperage has overhauled its maintenance practices, and its strategies are being adopted throughout Brown-Forman. TIMES-CIRCLE

THE MOST COMPREHENSIVE BALANCING SERVICE IN THE UK

We are the only company in the UK to offer the scope and scale of balancing machines and services and all from our headquarters in Manchester:

• Market leading horizontal, vertical and automatic balancing machines.

• Complete range of support services, delivered by our very own highly trained engineers, including installation and calibration.

• Help line offering advice and support with any machine or application issues.

• Portable instruments for convenient vibration analysis and two plane balancing.

• Comprehensive stock of genuine spare parts for swift availability.

• Sub-contract balancing services to cover capacity or capability constraints.

• Swift response times to your support requests to ensure production downtime is minimised. So whatever your balancing requirement we’ve got you covered.

For further information contact us:

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

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Magnetic stator wedges: The Challenges and solutions

Often used to improve starting performance of large induction motors, magnetic slot wedges are not without their reliability and maintenance challenges. Mike Davis from Electrical Machine Knowledge Exchange, discusses the function of stator wedging, the historical development of magnetic wedge material, their advantages and key maintenance considerations.

In large electrical machines, the stator slots are opened to the width of the slot to allow the fitting of coils. The stator core laminations are punched in a manner to allow the fitting of wedges in rebated landings at the top of the slot.

After coils are fitted and packed in the slots, wedges are fitted in the slot landing. The purpose of the wedging is to restrain the coils in the slot against steady-state bar forces (100Hz or 120Hz vibration) and transient bar forces (starting forces are proportional to inrush current squared).

In many cases, the material used for wedging is non-magnetic – typically an epoxy glass laminated board machined to match the stator slot landing. However, in some cases, the epoxy laminate is replaced with magnetic laminate.

MAGNETIC WEDGING

The typical material composition of magnetic wedging is 70% Iron, 19% binder and 11% glass fabric. The use of this type of material changes the wedge from a magnetically passive characteristic to being magnetically active. As a result, the normal wedging function of retaining the coils in the slot is changed to one of retaining coils and providing a low reluctance magnetic path across the opening on the top of the stator slot.

Providing a magnetic closure on the top of the slot can offer improvements, including reduced core losses, a lower magnetising current, a reduction in zig zag torque and improved efficiency.

The level to which these improvements are realised has wide variation and is dependent on the case-by-case design parameters of the machine.

In modern machines, it could be said that the addition of magnetic wedges is one way that manufacturers can reduce

the active material content of machines; the others are better insulation and smarter ventilation design. Studies have shown the net result of this trend of reducing active material content for given outputs has led to a 14 times reduction in the mass of machines at given outputs in the period of the 1920s to 1990s.

However, the machine performance benefits in the reduced life cycle power cost associated with using magnetic wedges can easily be lost in the additional reliability costs associated with magnetic wedge failure, particularly after the rewedging of machines.

Given magnetic wedges are subjected to un-remitting magnetic forces throughout their operational life, the challenge for designers is to apply wedges with considerations for material reluctance, flux densities and physical assembly to prevent looseness from developing in service. Meeting this

challenge has occupied designers since the 1920s.

The modern magnetic wedge material design and application approach relies heavily on ‘glueing’ the wedge in position with epoxy resin. The life limiter for wedge systems using this approach is the epoxy resin. In circumstances where localised temperature rise (hotspots) in stator cores occurs through high flux concentration, the thermal ageing of the wedge bonding epoxy is accelerated. Epoxy-based materials shrink with thermal ageing. Once the bonding is compromised, the wedges are free to move independently in response to the machine’s magnetic field. In circumstances such as this, wedges vibrate and are progressively reduced to iron powder and debris due to the abrasive nature of the stator slot landings.

One fix for this problem is to replace

Non-metalic stator wedges.

the magnetic wedge material with traditional non-magnetic material. The impact on machine performance in removing magnetic wedges and replacing them with non-magnetic wedges can range from no change up to a 50% reduction in magnetising current.

DETECTING FAILED MAGNETIC WEDGES

Machines with failed magnetic wedges may display one or more of the following operational characteristics:

• Higher no-load current when compared to the ‘type test’ value.

• Increased temperature rise.

• An increase in endwinding discharge due to the presence of wedge material contamination on the stator endwinding (HV machines).

• An increase in electrically excited vibration.

Due to the inconclusive nature of the above characteristics as an indicator of magnetic wedge failure, it turns out that the most effective detection technique is a visual inspection. The visual evidence for failed magnetic wedges includes ferrous contamination on the stator endwindings, ferrous and glass matting debris in the base of the machine, glass matting debris in the machine’s primary air circuit ducting or missing wedge sections from the stator slots (predominantly in the middle of the stator slots).

Having detected failed magnetic wedging, a maintenance choice needs to be made, which can include only rewedging slots where wedges have failed (partial re-wedge), completely re-wedging the stator, and replacing the wedge material with non-magnetic material. In each case, significant reliability risk can result from what appears to be simple maintenance.

MAINTENANCE CONSIDERATIONS

There are important considerations before attempting re-wedging maintenance where magnetic wedges are employed. These include:

Wedge removal – The removal of wedges is high risk maintenance, particularly on windings which have been vacuum pressure impregnated. The risk of causing impact damage to stator coil groundwall insulation needs to be evaluated. A low risk approach is

to run a saw down the centre of the slot to a depth slightly less than the wedge thickness and collapse the wedge in toward the cut.

Wedge size – It is important when surveying the wedge dimensions that accurate measurements are made. The wedge dimensions should match the profile of the slot landing and maintain the original design thickness. The finished wedge size should allow for a neat fit in the landing whilst applying downward pressure on the coils in the slot.

Vented core – When wedging machines with vented cores, attention should be paid to ensuring the wedges are notched at a location corresponding to the core vent to ensure no ventilation restrictions occur.

Lamination shuffle – When laminated stator cores are assembled, the laminations never align in precisely the same location due to manufacturing tolerances. This results in what is termed lamination shuffle. When fitting wedges, lamination shuffle can impact the fit of the wedge in the slot. The uneven edge of the slot landing serves to take material off the wedge as it is dredged into the slot. The results of this problem can be observed in machines with failed wedges, as most wedge portions fail in the centre of the slot – the location of wedges which have been dredged the greatest distance along the slot landing.

Slot length – When fitting magnetic wedges, the less force required to fit the wedge, the better. The force required to fit

wedges can be reduced by reducing the length of the wedges. Careful consideration should be given to ensuring that wedges are fitted in short lengths. In vented cores, the butted joints of wedge portions should always be positioned within the core packs.

Bonding material – The fit of magnetic wedges and downward force on the stator coils on their own are not enough to restrain magnetic wedges in the stator slots. To achieve bonding of the wedge to the slot landings, epoxy resins need to be applied during the fitting of the wedges. The epoxy used in this application should be of appropriate thermal rating.

IN SUMMARY

Magnetic wedges compensate for deficits in active material content; however, the impact of magnetic wedges on machine performance varies on a case-by-case basis. Detection techniques for magnetic wedge failure are limited, with visual inspection being the most useful. Careful consideration needs to be applied prior to re-wedging machines after magnetic wedge failure to ensure successful maintenance and design efficiency gains through employing magnetic wedges can be a fraction of the reliability cost of failed wedges. TIMES-CIRCLE

emkecoach.com

These magnetic slot wedges have been inserted in three pieces to minimise damage.

Early adoption pays dividends for motor repair expert

Engineering services specialist, RJW Engineering explains why it became the first customer worldwide for Megger's new ADX fully automatic static motor analyser, when it purchased the first two test sets to come off the production line through distributor P.A.R. Insulations and Wires.

Repairing and refurbishing electric motors is an important part of the business of UK-based independent engineering services company, RJW Engineering. And to support this aspect of its business, the company was, some 30 years ago, one of the first motor repairers outside the USA to invest in motor test equipment from Baker Instruments, which is now part of the Megger Group.

From the outset, those innovative test sets helped RJW detect winding faults that it would otherwise have missed and thus provide the level of service and quality its customers have come to rely on. As new developments made even better test equipment available, RJW made further investments, always sticking with Baker products. "Baker instruments have proved incredibly reliable over the years, they're always at the forefront of motor test technology, and the company has never let us down," said Lee Windsor, Director of RJW. "So what reason would we have to change?"

Having worked profitably with three generations of Baker motor test sets, all of which had earned their keep over many years, RJW was interested to learn that the new Baker ADX fully automatic static motor analyser was available from Megger. This device offers a comprehensive range of tests for assessing the condition of motors and for analysing faults. Tests include surge, turn-to-turn partial discharge, insulation resistance, polarisation index, DC Hipot and step voltage tests, as well as low voltage tests, including winding resistance, inductance and capacitance. A single set of plug-in high voltage Kelvin test leads means there is no need to change leads between tests, and a damaged test lead, for example, can be purchased and replaced without having to return the unit to a service centre.

All ADX models offer a choice of

manual, automatic or sequenced testing as standard. They also support configurable routebased site testing and incorporate a full range of asset management tools. Test results are displayed on an integrated 10.4-inch daylight viewable touch screen and are stored locally within the instrument. In addition, when an internet connection is available, the results are automatically synchronised with the cloud-based PowerDB Dashboard application, which provides additional facilities for analysis, trending of data, reporting and archiving. These features proved decisive for RJW. "While we could perform most of the tests with our existing instruments, we could see that the new ADX offered three important benefits. The first was that only one instrument was needed to carry out the full range of tests, whereas previously we would have needed to use two or more. The second was that there was no need to change connections between tests, which saves time and trouble. The third was the automatic test option, which is not only convenient but also removes operator influence on the test results."

Lee was also happy to find that P.A.R. Insulations and Wires, a specialist distributor of electrical insulation products for the manufacture and repair of electric motors, generators and transformers, with whom RJW had

worked for decades, had recently become a distributor for Baker products from Megger.

Paul Hirst, Managing Director of P.A.R., commented: "We probably know and/ or supply almost every motor repair and manufacturing organisation in the country, so it was a logical step to offer motor testing equipment alongside our traditional wire and insulation products.

"The names 'Megger' and 'Baker' are synonymous with motor testing, so to partner with Megger and be able to bring its range of high-quality equipment to our customers has certainly proved to be a great fit for our business.

"We have been excited about the ADX release for several months now, and I am very pleased to have been able to deliver the first units worldwide to RJW."

All of these factors contributed to RJW taking delivery of the first two ADX test sets to come off the production line,

which the company ordered via P.A.R. Just as RJW had been an early adopter for the original Baker test sets, it again demonstrated its confidence in the brand by becoming the earliest adopters worldwide for the new ADX test sets. And its confidence has been rewarded.

Lee continued: "We particularly like the 'press the button and the test set does the rest' functionality. This saves

time, and it means the results are totally consistent, with no variation from operator to operator. Another great feature is the ease with which we can produce the highquality reports that more and more of our customers are asking for. And, of course, we can have total confidence in the test results that are included in the reports to the extent that we now use them as the basis of our warranties."

The two ADX static motor analysers purchased by RJW are for use at the company's facilities in Wallasey and Manchester, where it carries out work on low-voltage machines. For this reason, the analysers are configured for testing at a maximum voltage of 4kV. A possible future purchase of an additional instrument for use at RJW Liverpool, where the company works with medium and high-voltage machines is under consideration. This would be configured to provide higher test voltages up to 15kV.

"The results from the new ADX test sets from Megger provide us with an accurate, dependable and comprehensive assessment of motor condition," concluded Lee, "and they deliver the results quickly and conveniently. We have no doubt that they are an excellent investment and that they will help us to continue delivering the uncompromising quality that, over the years, our customers deservedly expect." TIMES-CIRCLE

uk.megger.com/baker

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.

Gearbox considerations for hazardous environments

Marek Lukaszczyk, Marketing Manager for Europe and the Middle East at geared motor manufacturer WEG, explains the requirements of ATEX-certified geared motors.

Plans to replace the ATEX regulations for the use of equipment in explosive atmospheres with new UKCA (UKEX) standards have been paused. Instead, ATEX Type Certificates will remain critical for the use of equipment in hazardous environments – like in mining, quarrying and oil and gas – until the end of 2024.

If you plan to use a geared motor in an environment that includes any explosive atmospheres caused by flammable gases, mists, vapours or combustible dust, adhering to the relevant ATEX Directives is vital. Notably, Directive 99/92/EC, sometimes referred to as ATEX 137 or the ATEX Workplace Directive, focuses on protecting workers. In addition, Directive 94/9/EC, also known as the ATEX Equipment Directive, ensures the safety of equipment used in explosive atmospheres.

Plant operators working in hazardous atmospheres must comply with these directives at all times – not only when operating on site, but also when selecting machinery, parts and components, such as gearboxes and motors. This first involves understanding the environment and the specific types of hazards it presents.

HOW THE ENVIRONMENT IMPACTS MOTOR CHOICE

Hazardous atmospheres in plant environments are categorised as zones by the ATEX regulations – and these zones are numbered one, two, 21 and 22. ATEX zone one is characterised by high-risk gas and vapour, and zone two by medium-risk gas and vapour. Zone 21 is characterised by high-risk power and dust, and Zone 22 by the same elements as medium-risk.

These zones distinguish between places with a high chance of an explosive atmosphere developing and those where an explosive atmosphere may only occur occasionally or in abnormal

circumstances. This classification affects not only the health and safety guidance for workers in these areas, but also the equipment that can be used and how it should be mounted and installed.

Another ATEX regulation is Directive 2014/34/EU, with which equipment for operation in hazardous areas must comply. Plant managers can specify compliant equipment, certified by the manufacturer. Geared motors must comply with the ATEX Category 2G standard for zone one, ATEX Category 3G for zone two, ATEX Category 2D for zone 21 and ATEX Category 3D for zone 22. For example, the WEG WG20 range of geared motors is designed specifically for explosion-protected areas and carries an ATEX certification.

There are also installation differences for the different zones. Geared motors in zones two and 22 can be mounted directly, whereas an adaptor is required for zones one and 21. Mounting geared motors can reap technical benefits and is also a straightforward process. Market standards have dictated certain fitting dimensions for geared motors, so selecting a geared motor that is fully compatible with these standards is advantageous.

For WEG, designing motors to the

ATEX standard ensures plant managers do not have to modify their systems to meet the regulations. It also allows machine manufacturers to retrofit WEG’s motors to their existing equipment without major modifications.

Should a motor flange adapter be required, which is responsible for converting the transfer of motion from a motor or engine to another device machine, then manufacturers can use the adaptor to combine the gearbox with other equipment. For instance, the entire range of WG20 gear units can be combined with explosion-proof WEG IEC energy-efficient motors for applications in hazardous zones one and 21.

Overlooking these requirements can have dire consequences for machine manufacturers serving the oil and gas, quarrying and mining industries. Not only does adhering to ATEX regulations protect the manufacturer from non-compliance, but incorrect equipment used in these sectors can be incredibly dangerous –hence the stringent regulations associated with the markets. TIMES-CIRCLE

PINPOINT POTENTIAL PROBLEMS IN EXPLOSIVE ENVIRONMENTS WITHOUT THE PAPERWORK

TYPICALLY, INSPECTING IN ZONE 2 hazardous environments requires getting a hot work permit signed off by a manager. This can consist of extensive manual paperwork and requires that work ceases for at least one hour prior to inspection. It also requires that all potentially explosive materials (such as combustible dust and gases) are carefully measured and monitored to reduce the possibility of ignition.

To inspect key machinery components in these challenging environments, thermal cameras are often used to identify hotspots, gauge the temperature of machinery and check that parts such as valves are operating within expected parameters. Unfortunately, these cameras pose an indirect risk to the facility's safety because they are not intrinsically safe by design – which is why hot work permits must be approved before use.

The FLIR Cx5 thermal camera is designed to provide safer inspections in hazardous locations. The rugged housing which encases the lithium-ion powered thermal camera ensures high-performance thermography without the inherent risk associated with non-intrinsically safe products.

Whether in hazardous locations dealing with gas, vapour, dust or combustible chemicals, it eliminates the need for hotwork permits.

With a 3.5in touchscreen interface that is simple to use, and the 160 × 120

thermal resolution reveals the accurate temperature measurement of nearby targets between -20 and 400°C.

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GES Group

SERVICES INCLUDE

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

EUROSERV LIMITED

SERVICES INCLUDE

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• Motors

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• Servo Motors

APPROVED BY

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

R.E. Field Services Ltd

SERVICES INCLUDE

• Gearboxes

• Laser Alignment

• Condition Monitoring

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• Thermography

• Vibration

• Electrical

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• Generators

• Rewinds

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

Fyfe Wilson Ltd

SERVICES INCLUDE

APPROVED BY

BP E-ON SSE INTERGEN VEOLIA VIRADOR

• Spindle Motors

• Inverter Drives

• Electrical

• Mechanical

• Rewinds

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

APPROVED BY NIDEC SIEMENS MAVILOR BOSCH TECMOTORS SCHNEIDER

INTERNATIONAL REPAIR CENTRES

ADYARD ABU DHABI LLC

SERVICES INCLUDE

• Motors

• Fans

• Instruments

• Generators

• Rewinds

00 971-2-5547722

Adeel.Rehman@Altrad.com www.adyardabudhabi.com

LOCATION: U NITED ARAB EMIRATES

APPROVED BY

SIEMENS ABB

• Pumps

• Motors

• Gearboxes Fans

• Laser Alignment

• Transformers

• Balancing

• Machining

• Fabrication

• Rewinds

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

EXCLUSIVE TO AEMT MEMBERS

REACH THOUSANDS OF USERS OF ELECTROMECHANICAL EQUIPMENT WITH A LISTING IN THE REPAIR SERVICE DIRECTORY BOOK ONLINE AT WWW.BIT.LY/REPAIRDIRECTORY

OR CONTACT ANDREW CASTLE ANDREW@RENEW-MAG.COM +44 (0)7785 290034

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

Houghton International

SERVICES INCLUDE

• Electric motors

• Generators

• Pumps

• Gearboxes

• Transformers

• Condition Monitoring

• Electro-mechanical services

• Onsite testing and analysis

Ex repairs - IECEx approved

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

Mechanica Utilities Ltd

APPROVED BY

Baker Hughes

Arfon Engineering

SERVICES INCLUDE APPROVED BY

• Pumps

• Motors

• Gearboxes

• Fans

• Inverter Drives

• Laser Alignment

• Condition Monitoring

• Marine Repairs

• Thermography

• Switchgear

0151 334 6808 (Wirral) 01286 675 853 (Caernarfon) sales@arfonrewinds.com www.arfonrewinds.com

Wilson Fans Pumps and Motors

SERVICES INCLUDE

• Pumps

• Motors

• Fans

• Laser Alignment

• Panel Building

• Inverter Drives

• Balancing

• Electrical

• Mechanical

• Rewinds

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

ADC Electrical Ltd

SERVICES INCLUDE

• Pumps

• Motors

• Fans

• Transformers

• Balancing

• Condition Monitoring

• Marine Repairs

• Mechanical

• Rewinds

• Ex Hazardous Area

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

WEG Motors Wilo Pumps

Motors Dertec

Motors Hoyer Motors Elmo Rietschle Pumps Robuschi Pumps Parker Drives Mitsubishi Drives Hidrostal Pumps Wistro Force Vented Fans

SERVICES INCLUDE APPROVED BY

• Pumps

• Motors

• Gearboxes

• Laser Alignment

• Condition Monitoring

01304 206690

• Marine Repairs

• Vibration

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• Generators

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

SPP Pumps Belzona Coatings Hydromarque Pumps Brown Europe Gearboxes

Rotamec Engineering Solutions

SERVICES INCLUDE APPROVED BY

• Pumps

• Motors

• Gearboxes

• Fans

• Balancing

01934 743165

• Marine Repairs

• Electrical

• Mechanical

• Generators

• Rewinds

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

Lowara Grundfos Motovario Lenze TEC

NIDEC Marelli

SERVICES INCLUDE

• Pumps

• Motors

• Gearboxes

• Fans

• Laser Alignment

• Servo Motors

• Inverter Drives

• Condition Monitoring

• Rewinds

Fletcher Moorland Ltd 01782 411021 hello@fletchermoorland.co.uk www.fletchermoorland.co.uk

• Ex Motor Repair

CEMB Hofmann UK Ltd

SERVICES INCLUDE

• Laser Alignment

• Balancing

• Thermography

• Vibration

• Condition Monitoring

• Balancing Machine Service & Calibration

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

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

APPROVED BY

ABB

Start repairing circuit boards or be left behind

Willian Santos from Repair, Don’t Waste, an international movement created by ABI Electronics to emphasise the sustainability and cost-effectiveness of repair over replacement, asks what companies will do while UK, EU, and US projects aimed at reshoring semiconductor manufacturing are in their infancy for the next 10-15 years. Whilst chips are scarce, and net-zero pressures are continually mounting the movement believes that repairing and maintaining existing electronic circuit boards offers the perfect solution.

Signed into law in August 2022, the US Government’s CHIPS Act has been dubbed the most disruptive change to affect the electronics industry in a generation, with severe consequences for its supply chain expected to last well over a decade. In a desperate attempt to recoup semiconductor manufacturing capacity in the US – which dropped from 40% of global supply in the 1990s to just 12% today – the administration has pledged $52.7 billion in federal subsidies, much of which will go towards creating semiconductor fabrication plants. The European Union has also passed a similar act as part of the ‘Chips for Europe’ investment plan, which is planned to span to 2030 and gain over 20% of the global market share in the semiconductor industry by then. Britain has also followed in their footsteps, guaranteeing £1 billion in funding over the next 20 years to strengthen the UK’s prowess in the sector.

Microchips are the gold of the modern age. Every single piece of complex technology – from military, aerospace, communications, automotive, manufacturing and AI – has microchips driving and controlling them. Without chips, the modern world we know and the future we aspire to would not exist. So, it is no wonder that after years of offloading semiconductor manufacturing to East Asia, the UK, US, and Europe are investing so much in reshoring this vital industry.

As shown in the COVID-19 pandemic, chip shortages and supply chain issues can bring manufacturing to a grinding halt. The shortages are only just recovering, nearly three years after the pandemic started, which has profoundly affected industry and productivity. Additionally, the pandemic brought an increased consumer demand for electronic products, from appliances to computers to cars. Add this

to increased electrification globally – the starkest example being the boom in EV transportation – and you can easily see why an assured supply of microchips is critical.

Yet, for the time being, electronic chips are often hard to procure, are being supplied from afar, and many are being made obsolete by their manufacturers with little to no warning. What is a booming business to do in lieu of UK, European and American chip supply chains? Many already have the chips they need – in faulty PCBs.

Repairing a circuit board from a critical system can save multiple chips from becoming E-waste, and the system can be reinstated. By troubleshooting a PCB with specialist diagnostic equipment, it is often found that a component worth just a few dollars or less is the faulty culprit and can easily be replaced using industry repair standards. This saves time from procurement and production processes, alongside obvious financial and environmental savings. The Repair, Don’t Waste mindset can ensure that crucial systems are supported and maintained to the highest standard for years to come.

A further concern we have for these new investments in the semiconductor industry is the shocking lack of hands-on education in electronic engineering courses and the lack of interest or knowledge in electronic repair. Electronic engineering degrees in the UK are more concerned with design than the physical work needed to repair those designs when the hardware degrades. With such adventurous plans for semiconductor fabrication plants, we believe that Western governments

must invest in the practical education of engineering students; otherwise, who will manage these microchip powerhouses? Semiconductor design and manufacturing is far from unskilled work. Repair, Don’t Waste believes that focusing on rehauling electronics education is crucial to re-enter the global semiconductor industry as a serious player.

A repair-first strategy can help businesses support and manage their critical systems whilst microchip supply chains take form and well beyond that. Building and strengthening an industry from the ground up will take years, potentially decades, by which point the world will be ploughing headfirst into net-zero and sustainability initiatives. Repair, Don’t Waste gives companies freedom from the unpredictability of chip sourcing, alongside contributing to ESG targets and reducing the E-waste footprint. TIMES-CIRCLE

Excellence through expertise

Alpha Electrics is an industry-leading provider of specialist industrial electric motor and drive services, committed to ensuring your business keeps moving.

As a family-owned business run on family-based values, we are proud of the reputation and client base that we have developed over the last 30 years.

Our clients appreciate our high levels of customer service, transparency and sincere desire to always find the right solution to their needs. We are committed to excellence in everything we do and relish working in partnership with our customers.

Our Services include:

Supply New Motors & Drives

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Services Servo & Spindle Motor Repair

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Authorised distributors for...

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MENZEL Great Britain Ltd. | UK Branch Office

27 Hunt Drive | Melton Mowbray | Leicestershire LE13 1PB

Martin Rooney | Tel.: +44 1664 500 844 | Mobil: +44 7957 618046 martin.rooney@menzelgb.co.uk

MENZEL Elektromotoren GmbH | German Headquarters

Neues Ufer 19-25 | D–10553 Berlin | Germany

Tel.: +49-30-349922-0 | Fax: +49-30-349922-999

More than 20.000 motors available from stock!

24/7 emergency service

info@menzel-motors.com www.menzel-motors.com