© abb group may 15, 2015 | slide 1 the motoradvantage – how to save uk industry steve ruddell,...
TRANSCRIPT
© ABB Group April 18, 2023 | Slide 1
The MotorAdvantage –how to save UK industry
Steve Ruddell, Division Manager, Discrete Automation and Motion, ABB Ltd
© ABB Group April 18, 2023 | Slide 2
Low voltage electric motors today
UK motor repair industry twice size of new motor market
While mechanical repairs – such as bearings and shafts – will always be needed, why are there so many rewinds?
No one should be making inferior motors
Today’s technology gives motors 20+ year life expectancy
Yet many repairers are rewinding motors less than 5 years old
© ABB Group April 18, 2023 | Slide 3
Remember this?
1.3 OHV engine
4 Star leaded petrol
Max Speed 98 mph
No ABS,power steering or CAT
32 mpg
No air bag. No central locking
No engine management system
Need regular maintenance (Every 6000 miles)
For the enthusiast only!
1.25 Zetec Engine
Unleaded petrol
Max speed 112 mph
ABS and power steering and CAT
35-50 mpg
4 Air Bags. Central locking
Engine management system
Longer service intervals (12-18,000 miles)
3 Year Warranty
When was the last time your car broke down?
Is your car rusty?
Do you own a Haynes manual for your car?
Would you spend 50% of the value of a new Fiesta repairing the engine of your old Fiesta?
© ABB Group April 18, 2023 | Slide 4
Low voltage electric motors today
Significantly different from 20 years ago
Advances in materials and manufacturing processes = better reliability and efficiency
65% of industrial electricity consumed by electric motor
110kW IE3 motor running 8760 hours per annum will create 19 tonnes less CO2 emissions than a less efficient model
It is estimated that there are over 10 million motors running in the UK today
Why are motor owners acting like Fiesta enthusiasts?
© ABB Group April 18, 2023 | Slide 5
Confused?
Since 2005 ABB has conducted over 2000 drives energy appraisals in UK
Information suggests industry does not effectively manage its motor assets
Leads to unplanned downtime, increased repair costs and higher than necessary energy bills and CO2 emissions
With UK PLC fighting for survival why is nothing being done about this?
© ABB Group April 18, 2023 | Slide 6
Is this really a big problem?
Metals process line
Downtime is £400/hr
Rip out / repair / re-install time is 48hr
Unplanned outage cost is £19,200
This is the hard cost…
What about the soft cost?
Loss of reputation
Loss of customer
Loss of margin
© ABB Group April 18, 2023 | Slide 7
Help is at handMotorAdvantage
ABB believes UK industry is ineffectively managing its installed motors base
Leads to unplanned downtime, higher energy bills and higher CO2 emissions than necessary
Based on information collected over 5 years and from over 2000 plants we believe that there is an unarticulated need
Today we launch MotorAdvantage as a way of articulating and addressing that need
© ABB Group April 18, 2023 | Slide 8
MotorAdvantage from ABBWhat is it?
Motor management plan encouraging process industry to uncover true cost of running electric motors
Identify up to five motor-driven applications offering best potential for analysis
Site visit by motor engineer to assess identified motors
Shows financial impact of production loss through motor failure and recommends ways to minimise or mitigate
Shows energy savings and CO2 reductions by fitting premium efficiency motors and calculates payback period
© ABB Group April 18, 2023 | Slide 9
MotorAdvantage from ABB3 steps to improving profitability
1. Consultation
Examine plant installed motor asset register
Identify up to five critical applications running continuously or more than 4,000 hrs per annum
© ABB Group April 18, 2023 | Slide 10
MotorAdvantage from ABB3 steps to improving profitability
2. The Appraisal
Inspect selected motors; get an understanding of plant; inventory of spare motors; energy and maintenance plans
Old motor can be 1-5% lower in efficiency compared to new premium efficiency
If that motor is running continuously then typical payback of 2-3 years achievable if motor scrapped prior to failure
If the motor is replaced at point of failure then, taking rewind cost into payback calculation, new motor cost can be recovered in <12 months
© ABB Group April 18, 2023 | Slide 11
MotorAdvantage from ABB3 steps to improving profitability
3. Proving savings – report and recommendations
Findings analysed and potential savings identified using dedicated software
Among data available includes:
estimation of present energy usage
whether application benefits from variable speed control
payback time if investment is made in new motors
CO2 emission reductions
Cost of unplanned outage
© ABB Group April 18, 2023 | Slide 14
MotorAdvantage from ABBBenefit to motor user
Clearly determines:
Current policy in event of motor failure
Financial impact on company
Areas for improvements in maintenance and stockholding
Energy use of current installation
Repays investment in plan within weeks
ABB predicts when motor needs maintaining and overhauling
Downtime minimised – Profits maximised