© ABB Group May 15, 2015 | Slide 1 The MotorAdvantage – how to save UK industry Steve Ruddell,...

© ABB Group April 18, 2023 | Slide 1

The MotorAdvantage –how to save UK industry

Steve Ruddell, Division Manager, Discrete Automation and Motion, ABB Ltd


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


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?


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?


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?


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


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


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


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



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



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


MotorAdvantage from ABBSample report – Engineers Report


MotorAdvantage from ABBSample report – Executive Summary


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

© ABB Group May 15, 2015 | Slide 1 The MotorAdvantage – how to save UK industry Steve Ruddell,...

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Transcript of © ABB Group May 15, 2015 | Slide 1 The MotorAdvantage – how to save UK industry Steve Ruddell,...