Steve Ruddell, Division Manager, Discrete Automation and Motion, ABB Ltd
The MotorAdvantage –
how to save UK industry
© ABB Group
July 31, 2017 | Slide 1
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?
© ABB Group
July 31, 2017 | Slide 2

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?
 When was the last time your car broke
down?
 1.3 OHV engine
 1.25 Zetec Engine
 4 Star leaded petrol
 Unleaded petrol
 Max Speed 98 mph
 Max speed 112 mph
 Is your car rusty?
 Do steering
you own
a Haynes
 No ABS,power
or CAT
 32 mpg
 No air bag. No central locking


 ABS
power steering
manual for
yourand
car?
and CAT
 35-50 mpg
 Would you spend 50% of the value
of Bags.
a new
 4 Air
Central locking
No engine management system
Fiesta repairing the engine of your
old
 Engine management
Need regular
maintenance
Fiesta?
system
(Every 6000 miles)
 For the enthusiast only!
 Longer service intervals
(12-18,000 miles)
 3 Year Warranty
© ABB Group
July 31, 2017 | Slide 3
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
July 31, 2017 | Slide 4
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
July 31, 2017 | Slide 5
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?
© ABB Group
July 31, 2017 | Slide 6

Loss of reputation

Loss of customer

Loss of margin
Help is at hand
MotorAdvantage
 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
July 31, 2017 | Slide 7
MotorAdvantage from ABB
What 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
July 31, 2017 | Slide 8
MotorAdvantage from ABB
3 steps to improving profitability
1. Consultation
© ABB Group
July 31, 2017 | Slide 9

Examine plant installed motor asset
register

Identify up to five critical
applications running continuously or
more than 4,000 hrs per annum
MotorAdvantage from ABB
3 steps to improving profitability
2. The Appraisal
© ABB Group
July 31, 2017 | Slide 10

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
MotorAdvantage from ABB
3 steps to improving profitability
3. Proving savings – report and
recommendations
© ABB Group
July 31, 2017 | Slide 11

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 ABB
Sample report – Engineers Report
© ABB Group
July 31, 2017 | Slide 12
MotorAdvantage from ABB
Sample report – Executive Summary
© ABB Group
July 31, 2017 | Slide 13
MotorAdvantage from ABB
Benefit to motor user

© ABB Group
July 31, 2017 | Slide 14
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
July 31, 2017 | Slide 15