Lack of motor management awareness is costing UK industry dearly

Research by the company reveals that UK industry is failing to manage its motor inventory efficiently and incurring millions of pounds of unnecessary downtime, repair and energy costs. A new ABB scheme, called MotorAdvantage, involves a simple three stage approach which includes a site visit by a motor engineer who, after assessing the installed motor base of the plant, identifies up to five motor-driven applications that offer the best potential for further analysis. From this, ABB can assess the end-users current policy in the event of a motor failure and the financial impact on the company. The process can identify improvements that need to be made with regards to policy and stockholding and the energy use of the current installation can also be determined. While mechanical repairs – such as bearings and shafts – will always be needed, ABB thinks there is a lesser need for so many motor rewinds. "No one should be making inferior motors today,"explained Steve Ruddell. "The technology and materials used by today's motors gives them an expected life span in excess of 20 years. They should be durable and highly reliable. Yet many repairers have motors less than 5 years old on their benches for rewind alongside older motors having had multiple rewinds. It is analogous to the car industry. Today you rarely see a rusty car and very rarely see cars breaking down. Technology has improved the reliability and life span of cars and the same is true for low voltage motors." Ruddell believes the reason for so many rewinds and premature failures is a lack of awareness amongst end-users as to the need to create a motor management plan. "It appears much easier when a motor fails to have someone collect it, rewind it and reinstall it. But what if this is a critical, continuous process application? Taking it off line could cost hundreds of pounds per hour."