Engineering News and Mining Weekly
Firm hails efficiency plan’s stance on electric motors
The plan to apply the Minimum Energy Performance Standards (MEPS) for lowvoltage electric motors in South Africa has been hailed by solutions provider WEG Africa as an exciting step toward energy efficiency and a lower carbon future for the industry.
The Department of Trade, Industry and Competition recently announced its intention to put a stop to imports of lowefficiency motors – in the power rating range from 0.75 kW to 375 kW – in favour of motors in the efficiency class of IE3 and above.
“This is an important step in addressing South Africa’s energy poverty, while at the same time facilitating significant power cost savings for industry and reducing companies’ carbon footprint,” states WEG Africa electric motors manager Fanie Steyn.
He highlights that WEG Africa has for many years championed the benefits of high-efficiency motors. Once the MEPS is applied, he says, the country could save around 840 GWh a year, as about 60% of power consumed by industry is through the use of electric motors.
He emphasises that MEPS would not affect those motors already installed or held in stock by original-equipment manufacturers and distributors; it would only be applied at the point of imports.
“The MEPS makes complete sense for the economy and the environment. We have been encouraging customers to take advantage of IE3 technology as its financial benefit is so clear and immediate; many customers have a strong sustainability agenda that this shift also supports,” Steyn comments.
According to global research, about 97% of the total cost of owning and operating an electric motor comes from the electricity it consumes. Its purchase price makes up about 2.3% of its cost to the owner, while maintenance costs add up to only 1% on average.
“The saving on energy costs with an IE3 motor means that its payback period is as little as nine or ten months.”
However, despite the “compelling economic rationale” for transitioning to IE3 motors, “most motors in South Africa – perhaps 80% – are not energy efficient”, explains Steyn.
To promote the use of and facilitate easy access to IE3 motors, WEG Africa established dedicated assembly lines for these units at its Johannesburg facility. With the MEPS expected to be finalised and enforced in early 2024, this facility will assist in meeting rapid demand growth that will result.
Another important aspect of the shift towards higher efficiency in motors is that this technology will also extend the lifecycle of motors.
“Better efficiency means lower heat losses, and it is the heat of a motor that gradually degrades the insulation on the copper windings. The more heat in a motor, the more the insulation will deteriorate – and highefficiency motors reduce this heat build-up considerably,” elaborates Steyn.
He points out that other African countries such as Ghana and Mozambique are also looking at the application of MEPS within their boundaries. While low-efficiency motors will still be sold into Africa in the near future, the trend is towards a more regulated environment to reduce unnecessary levels of energy consumption.
Rotating machines repairer Delba Electrical stands at the forefront of innovation in the field of electrical rotating machine repairs, boasting a cutting-edge facility specifically designed for the repair and maintenance of medium and high voltage rotating machines, including DC machines, traction motors, wheel motors, alternators and stirrers.
Come and explore the key components of Delba’s repair facility, highlighting its largest Vacuum Pressure Impregnation (VPI) tank, curing oven, burnout oven and heavy-duty cranes, as well as the advanced test bay that ensures the highest quality standards.
Burnout Oven
The burnout oven is a critical component in Delba’s repair arsenal. This specialised, temperature-controlled oven with a quenching system is dedicated to the removal of old insulation materials from rotating machines, preparing them for the meticulous repair and rewinding processes. By employing advanced technologies in the burnout oven, Delba ensures the efficient and thorough elimination of old insulation, setting the stage for the motor’s rejuvenation.
VPI Tank
At the heart of Delba’s repair facility is its largest VPI tank, a technological marvel designed for the impregnation of medium and high voltage rotating machines. With a capacity to accommodate rotating machines of varying sizes, this technology ensures the thorough impregnation of windings with epoxy resin, enhancing insulation and overall performance. The VPI process helps eliminate air pockets and enhances the dielectric strength of the windings. Delba’s commitment to quality is evident in the meticulous process of impregnation that safeguards motors against environmental factors and operational stress.
Curing Oven
Delba Electrical’s repair facility is equipped with a state-of-the
art curing oven, essential for the post-impregnation phase. This oven provides controlled heating conditions to cure the insulation materials, promoting their uniform distribution and enhancing the overall reliability of medium and high voltage rotating machines. The precise temperature and time parameters of the curing process are meticulously maintained to meet stringent industry standards, ensuring motors leave the facility in peak operational condition.
50 t and 100 t Cranes
Handling medium and high voltage rotating machines requires precision and strength, and Delba’s repair facility addresses this with the inclusion of heavy-duty 50 t and 100 t cranes. These cranes facilitate the safe and efficient movement of rotating machines throughout the repair process, from initial disassembly to final reassembly. The robust lifting capacity of these cranes underscores Delba’s commitment to operational safety and efficiency.
Test Bay
Delba Electrical’s commitment to quality assurance is exemplified by its advanced test bay. This facility allows for comprehensive testing of repaired medium and high voltage machines under simulated operating conditions. From insulation resistance tests to load testing, each motor undergoes rigorous assessments to ensure compliance with industry standards and customer specifications. The test bay serves as the final checkpoint, guaranteeing that rotating machines leaving Delba’s facility are not only repaired but optimised for peak performance.
The company’s repair facility for medium and high voltage rotating machines stands as a testament to its dedication to excellence. Through the integration of cutting-edge technology, from the largest VPI tank to precision curing and burnout ovens, as well as heavyduty cranes and a sophisticated test bay, Delba ensures that each repaired motor meets and exceeds the expectations of its clients. In an industry where reliability is paramount, Delba’s commitment to quality repair processes positions it as a leader in the electrical motor repair domain.