Challenge
Our Client in automotive production faced challenges with old, obsolete, and inefficient effluent pump motors, requiring frequent maintenance. Seeking improvements in energy efficiency, reliability, and safety, they partnered with PRH Engineering Solutions to upgrade their system.
Objectives
- Reduce labour-intensive tasks and associated costs.
- Ensure flexibility and adaptability in the manufacturing processes.
- Achieve energy efficiency to reduce energy consumption and lower operational costs.
- Enhance motor reliability in demanding environments, prolonging motor lifetime and reducing maintenance needs.
- Improve safety in the manufacturing processes.
Implementation
- High Efficiency Motors: ABB’s IE5 ultra-premium SynRM motors were integrated for optimal performance, energy efficiency, and increased reliability.
- Variable Speed Drives Installation: ABB Variable Speed Drives provide precise control over motor speed, optimizing energy consumption and process efficiency.
- STO (Safe Torque Off) Integration: The introduction of STO replaced obsolete contactor control. Unlike isolating the drive, which would prevent interrogation of the inverter in the event of an emergency stop, STO allows for a safe and controlled shutdown while still enabling the retrieval of error messages from the inverter.
- Motor Thermistor Installation: Incorporating motor thermistors was a critical aspect of the upgrade, implemented on the older systems to bring them in line with the latest installation standards. These thermistors are strategically installed to continuously monitor the motor’s temperature. In the event of overheating, the system can proactively respond by triggering protective measures. This proactive approach not only prevents potential damage but also contributes to the overall reliability of the system. Additionally, the thermistors aid in the implementation of predictive maintenance strategies to further optimize the efficiency and longevity of the motors.
- Laser Alignment: Specialist laser alignment equipment was utilized to ensure precise installation of the motors. This step ensures that the motors are fully aligned with the pump impeller, reducing pressure on the motor coupling and, consequently, minimizing the requirement for maintenance and parts.
- Checked Alignment and Increased Ramp Times: Inverter-driven motors underwent a meticulous alignment check, and ramp times were increased to reduce strain on the flexi-coupling. This enhancement not only improves reliability but also extends the lifespan of the system by mitigating stress on components.
- Commissioning Process: Our team of engineers, serving as the principal contractor, conducted an extensive commissioning process, ensuring full functionality and verifying the operational status of safety protocols.
- Training and Integration Support: Comprehensive training on system operation and maintenance, covering ABB’s SynRM motors, Variable Speed Drives with STO, and other critical components.
Results
- Energy Efficiency: ABB’s SynRM motors and Variable Speed Drives deliver exceptional energy efficiency, contributing to reduced energy consumption and operational costs.
- Reliability in Demanding Environments: ABB’s SynRM technology, coupled with motor thermistor protection, increased motor reliability and lifetime while minimizing maintenance needs.
- Precise Speed Control: ABB Variable Speed Drives allow precise control over motor speed, optimizing processes and enhancing overall energy efficiency.
- Enhanced Safety with STO: Integrated STO functionality within Variable Speed Drives provides a safe and controlled shutdown in emergency situations, improving overall safety.
- Motor Thermistor Protection Installation: The addition of motor thermistor protection ensures proactive protection against motor overheating, adding an extra layer of reliability and preventing potential damage. This contributes to continuous operation and further enhances the overall reliability of the upgraded system.
- Checked Alignment and Increased Ramp Times: Meticulous alignment checks and increased ramp times on inverter-driven motors reduce strain on flexi-couplings, improving reliability and extending the lifespan of the system.
- Project Management: Serving as the principal contractor, our team managed the project, ensuring seamless integration of components and adherence to timelines.
- Health and Safety: We were responsible for all health and safety requirements, implementing measures to ensure a secure working environment throughout the project.
- Production Efficiency Gains: The combined solution led to a significant increase in overall production efficiency, reducing cycle times and enhancing throughput.
- Quality Control Enhancement: Vision systems, along with ABB’s SynRM motors, improved quality control measures, ensuring a consistent standard of high-quality products.
- Labor Cost Reduction: Automation of tasks, along with energy-efficient and reliable motors, resulted in reduced manual labor requirements, further decreasing operational costs.
- Adaptability and Scalability: Modular systems, combined with ABB’s advanced motors and Variable Speed Drives, allow for easy adaptation to changing production requirements and scalability for future growth.
Conclusion
The collaborative effort between Our Client showcased energy efficiency, increased reliability, and improved safety. The integration of ABB’s SynRM motors, Variable Speed Drives, motor thermistor protection, and other critical components further strengthened the system’s robustness. Serving as the principal contractor, we managed the project with a focus on health and safety, contributing to substantial energy savings, operational cost reductions, and enhanced performance in demanding industrial environments.