Tag Archives: a Zest WEG Group company

ENERGY EFFICIENT WEG W22 IE3 MOTOR KEEPS SA ECONOMY ALIVE

Reducing energy consumption is a reality for all industries in South Africa, and the WEG W22 IE3 premium efficiency electric motor can rightfully claim to be the most efficient motor that is turning industry in the country.

Available from Zest WEG Group, the WEG W22 IE3 is available in models with a rated capacity up to 1,000 kW and has been engineered specifically to reduce energy consumption optimising on total cost of ownership in numerous applications.

The WEG W22 IE3 product line was engineered using the latest generation computational tools such as structural (finite element method) and fluid flow analysis as well as electric design optimisation software.
This resulted in a robust product that offers reduced energy consumption and thermal efficiency as well as a reduction in noise and vibration levels.

Fanie Steyn, manager responsible for rotating machines at Zest WEG Group, says that because a chain is only as strong as its weakest link, during design close attention was paid not only to the internal efficiencies of the working motor, but also to the elements constituting the external components of the designed motor.

Focus on the frame/housing
The frame is a fundamental component in the design because, besides constituting the mechanical structure reference, it is the main conduit responsible for the heat dissipation generated inside the electric motor.

“In addition, the frame and the end shields ensure the enclosure of the electric components, protecting them against the environment where the motor is installed,” Steyn says. “The frame design ensures high thermal exchange and high reliability where mechanical strength is essential.” The terminal box is located at the front of the frame thereby increasing the heat dissipation area and providing a uniform air flow over the motor frame.

Reliability of the frame was also deemed important, so careful consideration of construction materials led to the selection of FC-200 cast iron which is produced in WEG’s own facilities. Interestingly, this is the same material that is used in WEG’s explosion-proof motors.

Fan and fan cover
The main function of the fan, when assembled directly on the motor shaft, is to promote the air flow over the frame fins, thus dissipating the heat generated inside the motor.

The function of the fan cover is to protect the fan against external agents and to ensure continuous air flow over the motor fins regardless of the environmental conditions within which the motor is operating.
As a natural consequence, when the cooling system is operating to promote heat dissipation, it generates acoustic noise and mechanical losses which can be caused by a combination of the friction of the fan blades through the air and ineffectual design of the fan cover’s shape.

Good ventilation is key to reducing the mechanical losses, particularly for two-pole motors.
Due to its high efficiency, an IE3 motor has inherently less demand for heating removal, so the ventilating system can be optimised to reduce mechanical losses and consequently acoustic noise.

WEG’s design on the cooling system on these new motors was conceived using the most advanced simulation software and fluid flow analysis software, resulting in an innovative aerodynamic profile with reductions in both mechanical and acoustic noise.

Terminal box
Because the terminal box is the point of contact between the user and the motor, WEG first carried out a field survey amongst installation and maintenance experts to determine optimal design performance.
This research resulted in a new terminal box concept that prioritises the interface with the user, providing easier access and handling of the power and accessory cables and ensuring more reliability and versatility in the motor installation.

The new terminal box allows improved cable housing, ensuring larger contact areas between the cables and the motor terminals and allowing correct tightening torque.
The diagonal cut design of the terminal box base and the terminal box cover enables easier access to the electrical connection and gives a better view of the interior of the terminal box during installation procedures.

Using the same WEG exclusive BMC (polyester with 20% fibreglass) die-cast terminal blocks that are used for the terminal blocks of hazardous area motors ensures high electrical insulation resistance and durability. In addition, the accessory cable connections are made with quick coupling connectors.

“With a focus on designing for efficiency, coupled with the ability to understand and implement market needs, WEG W22 IE3 motors are a long-term solution to the ongoing need for energy usage reductions,” Steyn concludes.

ZEST WEG GROUP PACKAGES DIVERSE PORTFOLIO INTO MINING SOLUTIONS

On display at Zest WEG Group’s large outdoor stand at Electra Mining Africa this year will be not only its growing range of products but its integrated approach that offers customers significant added value in the execution of large projects.

One of the new products being launched at the event which is expected to draw the attention of visitors and customers is the WEG Motor Scan solution. This innovative device facilitates the monitoring of electric motor performance from a mobile phone and will help mines to avoid unplanned downtime.

According to Alastair Gerrard, integrated solutions executive at Zest WEG Group, the group’s entrepreneurial approach to aligning with customer requirements has led to the cost effective packaging of its offerings.

“In today’s mining sector, it is no longer enough to come to the market with a good product,” says Gerrard. “It is increasingly important to partner with customers in the design and delivery of integrated solutions that will enhance their bottom lines and achieve lower cost of ownership.”

The growth of Zest WEG Group’s product portfolio – as well as the increased size of many aspects of its equipment range – will see the company consolidate its exhibition on one large outdoor stand near the show’s main entrance.

“Moving with the trend of tailor-made solutions that leverage off our extensive portfolio, our integrated solutions approach will provide significant benefits to customers. It also strengthens our ability to supply and manage large projects,” he says.

He emphasises the value of early engagement with customers, which facilitates an in-depth understanding of the specific demands of projects. This enables Zest WEG Group to identify where it can contribute added-value offerings, drawing on its diverse product range that includes electric motors, vibrator motors, variable speed drives, switchgear, motor control centres, mini-substations, generator sets, transformers, containerised or and mobile substations and E-houses.

Also, of interest will be WEG’s recent acquisition of steam turbine manufacturing specialist TGM, which has a well-established reference base in the Brazilian market. Together with this, Zest WEG Group is growing its energy generation offering to include solutions in the renewable energy space.

Gerrard highlights the company’s Level 2 B-BBEE status and its extensive local manufacturing capabilities with four standalone facilities, enhancing its procurement value to customers in the mining sector.

IINSERT BOX
WEG Motor Scan is a performance monitoring solution for electric motor installations. This innovative solution is designed to optimise access to information about the motor’s performance and allows data to be extracted and sent to the cloud. The access to real-time information allows preventive actions to be taken, avoiding unscheduled downtime.

Information is collected by the App using either a smart phone or tablet device, in either Android or iOS versions, and is sent to the cloud via Bluetooth or gateway. The stored data can be analysed on the device screen in a dynamic way or in greater depth on the WEG IoT Platform.

WEG Motor Scan will allow the connection of all the sensors in the plant, enable naming and monitoring of as many electric motors as required, analyse data sent to the cloud and synchronise the data through the WEG IoT Platform. But, most importantly, this solution will allow end-users to find their motor from anywhere in the world.

ENGINEERING OPTIMAL ENERGY SOLUTIONS FOR AFRICA

Zest WEG Group combines its local manufacturing capability with WEG’s range of world class products to engineer energy solutions for customers around Africa, according to the group’s integrated solutions executive, Alastair Gerrard.

Gerrard also emphasises Zest WEG Group’s extensive network of agents and distributors across the continent, who provide vital insights into local conditions, needs and constraints.

“Our solutions are not off-the-shelf, and are tailor made for individual application requirements,” he says. “Our team spends time gaining an in-depth understanding of what the customer really needs, and what the operational constraints are.
In this process, we collaborate with reliable, in-country partners who have local knowledge and experience. This local presence also facilitates quick response times and 24/7 after-sales support.”

Gerrard also emphasises the use of parent company, WEG’s range of motors, variable speed drives and soft starters, as well as its low voltage and medium voltage switchgear.
These products are an integral part of the fit-for-purpose solutions, as is Zest WEG Group’s South African manufacturing capability in terms of generator sets, transformers, substations and other mobile energy solutions.

“Operating a local gen set manufacturing facility staffed by experienced engineers allows us the flexibility to package this offering with an engine and alternator combination to suit the customer preference,” he says.
Zest WEG Group also offers a standard off-the-shelf range of gen sets.

Forming part of Zest WEG Group’s manufacturing operations in South Africa is WEG Transformers Africa which has two facilities capable of producing transformers up to 45 MVA/132 kV and a range of mini substations up to 33 kV.
Also, part of the group is Shaw Controls which is a leading local manufacturer of custom electrical panels, motor control centres (MCCs), containerised electrical solutions and E-houses. He says that E-houses have become popular in Africa as these are pre-assembled and tested in a factory prior to being transported to site by truck.

The focus is on providing integrated solutions in four main areas, says Gerrard, being power generation, electrical infrastructure, mobile energy solutions and group product packages.
Power generation options include diesel, gas, steam, hydro and renewable energy generation solutions, while the electrical infrastructure offering ranges from supply and refurbishment of outdoor and indoor substations to the provision of overhead lines.

Mobile energy solutions, which are engineered to meet specific customer and site needs, are popular in the mining industry but are relevant to any application where operations need flexibility when deploying their electrical systems such as gen sets, substations, skid type solutions or circuit breakers.

WTA OIL LAB HELPS USERS AVOID TRANSFORMER FAILURE

Testing transformer oil is a key function end-users should build into their maintenance programmes, as it speaks volumes about the condition of the transformer itself, according to Ronaldo Bertoldi, engineering manager at WEG Transformers Africa.

As one of the largest manufacturers of transformers in South Africa, WEG Transformers Africa has a state-of-the-art oil laboratory at its production facility in Heidelberg, Gauteng, and offers an extensive range of services to transformer owners.

“The dissolved gas analysis (DGA) test is one of the most important for a customer to conduct,” says Bertoldi, “as it provides the first available indication of malfunction within a transformer unit.”

Bertoldi highlights that the DGA indicates the internal condition of the unit, and identifies degradation taking place. It is therefore essential for effective monitoring and trend analysis.

The laboratory is able to perform a range of important routine tests, starting from the ‘kV’ test which passes current through the oil to test its insulative properties. The water test would then measure the parts per million of water in the oil; as a conductor of electricity, high levels of water become both damaging and dangerous to the transformer’s continued operation.

“It is also important to measure the amount of cellulose in the oil, as this is an indication of the extent to which the paper around the winding is degrading and turning to sludge,” Bertoldi says. “Judging by how much cellulose is in the oil, a prediction on the life expectancy of the transformer can be provided.”

Even the simple oil colour test has a useful function in showing oil quality, indicating that further investigation may be necessary to keep the transformer well maintained.

“All test results are kept in our extensive database, which allows a history of the trend analysis to be available to each of our customers,” Bertoldi says. “We use these figures daily in developing trends for a particular customer or even a particular transformer unit.”

Access to regular oil test results makes it easier for customers to identify potential problems arising in their transformers, and to take corrective action to avoid expensive damage or unplanned downtime.

Oil analysed for paper in oil content

TALK TO THE EXPERTS WHEN SIZING TRANSFORMERS

A range of factors need to be considered when correctly sizing a transformer for optimal performance in any application, according to Ronaldo Bertoldi, engineering manager at WEG Transformers Africa (WTA).

Ranked among the largest manufacturers of transformers in South Africa – and serving a range of sectors including mining, industry and agriculture – WTA is a leader in distribution transformers, power transformers and mini substations.

“Sizing a transformer for a particular application can be done using a simple equation, but the selection process requires many other factors to be taken into account,” says Bertoldi. “Determining the right transformer for the job requires an in-depth assessment of the conditions under which the transformer will operate.”

He emphasises the difference between the full load current required by an application, and the start-up current if there is a direct online starting process. If the motor is initiated by a direct online start, this part of the operation could require a much higher current than when it is running.

Bertoldi also points out the significance of the distance between the source of the power and the equipment consuming the electricity, as will be a voltage drop that will affect the sizing of the transformer.

“Transmitting low voltage over long distances can also be more expensive due to the thicker cables required by the higher current,” he says. “Users can achieve a more cost effective solution in many cases by considering a step-up, step-down configuration, where the voltage is increased to facilitate longer distances, then reduced to the requirement of the equipment at its point of location.”

WTA’s years of expertise in manufacturing and repair equips it well to advise customers in the sizing and selection of the right transformer for their specific needs. Its Heidelberg facility is capable of locally manufacturing power transformers up to 40 MVA in voltages up to 132 kV as well as mini substations and ring main units. All distribution and power transformers are manufactured to SANS 780, BS 171 and IEC 60076 specifications under ISO:9001 quality standards.

The WTA mini substation production line.

ZEST GENSETS KEEP FARMS RUNNING SMOOTHLY IN OUTAGES

Any type of power outage, no matter how short, can place crops and farm animals at risk – which is why a reliable source of backup power has become vital for agricultural operations to operate efficiently and safely.

Power disruptions on farms are even more damaging due to the economic pressures and the difficulty of surviving in this ever-changing market sector. Today, there are many factors outside of the farmer’s control that can affect profitability. Modern farming methods are also increasingly assisted by a range of automated equipment that relies upon a steady supply of electricity to do its work.

The rural and often isolated setting in which many farms operate make them even more vulnerable to power cuts and damaged power lines, as electricity supply generally takes longer to restore – thereby aggravating the impact on normal farm activities.

The result is that agriculture – like many industries – can experience catastrophic consequences as a result of power outages, and this has made it a business imperative for every farm to have a sustainable and secure supply of energy.

The good news is that solutions are available, to empower farmers to get the most out of their farming equipment without having to risk a power outage turning into a disaster. A good, dependable backup diesel power generator set – or genset – can effectively keep everything running smoothly until mains power is restored. While a quality genset does require an initial capital outlay, the benefits and cost saving in the long run turns it into a positive expense.

Industry experts like the Zest WEG Group offer the experience and capacity to design and provide high quality agricultural generator solutions with top engine brands, for reliable backup or continuous power in various farming applications.

The right solution begins with making the appropriate generator selection, by considering the load size, voltages, running cycles, access to site and delivery constraints. The Zest WEG Group – which locally manufactures generator sets at its Cape Town facility – offers fit-for-purpose solutions that are either standard off-the-shelf units or custom-built for specific applications.

The Zest gensets can be supplied in stationary or mobile configurations from 10 kVA up to 3 350 kVA – and their capacity can be increased upwards with multiple synchronised sets. All generator sets are supported by customised service and maintenance agreements.

Integrated packages that include mechanical and electrical manufacture and assembly as well as electronic design incorporating in-house control panel manufacture are available. The company also provides supply and installation of transformers, cabling, bulk fuel systems and sound attenuation with standby generators on a turnkey basis, together with project management, installation, commissioning and maintenance.

Zest WEG Group’s power generator offering comes in three ranges: the value range; the premier range; and the custom range. The value range is a cost effective 10 kVA to 2 250 kVA 50 Hz/60 Hz solution with the option of FAW, Doosan or Mitsubishi engines. The premier range is also made up of 10 kVA to 3 350 kVA 50 Hz/60 Hz units, but with engine offerings from Perkins, Volvo, Scania, Cummins, MTU and Deutz. The custom range is tailor-made for customers, built and installed for their specific applications.

The company is able to assist customers with correct generator sizing by calculating their required kVA generator load based on their unique on-site load requirements.

To keep costs down for farmers, Zest WEG Group also offers WEG softstarters and WEG variable speed drives (VSDs), which reduce the required genset power capacity.

VSD technology reduces the electric motor’s start-up current, which assists with peak load demands, and also eliminates the need to oversize the generator which would have been a requirement without a VSD.

Another important benefit of using VSDs is the power saved by controlling the output speed of the electric motor, ensuring that the customer uses less energy. Using a VSD allows for the right sizing of the generator which means that the diesel engine will run at its rated loads and maintenance and operating costs are significantly minimised. In many cases, engine capacity can be reduced, with reductions in oil and fuel consumption being realised as a result. Using a smaller engine will also have a positive effect on the cost of parts.

SHAW CONTROLS FAST TRACKS UPGRADE AT AUTOMOTIVE COMPONENT MANUFACTURING PLANT

A wide-ranging upgrade of the electrical distribution network at a catalyst manufacturer’s plant near Johannesburg has been successfully – and speedily – completed by Zest WEG Group companies led by Shaw Controls.

According to Shaw Controls chief operating officer Bevan Richards, the work was efficiently coordinated between companies in the Zest WEG Group so that the contract could be fast tracked during a special weekend shutdown to minimise the production disruption at the facility.

“This major upgrade of the plant – which included the moving and replacement of 17 transformers and 22 medium voltage outdoor panels – had to be completed in just five days,” says Richards. “With careful planning and preparation, along with the close collaboration of the customer, we were even able to complete the job with a day to spare, allowing production to resume earlier than expected.”

To meet these demanding timeframes, Shaw Controls proposed and implemented a solution that involved an E-house – a prefabricated walk-in modular enclosure to house switchgear and auxiliary equipment – as well as two containerised substations, built in-house at the company’s ISO 9001 Bureau Veritas-certified manufacturing facility in Heidelberg.

The E-house was equipped with free-issue medium voltage switchgear from the customer, and the substations were each equipped with a 400 V main distribution board. These modular solutions allow for assembly and testing in the factory, where customers can view the build progress as well as witness the performance of the finished product before delivery is finalised.

“The medium voltage panel was installed, pre-tested, commissioned and the relays programmed before delivery,” he says. Once at the customer site, it was simply a matter of connecting the cables before getting the system ready to be re-energised.

“Part of our project management role was to develop the design and construction drawings, working in conjunction with the customer’s consulting engineer,” he says. “We brought in group companies WEG Transformers Africa (WTA) to provide two 3 MVA oil transformers that stepped down from 11 000 V to 400 V and EnI Electrical to conduct the on-site construction work, which included medium and low voltage supply, installation and termination of cabling.”

EnI Electrical received all equipment on site, undertaking substantial site preparation and pre-works prior to the plant shutdown. It then instituted a two-shift system of 12 hours each over the project period, while Shaw Controls was on-site providing overall project management. On the first day of the shutdown, with the assistance of a mobile 250 tonne crane, EnI Electrical was able to remove all the old equipment and place the new items in position ready for cabling to begin. Access to the work area was also constrained, requiring the crane to reach over an existing building.

By the end of the project, 380 metres of 11 kV cable had been laid, with two cable joints and seven terminations, as well as 1 560 metres of 400 V cable with 21 joints and 132 terminations.

“A turnaround as fast as this is really only possible due to the utilisation of the E-house and containerised substation option,” he says. “Delivering all the equipment in loose pieces and building everything on site, as well as the necessary re-testing, would take much longer and would involve considerably more production downtime for the factory.”

The new system was designed by Shaw Controls and the consulting engineer to give the customer a highly stable system with more flexibility in terms of how the loads are distributed to the plant.

Added benefits of the E-house solution for the customer are that they do not have to manage multiple service providers and suppliers in the various aspects of constructing a substation, says Richards. The process could be potentially complex, time consuming and expensive, especially when conducted in remote sites where access is difficult and infrastructure is weak.

GET WISE ABOUT USING VARIABLE SPEED DRIVES

The benefits of variable speed drives (VSDs) are making this technology a popular choice among users of electric motors; now, with the introduction of the WEG Insulation System Evolution (WISE®) to all WEG motor lines, customers have full assurance that all WEG motors are VSD-compatible.

“Not all standard electric motors are suitable to be used with VSDs,” says Fanie Steyn, manager rotating machines at Zest WEG Group. “The motor insulation systems are susceptible to insulation damage caused by the harsh switching frequencies and voltage peaks generated by VSDs.”

Steyn explains that VSDs use power transistors – typically insulated-gate bipolar transistors or IGBTs – for the switching process. To achieve the high frequencies necessary for switching, the transistors have to turn ‘on’ and ‘off’ to conduct current repeatedly at high speeds. This results in voltage pulses with a high dV/dt, or rate of voltage change over time.

“When squirrel cage electric motors are fed by these high frequencies, the voltage pulses – combined with the cable and motor impedances – may cause repetitive conditions of over voltage or voltage overshoots at the motor connection terminals,” he says. “This may degrade the motor insulation system and reduce the motor’s useful lifespan.”

To ensure that this does not occur in WEG motors, the WISE® insulation system has been developed through the use of enhanced materials in the production of the motor insulation. These materials include VSD‑compatible wire, insulation film, impregnation material and suitable cables.

WEG has also specially developed its LackTherm varnishes for the insulation systems of its electric motors, which are applied to the 99,9% pure copper wire during the enamelling process. These LackTherm varnishes have excellent dielectric strength, flexibility, hardness and chemical resistance, as well as strong adhesion properties.

During the impregnation process, the stator coils receive layers of high‑solid resins and water‑based coatings which are environmentally‑friendly and free from harmful solvents – as required by the ISO 14000 guidelines.

“This process allows any WEG motors to be used with VSDs, as the WISE® insulation system ensures that the motor windings are protected against voltage peaks and voltage variations,” says Steyn.