The electric motor is known as the workhorse in the mining and other industrial sectors and plays a critical role in ensuring optimum productivity at every plant. However, a major problem associated with electric motors is that most often they are not optimised for maximum efficiency.
BMG’s Synergy IE3 electric motors set a benchmark locally for heavy-duty high-efficiency motors.
“It is estimated that almost two thirds of the power consumed by the mining sector is associated with electric motors, particularly those used for pumps, fans and conveyors,” says Graeme Neilson, Business Unit Manager, Electric Motors, at electromechanical specialist company BMG. “This is a concern for the mining sector – particularly at a time when the country’s power crisis is deepening.
“At BMG we work closely with our customers to meet their needs for continuous operation and high productivity in arduous mining conditions, through the development of energy efficient electric motors. Our team of electric motor designers and engineers has collaborated with global electric motor specialists to develop Synergy IE3 electric motors that meet strict quality standards and set the benchmark locally for heavy-duty high-efficiency motors.
“As well as critical energy-saving features, BMG’s Synergy IE3 motors offer important advantages over other electric motors on the market. These benefits include lower cost of operation, suitability for voltage variation applications, reduced temperature rise and minimal maintenance requirements. Synergy motors also offer greater reliability, reduced noise and vibration levels, more flexibility and longer service life.”
Additionally, standard features of the BMG range of Synergy IE3 motors – developed specially for harsh mining conditions in Africa – include IP66 protection against dust and water ingress and Class H insulation, with a Class B temperature rise. This means the insulation can handle much greater heat than the motor’s operating temperature at full load. “An important performance feature,” Neilson points out, “is that Synergy motors are most efficient when running at between 75% and 100% of full load.
“The motors have a rated voltage of 400 V and 525 V and rated frequency of 50 Hz. The efficiency and power factor values make the motors cost-effective, with an ROI of between three and five years.”
An electronic soft starter, which controls parameters like current and voltage, ensures the starting sequence is efficiently controlled. Whereas standard motors operate at fixed speed, irrespective of the actual output required, Synergy motors can operate efficiently, without cogging at low speed, in conjunction with a variable speed drive (VSD), reducing energy consumption by over 50%.
VSDs are designed to manipulate power from a constant 3-phase 50/60 Hz supply, converting it to variable frequency. This enables the speed of the motor to be controlled to achieve maximum efficiency at the required load.
Synergy IE3 motors are surface treated to ensure extended service life in the mining environment. For maximum flexibility during installation, integrated or removable feet are available. Solid motor feet provide a more resistant structure against vibration, whereas removable feet can be placed in different positions of the motor frame. The latest design allows the terminal box to be mounted top, right or left and the cable entry can be rotated 360°, without disassembling the complete motor. This minimises modification time and reduces stockholding requirements.
BMG specialists also recommend installing an SPM bearing monitoring device for continuous monitoring of the bearing condition.
Synergy has developed aluminium housing motors, with cast iron end shields, for frame sizes from 56 to 180. Advantages of this design include a robust structure and reduced noise.
BMG offers a full range of Synergy IE3 motors ex stock and can also supply IE4 and IE5 units from the factory, to meet specific requirements on every mine.
Standard Synergy 3-phase asynchronous cast iron motors incorporate the latest technology in electric motor design and are used in many industries, including mining and metallurgy, water treatment, petroleum, chemicals, cement and sugar production and paper milling.
The electromechanical team at BMG offers a technical advisory and support service throughout southern Africa.
For more information visit: www.bmgworld.net
