An Introduction to the Methodology of Electric Motor’s Maintenance and Replacement to Guarantee Efficiency in the Industrial Process

Electricity consumption in electric motors systems represent %70 of the global electricity consumption in the industrial sector. Electric motors are used in multiple manufacturing processes.including pressing, transferring, and moving materials, as well as in ventilation and cooling systems, water pumps, and air compressors. Studies and experience have shown that there are great untapped opportunities and potential for optimizing the energy used for electric driven motor systems in both developed and developing countries.

The International Energy Agency (IEA) estimates that the potential savings in electric motors systems in the industrial sector is %20 to %30 of the electricity consumed, which can reduce global electricity demand by % I 0. However, I EA proposes a more realistic and attainable target for the International plan of action, which is to improve the optimum use of electric motor systems by % I O to % I 5.

But the pressing need for continuous production reduces the chances of reconsidering the method of purchasing, maintaining and replacing electric motors so as long as no one is held accountable for the responsibility of managing electric motor’s operating systems maintaining, repairing and replacing spare parts of electric motors will continue to be implemented in a traditional manner without contemplating the cost of the motor (both initial and operating costs). A management plan for the motor’s maintenance and replacement can help achieve long-term energy savings in factories, as it ensures that motors are being replaced in a timely manner and efficiently maintained. Following up on motor’s performance and finding modern management plans include aspects of preventive and predictive maintenance, which ensures the motor’s operation without encountering malfunctions which would hinder the production cycle.

In some cases, it may be better to repair the engine (rewind it) when it malfunctions rather than buying a new one. When repairing or rewinding a motor, it is important to follow unsurpassed standards in order to minimize losses from potential efficiency reduction. Those standards were defined by the United Nations Industrial Development Organization (UNIDO) and the best practices they have for motors rewinding within the framework of implementing the “Egyptian Program for Promoting Industrial Motor Efficiency” in cooperation with the Industrial Modernization Center.

Selection of a high-efficiency electric motor depends on the operating conditions of the motor and the life-cycle costs associated with the investment. Generally, highefficiency electric motors are economically attractive to replace with motors that have an annual operating life of more than 4000 hours. In many occasions replacing the motor with a more efficient model may pay off more financially than cheaper motors with low-efficiency.As per the data issued by Chemonics Egypt, a consultancy firm specializing in resource efficiency and industrial activities, replacing a lowefficiency industrial motor (with efficiency class IE I) with a more efficient motor can help save costs paid to purchase the new engine in a period of less than 18 months. The energy efficiency of electric motors in industrial processes follows the UNIDO methodology, which promotes the use of high-efficiency motors in the industrial sector.

Therefore, lots of information was disseminated to raise awareness on the technical, financial and environmental benefits to improve the efficiency of electric motor systems in the industrial sector and to develop the local market for using highefficiency motors with the aim of boosting efficiency and reducing greenhouse gas emissions in Egypt and increasing the profitability of the industrial sector in Egypt.
All technical publications may be found on “Egyptian Program for Promoting Industrial Motor Efficiency” official website:

Source: The Egyptian Gazette, issue 45,968 dated 10 August 2022, page 3

Originally published in the Egyptian Gazette.