Tips to avoid the pain of motor replacement procrastination

ELECTRIC motors consume nearly half of the world’s electricity (IEA). From heavy-duty cranes and pumps to conveyor belts and air conditioning, the world literally moves on electric motors. Improving their efficiency will produce enormous cost savings and energy gains, which is why numerous countries, including South Africa, have established Minimum Energy Performance Standards (MEPS) regulations.

MEPS requires most electric motors to eventually adopt the IE3 standard, replacing IE1 and IE2 motors. While motor operators can phase out older motors, IE3 motors are significantly more efficient and lower maintenance. Businesses should start developing their replacement plans. 

“Yet, many are unsure of the best approach to exploit the MEPS transition,” says Fanie Steyn, (pictured) LV&HV executive of WEG’s Electric Motor division.

“The average mid-sized factory can run several dozen to a few hundred electric motors. Some are delaying replacements because they worry that it will draw attention and resources away from their main priorities. They’d rather wait until a motor breaks and replace it then. But that approach costs more because it leaves savings on the table and rushes preparations such as procurement training. Right now, is the best time to start thinking about how MEPS affects them.”

Preparing for MEPS doesn’t mean replacing every motor. There are several ways to build towards a smooth and even lucrative transition. WEG shares seven tips to get the most benefit and value from MEPS:

• Conduct motor inventories: Use MEPS to motivate a survey of current motor inventory for maintenance, redeployment, and replacement planning. MEPS doesn’t require replacing current motors until they reach the end of their lifespans – a survey will catalogue motors based on their expected lifespans to inform maintenance and replacement timelines.
• Update procurement: Start updating procurement policies and train procurement staff to support the MEPS transition. Vet motor suppliers to ensure they hold appropriate stock for replacements and can provide information on motor efficiency classes, performance tests, and warranty conditions to ensure quality and compliance. Provide training and update processes for procurement teams to support MEPS requirements and vendor assessments.
• Focus on TCO: An appropriate and maintained IE3 motor can recoup its costs in one to five years, or even in months for continuously running motors. A lower total cost of ownership (TCO) is more likely when an old motor is replaced with an IE3 model instead of repairing or rewiring it. Speak to efficiency experts and motor vendors to determine the best cost strategy. 
• Prioritise high-performance workloads: The sheer number of motors being relied on could overwhelm best transition intentions. Manage this issue by creating motor inventories and then prioritising high-performance motors first. These are typically motors that run continuously, such as for HVAC systems, pumps, compressors, and escalators. 
• Use energy audits: Energy audits will identify motors with the highest operational cost. If those are replaced first, they maximise short-term savings while getting more mileage from less impactful motors. The combined savings can help fund a steady rollout of replacement motors. Top electric motor vendors have the experience and skills to help with energy audits. 
• Replace motors iteratively: Apart from a few exceptions, all electric motors will eventually be replaced by IE3-standard or better models. Rather than wait until the last minute to replace motors, which is costly, inefficient, and disruptive, strategically retire motors and spread out capital investment. 
• Selectively redeploy motors: While MEPS covers a wide range of motor uses, some IE1 and IE2 motors can be redeployed to applications with less stringent efficiency demands. 

“My advice to electric motor operators is, ‘Don’t procrastinate!’. You either take advantage of the change, or it will force you to act. MEPS doesn’t mean you must replace everything right now, so use this window to revisit your motor inventory and plan around maintenance and replacement. By taking a phased approach, you’ll achieve both compliance and proactively improve your overall motor management strategy,” says Steyn.