Comprehensive energy-efficiency upgrade for multiple high-power mill and fan motors at a cement plant, delivering 12% energy savings and rapid ROI.
Review the project background, diagnosis, intervention steps, standards, and results summarized below.
Project Background
A large cement plant operated multiple high-power mill and process fan motors at below expected efficiency, driving excessive energy consumption and higher operating costs in an already competitive market.
Assessment & Diagnosis
Conducted on-site electrical and mechanical audits for selected critical motors.
Analysed load profiles, operating hours and historical failure/maintenance data.
Performed detailed testing (IR, PI, no-load, vibration, temperature profiles) to benchmark current performance.
Identified design and insulation limitations in legacy windings contributing to higher losses and heating.
Execution & Intervention
Developed a phased upgrade plan to minimise production disruption.
Rewound selected motors using premium-grade conductors and modern insulation systems.
Optimised slot fill, coil design and ventilation to reduce losses and improve cooling.
Balanced rotors and aligned couplings to reduce mechanical stresses and vibration.
Implemented a monitoring plan to track energy consumption and performance post-upgrade.
Quality & Standards
Rewind and testing activities under ISO 9001:2015 quality framework.
Testing and acceptance in line with IEC 60034 and relevant IEEE standards.
Safety and environmental practices aligned with ISO 45001 and ISO 14001.
Measurable Results
Achieved approximately 12% reduction in energy consumption on upgraded motors.
Realised project ROI in about 18 months due to energy savings alone, based on measured kWh reduction on upgraded drives.
Improved thermal profile (stator and bearing temperatures reduced by 5–10°C under comparable loading) and reduced unplanned stoppages for upgraded equipment.
Lower maintenance frequency and improved reliability across critical drives.
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