Sustainability in industrial maintenance has become a key aspect for companies seeking to optimize their processes while reducing their environmental impact. Implementing sustainable strategies not only helps comply with increasingly strict environmental regulations, but also improves operational efficiency and reduces long-term costs.
Factors such as efficient use of resources, proper waste management and the adoption of energy-efficient technologies are essential to ensure sustainable and responsible industrial maintenance.
How to implement sustainable industrial maintenance?
To achieve sustainable industrial maintenance, it is essential to continuously evaluate the processes and equipment used in production. Replacing obsolete machinery with more efficient equipment, using monitoring systems to detect energy inefficiencies, and implementing predictive maintenance programs can significantly contribute to energy savings and reducing the carbon footprint.” – explains Iñaki Espinal, project manager of the initiative Gurpea is developing for Edison Next.
In addition, training personnel in sustainable practices helps optimize resource usage, extend asset lifespan and minimize waste generated during maintenance operations.”
Main actions to implement sustainability in industrial maintenance
Among the main improvements that can be implemented in terms of sustainability in industrial maintenance, the following stand out:
- Optimization of energy consumption through process automation,
- The use of biodegradable lubricants and materials, as well as the recycling of components at the end of their life cycle.
- In addition, integrating renewable energy sources into industrial facilities and adopting low-consumption technologies contribute to a more efficient and sustainable system.
- Choosing a responsible approach to industrial maintenance not only strengthens business competitiveness but also reinforces their long-term commitment to the environment and sustainability.
Interview with Iñaki Espinal, Project Manager for the project developed by Gurpea for Edison Next, at Solidus San Andrés
Q: What is the main objective of this motor replacement project at Solidus San Andrés, contracted by Edison Next?
A: The main objective is to achieve greater energy efficiency in the plant by acting on its water-movement processes. Through the renewal of the motors in the current installation, and their control systems, we reduce electrical consumption, minimize carbon emissions and optimize production, thus contributing to Solidus San Andrés’ sustainability goals.
Currently, the pumps are driven by old and low-efficiency induction motors, with direct starts or star-delta starters for the more powerful ones. In this regard, Gurpea has implemented energy-efficiency measures at three points in the process:
- Drive replacement: Direct or star-delta starters are replaced with variable-frequency drives (VFDs).
- Motor replacement: Low-efficiency motors are replaced with IE4 motors, currently the highest possible efficiency.
- Pump replacement: The old pump is removed and replaced with a more efficient one.
Q: Why did Edison Next choose Gurpea for this project?
A: Edison Next is a company specializing in energy generation and savings, with a strong commitment to carbon-footprint reduction. Solidus San Andrés, with whom we have a long-standing relationship, recommended us to Edison for this project due to our experience and ability to address both the mechanical and electrical aspects of this type of intervention.
We have a team of highly qualified, multidisciplinary technical professionals with hands-on experience in industrial companies across all sectors, which allows us to take on the entire project. We can handle any necessary adjustments that may arise during commissioning.
Q: What are the main technical challenges involved in this motor replacement?
A: One of the biggest challenges is ensuring that the integration of the new motors into the production line is carried out without affecting plant operation. In addition, electrical and mechanical adaptation requires precise planning to avoid long downtime.
More specifically:
- From an electrical point of view, the new VFD-driven systems must be integrated into old installations dating back to the 1960s, reusing old control circuits and updating obsolete signaling equipment. Field programming of the VFDs must be performed with continuous monitoring, adjusting control loops according to the needs of each pumping system.
- From a mechanical point of view, motor changes must be carried out during short scheduled stops, performing precise shaft alignment, coupling and adjustment with the pumps.
Q: What benefits are expected for Solidus San Andrés with these new motors?
A: The new motors installed are currently the most efficient according to international standards. IE4 (International Efficiency 4) motors represent the highest level of energy efficiency available today and are the best option for applications where energy savings are critical.
If we talk about objective benefits:
- The difference in consumption between an IE2 and an IE4 motor is around 20–25%.
- Estimated annual usage is 7,752 hours, which translates into a total action impact of 1,483 MW/h.
- The estimated savings can reach up to 25% of that amount, i.e. 370 MW/h, which in economic terms equals €40,000 annually.
- They also require less maintenance and are quieter.
Q: What is the planned timeline for executing the project and what human and technical resources is Gurpea providing?
A: The initial plan is a five-week intervention, but we must adapt to Solidus San Andrés’ production schedule, so an extension of up to two additional weeks is possible.
The phases established in the timeline include, in order of execution:
- Laying new wiring.
- Installation and connection of new electrical panels and VFDs.
- Motor and pump replacement and connection to old lines.
- Programming, new wiring integration and commissioning of each motor.
In terms of human resources provided by Gurpea:
- A team of four electrical technicians, working in pairs.
- Another team of four mechanical technicians.
- Two project managers, one electrical and one mechanical.
Q: How is this project contributing to Solidus San Andrés’ sustainability goals?
A: By implementing these energy-efficient motors, Solidus San Andrés will reduce its carbon footprint, aligning with environmental regulations and reinforcing its commitment to sustainability.
It will also allow them to benefit from the Energy Savings Certificates (CAE), a way to monetize investments in energy efficiency, enabling the end user to receive financial compensation by selling the savings obtained.
Q: Any recommendations for companies considering a similar modernization of their systems to achieve energy savings?
A: It is essential to carry out a detailed preliminary analysis of energy needs and work with a technical partner experienced in implementing efficient solutions tailored to each industrial environment.
