Implementing Sustainable Industrial Maintenance: Edison Next Project

Sustainability in industrial maintenance has become a key issue for companies seeking to optimize their processes while reducing their environmental impact. Implementing sustainable strategies not only helps to comply with increasingly stringent environmental regulations, but also improves operational efficiency and reduces costs in the long run.

Factors such as the 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 contribute significantly to energy savings and carbon footprint reduction." - Explains Iñaki Espinal, manager of the project that Gurpea is developing for Edison Next.
 

In addition, training personnel in sustainable practices optimizes the use of resources, prolongs the useful life of assets and minimizes waste generated during maintenance operations".

• Main actions to implement sustainability in industrial maintenance

Iñaki Espinal, Electrical Manager of the project that Gurpea is developing for Edison Next at Solidus San Andrés.

Among the main improvements that can be implemented in terms of sustainability in industrial maintenance, the following stand out:

1. The use of biodegradable lubricants and materials, as well as the recycling of components at the end of their useful life.

2. In addition, the integration of renewable energies in industrial facilities and the adoption of low-consumption technologies contribute to a more efficient and sustainable system.

3. A responsible approach to industrial maintenance not only strengthens the competitiveness of companies, but also reinforces their commitment to the environment and long-term sustainability.

• Interview Iñaki Espinal, Project Manager, developed by Gurpea for Edison Next, at Solidus San Andrés.

Q: What is the main objective of this motor replacement project at Solidus San Andres, contracted by Edison Next?
A: The main objective is to achieve greater energy efficiency of the plant by acting on its water movement processes. By renewing the motors of the current installation and their drive, we managed to reduce electricity consumption, minimize carbon emissions and optimize production, thus contributing to the sustainability objectives of Solidus San Andrés.

Currently, the pumps are driven by old, low efficiency induction motors, with direct or star-delta starts in the most powerful ones. In this sense, Gurpea has implemented energy efficiency measures in 3 points of the process:

• The change of the drive: Direct or star-delta drives are replaced with the implementation of a frequency inverter.
• Motor replacement: Low-efficiency motors are replaced by IE4 motors, the highest efficiency currently possible.
• Pump replacement: The old pump is eliminated and replaced by a more efficient one.

Q: Why did Edison Next choose Gurpea for this project?

A: Edison Next is a specialist in energy generation and savings, with a strong commitment to carbon footprint reduction. Solidus San Andres, with whom we have a long-standing relationship, recommended Edison for the execution of this project because of our experience and ability to address both the mechanical and electrical aspects of this type of intervention.

We have a multidisciplinary and highly qualified team of technical professionals, with a practical support in industrial companies of all sectors, which allows us to cover the project in its entirety. We are able to face any possible adjustments that may arise during the project start-up.

Left to right: Gaizka (Mechanical Technician), Joel (Mechanical Project Manager), Mikel (Electrical Technician) and Iñaki (Electrical Project Manager).

Q: What are the main technical challenges involved in this engine replacement?

A: One of the biggest challenges is to ensure that the integration of the new engines into the production line is done without affecting plant operations. In addition, electrical and mechanical retrofitting requires precise planning to avoid prolonged downtime.

More specifically:

•   From the electrical point of view The new drives with frequency converters must be integrated into old installations dating back to the 1960s, reusing old control systems and updating obsolete signaling equipment. The field programming of the drives must be carried out with continuous monitoring, adapting the control loops according to the circumstances of each pumping operation.

•    From the mechanical point of view the motors have to be changed during the short programmed stops, aligning the shafts, coupling and adjustment with the pumps in a very precise way.

Q: What benefits does Solidus San Andrés expect to obtain with these new engines?

R. The new motors installed are currently the most efficient according to international standards. IE4 (International Efficiency 4) represent the highest level of energy efficiency available on the market today, the best choice for applications where energy savings are critical.

Gaizka (Mechanical Technician) working on one of the motors to be replaced.

New vs. old engine, ready for replacement.

If we talk about objective benefits:

• The difference in consumption between an IE2 and an IE4 is around 20-25%.
• An annual use of 7,752 hours is estimated, which translates into a total performance of 1,483MW/h.
• The estimated savings can reach up to 25% of that amount, i.e. 370MW/h, which translated into economic cost, is 40,000€ per year.
• They also require less maintenance and are quieter.

Q: What is the schedule foreseen for the execution of the project and what human and technical resources is Gurpea providing?

A. The initial action plan is for five weeks, but we will have to adapt to the production of Solidus San Andres, so we are considering a possible extension of 2 more weeks.

The phases established in the schedule include, in order of action:

• Laying of new wiring.
• The implementation and connection of new panels and variators.
• The change of motors and pumps and connection of old lines.
• Programming, reconnection and start-up of each motor. As for the human resources made available by Gurpea for the project, we have:

As for the human resources made available by Gurpea for the project, we have:

• A team of four electrical technicians, working in teams of two.
• Another team of four mechanical technicians.
• Two project managers, one electrical and one mechanical.

Mikel, electrical technician, acting on the installation.

Gaizka y Joel, reviewing the installation specifications are corrects before acting..

Q: How is this project contributing to Solidus San Andres' sustainability objectives?

A: With the implementation of these energy-efficient motors, Solidus San Andres will be able to reduce its carbon footprint, aligning itself with environmental regulations and reinforcing its commitment to sustainability.

It will also allow you to take advantage of the Energy Savings Certificate (ESC) system, a way to monetize the investments made in energy efficiency so that the end user can receive an economic consideration by selling the savings obtained.

Q: Recommendation for other companies considering a similar energy-saving upgrade of their systems?

A: It is essential to carry out a detailed analysis of the energy needs and to have a technical partner with experience in the implementation of efficient solutions adapted to each industrial environment.