Enhancing Efficiency and Reliability: The Importance of Energy-Efficient Motor Repair and the India Motor Rewinder Certification System

In India, the industrial sector heavily relies on electric motors, with millions of units installed across various industries and more than 2 million motors produced domestically each year. However, motor rewinding, a common practice in case of motor failure, can lead to significant efficiency losses. Recognizing the need for standardized rewinding processes and improved motor repair practices, the International Copper Association (ICA) India and the Confederation of Indian Industry (CII) have developed the Motor Rewinder Certification System (MRCS). This voluntary certification system aims to enhance the performance, reliability and lifespan of rewound motors, while also promoting energy efficiency and sustainability.

A Need for Standardization

Electric motors play a crucial role in driving industrial operations, consuming a substantial amount of electricity. However, when a motor undergoes rewinding due to failure, there is a potential efficiency drop of up to 5 percent. This leads to increased energy consumption, higher greenhouse gas emissions, and reduced overall efficiency.

To address the efficiency losses caused by motor rewinding, it is essential to identify the root causes of motor failure and adopt best practices during the rewinding process. A lack of existing infrastructure and capacity have created barriers to a systematic development of a united standard, as has a lack of awareness of energy-efficiency losses during the rewinding process. Furthermore, standardization requires an investment in training and resources by rewinders, creating additional challenges for small and medium-sized enterprises (SMEs). As a result, there has been no standardized system in place to ensure consistency in the rewinding process or to compare the quality of rewinders. This lack of standardization poses a significant challenge to improving the efficiency, reliability and lifespan of rewound motors.

The Motor Rewinder Certification System (MRCS)

The Motor Rewinder Certification System (MRCS) is a voluntary mechanism and framework developed by ICA India and CII to assess and certify motor rewinding units in India. The MRCS certification process involves a comprehensive evaluation of motor repair centers in India based on the quality of the rewinding process, the use of energy-efficient practices and adherence to safety standards. Overall, the MRCS aims to enhance the skills of rewinding professionals, promote the adoption of best practices and guide motor repair centers toward becoming nationally and globally recognized entities.

The system was designed to address all types of motor repair centers in India, including electrical motor repair centers in the open market, in-house repair workshops in large industries and energy management centers focused on SMEs. The implementation of the program is supported by state-designated agencies under the Indian Bureau of Energy Efficiency (BEE).

Assessment and Certification Framework

The MRCS follows a comprehensive framework surrounding five key elements to assess the quality of the rewinding process through an assessment of the current repair process and standard operating procedures (SOPs) followed by the repair unit.

  1. Technology Adoption
  2. Best Practices for Motor Repair
  3. Capacity and Capability Development
  4. Systems and Standards
  5. Sustainability Initiatives

After enrolment and a pre-assessment, training and awareness sessions are conducted based on MRCS guidelines to equip service technicians with the required skillsets and industry best practices. Small changes and guidance can make a big impact on efficiency. For example, using the right size of magnet wire in electric motors could lead to 2.38 TWh annual energy savings in India. The certification also has a clear impact on improving safety standards in the industry, ensuring rewinders have the necessary skills and knowledge to perform the task safely. 

An onsite assessment visit by independent assessors and representatives from CII is carried out to validate data, assess rewinder competence and ensure compliance with requirements. The five-point certification levels awarded to the repair units are based on their assessment scores.

National Impact for Companies and Consumers

The India Motor Rewinder Certification System (MRCS) can also help achieve cost savings. By improving safety standards and increasing efficiency and performance, the MRCS can help reduce the number of accidents and breakdowns related to rewinding, which can result in costly repairs and replacements. Additionally, the MRCS helps ensure that the rewinders have the necessary skills and knowledge to perform the task efficiently and effectively, which can help reduce labor costs.

Industries can benefit from lower efficiency drops in rewound motors, resulting in higher energy savings, reduced downtime, and enhanced reliability. On a larger scale, India can achieve reduced energy consumption, lower greenhouse gas emissions and the creation of green jobs.

By promoting best practices and standardized rewinding processes, the MRCS helps motor repair centers benchmark themselves nationally and internationally. With the potential to reduce energy consumption, decrease greenhouse gas emissions and create skilled jobs, the MRCS paves the way for a more sustainable and efficient industrial sector in India. As the program grows, it will continue to contribute to climate change mitigation and support the growth of the nation’s economy.

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