PRESSESERVICE

MENZEL

Single source for complete generator sets for test fields

Menzel Elektromotoren supplies complete rotary converter sets for test fields, with motors and generators from its own production, frequency converters, transformers, all accessories, controls and software programmed in-house.

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Menzel Elektromotoren supplies complete rotary converter sets for test fields, with motors and generators from its own production, frequency converters, transformers, all accessories, controls and software programmed in-house. The German manufacturer, who specializes in large machines, does all the calculations for the individually required performance profile as well as optional inspection and acceptance as a complete system. This service covers capacities up to 20MVA and voltages up to 13.8kV. The latest project is a 7.5MVA generator set for a transformer test stand. The system weighing a total of 60 tons is currently being shipped to Egypt where Menzel will see through its commission. It was important to the customer that Menzel especially configured the rotary converter set for this application and supplied it completely from a single source. The 7.5MVA synchronous generator and the 2.3MW squirrel-cage motor are Menzel products featuring high efficiency and great robustness. The frequency converters and transformers come from reliable partner companies and the control cabinets are supplied by Pawils Elektromaschinenbau, a member of the Menzel Group. The scope of delivery also includes various auxiliary drives, for example for forced fans, an oil supply system with a pump for lubricating the generator bearings, a coupling and numerous small parts. A special requirement was that the generator must work in 3-phase as well as 1-phase operation; Menzel planned a single to three phase switch for this purpose especially.
More information is available at https://www.menzel-motors.com/converter/.

date: 2022-11-22 | characters: 1617 | download: document, picture 1

MENZEL

Crane motors with exactly replicated interfaces

Menzel Elektromotoren has manufactured four crane motors with the exact electrical and mechanical interfacing positions of a make that is no longer available today. The new slip ring motors based on a cost-efficient motor series will drive hoists on overhead cranes in a Chilean cement plant.

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Menzel Elektromotoren has manufactured four crane motors with the exact electrical and mechanical interfacing positions of a make that is no longer available today. The new slip ring motors based on a cost-efficient motor series will drive hoists on overhead cranes in a Chilean cement plant. Since standard motors do not fit the existing positions and dimensions for feet, shafts and shaft height, and since constructive changes on the cranes are impossible or not desirable due to technical and safety approvals, Menzel tailored foot adapter rails. The motors have two shaft ends, with the drive end coupled to the gearbox, which connects to the rope drum, and a brake installed on the non-drive end. At the customer’s request, the stator and rotor connections are implemented in a common terminal box, which is symmetrically positioned and can be simply rotated in the direction of the connection cables. This allows the customer to deploy the motors in different locations with limited space. The slip ring motors from the energy-efficient, low-noise MEBSGR series provide high starting torques at low starting currents and have a high overload capacity. They have a rated power of 63 kW, a rated voltage of 550 V and a rated torque of 617 Nm. The motors are designed for periodic intermittent operation (S3 40%). As a family-run, medium-sized manufacturer, Menzel is very customer-oriented, responds flexibly to special requests and can therefore also serve those inquiries that many competitors routinely reject for requiring too much effort. The crane motors adapted for the cement manufacturer fit exactly in terms of electrical performance data and mounting dimensions and can be directly mounted on the cranes.
Motors for cranes and hoists: https://www.menzel-motors.com/crane-drive/

date: 2022-10-05 | characters: 1720 | download: document, picture 1

MENZEL

Bespoke pit fan motors with fin cooling

Menzel Elektromotoren has designed and manufactured three powerful 6600 V squirrel cage motors as integral components for pit fans. The customer specified cylindrical motor casings as compact as possible.

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Menzel Elektromotoren has designed and manufactured three powerful 6600 V squirrel cage motors as integral components for pit fans. The customer specified cylindrical motor casings as compact as possible. The greatest challenge was to implement the required rated power of 1700 kW in cylindrical casings. Menzel therefore designed fin-cooled motors (cooling type IC 411) in frame size 630, an extremely unusual design for motors this large. The manufacture is complex but the result is optimal for the constricted installation conditions. In order to save additional space, all connection cables are routed out of the motors and the terminal boxes are mounted outside the fans. Since the driven fan wheels are mounted directly on the motor shafts, the motor bearing must compensate additional high loads: radial loads up to 20700 N and axial loads up to 27000 N. For the required bearing service life of 100,000 hours, Menzel implemented a special rolling bearing setup. In addition, the motors have a second shaft end for a holding brake. The three-phase squirrel cage motors are designed for operation on a frequency converter (duty type S9) with speed changes and reversal of the rotation direction. This allows the pit fans not only to ventilate the mine, but also to extract dangerous firedamp if necessary.
Surface-cooled motors from Menzel: https://www.menzel-motors.com/slip-ring-motor/ic411/

date: 2022-09-14 | characters: 1312 | download: document, picture 1

MENZEL

Cement mill motor in economic 1-for-3 design

Menzel Elektromotoren supports customers‘ economical spare parts management by configuring large industrial motors as common parts. The German, family-run company has built a replacement motor for a cement plant in Pakistan that can drive any one of three applications: the raw mill, another cement mill or a fan.

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Menzel Elektromotoren supports customers‘ economical spare parts management by configuring large industrial motors as common parts. The German, family-run company has built a replacement motor for a cement plant in Pakistan that can drive any one of three applications: the raw mill, another cement mill or a fan. The motors originally installed differ in various features. But most importantly, the available installation space is extremely limited. Therefore, a Menzel engineer visited the site to take all the measurements. The solution was a compact slip ring motor in frame size 710 with the cooling system tailored to fit around a steel girder in the cement plant. To accommodate the existing couplings in two different sizes, Menzel designed the replacement motor with two shaft ends with different diameters. The motor output is configured to ensure efficient continuous operation in each of the three applications. The machine has a rated output of 4600 kW and a rated voltage of 6300 V. It complies with protection class IP55. At the customer’s request, it was designed in cooling type IC 666, i.e., with permanent external ventilation of the inner and outer cooling circuit. Before delivery, Menzel ran a load test in its inhouse test field. Although the customer could not be there in person, they attended the load test live via video streaming, which Menzel offers as a standard service.
Additional reference projects: https://www.menzel-motors.com/mill-drive/

date: 2022-08-24 | characters: 1401 | download: document, picture 1

MENZEL

Foundation stone ceremony for new motor plant of Menzel Elektromotoren

Menzel Elektromotoren launched the construction work for its new plant in Hennigsdorf on the outskirts of Berlin with the laying of the foundation stone on 11 June 2022. The new, purpose-built headquarters will be erected on a 24,000 m² plot.

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Menzel Elektromotoren launched the construction work for its new plant in Hennigsdorf on the outskirts of Berlin with the laying of the foundation stone on 11 June 2022. More than 200 guests and employees attended the celebrations. The new, purpose-built headquarters will be erected on a 24,000 m² plot. All administrative and production workplaces are to be relocated by January 2024. When complete, the new motor plant with an effective floor space of 8,500 m² will increase the manufacturer’s production capacities, allow the expansion of the workforce and earn significant efficiency gains through an optimized floor plan. The production area of about 3,800 m² will accommodate the assembly, metal processing, fabrication and winding workshops, paint shops and three state-of-the-art test fields. In addition, there will be roomy offices, logistics zones and storage areas. The spacious property allows for future expansions and is easy to reach via public transport, motorway or the Berlin Brandenburg International Airport. The move heralds a new era for the motor company, which was founded in 1927. Under the management of Mathis Menzel, who runs the family business in the third generation, Menzel has experienced significant growth in recent years. The new building allows for a streamlined and ergonomic layout for all production processes and thus a higher throughput. Crane capacities will be significantly increased in order to meet the demand for ever larger motor systems from customers in all industries. Menzel manufactures three-phase asynchronous motors with squirrel cage or slip ring rotors up to 20 MW and DC motors up to 2 MW. Menzel offers several powerful own-brand motor series and is also specialized in customization as well as identical replication of existing motors. Menzel keeps various motor versions up to 15 MW permanently in stock and adapts them at short notice for a wide variety of applications and locations. Furthermore, the company offers comprehensive testing services for electric motors, generators, transformer-converter-motor systems, gearboxes and frequency converters, idle tests up to 10 MW, load tests up to 1.8 MW and multi-frequency heat load testing up to 5 MW. The new test fields will be larger, too, to allow for future expansions of the company’s testing services.
Updates on building phases: https://www.menzel-motors.com/news/

date: 2022-06-13 | characters: 2323 | download: document, picture 1

MENZEL

TĂśV attestation for IP67 motors

Menzel Elektromotoren manufactures IP67 low and medium voltage squirrel-cage motors up to size 355. TĂśV SĂĽd has recently attested the dust- and waterproof construction according to protection class IP67 of an entire low voltage motor type series.

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Menzel Elektromotoren manufactures IP67 low and medium voltage squirrel-cage motors up to size 355. TÜV Süd has recently attested the dust- and waterproof construction according to protection class IP67 of an entire low voltage motor type series. The series extends to outputs of 400 kW and voltages of 1000 V. In addition, TÜV Süd has attested Menzel’s procedures for IP67 testing, which the manufacturer also offers for medium voltage motors from its own brand up to 11 kV. Menzel builds IP67 motors with minimal tolerances, waterproof encapsulated cast-iron casings and terminal boxes. The manufacturer holds stock in its main warehouse of all basic components for dust- and waterproof squirrel-cage motors and can therefore realize very short delivery times for standard designs of IP67 motors. The motors are used worldwide, mainly in pump stations, flood-prone areas, food and drink industries and maritime applications. They can be fully immersed at standstill for a period of 24 hours without any ingress of water. Subsequently, when water has receded, the motors are ready to be switched on again directly. The manufacturer runs comprehensive acceptance tests on its motors in its inhouse load test field before shipping. As part of the test spectrum, Menzel also offers underwater tests for all induction motors with cage or slip ring rotors. At the 2021 AEMT Awards of the Association of Electrical and Mechanical Trades, Menzel IP67 motors were voted the Product of the Year.
Product page: https://www.menzel-motors.com/ip67-motor/

date: 2022-06-10 | characters: 1486 | download: document, picture 1

MENZEL

Spare motor for four sugar plants

Menzel Elektromotoren has configured a flexible spare motor for one of Europe’s leading sugar producers, which can replace motors of various other makes if necessary.

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Menzel Elektromotoren has configured a flexible spare motor for one of Europe’s leading sugar producers, which can replace motors of various other makes if necessary. While the customer can basically employ the three-phase squirrel cage motor in any of its plants around the world, it is in fact specifically designed for the sugar beet pulp dryers in four plants in Germany and Sweden. With a rated output of 1400 kW, it covers the drive power requirements of four separate systems, which range from 1000 kW to 1400 kW. It is designed as a vertical motor for flange mounting (IM V1 standing or IM V3 suspended). In addition, an adapter also manufactured by Menzel enables foot mounting in a system with a V2 flange. The motor with cooling type IC 616 meets the protection class IP55. The customer was on site for acceptance testing at Menzel’s Berlin plant. More and more large organizations are looking to utilize spare assets over multiple processes and Menzel is the go-to supplier in this niche market. The modular MEBKSL motor series enables a variety of cooling types and ingress protection ratings as well as various mounting options at optimized production costs. The tried-and-tested design meets high standards in terms of size, performance, cost-effectiveness and reliability.
More about three-phase asynchronous motors with squirrel cage rotors: https://www.menzel-motors.com/squirrel-cage-motor/

date: 2022-06-10 | characters: 1288 | download: document, picture 1

MENZEL

Large slip ring motor quickly customized

Menzel Elektromotoren has adapted and delivered a 6500-kW slip ring motor for a cement mill at short notice. The MEBSSL-type motor is ideally suited for industrial applications with high starting torques.

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Menzel Elektromotoren has adapted and delivered a 6500-kW slip ring motor for a cement mill at short notice. The MEBSSL-type motor is ideally suited for industrial applications with high starting torques. Menzel adapted the internal motor winding connections for a 60-Hz mains voltage in the country of operation, Canada, and moved the terminal box according to customer specifications. The capability to provide such a flexible, on-schedule customization was decisive for winning the contract. The motor design moreover ensures long-term reliable operation in the target application. The motor series is characterized by high efficiency, high power density, a compact design, robust bearings and high load capacity. The welded-steel housing is designed for maximum torsional rigidity and optimal cooling. The motor features protection class IP55, cooling class IC 611 and a nominal torque of 52076 Nm. The enclosed self-cooling system, a detached air-to-air heat exchanger, ensures high efficiency and optimal dust protection. Slip ring motors are still the preferred choice of many cement plant operators. In dusty environments, they offer great advantages over the combination of squirrel-cage motors and frequency inverters because they need no power electronics and are therefore much more resilient. Not least, there is a considerable price difference in this performance class. Three-phase slip ring motors, which are started with a liquid starter, offer an economic solution for driving mills, crushers and conveyors. They only require small starting currents and provide the full torque from standstill.
More about modular slip ring motors up to 8000 kW: https://www.menzel-motors.com/slip-ring-motor/ic611-ic616-ic666/

date: 2022-06-10 | characters: 1612 | download: document, picture 1

MENZEL

New motor plant for Menzel Elektromotoren

Menzel Elektromotoren has signed the construction contract for a new, larger motor plant in Hennigsdorf, near Berlin. The manufacturer has experienced substantial growth in recent years.

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Menzel Elektromotoren has signed the construction contract for a new, larger motor plant in Hennigsdorf, near Berlin. The manufacturer has experienced substantial growth in recent years and has outgrown its present headquarters in central Berlin. “Our new location will feature state-of-the-art machinery, efficient logistics, larger hoist capacities for optimized production processes and high energy efficiency,” says CEO Mathis Menzel on the occasion of the signing of the contract. “We will also expand our team and create around 100 new jobs in production and administration in the medium term.” The new site offers optimal conditions for this: a gross floor area of around 8500 m˛ will accommodate a motor plant with production, testing and storage areas as well as offices. The extensive plot allows for flexible expansions to meet future growth requirements. Construction is to start in the summer, with final acceptance scheduled for August, 2023.
The Vollack Group, an expert in methodical building conception, oversees planning and construction. Thanks to resource-saving building technology with heat generation from the local heat network, the building will meet the EG40EE energy efficiency standard and thus qualify for funding from the state. “In planning and implementing this project, we emphasize lean processes and resource conservation at all levels,” says Matthias Jordt, partner at Vollack. This generates added value for Menzel, with positive effects on quality, time and costs.
With this investment and the move to the new location, Menzel Elektromotoren positions itself sustainably for the future. The family-owned company, which is celebrating its 95th anniversary this year, stands for high-quality production of powerful electric motors for industrial plants all over the world. Menzel offers several own-brand motor series and is also specialized in customization as well as identical reproduction of existing motors. The company keeps various motor versions up to 15 MW permanently in stock and adapts them at short notice for a wide variety of applications and locations. Furthermore, Menzel offers comprehensive testing services for electric motors, generators, transformer-converter-motor systems, gearboxes and frequency converters, idle tests up to 10 MW, load tests up to 1.8 MW and bifrequency heating testing up to 5 MW.
Updates on building phases: https://www.menzel-motors.com/news/

date: 2022-02-28 | characters: 2358 | download: document, picture 1

MENZEL

Pump motor with special flange for chemical plant

Menzel Elektromotoren has realized an unusual motor configuration to help out a customer: the operator of a large chemical plant needed a replacement for a failed pump motor. It seemed difficult, at first, to find a machine able to accommodate an existing oversized pump flange dimension. Only the family-run company Menzel offered a size 400 motor that matched the performance profile and was light enough.

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Menzel Elektromotoren has realized an unusual motor configuration to help out a customer: the operator of a large chemical plant needed a replacement for a failed pump motor. It seemed difficult, at first, to find a machine able to accommodate an existing oversized pump flange dimension. Only the family-run company Menzel offered a size 400 motor that matched the performance profile and was light enough. The Berlin-based manufacturer converted a stock, IM B3 type motor (foot mounting) to type IM V1 (vertical flange mounting). For this purpose, the drive-end bearing seat was converted for the installation of a thrust bearing. Menzel also manufactured the special flange in-house and adapted it to the shaft, which could only protrude 120 mm from the flange. Menzel prepared the motor for quick installation at the customer’s site, shifting the main terminal box to the most accessible position and mounting a cable entry that could be readily adapted to the existing cable diameter on site. By installing both the heater and PT100 connections in one auxiliary terminal box, Menzel was able to save one terminal box. The motor, which is now successfully in operation in the customer’s plant, has a rated output of 315 kW and a nominal voltage of 5000 V. It features the cooling type IC 411 and an IP55 protection rating and weighs 4900 kg.
More information about squirrel-cage motors with cooling type IC 411 is available at https://www.menzel-motors.com/squirrel-cage-motor/ic411-ic416/.

date: 2021-09-01 | characters: 1493 | download: document, picture 1

MENZEL

Motor replicas with two shaft ends

Menzel Elektromotoren built two bespoke slip ring motors to drive the mills in a cement plant in the Middle East: replicas of the original motors, each with two shaft ends and precisely fitting all existing interfaces.

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Menzel Elektromotoren built two bespoke slip ring motors to drive the mills in a cement plant in the Middle East: replicas of the original motors, each with two shaft ends and precisely fitting all existing interfaces. One shaft end is coupled to the respective cement mill via a gearbox, while the second shaft end connects to an auxiliary drive that is used to position the rotor during maintenance work. Menzel’s motor design ensures full mechanical and electrical compatibility with the failed previously installed machines of Japanese make. The original manufacturer no longer offers this design, which features relatively unusual dimensions. The 6-pole AC motors with a rated power of 2400 kW and a rated voltage of 6600 kV are in accordance with the IEC / EN 60034-1 standard. The carefully replicated design included, among other things, fitting the motors with sleeve bearings. In addition, the German manufacturer designed the motors for double-pipe ventilation (IP23/IC37, previously: IPR44). This cooling type in particular required the motors to exactly match the in-situ parameters. The very short total length of the motors is determined by fixed couplings on both ends. In order to meet this requirement, Menzel positioned the slip ring chamber not externally but between the bearing seats. More information about tailor-made replicas as well as exact copies of existing motors: https://www.menzel-motors.com/replacement/

date: 2021-08-04 | characters: 1306 | download: document, picture 1

MENZEL

6-MW high-voltage extruder motor speedily adapted

When large motors operating at high output fail, a replacement manufactured from scratch can hardly be the solution because of the long lead times and the resultant loss of production. Instead, customized configuration of a suitable standard motor is an economical alternative.

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When large motors operating at high output fail, a replacement manufactured from scratch can hardly be the solution because of the long lead times and the resultant loss of production. Instead, customized configuration of a suitable standard motor is an economical alternative. A case in point: a petrochemical plant operator urgently needed to replace a failed extruder motor featuring 6000 kW rated power, 10 kV nominal voltage, requiring >57 kNm nominal torque. Originally, the extruder was driven by a squirrel-cage machine. However, a motor with similar design parameters was not readily available on the market. Fortunately, Menzel Elektromotoren based in Berlin, Germany, was able to offer a suitable three-phase slip ring motor. This design also offered significant advantages for the target application, driving an extruder, as it provides the required full torque from standstill. Menzel could quickly procure a starter for the slip ring motor as well as implement all necessary modifications in-house. Thanks to a delivery time of only two weeks, the customer restarted the extruder system at the earliest possible moment. The modular MEBSSL motor series is explicitly designed to enable flexible configuration for various applications and conditions. One of the most time-consuming jobs was fitting a bushing in the customer’s coupling hub, machining it from a diameter of 280 mm to 240 mm. In addition, Menzel manufactured adapter plates for the motor to adjust the shaft height from 800 mm to the failed motor center height of 900 mm. The replacement motor is designed with protection class IP55 and cooling type IC 611 with an air-to-air heat exchanger. More information about high-voltage motors: https://www.menzel-motors.com/high-voltage-motors/

date: 2021-07-07 | characters: 1667 | download: document, picture 1

MENZEL

Highly overloadable mill motors in several sizes

Menzel Elektromotoren manufactures DC mill motors according to AISE standards. Few manufacturers produce this special type of motors nowadays, which feature extremely high overload capacity and mechanical load capacity. Menzel offers mill motors in various sizes: 802 / 803 / 804 / 806 / 808 / 810 / 812 / 814 / 816 / 818 / 62* (MEBG** series).

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Menzel Elektromotoren manufactures DC mill motors according to AISE standards. Few manufacturers produce this special type of motors nowadays, which feature extremely high overload capacity and mechanical load capacity. Menzel offers mill motors in various sizes: 802 / 803 / 804 / 806 / 808 / 810 / 812 / 814 / 816 / 818 / 62* (MEBG** series). AISE compliance ensures full interchangeability of the motors with existing machines. In addition, Menzel offers customer-specific adjustments and special solutions (e.g. for special load cycles or shock stressing, as well as metric mechanical adjustments). Menzel manufactures fully laminated mill motors by default. In special cases or on request, split case designs are also possible. Typical applications are in steel and aluminum rolling mills as well as mining. For a South European steel plant, Menzel has recently built three mill motors in size 812, with 200% overload capacity, 16 kW / 23 kW output power, protection class IP54, and cooling type IC 37. These are used on pinch and work rollers. For easy integration at the customer’s site, Menzel designed the new mill motors with the same dimensions and electrical specifications as the existing motors. Working closely with the customer, the German company was able to compile all the necessary data despite the lack of technical documentation. Due to space restraints in the installation position, the cable outlets were positioned in exactly the same position as with the old motors. At the customer’s request, Menzel built the motors with a split case to enable easy, fast revision and maintenance. More reference projects for rolling mill drives: https://www.menzel-motors.com/rolling-mill-drive/

date: 2021-06-01 | characters: 1607 | download: document, picture 1

MENZEL

Menzel Elektromotoren forms U.S. partnership

German motor manufacturer Menzel Elektromotoren has recruited an industry expert as a representative in the U.S. to serve customers even better: Marc Amato has 27 years of experience in the electric motor and machine industry, particularly in motor manufacturing, re-manufacturing, troubleshooting, and machine applications.

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German motor manufacturer Menzel Elektromotoren has recruited an industry expert as a representative in the U.S. to serve customers even better: Marc Amato has 27 years of experience in the electric motor and machine industry, particularly in motor manufacturing, re-manufacturing, troubleshooting, and machine applications. He has led teams of engineers and technicians during installation, startup, and commissioning of machines up to 30,000 hp (20 MW). He has an in-depth background in forensic failure analysis and is a specialist in bearing systems. He is well connected in the power, cement, mining, steel industries, which are all focal sectors for Menzel. The manufacturer supplies the U.S. market with large special motors in the medium and high-output range and with smaller special motors such as roller table motors and crane motors. The company has a large stock of AC and DC motors for urgent replacements, and specializes in quickly adapting them for various applications as well as manufacturing bespoke motors from scratch. The portfolio includes DC motors up to 3,000 hp (2,000 kW) from 160 V to 1,000 V and induction motors from 220 V to 13,800 V: squirrel cage induction motors up to 33,000 hp (25,000 kW) and slip ring induction motors up to 20,000 hp (15,000 kW).
More information: https://www.menzel-motors.com/special-electric-motors/

U.S. sales contact:
Marc Amato
Phone: +1 401.640.7169
marca@menzel-motors.com

date: 2021-04-28 | characters: 1285 | download: document, picture 1

MENZEL

Asynchronous generator with special shaft for Pelton wheel

Menzel Elektromotoren has built an asynchronous generator with a special shaft and a special flange for operation on a Pelton wheel in a Scandinavian hydroelectric power plant. The large radial forces acting on the shaft end in this application had damaged the existing generator to the extent that it was a total write-off.

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Menzel Elektromotoren has built an asynchronous generator with a special shaft and a special flange for operation on a Pelton wheel in a Scandinavian hydroelectric power plant. The large radial forces acting on the shaft end in this application had damaged the existing generator to the extent that it was a total write-off. The customer required a more robust shaft construction to avoid such damage in the future. In addition, the new generator had to be identical to the old one and have the same electrical parameters. Menzel’s subsidiary Franz Wölfer Elektromaschinenfabrik designed and manufactured a shaft made of 42CrMo4 high-tensile strength special steel, reinforced on the turbine side. The concentrated collaborative expertise within the Menzel Group made it possible to quickly prepare a verified offer and complete the generator within two and a half weeks. Menzel could deliver fast thanks to clever warehousing: a prefabricated three-phase asynchronous generator met the requirements of the application in the hydroelectric power plant. Menzel merely designed and manufactured a new bearing shield for the reinforced shaft and bearing. This generator order came in through Menzel’s Swedish subsidiary, which, like numerous offices and partners around the world, provides customer-oriented advice and service. More about asynchronous and synchronous motors: https://www.menzel-motors.com/specialized-motors/generators/

date: 2021-03-04 | characters: 1324 | download: document, picture 1

MENZEL

Compressor motor rush job secures oxygen supply

Working under high pressure, Menzel Elektromotoren completed two much-needed compressor motors and delivered them in just two weeks at the turn of the year, despite a company holiday from Christmas to the New Year. An order from Bangladesh was to ensure the supply of medical oxygen, which gave added urgency during the current pandemic.

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Working under high pressure, Menzel Elektromotoren completed two much-needed compressor motors and delivered them in just two weeks at the turn of the year, despite a company holiday from Christmas to the New Year. An order from Bangladesh was to ensure the supply of medical oxygen, which gave added urgency during the current pandemic. A Spanish gas manufacturer needed to replace a failed motor quickly to minimize production downtime and revenue loss. Menzel was able to provide high-voltage motors with outputs of 3000 kW and 5200 kW as well as coolers from its extensive stock. All necessary interface modifications were carried out in-house in the short time available, including the conversion from air-to-air to air-to-water cooling IC 81W, machining the shaft end, installing a support and flange for an oil pump, converting the terminal boxes, and boring new foot holes. Special technical expertise was required to secure the oxygen supply even in the event of grid fluctuations; Menzel’s technical department and the start-up transformer manufacturer together calculated the ramp-up to ensure that the new motor was compatible with the existing starter. Both orders came from existing customers and were executed to their full satisfaction. Further reference projects for compressor motors can be viewed at: https://www.menzel-motors.com/compressor-drive/.

date: 2021-02-10 | characters: 1368 | download: document, picture 1

MENZEL

Backup DC motor for two rolling mill applications

Menzel Elektromotoren has built a replica of an old DC motor for a large German steel strip manufacturer. The new motor was designed as a reserve for two site applications, a roller motor and a coiler drive.

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Menzel Elektromotoren has built a replica of an old DC motor for a large German steel strip manufacturer. The new motor was designed as a reserve for two site applications, a roller motor and a coiler drive. This flexible configuration saves the customer money and storage space, whilst protecting the rolling mill against downtime in the event of either existing motor suffering damage. To determine the essential data, Menzel engineers worked closely with the customer, studied the existing motor’s documentation, and took additional measurements. Menzel manufactured a special construction with two shaft ends, foot dimensions matching both installation sites, as well as provision for a special encoder including an insulated coupling. The positions of the terminal box and the air inlet opening were adapted to the existing connections on site. The DC motor featuring 450 kW rated power and 530 V rated voltage is also characterized by a high field-weakening range. A family-run, customer-focused business, Menzel fulfills even demanding individual requests. Replicas of old motors are something of a specialty of Menzel’s – from electrically and mechanically suitable replacements to exact copies. The current customer is fully satisfied with the DC motor supplied and has already placed a second order. More about Menzel’s expertise in the construction of DC motors: https://www.menzel-motors.com/dc-motors/

date: 2020-10-21 | characters: 1309 | download: document, picture 1

MENZEL

Plug & play compressor motor for Tata Steel

Menzel Elektromotoren has customized a motor for a compressor drive operated by Tata Steel, shipping it within just two weeks. A motor failure had stalled the booster air compressor, which is integral to one of the corporation’s Indian steelworks, providing oxygen necessary for steel production.

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Menzel Elektromotoren has customized a motor for a compressor drive operated by Tata Steel, shipping it within just two weeks. A motor failure had stalled the booster air compressor, which is integral to one of the corporation’s Indian steelworks, providing oxygen necessary for steel production. Thanks to its modular warehousing strategy, Menzel was able to speedily configure a squirrel-cage motor in accordance with customer specifications. The MEBKSL-type motor was electrically and mechanically adapted to enable installation and commissioning by the customer without further modifications of the motor or the site. The motor with an operating voltage of 6600 V and a rated power of 3200 kW was fitted with an air-to-air heat exchanger (cooling type IC 611). Menzel staff at the Berlin plant shortened the motor shaft, milled the shaft end, and produced intermediate plates to adjust the fixing dimensions to the existing installation site. The 2-pole motor was designed with sleeve bearings with 2-wedge bearing shells to avoid any critical speed in the vicinity of the operating point of 2987 rpm. The motor is also designed for demanding conditions with ambient temperatures up to 50 °C and humidity up to 95%. It features a tropicalized motor winding in temperature class „F“ and the increased protection class IP55. Menzel manufactures motors for large industrial compressors in various types and offers several feature options. The company’s large stock includes several series of squirrel-cage and slip ring motors with air or water cooling or open-circuit ventilation, optionally with self-ventilation or forced ventilation, and prepared for inverter operation.
More customer references: https://www.menzel-motors.com/compressor-drive/

date: 2020-09-22 | characters: 1674 | download: document, picture 1

MENZEL

New synchronous generator more economic than repair

Menzel Great Britain Ltd has supplied a synchronous generator with a power rating of 11380 kVA to Westfield Power Station in Scotland. The plant operated by the Independent Power Producer (IPP) Melton Renewable Energy UK Ltd had suffered a failure of the existing generator.

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Menzel Great Britain Ltd has supplied a synchronous generator with a power rating of 11380 kVA to Westfield Power Station in Scotland. The plant operated by the Independent Power Producer (IPP) Melton Renewable Energy UK Ltd had suffered a failure of the existing generator. Purchasing the replacement generator, which was delivered in only two weeks, was significantly more cost-effective than a lengthy repair, as the IPP may incur revenue losses when the power supply is interrupted. It was fortuitous that a synchronous generator of suitable rating and performance class was readily available on the market, as this application and configuration are very rare, and such generators are usually manufactured with long lead times. Menzel Great Britain is a subsidiary of German motor manufacturer Menzel Elektromotoren who maintains a very extensive inventory and is specialized on customized adaptations on short notice and who was therefore well prepared to answer this urgent request. The generator is powered by a steam turbine. It operates at 11 kV supply voltage and weighs more than 35 tons. Menzel completed the various customer-specific interface modifications in the short time available. Preparing the shaft to match coupling interfaces was particularly complex, since it had to be shortened, machined for a smaller diameter, and the appropriate flange had to be weld-fitted and subjected to an ultrasound check, which ensured that the modification was sound. In order to match site requirements, Menzel also changed the cooling type of the replacement generator from IC 01 open-circuit ventilated to IC 81W air-water heat exchanger, building an adapter frame and mounting a suitable twin element heat exchanger from existing stock. Westfield Power Station, which was commissioned in 2000, is the only biomass power plant in Scotland fueled by poultry litter. It is a key partner to the region’s agricultural industry both for disposing of a high-volume waste product and as a supplier of power and fertilizer – the nutrient-rich ash produced is a precious natural alternative to artificial fertilizers. The 9.8 MW biomass steam power plant also stands out technologically as it is one of a limited few in the world utilizing fluidized bed technology. The CO2 savings compared to gas-fired power plants are considerable.
Three-phase synchronous and asynchronous generators for highest efficiencies: https://www.menzel-motors.com/specialized-motors/generators/

date: 2020-09-01 | characters: 2330 | download: document, picture 1

MENZEL

Pump works, summer is saved

Baden-WĂĽrttemberg state water supply, a German special-purpose association, urgently needed a new motor for a pump that is only used at peak times during the summer. Since Menzel Elektromotoren had already proven itself as a reliable supplier in the past, nothing was more obvious than a quick call to the Berlin-based manufacturer.

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Baden-WĂĽrttemberg state water supply, a German special-purpose association, urgently needed a new motor for a pump that is only used at peak times during the summer. Since Menzel Elektromotoren had already proven itself as a reliable supplier in the past, nothing was more obvious than a quick call to the Berlin-based manufacturer. Menzel has the largest inventory of industrial motors in Europe and had a suitable three-phase slip ring rotor motor on hand, with a 710 mm shaft height, 3700 kW rated power, and 5000 V rated voltage. A member of staff took the measurements on site in the pumphouse. Since the old, failed motor had a flanged shaft with a permanently fixed coupling half, Menzel procured a new coupling half. The team also welded a base frame to bring the new, more compact motor to the shaft height of original. The existing installation was special in that all supply lines were fed in from below. Therefore, new cable ducts were implemented in the station floor next to the motor, whilst Menzel repositioned the terminal boxes. Menzel staff also commissioned the motor and could therefore check firsthand that the installation was complete and subsequent startup was flawless. Menzel has manufactured pump motors for a wide range of applications in the past. More information is available at https://www.menzel-motors.com/pump-drive/.

date: 2020-06-18 | characters: 1329 | download: document, picture 1

MENZEL

12-pole extruder motor

Menzel Elektromotoren has supplied a 12-pole 225-kW motor for a rubber mixing machine. Though this large number of poles is unusual for such a relatively small output, the German motor builder had a suitable unit on stock in its large warehouse. The motor is configured for frequency inverter operation in 60-Hz networks.

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Menzel Elektromotoren has supplied a 12-pole 225-kW motor for a rubber mixing machine. Though this large number of poles is unusual for such a relatively small output, the German motor builder had a suitable unit on stock in its large warehouse. The motor is configured for frequency inverter operation in 60-Hz networks. The rated speed is 710 min-1. This robust motor provides high starting torques and high overload capacities at low speeds. The customer, the global market leader in production of elastomeric insulation systems for thermal and acoustic insulation, needed this motor for a plant in Mexico. To ensure commissioning of the facility on schedule, Menzel adapted the motor in only three and a half weeks. This included a newly engineered and individually welded motor housing that is compatible with the customer’s special coupling and existing foundation interfaces. More reference projects and inquiries: https://www.menzel-motors.com/extruder-drive/

date: 2020-05-27 | characters: 882 | download: document, picture 1

MENZEL

High-voltage compressor motor for steelworks

Linde India Ltd. was able to quickly source a new 11-MW high-voltage motor for a compressor in a steel plant from German manufacturer Menzel Elektromotoren. After the originally installed third-party motor had failed, downtime in the plant in the eastern state of Odisha could thus be kept short.

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Linde India Ltd. was able to quickly source a new 11-MW high-voltage motor for a compressor in a steel plant from German manufacturer Menzel Elektromotoren. After the originally installed third-party motor had failed, downtime in the plant in the eastern state of Odisha could thus be kept short. Menzel has an extensive inventory, which is adapted to the demand. The motor manufacturer picked a modular squirrel-cage motor from its MEBKSW series for this project. These motors are by default very well adapted to the ambient conditions with temperatures up to 50 °C and a humidity of up to 95 %. Their tropics-proof motor winding conforms with temperature class F. Menzel fitted the motor with an air-to-water heat exchanger (cooling type IC 81W), which is ideal for environments with high humidity and highly polluted atmosphere, and implemented an increased IP55 ingress protection. Menzel also made several mechanical and electrical adjustments to ensure smooth installation on site. One noteworthy challenge was that the original terminal box, complete with the sensors installed inside, should be moved to the new motor. To accomplish this Menzel not only manufactured a mounting adapter, but also changed the winding ends and routed them from the overhang to the terminal box along the side of the motor housing. Menzel furthermore built a base frame to adapt the motor size and mounting dimensions to the existing foundation. The motor with a rated voltage of 11 kV is designed for 50-Hz operation with a rated speed of 1492 min-1 in continuous operation (operating mode S1). Its total weight is 23.5 tons. Before shipping, the motor underwent extensive tests in Menzel’s load test field with the customer present. The manufacturer was also in charge of commissioning. More information about water-cooled squirrel-cage motors for extreme ambient conditions is available at https://www.menzel-motors.com/squirrel-cage-motor/ic81w-ic86w/.

date: 2020-04-29 | characters: 1942 | download: document, picture 1

MENZEL

Despite coronavirus: Large motors ex stock

German motor builder Menzel Elektromotoren keeps a large inventory of motors in stock and is able to fulfill orders even in these times of the coronavirus. The family-run company is the go-to-source when motor failures cause plant standstills or if the usual suppliers cannot maintain delivery dates.

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German motor builder Menzel Elektromotoren keeps a large inventory of motors in stock and is able to fulfill orders even in these times of the coronavirus. The family-run company is the go-to-source when motor failures cause plant standstills or if the usual suppliers cannot maintain delivery dates. Quick shipping of replacement motors has oftentimes prevented production downtimes in the past. Brand-new AC and DC motors are available in various sizes and cooling types: low-voltage motors up to 2500 kW, medium and high-voltage motors up to 15000 kW, AC squirrel-cage and slip ring motors, DC motors up to 600 kW. All these motors comply with the current EN60034, IEC60034, VDE, DIN, and ISO standards. Menzel supplies customers worldwide, adapting the motors individually for each respective customer application. Production and inspection are still being kept up, even now, with staff working two separate shifts and additional measures being taken for maximum protection against infection. More information and 24/7 inquiries: https://www.menzel-motors.com/article/large-lv-mv-hv-motors/

date: 2020-03-30 | characters: 996 | download: document, picture 1

MENZEL

Motors for swift shipping

Menzel Elektromotoren has modified, tested, and delivered two 2400-kW motors for the fast RoPax ferry MV Ulysses meeting extremely tight deadlines of two and three weeks. Operated by Irish Ferries, Ulysses is one of the largest ferries in the world servicing the busy Dublin—Holyhead route.

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Menzel Elektromotoren has modified, tested, and delivered two 2400-kW motors for the fast RoPax ferry MV Ulysses meeting extremely tight deadlines of two and three weeks. Operated by Irish Ferries, Ulysses is one of the largest ferries in the world servicing the busy Dublin—Holyhead route. It has 12 decks for up to 2000 passengers and 1340 cars or 240 trucks. The operator urgently needed new motors for two of the four azimuth thrusters – propellers used for sideways maneuvering in ports. One of the German motor builder’s experienced service staff took measurements on site in order to adhere to tight refit specifications and timelines, and to avoid the kind of installation difficulties caused by earlier replacement motors. Menzel adapted two squirrel-cage motors from their large inventory of motors and components for many common applications. The selected motors are by default suitable for high humidity environments. Menzel provided them with IP54 protection for maritime application and made numerous additional adjustments in the shortest possible time. The team converted the stock motors from horizontal to vertical operation, modifying the bearings accordingly, installing new thrust bearings, and producing a special vertical-mounting flange. They dismantled and re-configured the fan design in order to change the rotational direction. They shortened the shafts and machined them for smaller diameters. To meet the vessel’s mechanical interfaces, the terminal boxes had to be installed in exactly the right position; even the arrangement of the terminal studs was predetermined. The customer provided the water coolers, whilst Menzel modified the stator frames to connect the coolers, implementing cooling type IC 81W. Ultimately, the manufacturer tested the motors in their own load test field, with the customer present on site in Berlin for the final inspection. Menzel completed both motors on time, thus once again proving themselves to be an exceptionally flexible supplier. More information about modular squirrel-cage motors with a wide range of design options is available at https://www.menzel-motors.com/squirrel-cage-motor/ic81w-ic86w/.

date: 2020-03-18 | characters: 2166 | download: document, picture 1

MENZEL

High-powered dual-speed medium voltage motors

Berlin-based Menzel Elektromotoren is one of the few manufacturers of large dual-speed or pole-changing low and medium voltage motors today.

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Berlin-based Menzel Elektromotoren is one of the few manufacturers of large dual-speed or pole-changing low and medium voltage motors today. This motor type can propel fans, pumps, hoists, and other machines at two different speeds without a frequency inverter – a cost-saving solution for applications requiring only two speeds that moreover reduces the risk of failure. Typically, these motors are designed for an operating speed and a slower speed to facilitate startup. Dual-speed designs of large motors have become a rare exception. However, the family-run company Menzel continues to offer this option. In a current project, the end customer had explicitly specified pole-changing motors. To implement the particular speed ratios, Menzel manufactured three-phase asynchronous motors with two independent stator windings, a 6-pole and an 8-pole winding combined in one housing. The motors intended to power fans in a cement plant have a rated voltage of 6000 V with rated operating speeds of 988 min-1 and 746 min-1 at rated outputs of 850 kW and 500 kW respectively. As another special feature, these customized motors withstand ambient temperatures from -38 °C to 40 °C. Menzel, a motor manufacturer serving customers worldwide, individually assesses requests for larger low and medium voltage motors for optimum feasibility whilst supporting customers in choosing the right solution. Additional references as well as contact details for specialized technical staff can be found at https://www.menzel-motors.com/article/dual-speed-motors/. Hannover Messe: Hall 5, Stand C36

date: 2020-02-26 | characters: 1546 | download: document, picture 1

MENZEL

Large low voltage motors for special applications

Menzel Elektromotoren has built eight low voltage motors with a shaft height of 500 mm for a rolling mill. The company, which specializes in tailor-made solutions, played to its strengths in this project by building the mill drives from scratch, according to the plant manufacturer’s requirements, while meeting a very tight 16 week timeline.

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Menzel Elektromotoren has built eight low voltage motors with a shaft height of 500 mm for a rolling mill. The company, which specializes in tailor-made solutions, played to its strengths in this project by building the mill drives from scratch, according to the plant manufacturer’s requirements, while meeting a very tight 16 week timeline. The technologically demanding and high-end design ensures reliable operation under high mechanical stress. Robust welded steel housings ensure maximum torsional rigidity. At the customer’s request, Menzel implemented a water cooling system (cooling type IC 86W). The motors feature a rated voltage of 690 V and provide 1000 kW rated power. Menzel designed them for the application-specific load points at a nominal frequency of 25 Hz and installed a special rotary encoder for inverter operation. The customer is completely satisfied and has already placed a follow-up order for four additional motors of the same type. More information is available at: https://www.menzel-motors.com/squirrel-cage-motor/ic81w-ic86w/

date: 2019-09-04 | characters: 962 | download: document, picture 1

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