Machinery & Equipment MRO December 2011

MACHINERY AND EQUIPMENT

How to get optimal performance from pumps Precise drives stand the test of time What’s new in industrial lubrication

Vol. 27, No. 6

DECEMBER 2011

Maintenance 101: Getting to know your equipment PTDA event focuses on future changes

DISASTER AT HALIFAX WATER HOW THE PLANT RECOVERED

Publications Mail Agreement #40069240

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centres located in North America, Western and Eastern Europe, and Asia Pacific.

Altra Industrial Motion

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Gear drive product offering expanded

Online Reader Inquiry No. 886

Cordless work light adds upgraded model

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Maxxeon has upgraded its WorkStar cordless LED work light with the introduction of the WorkStar 2000 model. This model retains the multi-directional lighting head, but light output has been significantly increased. Technicians simply suspend the light and turn the LED light head to direct the light where they want it, leaving their hands free. Once in position, the light head stays put. Features include dual light level, integral magnets, retractable hook and ergonomic design. The light includes a belt clip, and 12-V and 110-V chargers, and has a connection in

Online Reader Inquiry No. 884

Shaft collar line is built for heavy-duty applications

A line of large-bore shaft collars for heavyduty applications in the construction, defence, excavation, heavy equipment, mining, pulp and paper, petro-chemical, waste processing and similar industries is available from Stafford Manufacturing. These shaft collars feature bore sizes up to 14 in. I.D., are offered in one- and two-piece clamp-type configurations with smooth- or threadedbores and are supplied with one or more alloy socket cap screws. They can be machined from steel, stainless steel, brass, bronze and other materials with varying widths

A Better IEEE 841 Super-E® windings meet or exceed NEMA Premium® efficiency standards

All internal rotor, stator and shaft surfaces are epoxy coated to prevent corrosion

High strength cast iron frame, endplates, conduit box and fan cover are designed to reduce vibration and assure accurate mounting dimensions

Oversize bearings on each end for long life

Insulation system meets requirements of NEMA MG 1, Part 31.4.4.2 for VFD use and considered inverter-ready

Inpro/Seal™ VBXX Bearing Isolators at both ends assure protection from contamination

Exclusive PLS® (Positive Lubrication System) assures proper bearing lubrication in all mounting positions

Two-part epoxy primer inside and out, plus epoxy finish coat to prevent corrosion

and O.D.s up to 2 in. Custom features can include tapped mounting holes, spanner wrench holes, keyways, slots and more on the face or O.D. Stafford Manufacturing

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Altra Industrial Motion has acquired the German company Bauer Gear Motor, a European manufacturer of gear motors, offering engineered solutions to a variety of industries. As part of Altra Industrial Motion, Bauer joins the North American company Boston Gear. Both companies have extensive experience and application knowledge in industries that include material handling, food processing, packaging, bottling and metals. Altra has integrated the expertise of these two brands to develop the Series 2000 C-face gear drive/integral gear motor line, a helical bevel offering that is dimensionally interchangeable with the industry standard envelope. Boston and Bauer customers are supported worldwide with Altra global sales offices, manufacturing facilities and assembly

the base to allow mounting to a tripod.

The WorkStar 2000 work light replaces the WorkStar 1400.

Maxxeon

December 2011

Online Reader Inquiry No. 887

Laser pulley alignment system is quick and easy to use

Hyatt Industries has introduced the PulleyALIGN Green laser pulley alignment system. Claimed to be 10 times brighter to the operator than a red laser line, the reflected laser beam technology provides reliable and accurate readings. The lightweight, compact unit attaches magnetically to the inside or outside face of the pulley or sprock-

et, has no small parts or targets to lose and can measure a span up to 6.10 m (20 ft) or better with any size pulley. A single operator can perform the task in minutes, and no manual or training is required.

Hyatt Industries Online Reader Inquiry No. 851

Cleaner/degreaser works hard without harming the environment

Mean Green industrial strength cleaner and degreaser features a blend of biodegradable detergents that are specially formulated for challenging metalworking and parts-cleaning applications. Tough on dirt but emitting no harmful fumes, the cleaner/degreaser suits a wide variety of manufacturing and metalworking applications. In addition to its use in dip tanks and parts washers, it can be used for the removal of grease and grime from machinery and manufactured parts, hydraulic cylinders and other heavily soiled products without applying environmentally harmful solvents. It is packaged in sizes ranging from a 32-oz trigger spray bottle to 55-gal. drums.

CR Brands Online Reader Inquiry No. 888

All joints gasketed and sealed for added protection against contaminant entry

Adjustable mini-clamp is available in metric sizes

Foot flatness within 0.005 inches for precision alignment to driven equipment

Inside and Out Baldor•Reliance® 841XL severe duty motors are engineered and built to meet or exceed the most rigid severe duty service standards. You’ll find Baldor•Reliance severe duty motors hard at work around the world in some of the most brutal conditions you can imagine, like petrochemical, pulp & paper and mining operations.

So, no matter how you look at it, you can always count on Baldor•Reliance severe duty motors to perform under the most extreme conditions...inside and out.

• Energy Efficient • Unmatched Quality • Superior Reliability

Exceeds IEEE Std. 841-2009 baldor.com

• Quickest Delivery Available

479-646-4711

J.W. Winco Canada offers Series GN 475 adjustable two-way connector mini-clamps in metric sizes.

Mini-clamps are typically used to build support structures for mounting sensors, Plexiglas guards or other elements. The clamping bores of these RoHS-compliant mini-clamps are designed for GN 480.1 tubings. The two segments of the mounting can be twisted to accommodate the juncture of tubing at different angles. In the standard version, the clamping force of the clamp on to the tube is achieved via the socket cap screws. Clamp mounting is of aluminum and offered in either a matte version or an anodized version. Cap screws are DIN 912, in stainless steel, while the grub screw is DIN 915, also in stainless steel. Adjustable lever kits are available to replace the cap screws.

J.W. Winco Canada Online Reader Inquiry No. 889

©2011 Baldor Electric Company

Online Reader Inquiry No. 115

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Obtain free additional information about any of these items by using our online reader reply card at www.mromagazine.com/rsc.

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• USA RolleR ChAin • ConveyoR & engineeRed ClASS ChAin • P R e C i S i o n At tA C h m e n t C h A i n F u lto n , I l l I n o I s Phone: 800-435-0782 w w w. d r I ve s I n c . c o m

Online Reader Inquiry No. 116

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C O N T E N T S

Machinery & Equipment MRO

December 2011

in this issue Case study: Dead in the water / 12

A power outage cascades into a disaster at the Halifax Wastewater Treatment Facility.

Here’s how it was recovered.

How to get optimal performance from pumps / 14

Knowing how to maintain pumps and their components, while dealing with malfunctions, effectively goes a long way to improving pump performance.

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columns

departments

It’s a five-point TREAT / 18

Editor’s Notebook / 6

Follow along with Step 42 in a journey to world-class maintenance at the Plentya Paper Company as the maintenance team is recognized for its contribution to increased mill production.

Industry Newswatch / 8 Business Briefs / 10

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Mr. O, The Problem Solver / 11 Maintenance Management / 18 Maintenance 101 / 20

Maintenance 101: Getting to know your equipment / 20

The Safety File / 21 MRO On The Road / 30

Part 2: The second set of activities in this eight-stage program on achieving world-class maintenance will help you evaluate equipment and its level of deterioration.

Product News Product Spotlight / 2 Focus on Lubrication / 24 Focus on Pumps / 25

Assessing your fire risk / 21

Focus on Alignment / 26

Is your facility at a high level of risk?

Each year in Canada, over 1,500 industrial fires occur, causing approximately $140 million in property damage.

Here’s a tool you can use to evaluate the risk of your own facility.

Focus on Electrical and Electronic Components / 27 Focus on Hand and Power Tools / 28

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Drives stand the test of time / 17

The study of quarks and gluons relies on specialized drive technology that is both compact and can produce extremely slow speeds.

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PT industry gathering focuses on the future / 30

Photographs and a report from the annual Industry Summit of the Power Transmission Distributors Association (PTDA), held this year in Washington, DC.

industrial lubrication Wind turbine gearbox lubrication requires special consideration / 23

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Learn what these gearbox lubricants must do, how they are formulated and tested, and how they work in the system, based on a presentation to a technical meeting of the Toronto Chapter of the STLE. What’s new in lubrication / 24

Lubrication products and services, including new food-grade greases and oils, mobile lubricant dispensing, pneumatic lubricants for compressed air, and an oil mist collector, among others.

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Cover photo: ©Hemera/Thinkstock

‘Since one of the two cranes built into the wet well for removing the pumps had drowned, crews had to bring in manual hoists to lift the pumps one-by-one.’

Susheell Arora / 12 ‘All mechanical seal faces leak, albeit at a very slow rate.’

Steve Gahbauer / 14 ‘Grease lubrication enable the drives to withstand radiation better than oil-lubricated drives.’

Paul Brindza / 17 ‘Restoring equipment to its basic condition eliminates forces that contribute to its deterioration.’

Peter Phillips / 20

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December 2011

Take Back Manufacturing program looking for support

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ccording to reports from Statistics Canada, 322,000 manufacturing jobs disappeared from the Canadian economy between 2004 and 2008 (prior to the past recession), including the production of truly Canadian items like hockey sticks. So a new program devised by the Toronto chapter of the Society of Manufacturing Engineers (SME) called Take Back Manufacturing (TBM) aims to bring those jobs back by promoting a more balanced approach to sourcing of raw materials that keeps manufacturing costs down.

The TBM campaign has garnered the support 25 technical associations and three trade associations, as well as representatives from education, government, media and business. The goal is to

bring offshore manufacturing back to North America.

“Right now we’ve still got the means, the opportunity and the motive to make this happen,” said Marie Laird, chair of the Toronto chapter of SME.” Canada has allowed too many manufacturing jobs to shift to China and other developing countries, said Nigel Southway, SME operations lead. “Now we’ve got kids thinking that we can’t make hockey sticks,” he said.

The SME believes we are now in a situation where our youth are no longer seeking careers in manufacturing in great numbers – in large part because there are very few jobs. The other side of that coin is that the expertise we have in our current

manufacturing population will be lost in the coming years as the experts retire and there is no next generation to whom they can pass along their skills.

With the frenzied rush to China over the past years, Southway suspects companies have lost sight of the hidden costs. It might make economic sense to make products offshore with a labour cost input of 70% and higher, but below that threshold, fuel costs and the longer supply chain eat away at profit margins.

“Offshore can be more expensive than doing it right here,” he said, adding he’d like to see a better mix of offshore and domestic sourcing based on true costs.

According to Laird and Southway, we’re paying a high price – both economic and through our declining quality of life – to support a supply chain that verges on ridiculous. Canada ships raw resources to China, where they’re manufactured into products and shipped to the US. From start to finish, the raw materi-

als and finished products travel thousands of kilometers and six weeks each way – costing millions in shipping and environmental impact. Canada should add value to its natural resources by making the products here and shipping to the US directly, they assert.

“Why don’t we just export something other than our resources?” Laird asked.

The colleagues also pointed out the need to be prepared if and when the jobs return.

The last thing manufacturers need is to win back orders, only to discover they lack the skilled workforce to complete them.

That’s why TBM has a skills development component, aimed at promoting new entrants to the field through four career stages: trade, technician, technologist and engineer.

Manufacturers are being advised to learn more and sign on to TBM. To learn why and how TBM was created, or download a starter kit, visit sme-tbm.org.

Bill Roebuck, Editor & Associate Publisher

MACHINERY AND EQUIPMENT

MAINTENANCE, REPAIR AND OPERATIONS

DECEMBER 2011 Volume 27, No. 6 Established 1985 www.mromagazine.com www.twitter.com/mromagazine EDITORIAL Bill Roebuck, Editor & Associate Publisher 416-510-6749 broebuck@mromagazine.com Ellie Robinson, Art Director Contributing Editors Richard G. Ensman Jr., Simon Fridlyand, Carroll McCormick, Peter Phillips, Angela Webb, Cliff Williams BUSINESS

machine tools x foundries x metalworking machinery x lawn & garden x speed reducers medical x instruments x transmissions x kilns x mining x pharmaceutical x HVAC x hoist transportation x agriculture x washdown x construction x gear box x pumps x steel mills railway x band saws x aggregates x pulp & paper x spindles x grinders x textiles x vibrating screen x hand tools x electric motors x power generation x compressors x automation x idlers

Just some of the places you’ll find Koyo bearings. wind turbines x automotive x conveyors x aerospace x stamping x recreation vehicles blowers x food & beverage x winches x cranes x excavator x fans x robotics x sander x mixer back-up roll x paver x printing press x debarker x head pulley x dryer x track roller x planer oil & gas x clean room x extreme environments x forestry x return rolls x traction motors x tunnel boring x rock crushers x rolling mills x work rolls x smelting x sawmills

Nick Naunheimer, Publisher 416-510-6868 nnaunheimer@mromagazine.com Eric Achilles Cousineau, Adv. Sales Manager 416-510-6803 eachilles@mromagazine.com Kimberly Collins, Advertising Production 416-510-6779 Melinda Marasigan, Subscription Enquiries 416-442-5600 x3548 Machinery & Equipment MRO is published six times a year to help improve the effectiveness, productivity and practical knowledge of maintenance professionals in Canada’s manufacturing, utilities and resource industries.

Editorial & sales office: 80 Valleybrook Drive, Toronto, ON Canada M3B 2S9; tel: 416-442-5600, 1-800-268-7742; fax: 416-510-5134.

Subscription rates. Canada: 1 year $57.95, 2 years $92.95. United States: 1 year $85.95. Elsewhere: 1 year $85.95. Single copies $10 (Canada), $16.50 (U.S.), $21.50 (other). Add applicable taxes to all rates.

On occasion, our subscription list is made available to organizations whose products or services may be of interest to our readers. If you would prefer not to receive such information please contact us via one of the following methods – phone: 1-800-668-2374, e-mail: privacyofficer@businessinformationgroup.ca, fax: 416-442-2191, mail to Privacy Officer-Business Information Group, 80 Valleybrook Drive, Toronto, ON Canada M3B 2S9. ©2011. Contents of this publication are copyright and may not be reproduced in whole or in part in any form without written consent of the publisher. The publisher cannot assume responsibility for the validity of claims in items reported or advertised.

Machinery & Equipment MRO is published by BIG Magazines LP, a div. of Glacier BIG Holdings Company Ltd. Bruce Creighton, President, BIG; Alex Papanou, Vice-President, BIG. Publications Mail Agreement No. 40069240. Return postage guaranteed. ISSN 0831-8603 (print). ISSN 1923-3698 (digital). Return undeliverable Canadian addresses and change of address notices to: MRO Circulation Dept., 80 Valleybrook Drive, Toronto, ON Canada M3B 2S9.

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Kinecor and Peacock are now proud to be Wajax Industrial Components We are a nationwide distributor of industrial components providing technical solutions and services to all major industries across Canada.

Over the years our company has forged itself through the contributions of numerous businesses, resulting in our present-day expertise.

Kinecor, one of Wajax Corporation’s three divisions, will now share the Wajax name. The Wajax company has existed for over 150 years and is largely recognized within the industrial sector of the Canadian economy.

Kinecor and Peacock will begin operating under the Wajax Industrial Components name on December 31st, 2011. Only the name of our facilities – head office, distribution centres and branches – will change; their locations will remain the same.

1.866.546.3267

www.wajaxindustrial.com Online Reader Inquiry No. 119

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discharge machining drill on the market; the first lathe to feature a built-in structure to minimize heat generation and vibration; plasma cutters, water jet cutters and more.

CANADARM MILESTONE COMES AT PIVOTAL MOMENT FOR CANADIAN ROBOTICS Montreal, QC – The iconic Canadarm, which first flexed its mechanical muscles on a space shuttle 30 years ago, has grown up – and it’s gotten smaller along the way. It was on Nov. 13, 1981, that the first robotic space limb was deployed on US Space Shuttle Columbia.

The anniversary, and the recent end of the shuttle program, provide an occasion to remember the past of the Canadian robotics sector and consider where it goes from here.

Over 30 years, the Canadarm has helped build the International Space Station, repaired satellites in space and even fixed broken toilets. The huge robotic arm with its Canada wordmark retired in July 2011 after making the last of its 90 shuttle missions and voyages, totalling over 624 million km.

MacDonald, Dettwiler and Associates (MDA), Richmond, BC, built five Canadarms in all. Two other robotic arms – Canadarm2 and Dextre, a two-armed, $200-million robot – are still on the job on the space station.

Kevin Shortt, the head of the Canadian Space Society, says the original Canadarm was a great piece of equipment that Canadians can be proud of – but it’s history. “We can’t continue to keep going back to that because countries like Germany and Japan are hot on the heels of building their own technology in that respect,” he said. “I think they’re knocking on our doorstep.”

General Motors has developed the R-2 (see MRO Magazine’s Sept. 2010 cover feature). The humanoid-style robot (also known as a cobot – a collaborative robot that can work alongside people) cannot perform all the operational functions of its complex Canadian counterpart, Dextre.

But, in Shortt’s view, the realistic-looking robot, “basically leaves Dextre in the dust.”

A version of the GM robot is already up on the station doing indoor experiments.

Photo: Canadian Space Agency

Toronto – From standing room only at the keynote address and a show floor that was almost double in size compared to 2009, to an overall 10% increase in attendance and a sold-out technical conference, the success of October’s Canadian Manufacturing Technology Show (CMTS 2011) in Toronto reflected the growing optimism of the Canadian manufacturing industry in general, according to show organizers.

“We took some big steps this year, using the latest in social media to create a more personalized experience for delegates, while expanding the show floor to include significant educational and networking components, and our expectations were exceeded,” said Nick Samain, event manager with the Society of Manufacturing Engineers (SME), organizer of the event, which takes place every two years.

“People told us they liked what they saw and the result is an unprecedented 80% of exhibit space already re-booked for 2013, when we move back to the Toronto International Centre for an even more expansive event.”

Adding to the buzz around this year’s show was a thought-provoking keynote address by Kevin O’Leary, best known as the ruthless judge on CBC Television’s Dragon’s Den. O’Leary’s mission was to deliver practical advice for business growth and he didn’t hold back, telling delegates it’s time to look beyond the US to potential export markets in Brazil, India and Asia. He also encouraged ongoing investment in technology, saying: “People think that automation is killing jobs in Canada, when in fact, it’s enhancing the value of jobs you can provide.”

Also of note was a clear message from Take Back Manufacturing (TBM), an aggressive campaign launched by the Toronto chapter of SME to get government, education, business and media representatives working together to bring off-shore manufacturing back to North America.

The event included a 500-exhibit trade show featuring 150 new products and live demonstrations, including the world’s first punching machine with skeleton-free processing and a 20-ton punching force; the largest electrical

“Canadarm was a great piece of equipment that Canadians can be proud of – but it’s history,” says Kevin Shortt, the head of the Canadian Space Society.

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Photos: Eric Achilles Cousineau

CMTS sees growing optimism in manufacturing CMTS included a 500-exhibit trade show featuring 150 new products and live demonstrations. Among those exhibiting on the show floor were Walter Surface Technologies, SKF Canada and Specialty Tools Canada.

Steve MacLean, the head of the Canadian Space Agency, says Canada has to continue to invest if it wants to maintain its advantage in robotics. MacLean sees opportunities in a number of areas like robotic servicing, where a small arm could be used to refuel and repair orbiting satellites.

“What we would like to do is concentrate on a few areas where robotics can make operations more efficient and actually make space operations safer,” he said.

MacLean says private companies are now doing work on prototypes for the next generation of Canadarms that would put robotic technology to use on different-sized rovers.

For Chris Hadfield, the Canadarm has been a staple of his entire career, which began when he was hired by the Canadian Space Agency in 1992. He was the first Canadian to operate the giant robotic arm, which he did on the Shuttle Atlantis in 1995 during its visit to the now-defunct Russian space station Mir. Hadfield also helped install Canadarm2 on the current space station in 2001.

“The things that it has led to have really been pivotal to the things that I have had a chance to do,” he said in an interview from Cologne, Germany. Hadfield is currently training for a six-month visit to the space station which will begin in late 2012. [The Canadian Press]

Territories, who have already expanded their eligibility for workplace stress benefits. [The Canadian Press]

WINNERS OF ‘DIRTY WORK’ CONTEST HONOURED Richmond, VA – DuPont Protection Technologies has named Joel Turner, Robert Maddox, Dennis Rains and James White as the winners of the DuPont Tyvek ‘Dirty Work’ Photo Contest. The online contest demonstrated the many ways in which workers use Tyvek garments to help keep safe and clean on the job. A worker in Canada beat out entries from runners-up based in the United States.

For the contest, entrants were asked to submit original photos of themselves wearing a Tyvek garment after complet-

M M

STRESS NOW COVERED BY BC WORKERS’ COMP Victoria – Stressed-out employees in British Columbia will soon be eligible to receive expanded workers’ compensation benefits. The provincial government is amending the Workers’ Compensation Act to broaden mental stress benefits for workers beyond the current ‘acute reaction to a sudden and traumatic event’.

This means that workers suffering from cumulative work-related stress may be granted benefits under the amended law. But being fired, disciplined or forced to adapt to changes in workplace conditions are excluded from coverage and workers must receive a recognized stress diagnosis to receive compensation. ‘’We want to have psychologically healthy workplaces and many employers have taken those steps, but we need to do more of that,’’ said Labour Minister Margaret MacDiarmid, who worked as a family physician before entering politics.

She said there are estimates that the amended law could increase WorkSafeBC annual costs between $10 million and $18 million, but helping people pays off in many ways. ‘’There is a huge hidden cost to not addressing mental illness,’’ said MacDiarmid. ‘’If you’re a worker and you’ve had a chronic problem at work and you continue to work, this can really decrease productivity. It can cause sick time. It can cause actual accidents in the workplace.’’

BC will join Alberta, Saskatchewan, Quebec, Yukon, Nunavut and Northwest

Joel Turner was the grand prize winner, sending the grimiest photo of them all, capturing his garment covered in dirt and fireproofing material.

ing their dirty work. Entries were judged based on a variety of criteria, including how well the garment and dirty work were portrayed in the photo.

Joel Turner, who works in Ontario, was the grand prize winner, sending the grimiest photo of them all, capturing his garment covered in dirt and fireproofing material. As the grand prize winner, Turner received a $2,500 American Express gift card.

“My job is very dirty – spraying fireproofing material on steel. The mud we spray gets everywhere and it is wet, thick and can harm your skin. In my job, I help keep buildings safe from collapse in case of fire. In turn, Tyvek is my lifesaver, it helps keep me dry and limits the amount of harmful sludge that contacts my skin,” said Turner.

For more details, visit the website www.tyvekphotocontest.dupont.com.

QUIZ TESTS KNOWLEDGE OF PUMPS TO PROMOTE HEART HEALTH Seneca Falls, NY – ITT Goulds Pumps has announced an online quiz aimed at raising awareness of the worldwide industrial pump

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business and generating company donations to teach first aid and cardiopulmonary resuscitation (CPR) around the world.

Spotlighting pumps as the ‘heart of industry’, the company has structured the promotion to benefit a global hearthealth program that teaches first aid, including the recommended method for hands-only CPR. The World of Pumps Quiz begins runs until April 1, 2012. Following the end of the quiz, on Pump Appreciation Day on April 10, 2012 (an international celebration of pumps conceived by Goulds), the company will make a donation for each correct answer to the global Emergency Cardiovascular Care Program, which is supported by the American Heart Association and its global partners. For adults who suffer sudden cardiac arrest, receiving bystander-administered CPR can double or even triple the chances of survival.

Over the 20 weeks of the World of Pumps Quiz, participants can answer up to 10 questions – a new one is added every two weeks. Question topics range from pump applications to pump technology and Goulds Pumps around the world.

To enter the quiz, participants can go to www.worldofpumpsquiz.com.

ing Corp. will receive energy rebates of two cents per kilowatt-hour (kWh) to help manage its electricity costs and improve its energy efficiency and sustainability.

Ontario has provided more than $4 million to the Williams Operating Corp., and the company will be eligible for further rebates. The three-year NIER program is averaging $150 million per year in assistance.

“At our operations here at the Williams and David Bell mines, we’re actively pursuing ways to reduce our production costs and increase competitiveness for the benefit of our company, our employees and our community,” said Andrew Baumen, general manager, Barrick Hemlo.

Williams Operating Corp. is one of the largest gold producers in Canada. The Williams and David Bell mines are owned and operated by Barrick Gold Corp.

Online gallery has more photos of events When you see reports of industry events in Machinery & Equipment MRO , there’s a good chance you’ll find many more photos on the MRO Photo Gallery at www.mromagazine.com/gallery, or go to our home page and select the Photos link in the menu bar under the magazine logo. Simply choose the event you’re interested in to view thumbnails of the images. You can enlarge the view of each photo by clicking on it.

GUIDE TO BEARING INSTALLATION AND MOUNTING TOOLS PUBLISHED Glen Ellyn, IL – The Bearing Specialists Association (BSA) has published new Bearing Briefs that can help end users maximize their bearing investment.

Bearing Installation – Fitting Practice and Bearing Mounting Tools is a guide that offers essential installation information for the distributor, manufacturer and the end-user.

It details the steps in achieving proper radial retention of bearing rings on their respective seats. Also covered is the proper selection of shaft and housing bore dimensions and tolerances to prevent rings from rotating on their seating surfaces and avoid unnecessary abrasion.

The Bearing Brief also explains the

HEMLO GOLD MINE RECEIVES ENERGY REBATES TO REDUCE PRODUCTION COSTS Marathon, ON – A gold mine in the Hemlo area near Marathon is getting assistance to reduce its energy costs, stay competitive and protect 545 jobs. Through Ontario’s Northern Industrial Electricity Rate (NIER) program, Williams Operat-

You can also save photos that you want. High-resolution originals, or quality prints ideal for framing, are available at a nominal cost; please contact Eric Achilles Cousineau at MRO Magazine for details by sending an e-mail to eachilles@mromagazine.com.

International Standards Organization (ISO) coding system and its established standards for machining quality and degree of interference/clearance between the ring and the seat. This standard allows manufacturers worldwide to clearly communicate fitting practice.

Another new brief, Bearing Mounting Tools, focuses on the importance of proper handling practices before and during bearing installation to avoid damage

that will have an impact on performance.

It covers the use and limits of tools such as a bearing heater, spanner wrench and dead blow hammer.

Bearing Briefs are available as free, downloadable PDFs from the BSA website, www.bsahome.org.

MRO More detailed versions of these stories, along with many additional news items, can be found online at mromagazine.com.

MAXIMUM SUPPORT. MAXIMUM RIGIDITY. MAXIMUM RELIABILITY.

ANGULAR CONTACT THRUST BALL BEARINGS NSK’s TAC B series bearings provide highly rigid and accurate ball screw support for machine tools. Our high precision bearings are manufactured from EP steel to extend fatigue life by 3x and are available in sealed design for 50% longer grease life and excellent resistance to ingress of coolant and metal chippings. To increase efficiency through unparalleled reliability, Think NSK.

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Online Reader Inquiry No. 120

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December 2011

Business Briefs

News and views about companies, people, product lines and more.

• ITT Goulds Pumps, Seneca Falls, NY, is a new company that resulted from a three-way ITT Corporation spin-off on October 31, 2011, says Robert J. Pagano Jr., president of the ITT Industrial Process business, which includes ITT Goulds Pumps. Subsidiary Goulds Pumps Canada is based in Guelph, ON. • Since 1991, a group from the power transmission industry has held a golf tournament following the annual Industry Summit of the Power Transmission Distributors Association (PTDA). This year’s 23-man group, traditionally known as the ‘Guns ‘n Smurfs’

because of the mix of tall and short players, plays homage to former members Dan Thrussel, Ken Fee and Ron Starr, industry stalwarts who have since passed away. The winner of the 20th annual tournament was Bob Marshall, who is retired from FAG Bearing/Shaeffler Group.

• Altra Industrial Motion, Braintree, MA, has acquired Bauer Gear Motor, Esslingen, Germany, a manufacturer of gearmotors offering engineered solutions to a variety of industries. As part of Altra Industrial Motion, Bauer joins the North American company Boston Gear. Both

The 2011 ‘Guns’n Smurfs’ are, from left to right: Chip Myer, Rod Machtmes, Steve O’Brien, Scott MacPherson, Robby MacPherson, John Grainger, James Ashby, Don Freitas, Bob Marshall, Steve McCauley, Bill Starr, John Armolea, Pierre Bouchard, Terry Tillsley, Harold Benz, Paul Dent, Fred Hagino, James Bartsch, Marek Nesvadba, Jude May, Peter Mitchell, Greg Stephen and Gerry Brownrigg.

Bauer Gear Motor products have been integrated with the Boston Gear division of Altra Industrial Motion.

companies have extensive experience and application knowledge in industries that include material handling, food processing, packaging, bottling and metals.

• Metso Paper Ltd., Montreal, QC, has contracted Usinage Bertrem, Sorel, QC, to be an authorized Canadian service centre for roll repairs for paper mills.

The company operates a 22,000 sq ft workshop in Sorel. The services offered at this location will mainly focus on mechanical roll repairs, but because of existing links to other Metso roll repair and covering facilities in the US, additional roll services can be accommodated.

• NTN Bearing Corp. of America, Mt. Prospect, IL, has promoted Pete Eich to executive officer of NTN Corp., Osaka, Japan, and deputy general director of the Americas Region. Eich will also retain the title of president, NTN Bearing Corp. of America. He will oversee NTN’s sales operations for the entire Americas region, including the United States, Canada, Mexico and Central America.

• The Timken Company, Canton, OH, has appointed Evan J. Boere to the position of business development manager in Canada. He will be responsible for identifying and planning the expansion of Timken’s business into new markets for the process industries segment and the offhighway business of its mobile industries segment. Boere has served as regional sales manager in Canada for the past 13 years. Timken also appointed Frank G. Mascia to the position of general manager of sales in Canada. In this role, Mascia will be responsible for sales and marketing in Canada for Timken’s process industries segment and the off-highway business of its mobile industries segment.

He also will oversee customer service and business development for these units in Canada. Prior to joining Timken, Mascia served as general manager of Hansen Transmissions Inc., Toronto.

• The Timken CompaTimken’s ny, Canton, OH, has Evan Boere. been named the winner of Ann Arbor, MI-based Humantech Inc.’s fifth annual Find It-Fix It Challenge. The Find It-Fix It Challenge recognizes and rewards simple and effective workplace solutions that result in increased productivity, improved worker morale, and fewer workplace injuries and illnesses. Honourable mentions for the Challenge were given to John Deere Turf Care, located in Fuquay-Varina, NC, and to the Ashland Water Technologies site in Nantou, Taiwan.

The contest was derived from Human-

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Winners of the Find It-Fix It Challenge are featured on www.humantech.com.

Timken’s winning entry, shown here, made a tough job more comfortable.

tech’s Rapid Team Events, which are based on the concept of making quick, simple, visible changes to improve ergonomic issues in the workplace. From over 200 entries received, representing 17 companies, one winner was selected and two honourable mentions were recognized.

Timken’s Manchester Plant in Manchester, CT, took top honours with its Bull Gear Deburring Fixture entry. The associate responsible for the task suggested an opportunity for improvement and the idea went straight to the plant’s safety manager.

“Competing in the Find It-Fix It Challenge is a great way to inspire our associates to develop ergonomic solutions. This is a perfect example of continuous improvements in our operations. We improved our associates’ work environment and employed lean processes to streamline our manufacturing processes, reduc-

ing processing speed and increasing quality levels,” says Bob Scott, principal ergonomics engineer at Timken.

Timken focused on improving the deburring process (a finishing method in which rough edges of metal are smoothed) of a planetary gear weighing more than 400 lb. Prior to the improvement, the operation was performed with the gear placed in a horizontal position, requiring the operator to bend over to grind the edges off the gear teeth. Because of the limited reach in this position, the operator had to lift the gear multiple times throughout the process to successfully deburr the entire component.

“Through teamwork and engineering problem-solving, we achieved substantial ergonomics improvement by creating a fixture to hold the gear in a vertical position, and using a roller system that allows for fast and easy adjustment.

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Mounting the fixture on a portable, adjustable table allows the associate to perform the work more comfortably,” says Scott Amendola, EHS analyst at Timken. “In less than four months, the project also achieved its return on investment and has improved customer service by reducing delivery times,” he adds.

“Winning the challenge is a great achievement that belongs to our associates, who are dedicated to making our workplace safer, and we look forward to participating in next year’s Find It-Fix It Challenge,” says Scott.

John Deere Turf Care received an honourable mention with its Mid-Z Eyebolt entry. Prior to the improvement, the operator had to manually turn a nut on the eyebolt three-quarters of the way down, 240 times a day. By mounting an air tool to a fixture with a foot control, the operator only has to start the nut; the tool turns the nut to its required location on the eyebolt within seconds.

Ashland Water Technologies also received an honourable mention with its Raw Material Transfer entry. Prior to the improvement, the operator had to break apart frozen material by striking it with a stick.

By providing equipment to compress the pail hard enough to break the frozen material, the operator is no longer required to manually strike the container, which eliminates all hand, leg and back issues.

To view a webinar announcing the winners and highlighting the 15 finalists, visit http://www.humantech.com/about/ find-it-fix-it-challenge.

The 2012 Find It-Fix It Challenge is scheduled to kick off in early summer 2012.

MRO

Mr.0 The Practical Problem Solver

Bearings & heat damage Problem: If a bearing is heat-treated, why can’t I use a torch to heat it up to remove it?

Solution: Most bearings are heattreated to at least 125°C (257°F) during manufacture. To be safe, you should never apply heat (such as a torch) directly to a bearing ring to mount or dismount.

You’ll know if you have gone too far as the bearing material will change colour: first to a ‘true straw’ colour, then straight up through the rainbow as the heat increases. Any colour change means a loss of material hardness, dooming the bearing to an early death.

As well, if you use a torch to burn a bearing off a shaft, not only will you ruin the bearing, you risk bending the shaft. Be safe: use the right tools for mounting or dismounting.

For the past decade, Joe Conyers has been a senior consulting engineer for the SKF Reliability Maintenance Institute in training and development. This tip is from his blog at www.maintenancebits.com.

Do you have a solution for a maintenance problem? Send it in and if it’s published, we’ll send you a Mr. O Problem Solver T-shirt. Include your address, telephone number, print complete details and, if possible, add a sketch to help explain your tip. Send your tips to Mr. O, Machinery & Equipment MRO, 80 Valleybrook Drive, Toronto, ON M3B 2S9.

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Dead in the Water!

Machinery & Equipment MRO

December 2011

A POWER OUTAGE CASCADES INTO A DISASTER AT THE HALIFAX WASTEWATER TREATMENT FACILITY. HERE’S HOW IT WAS RECOVERED.

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ike a line from a bad novel, it was a dark and stormy ike a line from a bad novel, it was a dark and stormy night in Halifax back on Jan. 14, 2009. Then the power went out. Two backup generators kicked in at the yearold Halifax Wastewater Treatment Facility (WWTF), operated by Halifax Water, bringing the plant’s systems back on line.

Then one of the backup generators overloaded. Wastewater pumps shut down and control power to the inlet gate for the 2.4-m (8-ft) dia. sewage inlet tunnel failed.

In about 20 minutes flat, raw sewage roaring past the partially open gate flooded the 10.7-m-wide by 26.5-m-long by 20.2-m-deep (35x87x66 ft) wet well under the building, including underground chambers full of control and process equipment, rising to the hydraulic grade level – about one metre below street level.

This unexpected chain of events, triggered by an imbalance in how the generators shared the demand on them for backup power, resulted in massive equipment damage and a total shutdown of the facility. It took 17 months to return it to full operation.

The facility’s six-person maintenance team is made up of process technicians, operators and labourers performing the regular maintenance required for dayto-day operations. “All the bigger work [is contracted] out to Black & MacDonald and other contractors,” says Susheell Arora, director of wastewater operations at the facility. “Siemens, for example, does the thermographic scans. We don’t

have electricians or mechanical people who can handle a problem this large.”

At the bottom of the wet well, only the lower four metres of which is actually supposed to be wet, sit five 650-hp pumps that weigh five tonnes apiece and stand 4.3 m (14.1 ft) high. When the rising sewage got into the junction boxes in the wet well, it travelled through the electrical cables and into the pumps, ruining them.

Other equipment that lay submerged and ruined under the sewage included the boilers that heat the plant, 17 sludge pumps, 10 chemical feed pumps, the water recycling system and its three 30-hp motors, all the processing systems that run the plant, and the 4.6 m by 6.1 m (15.1 × 20 ft) motor control centre – packed with starters, variable-frequency drives, big electrical panels and control panels that run the systems and equipment.

Adding insult to injury, a two-day snowstorm hit the city starting the very next day, yet the plant doors had to be left open because the ventilation system was down.

The city hired Black & MacDonald, a multi-trade contractor offering maintenance and other services, as the prime contractor for the plant cleanup and rebuilding operation, but first, the flooding had to be brought under control and the facility systems safely secured. “Water was still coming in, so upstream of the plant we lowered a pump into a chamber and pumped away most of the flow before it could enter the plant,” Arora explains.

“We drained down the wet well to 3.7 me-

Fig. 1

Harbour Solutions

Halifax Wastewater Treatment Facility

Top photo: Hemera/Thinkstock; All figures courtesy Halifax Water.

BY CARROLL MCCORMICK

Fig. 2

How Halifax sewage is treated All the wastewater that flows from Halifax is treated at the Halifax Wastewater Treatment Facility, one of 15 plants operated by Halifax Water to service the wider Halifax Regional Municipality: 40% via a pump station for Halifax’s North End, 50% from a pump station for the South End, and 10% of the flow that is gravity fed.

The wastewater enters the plant via an 2.4-m-dia (8-ft) tunnel. Debris is screened out with a 51-mm (2-in.) screen before the wastewater reaches the huge pumps on the floor of the wet well. The wastewater is then pumped up and through 10-mm (0.4-in.) screens.

From there, it goes through a process called grit removal, where heavier debris falls out of the wastewater and is taken away.

The water is then taken to chemical process tanks where flocculants are added, causing sediment to fall to the bottom, where it is removed. The water is then treated with ultraviolet disinfection lights and discharged into the Halifax harbour.

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Fig 1: This cross section of the wet well and treatment plant shows the extent of the flooding, nearly to street level (the brown line indicates solid ground).

Fig 2: Draining the wet well began with pumps set up outside the treatment plant.

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tres (12 ft) below ground with an outdoor pump. Then we brought pumps inside, lowered them through an access way into the wet well, and drained the well.”

Removing the five-tonne pumps illustrated the many difficult tasks that the contractors faced. Since one of the two cranes built into the wet well for removing the pumps had drowned, crews had to bring in manual hoists to lift the pumps one-by-one, about six metres, then transfer them laterally to a second crane and out of the building. “It was a big task,” Arora recalls.

From the beginning of the recovery, the facility’s maintenance and operational staff made sure that conditions were safe for the cleanup and repair crews, and lent their expertise to the operation. Their first task was to secure the facility and make sure all personnel were safe. Then they began planning the restoration effort, from pumping out the wet well to organizing the ordering of replacement equipment.

“Our people coordinated the contractors [and] gave the guidance – for example, explaining the consequences of touching electrical panels or turning on pumps.

These are complex systems. Our people were busy inventorying equipment, planning and working around the clock. Our operators are knowledgeable about the plant and could tell the contractors about the consequences of any actions they would take,” Arora explains.

Replacing the damaged equipment was a massive task. Arora outlines the challenge. “The control panels were custom built. Hundreds of components go into the control panels and the manufacturers in the United States had to build new control panels from scratch.

“The pumps are not off-the-shelf. You have to replace the pumps with the same model and make, to fit the piping and electrical systems. The five big pumps came from Germany, with a six-month delivery time. Other equipment had an eight-month lead time … parts came from all over the place. There were hundreds of subcontractors and thousands of suppliers for the original equipment.”

It certainly helped that Black & MacDonald has a big presence in Halifax and could come over to the facility right after the flood. Halifax has several shipyards and also services offshore oil and gas production platforms, and the local suppliers that serve them were able to obtain a lot of the replacement equipment.

The post-flood investigation resulted in some changes designed to prevent such an event from happening again. For example, says Arora, “The junction boxes and control equipment are now upstairs where they cannot be flooded. We installed backup equipment that can close the gate and we made operational changes to handle the flows better in the plant.

We balanced the generators better so they would not overload.”

Halifax Water brought the facility back on line in stages: It began handling dry weather flows (sewage, but not rain runoff) in the fall of 2009; it returned the Advanced-Primary Treatment system to operation in May 2010; and the next month operators brought the ultraviolet disinfection back on-line, and the facility resumed full operations.

Among other measures to decrease the likelihood of a repeat flood, Halifax Water adopted the practice of conducting hazard operability assessments – a way to probe for problems and risks in plant designs and operations. Arora believes this is a valuable practice for any plant.

“Conduct tabletop exercises. Run all your scenarios and ask yourself ‘what will happen if this fails’? We are running a haz-

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Fig. 3

Fig. 4

ard operability assessment on a new plant we are building in the Eastern Passage. We bring in fresh eyes – facilitators who know the industry. It is a very open process.

“We now provide a lot more training to our people. You want to be prepared for any emergency.”

MRO

Fig 3: This image, taken after pumps drained the wet well, hints at the mess the flood made and the enormous cleanup the recovery crews faced.

Montreal-based Carroll McCormick is the senior contributing editor for Machinery & Equipment MRO.

Fig 4: Process pumps in the wet well have been cleaned but were not yet operational.

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How to get optimal performance from pumps

BY STEVE GAHBAUER

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nowing how to maintain pumps and their components while dealing with malfunctions effectively goes a long way to improving pump performance, increasing reliability and saving some money.

Here are some nuggets of pump wisdom gleaned from presentations at a recent Fluid Prime Movers seminar in Toronto organized by the Society of Tribologists and Lubrication Engineers (STLE).

Bearings and seals need special attention in all pump installations.

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Pump selection criteria When selecting positive displacement pumps, look at the following criteria: • capacity (constant or variable) • viscosity (high or low) • pressure (discharge and suction) • solids and abrasives (size, hardness and amount) • air and/or gas (volume, entrained, or slugs) • shearing properties (shear thinning, Newtonian, etc.)

• temperature (high, low, ambient) • whether a variable-speed drive pump is necessary for total process control.

Also consider pump material (soft, hard, coated, corrosion resistant); proper sealing (packing, seal type, magnetic drive); lubrication (product, grease, oil, oil mist or external system); relief valves in the system; and instrumentation for monitoring what’s going on inside the pump (pressure, speed, temperature, vibration).

The only thing that precedes Fluke’s highest standards of quality is our reputation for making the finest measurement tools in the world.

Fluke thermal imagers are no exception.

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Pump failure modes When a centrifugal pump does not reach design flow rate or design head, or operates for a short period but then loses prime, it probably has insufficient net positive suction head or entrained air.

The likely cause of a pump exhibiting similar symptoms, but also showing decreased power consumption with no discharge or flow while running, is a greater than anticipated system head. Other causes include the following: the direction of rotation is reversed, the pump speed is too low, or the impeller is too small. Also check for a plugged impeller, suction line or casing. Improper priming could be the cause of decreased power consumption.

There could be damaged bushings, thrust bearings or impeller rubbing when a pump runs with excessive noise from the wet end and exhibits an increase in power consumption. For noise in magnetic drive pumps, check for rubbing of the inner magnet against the shell. Excessive noise could also be caused by abnormal fluid rotation due to complex suction piping, which should always be straight.

There are several possible causes for increased power consumption and excessive noise from the power end, including: bearing contamination appearing on the raceways as scoring, scratching or rusting; brinelling of bearings caused by incorrectly applied forces during assembly, identifiable by indentation on the raceway; thrust overload on bearings; misalignment; a bearing out of square with the centreline; or a bent shaft.

©2011 Fluke Corporation. 4020056A

Care for pump components Bearings and seals need special attention. Pump bearings support the shaft, permit the shaft to rotate freely, keep lateral deflections to a minimum and maintain proper clearances between the impeller and the housing. continued on page 16

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December 2011

continued from page 14

Seven pump installation tips Proper installation practices, with attention to foundation, piping arrangement and shaft alignment, mean the difference between a pump that gives many years of trouble-free service and one that requires frequent and repetitive maintenance. Follow these tips: 1. Select the right pump for the job. Consider variable-speed technology for multiple operating conditions, instead of throttling. Trim the impeller to about 75%.

2. Balance the impeller after trimming. Couplings should be the elastomer type for soft start and balanced to the AGMA 8 standard, or AGMA 10 for pumps over 75 hp. Offset the pump and motor shaft/coupling hub keyways 180 degrees and cut keys to one-half unfilled keyway length.

3. Install the pump, base and motor level and free of soft foot. Provide at least 10 diameters of straight pipe from the suction inlet. Grout the baseplate with low-shrink cement or, better still, epoxy grout. Ensure pipe fasteners don’t exert a force on the piping.

4. Align properly. Use a laser or reverse dial indicator technology for correct alignment. Align before and after the pipe/pump bolt-up. Keep tolerances as small as practicable.

5. Lubricate properly. Change the lubricant at recommended intervals, protect lubricant from contamination, use synthetic lubes and sealed or vapour-block bearings, and maintain a mechanical seal flush environment.

6. Start-up properly. For safe and reliable operation, develop suitable start-up procedures and checklists, avoid rapid closing of process valves, and use a power monitor for minimum/maximum flow protection. Never run a pump dry. Operate spare pumps every three months.

7. Maintain tolerances. Use cartridge seals designed to reduce fretting corrosion and maintain critical impeller setting tolerances.

Bearing types are either fixed side or free side. Bearing cages keep rolling elements evenly spaced around the bearing and reduce friction by preventing rolling elements from coming into contact with each other. Cage materials can be steel or brass.

Metallic cages are most popular, however polyamide cages are quieter, but they’re more sensitive to poor lubrication or excessive temperatures.

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Pump seals Mechanical seals keep the fluid contained and prevent it from leaking along the rotating pump shaft. The seal faces, which rotate or are stationary and are angular to the shaft, are pressed on to the seat by axial forces.

The main components of a seal arrangement are a rotating or stationary seal face, a dynamic or stationary O-ring, and a spring. Static or hydraulic forces close the seal and the product or barrier medium serves as a lubricating and cooling agent.

Seals must operate within their design specifications, but leakage may occur before or after the seal’s designed life expectancy.

Seal performance can be improved by changing the design and type, or the material it’s made of. It’s also possible to improve installation, operating procedures and maintenance activities. But when seals fail – and they often do – look for and remedy the causes immediately.

Reasons for seal failures include: the wrong seal type for the application; wrong handling, installation or storage, which may cause a loss of elasticity; improper start-up or shutdown; improper operation of the pump; media contamination; shaft deflection or run-out; or worn seal faces.

Uneven wear patterns mean that the shaft is out of alignment or the seal face was not properly aligned. Out-of-alignment shafts also cause an eccentric wear pattern.

Radial cracks and heat checking indicate poor lubrication and overheating of contact faces. These conditions also cause blistering and pitting at the carbon faces.

Edge chipping on the contact face is a sign of incorrect handling, or shaft deflections beyond manufacturer’s specification, and possibly of bearing damage.

All mechanical seal faces leak, albeit at a very slow rate. For some high-temperature products, such leakage oxidizes or hangs up the seal face, while dissolved solids crystallize on the atmospheric side. A frequent liquid or gas quench is a very effective remedy for these conditions. MRO Steve Gahbauer is an engineer and a Toronto-based freelance writer.

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Drives stand the test of time

Machinery & Equipment MRO

The study of quarks and gluons relies on specialized drive technology.

BY MARYANNE BRONSON

O

ver two decades ago, a big research lab required drives that were compact, could produce extremely slow travel speeds, would withstand ongoing exposure to radiation and would need little maintenance. All this was necessary so the lab could study quarks and gluons – certainly an unusual and highly specialized application for industrial drives.

The drives were supplied to Thomas Jefferson National Accelerator Facility in Newport News, VA, also known simply as the Jefferson Lab. It’s a world-leading nuclear physics research facility funded by the US Department of Energy. It is devoted to studying the building blocks of matter.

International and US-based scientists use the lab’s Continuous Electron Beam Accelerator Facility (CEBAF) to probe the nucleus of the atom and study subatomic particles known as quarks and gluons. Like a giant microscope, CEBAF propels an electron beam at nearly the speed of light into targets located in the lab’s three experimental halls. When the beam strikes a target, the interactions are recorded and studied.

In 1987, when design and construction of this US$600-million facility began, Sumitomo drives were specified for every critical application requiring drives and controllers, including the levelling jacks that were designed to compensate for possible settling of the one-million-pound structure once it was moved into position, the Shield House Carriage Wheel Assembly, and the Spectrometer Support Structure Wheel Assembly.

The structure’s enormous size required extremely slow travel speeds, and compact drives were essential because the wheel drives were mounted directly on each wheel assembly.

Additional requirements included withstanding extended periods of radiation and providing relatively trouble-free service for a minimum of 20 years.

These applications required high reduction ratios in a compact, durable, lowmaintenance package. Sumitomo’s Cyclo drives offered all these features, as well as grease lubrication, which would enable them to withstand radiation exposure better than oil-lubricated drives.

For these reasons, Jefferson Lab designers and engineers determined that Cyclo was “really the only choice.”

The Spectrometer Support Structure and Shield House are supported by wheel assemblies that ride on curved tracks anchored to the concrete floor. Sumitomo adjustable frequency AC drives enable the entire structure to be precisely positioned.

More than 20 years later, the Jefferson Lab is building a new experimental research building and upgrading equipment in the three existing experimental halls. During the renovation of Experimental Halls A and C, it extended an invitation to a small group of employees from Sumitomo and industrial distributor Applied Industrial Technologies to tour the facility and see first-hand how well the drives had performed.

At the start of the tour, senior engineer Paul Brindza reported that Sumitomo’s drives had exceeded expectations. “They have been extremely reliable and accu-

rate,” he said. During the three-hour tour, Brindza commented several times that the Cyclo drives had withstood exposure to radiation very well, were very low maintenance, and operated virtually trouble-free.

As a result of the drives’ reliability and performance, the Jefferson Lab planned to once again specify the same drives for its new expansion and renovation project.

MRO

For more information, visit the website at www.suminet.com.

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Above: The structure’s enormous size required extremely slow travel speeds. Top right: The wheel assembly applications required high reduction ratios in a compact, durable, low-maintenance package. Bottom right: Adjustable frequency AC drives enable the entire structure to be precisely positioned.

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M A I N T E N A N C E

M A N A G E M E N T

BY CLIFF WILLIAMS

December 2011

a 5-point ‘TREAT’

Follow along with Step 42 in a journey to world-class maintenance at the Plentya Paper Company as the maintenance team is recognized for its contribution to increased production.

This article is part of an ongoing series.

The introduction appeared in Machinery & Equipment MRO’s February 2005 issue and the series has run in every issue since.

Previous instalments are archived online at www.mromagazine.com. This month, we pick up where we left off in the November 2011 edition, as maintenance manager Bob Edwards and his maintenance team are recognized for helping the company achieve a major production milestone.

E

veryone at the plant was delighted and proud that we had produced an average of 600 tonnes the previous week. When we met as a maintenance group, it was clear that they felt they had played a big part in the mill’s success.

“Thanks once again guys! To help keep up the momentum, I’d like to explain about the ‘15 Minutes of Fame’ idea I’m introducing. This will be your chance, one-on-one, to tell me what you think of our efforts so far. I’d like to hear your thoughts on the following questions: • What are the biggest challenges you face because of the changes in how we work?

• How can I help you with the challenges?

• What am I doing that I should do more of?

• What am I doing that I should do less of?

• What three things are we going to work on (to be developed at the meeting)?

I need to understand what we need to keep doing and what we need to change so we can make those additional small gains to get us where we need to be. In the same vein, Ben, one of our millwrights, has come up with a great idea on how to capture valuable information so we can learn even more from breakdowns.”

I explained that Ben had come up with a root cause method listing questions that would lead us to identifying and solving or mitigating the causes of breakdowns.

“Ben and our reliability manager, Carol, will be doing some training over the next week and I’d like to start using this method as soon as we can. I hope we won’t have too many breakdowns that we’ll be able to learn from, but we need to

p18-23 MRO Dec11 Columns.indd 18

be sure we get out of them what we can.”

I handed out the schedule for the ‘15 Minutes of Fame’ meetings and started the process that afternoon. It took just over two weeks to finish all the interviews, during which there were no major upsets – the mill seemed to be settling into a groove. Ben and Carol had finished the training on breakdown analysis, but luckily we had not had a chance to use the analysis, as we had set a starting point of breakdowns greater than one hour.

As I reviewed the answers to the ‘15 Minutes of Fame’ questions, it seemed that most people didn’t feel that the new way of working was a challenge – in fact it was the opposite, as quite a few had commented that they needed a new challenge.

The one comment that was made about my role was one that my wife Sandy had warned me about earlier – making decisions on the spot and not consulting others first. I had been making a conscious effort to control that tendency. I thought I had done a good job of involving people along the way, but obviously it was not good enough, although I hoped that Steve, another millwright, was right when he had said that, “With high involvement comes high expectation.”

Most of the comments from the team could be dealt with by continuing the communication that we had set up and by handing out more authority to the group. The one problem that had cropped up in many of the interviews was the need to get authorization for the purchase of low-value items. As Ben had put it, “You trust me on shift with your $500-million paper mill but you don’t trust me to buy a $50 bearing!”

This was a valid point and I decided to ask Joe, our plant manager, if we could get an authorization limit of $200 for each of the trades guys. We could issue them with their own code so we could track the purchases if there was a problem. I ran this by Carol, as she knew how the purchasing and maintenance modules were tied in on our software program, and she said there should be no issues with doing this.

When I asked Joe for permission to propose this to Corporate, he wasn’t really on board, “I think that’s going a little too far, Bob. Who knows what they’ll buy?”

When I told him what Ben had said and how I’d feel that I’d let down the group by asking them what they needed, and then just telling them they couldn’t have it, he seemed just a little more amenable. I explained about ‘15 Minutes of Fame’ program and what the comments had been, and he seemed ready to give in – but not before pointing out that the guys were right with their comments.

“Which do you mean, Joe? The challenges or the purchasing?”

“Neither. I’m talking about you making decisions on the spot without consulting people! You should have told me you were going to do this before you did it.

Not to get my permission, but just in case the guys asked for something we couldn’t give them – like this purchasing amount.

I’d have made sure that you told them that there were some decisions that would be out of our hands and that way, they wouldn’t be disappointed if they didn’t get everything they asked for.”

“They didn’t ask for this Joe, they just pointed out that it was a challenge to their working more efficiently – but I get your point. I do need to look around before making these decisions. It’s just that I trust the guys so much. These guys have earned my respect and ever since we converted Stan, the millwright from stock prep, way back when, there has been nothing but enthusiasm.”

“I know, Bob, and if I’m honest, the maintenance group has had a tremendous influence on the rest of the plant – so much so that if we just run at average speed tomorrow, this will be week two of producing 600 tonnes. Ok, let’s run this past Monte, the vice-president of finance.

“That reminds me, Bob. Corporate have been asking for us to send them some examples of the things we are doing so they can share them with the other mills. You should try and pull something together around the ‘soft’ things you’ve done and are doing – the meetings you

© iStockphoto/Thinkstock

Machinery & Equipment MRO

have, the authority you give, the involvement and so on.”

Monte was on board straight away, but offered some words of warning “You need to keep this under control because if it goes haywire, we’ll have to stop it and if you end up doing that, you’ll be further behind than if you didn’t give it to them.”

“You’re right, Monte. I’ll make sure everyone understands that this is still a privilege – one they’ve earned – but a privilege nevertheless.”

The week ended on a high note as the average production was well over 600 tonnes per day. Joe had set up a board on the paper machine floor that showed the average in big bold print each day, so everyone was aware of how we were doing.

This set me up in a good mood for the weekend. I talked with my wife, Sandy, about the week and how I didn’t really know how to go about getting something ready for Corporate to explain the ‘soft ‘ things we were doing.

“I can tell them about the PMs we’ve changed, the predictive stuff we do, Ben’s failure analysis, and so on, but the soft skills? I just treat them as responsible people – hopefully the way they want to be treated.”

Sandy just sat for a minute and then a smile appeared on her face.

“That’s it, Bob. You just tell Corporate how you treat your people.”

“That’s my point, Sandy. I don’t know how to explain that.”

“No Bob, you just explain how you TREAT them – with capital letters. Don’t you always tell me how you try and talk with the guys and how you encourage them to come and talk with you about any issue?”

“Well, yes.”

“Then you’ve got your first capital T – Talk. Didn’t you tell Joe about how you respect what they’ve done, and from the answers to ‘15 Minutes’, you must feel they respect what you’ve done?”

“Hm’mm.”

“Then you’ve got the capital R – Respect.

“I know that everyone has learned a lot more about maintenance through this process – because I have – so you could readily say that you’ve helped Educate the group – your capital E. Now you’ve just finished telling me about how you’ve got permission for the guys to purchase small items, and there have been other ways you’ve given them the Authority – the capital A. I think A for Acclaim may also fit in here, because I know you’ve made a point of praising at every opportunity.”

Sandy had a self-satisfied grin by now.

“Okay, your smugness, what do you suggest for the last letter T? I trust you’ve got something for that?”

“Yes.” “What?”

“You said it.”

“What?”

“Trust! You’ve said it so many times.

You trust the guys to do this or that, and if they didn’t trust you, there is no way they would have changed as much as they have. So that’s the five points of TREAT – Talk, Respect, Educate, Authority, Trust. All you need to do is expand a little on each, maybe give them an example, and I’m sure Corporate will be delighted.”

“I don’t know, Sandy. Sometimes I think you could do my job better than me.” MRO Cliff Williams is the corporate maintenance manager at Erco Worldwide in Toronto, ON, and a consultant with TMS – Total Maintenance Solutions Inc., Markham, ON. He can be reached by e-mail at williamscliff@rogers.com.

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20

M A I N T E N A N C E

1 0 1

Machinery & Equipment MRO

December 2011

Getting to know your equipment

BY PETER PHILLIPS

criticality is 99.99, so the total score is 18 × 99.99 = 1,799.92.

Once all your equipment has been scored, a simple method is used to determine the equipment’s priority. The lowest 20% score Priority 4; 20%-80% score Priority 3; 80%-95% score Priority 2; and 95%-100% score Priority 1.

THE SECOND SET OF ACTIVITIES IN THIS EIGHT-STAGE PROGRAM ON ACHIEVING WORLD-CLASS MAINTENANCE WILL

HELP YOU EVALUATE

I

©Goodshoot/Thinkstock

n the previous issue (November 2011), we launched this series of eight articles on what is involved in achieving a world-class maintenance (WCM) department. Stage 1 explored the eight activities necessary to prepare for professional maintenance. In this issue, we’ll look at Stage 2 – how to evaluate equipment and its deterioration.

There are five activities associated with Stage 2. They are: Activity 1: Prioritization of the equipment.

Activity 2: Evaluate equipment performance, including breakdown rates, maintenance costs, current maintenance practices, etc.

Activity 3: Prepare equipment ledgers.

Activity 4: Set maintenance goals.

Activity 5: Restore equipment and maintain basic equipment conditions, and eliminate forced deterioration due to the external forces around the equipment.

Lets look at each activity in detail.

ACTIVITY 1: Prioritization of the equipment When determining the priority of the equipment, we need to review and rank the equipment based on the two following criteria (a and b). a) The degree of influence the piece of equipment has on other equipment, safety, cost of quality, the environment and any other key items related to your facility and its processes.

For example, laboratory equipment such as bio-safety cabinets have a high priority because of their influence on safety to laboratory personnel, as well as the environment inside and outside of the facility. (Bio-safety cabinets are used to conduct experiments where the contents inside the safety cabinet must not escape into the surrounding environment.)

We score the degree of influence using high and low value rankings: • Affects other equipment (high 5, low 1) • Failure affects human safety (high risk 5, no risk 1) • Failure affects the environment (high risk 5, no risk 1) • Affects product quality (high 5, no effect 1) • Cost of failure in dollars, based on your

p18-23 MRO Dec11 Columns.indd 20

EQUIPMENT AND ITS LEVEL OF DETERIORATION.

cost to produce (greater than $2,000, score 5, less than $500, score 1). b) The criticality of equipment based on its ability to stop the production line or process flow. Here, we determine how the equipment failure affects the line. We measure the criticality based on its impact on the process.

• Low-priority equipment does not impact the line or process • Medium priority impacts the process for less than 24 hours • High priority impacts the line for more than 24 hours We then score the equipment criticality using these percentage rankings: • 33.33 - Does not impact the line or process • 66.66 - Medium impact of the line • 99.99 - High impact of the line.

Lets try a scoring model. As an example, an air compressor that has a standby could score the following: Degree of influence • Affects other equipment: Low, score 2 • Failure affects human safety: No risk, score 1 • Failure affects the environment: No risk, score 1 • Affects product quality: No effect, score 1 • Cost of failure in dollars: Less than $500 – score 1 • Score subtotal = 6. The equipment criticality is 33.33, so the total score is 6 × 33.33 = 199.98.

Lets compare this is to a piece of processing equipment in a manufacturing line.

Degree of influence • Affects other equipment: Mid, score 4 • Failure affects human safety: No risk, score 1 • Failure affects the environment: Some risk, score 3 (defect products go to a landfill) • Affects product quality: High, score 5 • Cost of failure in dollars: Greater than $2,000, score 5 • Score subtotal = 18. The equipment

ACTIVITY 2: Evaluation of equipment performance If there is basic maintenance being performed by operators, review the type and quality of the work they perform.

Review the current performance of the equipment; Number of equipment failures; Frequency of failures; Severity of failures and minor stops; MTBF (mean time between failures); Maintenance cost of selected equipment; Breakdown cost, material and labour; MTTR (mean time to repair); Current maintenance practices; Duration and frequency of maintenance; Type of maintenance, PMs, rebuilds; Percentage of PMs completed; Percentage of past-due PMs; Types of maintenance (corrective, PM, safety, quality or emergency breakdowns); and Backlog of maintenance work.

These findings will help us set maintenance goals in Activity 4.

Here are some ways to improve your MTBFs and MTTRs. How can we lengthen MTBF? • Maintain basic conditions by inspecting, cleaning, tightening and lubricating.

• Restore deterioration by replacing worn parts.

• Develop corrective action and repairs to prevent problems from recurring.

• Operate the equipment properly.

How can we lengthen MTTR? • Raise maintenance personnel skills and knowledge.

• Improve spare parts management.

• Improve hard-to-access equipment and components.

• Apply 5S methods to work areas and workshops.

ACTIVITY 3: Prepare equipment ledgers • Identity equipment subassemblies • Prepare detailed information on all components • Select appropriate maintenance activities for each piece of equipment and its components • Prepare a lubrication map and frequency schedules • Document all safety procedures, such as lock and tag.

By preparing equipment ledgers and breaking equipment down into its components, maintenance personnel become intimately familiar with the equipment.

This exercise promotes a strong understanding and knowledge of the equipment, which is something that will help the maintenance person repair and maintain the equipment.

Every ledger also identifies the spare parts/material list for each piece of equipment. Parts can be stocked or vendors can be identified to purchase the parts when necessary.

After the ledgers are completed, maintenance activities such as preventive maintenance, overhauls, calibrations, etc., can be developed. Lubrication maps and procedures can be developed to ensure proper lubrication methods and frequencies are applied to the equipment.

ACTIVITY 4: Set maintenance goals Now that we have completed the first three activities of Stage 2, we can set some maintenance goals. Based in the

priority of the equipment and its current performance, maintenance goals to improve its performance and reliability can be established. Choose equipment where your improvement efforts can make the most significant change.

Believe me, these improvements will be noticed. You will gain support for your efforts and get lots of encouragement to continue.

ACTIVITY 5: Restore equipment Finally we reach the fifth activity of this stage, restoring equipment to its basic condition and eliminating forces that contribute to the deterioration of the equipment.

When equipment has been neglected, deterioration tends to get worse over time and spreads throughout the work area. This generally leads to a huge increase in failures.

For example, a simple unchecked problem, such as a loose bolt, can cause vibrations that gradually increase, causing other bolts to come loose. This eventually results in an equipment failure.

There are two types of deterioration, natural and accelerated. Natural deterioration is simply the normal wear and tear that occurs in spite of our efforts to use the equipment properly and to carry out scheduled maintenance. Accelerated deterioration is caused by other factors, such as the neglect of basic maintenance like essential lubrication, cleaning and inspecting.

To prevent accelerated deterioration, some basics steps need to be followed: • Restore equipment to its base condition, replace worn parts, tighten loose fasteners, clean and lubricate.

• Develop inspection procedures to address these basic maintenance activities.

• Develop detailed preventive maintenance instructions and frequencies that will identify the equipment condition so problems found during the PM can be corrected.

• Conduct root cause analysis on chronic problems and develop corrective actions to eliminate or reduce the cause.

The goal here is to control or reduce deterioration to a level where the equipment becomes reliable and produces defect-free products.

This stage is all about a true and sincere evaluation of your equipment and your maintenance practices. You need to know what equipment to focus your maintenance efforts on first, by developing an equipment priority list. You need to know what makes the equipment tick; you’ll learn this through the equipment ledger.

You need to evaluate equipment performance so you can set goals to improve reliability and quality. If you are having trouble maintaining basic conditions, then you need to revamp your maintenance programs to get the equipment in the best condition it can be (like the usedcar dealers say, in ‘like-new condition’).

There is an immense about of work to do here but the skills and the knowledge you will gain about your equipment are priceless. The attitudes of your maintenance people will improve because they will have been given the time to use their expertise to make the equipment work better. After all, this is what they train for and why you hired them in the first place.

MRO Peter Phillips of Trailwalk Holdings, a Canadian CMMS consulting and training company, can be reached at 902-7983601 or by e-mail at peter@trailwalk.ca.

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M A I NT TH EE N SA AN FC EE T YM A F N I AL GE E M E N T December 2011

Machinery & Equipment MRO

Table 1: Likelihood Levels

ASSESSING YOUR FIRE RISK Is your facility at a high level of risk? Each year in

© istockphoto/Thinkstock

Description

Level

Specifics

Rare

1

- may occur in exceptional circumstances - no incidents in the past 15 years

Unlikely

2

- could occur at some time, especially if circumstances change - 5 to 15 years since last incident

Possible

3

- might occur under current circumstances - 1 incident in the past 5 years

Likely

4

- will probably occur at some time under current circumstances - multiple or recurring incidents in the past 5 years

Almost Certain

5

- expected to occur in most circumstances unless circumstances change - multiple or recurring incidents in the past year

Table 2: Consequence Levels Description

Level

Specifics

Insignificant

1

- no life safety issue - limited value or no property loss - no effect on general living conditions.

Minor

2

- potential risk to life safety of occupants - minor property loss - minimal disruption to business activity and/or - minimal impact on general living conditions.

Moderate

3

- threat to life safety of occupants - moderate property loss - could pose threat to quality of the environment.

Major

4

- potential for a large loss of life - would result in significant property damage - impact to the environment would result in a short-term, partial evacuation of local residents and businesses.

5

- significant loss of life - multiple property damage to significant portion of the municipality - long-term disruption of business - environmental damage that would result in long-term evacuation of local residents and businesses.

Canada, over 1,500 industrial fires occur, causing approximately $140 million in property damage.

BY SIMON FRIDLYAND

D

uring recent plant audits, I have noticed that a significant number of facilities do not comply with local fire code requirements. For example, flammable liquids are being stored in general warehousing facilities, dispensing is taking place in unauthorized areas, and there is a lack of low-level ventilation. These are just some examples of non-compliance I’ve seen.

In Ontario, Part 4 of the Ontario Fire Code, Flammable and Combustible Liquids, was originally introduced in 1997 and reconfirmed in 2007. This section outlines requirements for storage, handling and processing of flammable and combustible liquids. Also, Ontario’s Occupational Health and Safety Act, under Regulation 851 for Industrial Establishments, stipulates Pre-Start Health and Safety Reviews (PSRs) be carried out where flammable liquids are involved.

Statistically, each year in Canada, over 1,500 industrial fires occur, causing approximately $140 million in property damage. Therefore, it is important to evaluate the risk associated with using flammable and combustible liquids in our factories.

An industrial occupancy (a factory) is defined as one for the assembling, fabricating, manufacturing, processing, repairing or storing of goods and materials. This category is divided into low-hazard (F3), medium-hazard (F2) and high-hazard (F1) based on the facility’s combustible content and the potential for rapid fire growth.

Industrial occupancies constitute a special fire hazard due to their high levels of combustible, flammable or explosive content and the possible presence of oxidizing chemicals and gases. Processing and other activities that involve various ignition sources often occur in these occupancies. Industrial fires generally involve large quantities of combustible materials and potentially result in large financial and human losses.

A fire risk assessment attempts to answer the following seven questions: 1. What could happen?

2. When could this happen?

3. Where could this happen?

4. Who could this happen to?

5. Why could this happen?

6. How likely is it to happen?

7. How bad would it be if it did happen?

While answering these questions, one needs to keep in mind the likelihood of these scenarios occurring and their subsequent consequences.

Risk is defined as a measure of the

p18-23 MRO Dec11 Columns.indd 21

probability and consequence of an adverse effect to health, property, an organization, the environment or the community as a result of an event, activity or operation.

The probability or likelihood of a fire is often estimated based on the frequency of previous experiences. A review of past events may involve extracting relevant historical fire loss data. Professional judgments based on experience should also be exercised in combination with historical information to estimate probability levels. An evaluation of the probability of an event can be categorized into five levels of likelihood (see Table 1).

The consequences associated with a fire – the potential losses or negative outcomes – also can also be categorized into five levels, based on severity (see Table 2).

In order to establish an overall picture of the situation, the risk assessment is completed by assigning probability and consequence levels to potential adverse events or scenarios due to fire – and combining the two to arrive at an overall risk level. This process is called the Risk Analysis Matrix (see Table 3). The highest overall risk levels are located in the bottom right corner of the matrix and the lowest levels are at the top left corner.

This tool also allows the analyst to rank and classify the scenarios for the purpose of prioritizing risk-reduction measures.

The risk and priority levels are defined as follows: L = Low Risk. Priority Level 1 (L1) means to manage by routine programs and procedures, and to maintain risk monitoring.

M = Moderate Risk. Priority Level 2 (L2) requires specific allocation of management responsibility, including monitoring and response procedures.

H = High Risk. Priority Level 3 (L3) means senior management attention is needed.

E = Extreme Risk. Priority Level 4 (L4) indicates a serious threat, where detailed research and management planning are required at senior levels.

It is hoped that this simple tool will allow you to evaluate the risk of fire in your facility and the potential consequences for your organization.

MRO

Catastrophic

Table 3: Risk Analysis Matrix Level of Risk (Priority Level) Consequence Probability

1 Insignificant

2 Minor

3 Moderate

4 Major

5 Catastrophic

1 Rare

L (L1)

L (L1)

M (L2)

H (L3)

H (L3)

2 Unlikely

L (L1)

L (L1)

M (L2)

H (L3)

E (L4)

3 Possible

L (L1)

M (L2)

H (L3)

E (L4)

E (L4)

4 Likely

M (L2)

H (L3)

H (L3)

E (L4)

E (L4)

5 Almost Certain

H (L3)

H (L3)

E (L4)

E (L4)

E (L4)

Simon Fridlyand, P.Eng., of SAFE Engineering Inc., specializes in industrial health and safety concerns and PSR compliance. For more information, visit www. safeengineering.ca.

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Clarifiers Chains Sprockets Flights Wear Items Bearings Couplings 800-265-9970 www.renoldcanada.com Š 2011 Renold Jeffrey

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I N D U S T R I A L

23

L U B R I C A T I O N

December 2011

Machinery & Equipment MRO

Wind turbine gearbox lubrication requires special consideration © istockphoto/Thinkstock

Learn what these gearbox lubricants must do, how they are formulated and tested, and how they work in the system.

BY STEVE GAHBAUER

I

ndustrial gearboxes are highly engineered machines. Many components in gear drives have tight tolerance limits and an optimized gear geometry. It stands to reason that such equipment needs special care. The successful operation and longevity of a gearbox is directly related to regular maintenance and proper lubrication.

Gear oil has two main purposes: it reduces wear and dissipates heat. Most gearbox failures can be attributed to improper lubrication. If the wrong type of oil or incorrect viscosity is used, gear failures are sure to happen. But this is preventable. Proper oil viscosity provides a film between meshing gear teeth. It is very thin and keeps the gear teeth from contacting metal-to-metal. Oil suppliers provide product data sheets with useful information, but the true test of a gear oil is how it works in the system.

This is true for any type of gearbox, but proper lubrication and lube cleanliness are absolutely crucial to wind turbine gearboxes, because these present challenges that are not found in other equipment.

Gearboxes are the weakest link and the most expensive component in a wind turbine; they are expensive to repair and replace. They are relatively small but very complex with their low- and high-speed ge-

ometry. A gearbox in a wind turbine connects a low-speed shaft turned by the rotor blade with a high-speed shaft that drives the turbine. The low-speed shaft is typically supported by two large bearings. Lubricants in the gearbox and bearings play a vital role in ensuring that a wind turbine operates effectively.

Aside from suitable viscosity, wind turbine gearbox oils must have an extra-high film strength, low pour point and resistance to corrosion, good water tolerance, good cleansing and dispersing ability, they must be resistant to foaming and facilitate filtering, provide protection against micropitting, and they must be non-toxic.

Above all, they must be reliable and long-lasting, because access to wind turbine gearboxes is difficult and expensive.

Maintenance and oil changes require a tall crane and, in many cases, easement rights to properties.

At a recent technical dinner meeting of the Toronto Section of the STLE (Society of Tribologists and Lubrication Engineers), Michelle Graf, the product manager of hydraulic and industrial gear oils for the Lubrizol Corp. in Wickliffe, OH, presented an overview of wind turbine gearbox lubricants and performance parameters, followed by a discussion of tests needed to adequately evaluate lubricant perfor-

mance. Graf is also co-chair of the American Wind Energy Association’s Operation and Maintenance Working Group.

Graf spelled out the specific requirements for wind turbine gearbox lubricants, saying that they should be 90-99% base oil and 1-10% additives. The base oil can be either mineral oil or PAO. The base stocks need to be synthetic products because of the extended drain requirements of wind turbine gearboxes.

The potential benefits of synthetic base stock are that they can operate in a wide range of temperatures and that they have very versatile viscosity characteristics. Additives must be formulated for extra-high pressure, anti-wear, and rust inhibiting properties.

Aside from reducing friction and dissipating heat, wind turbine gearbox oils must also inhibit foaming. Formulation balance is critical because so many components of a formulation are surface-active. Thus, proper formulating is a real balancing act.

There are various key tests available to assure appropriate and effective performance of wind turbine gearbox oils.

They include general industrial gear bench tests, mechanical and field tests, and specific tests that OEMs can perform. The governing standard is DIN 51517-3. Wind turbine suppliers, gearbox manufacturers and lubricant vendors are useful sources of information.

Proper selection, application and condition monitoring of wind turbine gearbox lubricants is essential for achieving maximum service. Because oils and additives break down over time, it is essential that gearbox oil is replaced regularly.

An oil sampling program is effective in

monitoring gearbox health.

Checking oil levels regularly should be part of a preventive maintenance program. Too little lubrication can damage gearing; to much may cause churning and higher operating temperatures. Either result in decreased efficiency and reduced oil and seal life. It is important to check for leaks at shaft seal areas and to make sure that filters and strainers remove contaminants when the gearbox is equipped with a pressurized lubrication system. Replace them when changing the oil.

The choice of wind turbine gear lubricant depends on turbine size, turning speed, transmission design, operating range and filtration, and on the type of lubricant delivery system. There are many things to consider, but solutions are available. For instance, SKF offers a wide range of items for wind turbine gears and bearings that are designed to boost turbine performance and increase reliability.

Among them are new products related to automatic lubrication systems.

Other points to consider, says Graf, are anticipated oil life, compatibility with current lubes, and warranty issues. It is a good idea to discuss specific needs with suppliers and to look at the total cost versus only the cost of the oil.

Above all else, the main issue is to keep the gearbox lubricant as clean and contaminant-free as possible. This minimizes downtime, reduces maintenance and repair costs, and increases machine availability.

MRO Steve Gahbauer is an engineer and a Toronto-based freelance writer.

Online Reader Inquiry No. 904

Relax. HYDRex is on tHe job.

TM

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lubricants.petro-canada.ca

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Petro-Canada is a Suncor Energy business

™ Trademark of Suncor Energy Inc. Used under licence. † Measured against the number one selling North American hydraulic oil brand. †† Energy efficiencies apply to multigrades only.

LUB 2303E (2010.03)

Components by:

Online Reader Inquiry No. 130

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Machinery & Equipment MRO

What’s new in lubrication Portable lubrication system can be moved anywhere within large plants

A mobile lubrication system from The IFH Group provides storage and dispensing of lubricants, cutting oils, bearing oils, hydraulic fluids, transmission fluids and engine oils for plants requiring lubrication maintenance at multiple locations over a large area. The system can be placed in the bed of a heavyduty pickup truck for goanywhere mobility within the plant. It includes two 50gal. and two 25-gal. steel containers with PVC sight gauges. Air-operated piston pumps on top of each container provide a 5:1 pumping ratio, while filters on the side of each container remove any dirt or small

particulates. The system’s retractable hose reels feature metered dispensing control handles, and a large steel tool box with cabinets is placed underneath the reels for convenient storage of tools, greases, rags, etc.

The IFH Group Online Reader Inquiry No. 892

Food-grade grease maintains its integrity in hostile environments

Chain Guard FGG 2 H1 synthetic foodgrade grease has been introduced by Chain Guard Industrial Lubricants. The grease is a fully synthetic, formulated, polyalphaolefin-based lubricant designed for use in a wide range of industrial applications where NSF H1 regulations are enforced. Also, it is acceptable for use in Canada. It offers good anti-corrosion and water-washout properties while maintaining high load-carrying capacities,

December 2011

Food-grade compressor oil is formulated for long service life

Ultrachem has developed a line of food-grade rotary screw and reciprocating air compressor lubricants with good wear, oxidation and lubricity. Omnilube 32/46, 68 and 455 products meet the requirements of the USDA and FDA H-1 regulations and conform to the requirements of NSF. They are also approved by the Orthodox Union for Kosher use. Offering a service life of up to 8,000 hours in good operating conditions, these fully synthetic compressor oils are formulated from high-quality polyalphaolefin base oils with an additive package that promotes long life. Features include low varnish formation, low pour point and high flash point, and good compatibility with elastomers, seals, plastics and paints.

The products are suitable for use in meat, poultry and food processing (H1) plants.

Ultrachem Online Reader Inquiry No. 891

wide operating temperature ranges and long lubricating life. It also performs well under wet and humid conditions. Applications include enclosed gears, slide ways, medium- to low-speed bearings and anti-friction bearings, as well as all

types of food processing machinery.

Chain Guard Industrial Lubricants Online Reader Inquiry No. 890

Hydraulic fluid passes stringent test

Meeting specifications is key to servicing mining and construction industries. Petro-Canada Lubricants has announced that its Hydrex MV 36 hydraulic fluid meets Komatsu and JCMA HK-1 global specifications. Available in AW, MV and XV grades, this hydraulic fluid line offers long life and wear protection, helping to reduce downtime and maintenance costs for increased productivity. Achieving Komatsu endorsement opens the door for the company to new business opportunities in the mining and construction sectors.

Petro-Canada Lubricants Online Reader Inquiry No. 893

Oil mist collector has low operating cost

MRO Magazine

This advertisement prepared by: McGILL PRODUCTIONS • May 02, 2011

docket # SMP_11030.01

Royal Products’ Royal Filtermist mist collector collects oil mist and smoke generated by all types of metalworking machinery. It is available in four sizes ranging from 275 cfm to 1,200 cfm, and its flexible design enables it to be mounted in a variety of ways, including directly to the top of a machine tool, on a stand or suspended from a factory ceiling.

Maintenance and operating costs are minimal. The latest version, the Filtermist FXSeries, is the product of extensive computer-aided modelling and laboratory testing.

Royal Products Online Reader Inquiry No. 897

Envision a world that doesn’t just turn. It flies.

Prints: CMYK

For automatic cleaning and lubrication of the drive shaft, Uhing linear drives are available with a combination shaft scraper/grease fitting option.

This inexpensive addition removes excessive grease, dust and dirt from the shaft while the drive is running and simultaneously assures proof #1 shaft lubrication. The shaft adequate Client scraper is an O-ring made of specially formulated rubber mounted in a Delrin Creative Director plastic fitting. A felt wiper ring wicks oil out of the grease and applies a thin oil Art Director film to the shaft as the drive runs. Most standard grease gun nozzles fit these CopyWriter grease fittings.

Account Director Amacoil-Uhing A.IND.GLOBE.259.4C

Whether you build, produce, manufacture, run or generate, one fact is clear: better lubricants and better lubricant suppliers lead to increased productivity. That’s why Imperial Oil is proud to offer Mobil Industrial Lubricants – recognized worldwide by more than 5000 equipment builders. With the combination of Mobil Industrial Lubricants and Imperial Oil expertise, we don’t just elevate productivity – we help unleash it. Visit www.imperialoil.ca for more information.

11" x 16” + 0.25 bleed (LIVE AREA: 10” X 15”)

Economical linear drive option keeps shaft clean and lubricated

Online Reader Inquiry No. 898

MRO

Account Manager

Obtain free additional information about Prodution Manager any of these items by using our online reader reply McGill card at www.mromagazine.com/rsc.

Imperial Oil is a trademark of Imperial Oil Limited, Imperial Oil, licensee. Mobil and the Pegasus design are trademarks of Exxon Mobil Corporation or one of its subsidiaries, Imperial Oil Licensee.

Online Reader Inquiry No. 132 A.IND.GLOBE.259.4C.01.indd 1

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Machinery & Equipment MRO

What’s new in pumps t

Repair parts kit gets pump back in service quickly

Repair parts kits are available from Viking Pump for most of its standard pumps.

Two kits are available for each size and material of pump. The seal kit includes everything needed for a complete seal and bearing replacement, including the shaft seal, O-rings, gaskets, seal lubricant, bearings and bearing housing hardware. Rebuild kits include parts commonly needed for a complete wet-end rebuild, including an idler and bushing, head and pin assembly, bracket or casing bushing, and fasteners. Each kit, which should only be used with the specific pump for which it is designed, includes an exploded diagram and parts lists, with a link to the pump’s technical service manual.

Viking Pump

Bolted metallic pump line offers low cost of ownership

Versa-Matic has introduced the E40 1-1/2-in. bolted metallic line of pumps, featuring the newly enhanced Elima-Matic air valve system. This system consistently delivers on/off/on reliability, while maintaining superior air efficiency. The air-operated, double-diaphragm pump is accompanied by a brochure, service manual and data sheet, training materials and a competitive comparison chart. Versa-Matic pumps are available in a variety of plastic and metal materials, such as polypropylene, acetal, aluminum and stainless steel. Sizes range from 1/4 in. to 3 in.

Versa-Matic

Ruggedized air sampling pump withstands extreme environments

Casella’s Tuff line of personal air sampling pumps features a sealed case with over-moulding that protects it from damaging moisture, extreme temperatures, solvents and impact. Offering a flow range from 5 ml/min. to 4.5 lpm, these pumps are designed for a wide range of occupational health and safety applications from simple abatement sampling to more specialized industrial hygiene monitoring of dusts, fumes and gases. Pump operation is guided by an intuitive user interface displaying

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real time flow, sampled volume with run duration, as well as a simple battery fuel gauge and alarm for flow or battery fault conditions. Available models include Tuff Standard, Tuff Plus and Tuff Pro. They all use detachable and field-swappable NiMH battery packs featuring typical run times of

more than 30 hours (depending on media and flow rate).

Casella Online Reader Inquiry No. 862

MRO

Obtain free additional information about any of these items by using our online reader reply card at www.mromagazine.com/rsc.

Online Reader Inquiry No. 863

Submersible pump is designed as workhorse for wastewater treatment

KSB Canada has added the standard Amarex N submersible pump series to its portfolio. The pump has been designed to ensure long, troublefree service in the most demanding wastewater applications. It is straightforward to adapt to typical wet-well mounting arrangements, whether hoop, guide wire or guide rail. Several clog-resistant impeller designs are available to prevent blockages and reduce downtime.

The pump body and motor enclosure are cast as a single mono-block, which eliminates the possibility of leakage and ensures alignment between pump and motor components. The pumps are available with discharge nozzle sizes ranging from 35 mm to 100 mm and pumping capacities up to 53 lps.

KSB Pumps Online Reader Inquiry No. 861

Borehole pump can handle extremely aggressive fluids at great depths

KSB’s UPA and UPZ families of borehole pumps are efficient, multi-stage pumps designed to fit into a cylindrical space such as pipe or borehole. They are available in diameters from 50 mm to 200 mm (2 in. to 8 in.), in a variety of corrosion-resistant materials, and with capacities of up to 2,200 cm/h and heads as high a s 1,4 0 0 m.

Suitable for water supply, mining and oil and gas operations, these pumps have the potential of playing an important role in the Alberta oilsands industry, where they can be used in deep underground wells to pump water with high salt content.

KSB Pump Online Reader Inquiry No. 865

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Online Reader Inquiry No. 133

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Machinery & Equipment MRO

What’s new in alignment Four-axis receiver pinpoints machinery alignment problems

Pinpoint Laser Systems’ four-axis Microgage receiver provides useful alignment information for evaluating and correcting

A shaft balancing collar that provides a fast and easy way to resolve out-of-balance conditions causing vibration in drive systems has been introduced by Stafford Manufacturing. TrueBalance shaft collars feature two-piece construction and are supplied with five self-locking balancing set screws. The collar is simply clamped on to the shaft and set screws are added to offset the weight imbalance until satisfactory balance and smooth operation is achieved. Allowing the offset of outof-balance vibrating shafts without requiring system disassembly, the collar can be adjusted from 0.024 oz.-in. to 0.170

Coupling is designed specifically for encoders

Control-Flex couplings from Zero-Max are designed for the precision feedback requirements of encoder applications. These couplings have a parallel linkage system that minimizes reaction forces due to unavoidable shaft misalignments, and have high parallel, angular and axial shaft misalignment capabilities with less side loads on shaft bearings and seals. Suitable for use in packaging, medical device, machine tool, and conveying and automated assembly systems, they are designed with clampstyle zero backlash hubs, and have electrically insulating flex components with low weight and inertia.

Zero-Max Online Reader Inquiry No. 855

oz.-in. Standard balancing collars are offered in 3/4 in. to 6 in. I.D. sizes and can be supplied as specials up to 12 in. I.D. Stafford Manufacturing Online Reader Inquiry No. 857

Oldham coupling is not just for motion-control applications

t

machinery alignment problems. The 4D receiver measures two linear axes, X and Y, and their two angular components, yaw and pitch. The two linear axes show how well machinery is aligned along a common centreline and the angular readouts show if parallelism problems are present. Applications include the alignment of lathes, turning centres and spindles, as well as moving linear slides, rams and pistons, injection moulding machinery, moving mechanical sub-assemblies and more. A compact, digital display provides precise linear and angular readings and is easy and intuitive to use. The receiver operates over distances of 100 ft or more and delivers a measuring precision of 0.0005 in. and 0.002 degrees.

Pinpoint Laser Systems

Balancing collar resolves shaft vibration issues

December 2011

Oldham couplings from Ruland are typically used in motion control applications where zero-backlash performance is required. However, these couplings are increasingly used as an alternative to straight jaw couplings on general industrial equipment such as pumps, valves, gearboxes and conveyor systems due to their versatility, ease of assembly, and

Online Reader Inquiry No. 853

Mechanical troubleshooting redefined!

The new Fluke 810 Vibration Tester is a fantastic easy-touse troubleshooting tool for mechanical maintenance teams who need the answer NOW! It’s designed for professionals who need to troubleshoot mechanical problems and quickly understand the root cause of equipment condition.

Based on you.

Built by Fluke.

www.flukecanada.ca/810

extended life if misalignment is present.

The coupling comprises two anodized aluminum hubs and a torque transmitting centre disk, and can easily interchange inch to metric, different bore dimensions and keyed shafts. The company offers numerous standard bore combinations from 3 mm (1/8 in.) to 30 mm (1 in.), with hubs also available in stainless steel.

RotoPrecision Inc. Online Reader Inquiry No. 852

Stud type steel base levelling mount comes in range of metric sizes

J.W. Winco has announced that it is offering series GN 343.2 stud type steel base levelling mounts, with or without plastic or rubber cap, in metric sizes. These RoHScompliant levelling feet have a base and threaded stud of zinc-plated, blue-passivated steel. They are available with no cap (pad), or with a cap of white Delrin technopolymer plastic in a natural colour, or with a cap of black thermoplastic TPE rubber, 73 Shore hardness. Base diameters are offered from 25 mm to 60 mm, with studs in a variety of lengths from 40 mm to 158 mm, and threads ranging from M8 x 1.25 to M24 x 3.0.

J.W. Winco Canada Online Reader Inquiry No. 854

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Precision shim makes light work of machinery adjustments

The Microshim, a precision-adjustable shim from Pinpoint Laser Systems, is suitable for production plants, machine shops, utilities, and other industrial facilities where machinery must be precisely adjusted or levelled. Typical appli-

cations include positioning large machinery, levelling grinding equipment, adjusting roll assemblies, levelling extruders and injection-moulding equipment.

This simple, compact device is easy to use, versatile and affordable. Height adjustments of 0.001 in. are possible and each shim will lift and support 10,000 lb.

Pinpoint Laser Systems Online Reader Inquiry No. 860

Online Reader Inquiry No. 135

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MRO

Obtain free additional information about any of these items by using our online reader reply card at www.mromagazine.com/rsc.

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December 2011

What’s new in electrical and electronic components Plugs/receptacles for DC applications have long operating life

Online Reader Inquiry No. 848

Receptacle enables connection in adjustable angular position

Binder-USA has introduced receptacles with adjustable angular positions as part of the series 713, 763, 715 and 766 automation product ranges. The panel-mounted receptacles can be rotated during installation to allow a right-angle cordset to connect in a desired angular position. These M12 A- and B-coded connectors are commonly used for industrial networks and automa-

Adalet has received IECEx certification on its XCEX series of bolted flange flameproof enclosures and auxiliary devices. The enclosures include 81 standard sizes, all approved to gas group IIB with an IP66 rating. Available with window kits, conduit/cable entries and auxiliary devices, the enclosures are approved to IEC 60079-0, IEC 60079-1, IEC 61241-0 and IEC 61241-1 international standards. The company also manufactures enclosures with international certification rated to the ATEX Directive, as well as other country-specific approvals.

Adalet Online Reader Inquiry No. 844

Online Reader Inquiry No. 842

Transformer requires no external protection

Foster Transformer offers the Survivor series Inherently Limited Class 2 transformers in models ranging from 30 VA to 100 VA. Each model features proprietary short circuit and overload protection, which allows them to withstand a direct

short circuit in excess of 15 days. The transformers are available with either 60 Hz or 50/60 Hz ratings. Primary input voltages include 115 V, 115/230 V, and 200/230 V with 24-V output. IEC, EN and CE compliant designs are available, and alternative versions can be configured to meet specific customer requirements. Applications include medical instruments, HVAC and refrigeration, control panels, battery charger and any other applications requiring a Class 2 transformer.

Foster Transformer

and averages to 80 W in air and 240 W in oil. It can cope with ambient temperatures of more than 200°C (390°F) and atmospheric pressures of up to 1,700 bar (25,000 psi). Further requirements of the 22-mmdiameter motors are the capability to withstand vibration of up to 25 Gr m s as well as impulse and impact of up to 100 G – that is 100 times gravitational acceleration. The motor is especially suitable for high-precision positioning tasks, even at low speed, and can find application in space technology or in power plants, as well as in vehicle manufacturing, in the aircraft industry, in mining or in highly dynamic movements.

Electromate Industrial Sales

t

tures as a dead-front safety shutter, which prevents user access to live parts, and a padlockable pawl for easy locking in the connected or disconnected mode. These plugs and receptacles use solid silvernickel contact surfaces for performance and durability, along with spring-loaded, butt-style contacts that maintain contact force over thousands of operations.

Meltric

Kirk Key’s power panel switch interlock provides reliable electrical isolation in a flexible design to fit a variety of equipment configurations. Well-suited for switchgear, electrical distribution and machine guarding applications, the PPS is available in all three of the company’s duty series, with six standard contact arrangements, as well as custom configurations. It is suitable for switch ratings of 20, 25, 40, 63 or 100 amps. The duty series comprises standard duty (SD), medium duty (MD) and heavy duty (HD). The UL- and CSA-approved PPS is available in an IP65 polycarbonate enclosure. The MD and HD series will be available in an optional IP65 panel-mounted version as well.

Kirk Key

Flameproof enclosure series receives certification

t

A product line for electrical equipment powered by direct currents has been introduced by Meltric. The DSDC series plugs and receptacles provide safe and robust connections for direct current applications up to 200 A at 250 VDC, up to 100 A at 600 VDC or up to 30 A at 750 VDC. The product line offers such safety fea-

PPS lock achieves power panel isolation

Machinery & Equipment MRO

Online Reader Inquiry No. 843

Modular controller can be used safely in hazardous locations

The Modular Controller series from Red Lion Controls has been approved for use in Class 1, Division 2 hazardous locations, allowing the product to function in places where explosive gases, vapours and/or liquids may be present, such as the petrochemical industries. Companies working in hazardous environments can safely integrate multi-zone PID control, data acquisition and I/O into their industrial control systems, while also adding advanced

Online Reader Inquiry No. 846

tion applications in harsh environments.

The receptacles are available in both male and female versions and prewired with 20-mm wires. When fully connected to their mating parts, the connectors are IP67/IP68 rated, ensuring connections are protected from liquids and debris.

Binder-USA Online Reader Inquiry No. 841

Downhole drilling brushless servo motor withstands the most extreme conditions

The EC 22 HD electronically commutated motor from Maxon is designed for extremely harsh operating conditions, such as deep (downhole) drilling. Its assigned power rating depends on the surrounding medium

remote asset management and control features to their process. All connected devices can share data with the controller and each other, through a simple dragand-drop mapping of their registers. The high-density DIN rail design saves panel space and eliminates cutouts.

Red Lion Controls Online Reader Inquiry No. 847

Universal remote I/O module is versatile

Omega’s HE359 series is a cost-effective universal remote I/O module. It connects via a two-wire RS485 Modbus RTU to any Programmable Logic Controller. A total of 31 I/O modules may be daisy-chained on a single RS485 link. Available I/O modules include digital in, relay out, analogue in, analogue out, RTD and thermocouple. The modules are suitable for remote temperature and pressure measurement in water treatment, agriculture and automotive industry applications.

Omega Online Reader Inquiry No. 849

Terminal block’s low profile reduces shadowing in LED applications

Wago’s 2060 series two-pole SMD terminal block provides class-exclusive, pushbutton termination/re-terminations for a broad range of solid/stranded conductors sized AWG 24-18. With UL/CUL ratings of 9

A/250 V, the series is a labour-saving alternative to soldering leads for PCB-based LED products. Just 4.5 mm tall, the device features a contoured, light-grey housing that minimizes on-board LED shadowing.

It is available in tape-and-reel packaging for automated PCB assembly, and a large pick-up area makes it compatible with pickand-place equipment. Two upcoming variants will provide additional termination options for one- and three-pole applications, as well as board-to-board applications.

Wago Online Reader Inquiry No. 845

MRO

Obtain free additional information about any of these items by using our online reader reply card at www.mromagazine.com/rsc.

Online Reader Inquiry No. 136

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What’s new in hand and power tools Non-sparking grinding tool promotes safety and productivity

Online Reader Inquiry No. 870

Pump pliers incorporate reaming head and handles

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30734 AGI

High-speed grinders produce flying sparks, high noise and vibration levels, inhalation of hydrocarbon gases and/or toxic fumes, clogging of files/ discs, downtime to replace the files/discs, and more. Specialty Tools Canada has introduced a non-sparking, cold grinding technology, which helps increase safety in the workplace, reduce health issues, save time and money, and increaseBrand product quality.3 The Temporary Ad-MRO_EN:Layout 8/26/11

grinders are available in two versions.

The first version comprises several grinders certified for use in Ex-zones 1 and 2. The second product line is the Giant Grinder series, consisting of high-performance grinders for use in any machine shop.

Specialty Tools Canada

Milwaukee Tool has introduced five pump pliers that feature a reaming head that makes for easy and Page 1

December 2011

Cordless power tools can be purchased without batteries

Metabo offers six of its 18-V PowerMaster series cordless power tools for purchase without the battery. The BHA18 rotary hammer, SB18 LTX hammer drill/driver, SSD18 impact driver, SSW18 impact wrench, STA18 cordless jig saw and the W18LTX cordless angle grinder are all powered by the company’s 18 V, 3.0 Ah Li-Power Extreme batteries, which can be shared by all six tools. The lithium-ion batteries are compatible with the ASC30 30-min. air-cooled charger. Because the batteries are interchangeable among the tools, operators can carry additional tools without the need for several extra batteries.

Metabo Online Reader Inquiry No. 874

efficient deburring of pipe. The additions include 8-in., 10-in. and 12-in. quick adjust reaming pliers designed for electricians, as well as 10-in. and 12-in. tongue and groove pliers for plumbing

applications. The reaming pliers can deburr 1-1/2-in. to 2-3/4-in. pipe, and their reaming handles can deburr up to 1-in. conduit. Their narrow head allows the tools to fit into electrical boxes and fasten in lower-profile areas. The pliers are made with forged metal and are precision-machined for strength and durability, and feature rust protection to increase tool life and reduce corrosion.

Milwaukee Electric Tool Online Reader Inquiry No. 873

Cordless bandsaw is versatile

The Bosch BSH180 cordless bandsaw cuts a variety of materials, including metal, copper pipes and electrical cables, and can be used in tight spaces. This rugged tool is powered by an 18-V fat or slim battery pack, which allows for more than

150 cuts per charge in a 1-in. conduit. At 7.7 lb, its light weight makes it extremely portable and suitable for use in overhead applications. It accommodates most common size materials cut by core trade users up to 2-1/2 in. on a single pass. Included are two FatPack lithium-ion batteries, 30-min. charger and carrying case.

Bosch Power Tools & Accessories Online Reader Inquiry No. 871

Wrench sets offer wide range of sizes

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1-888-602-0000 Online Reader Inquiry No. 137

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acklandsgrainger.com

The Cougar Pro line of professional-grade hand tools has expanded to include combination wrench and reversible-ratcheting combination wrench sets. The combina-

tion wrenches are available in two SAE sets and two metric sets. The 11-piece SAE set (E911) and the 14-piece SAE set (E914) consist of wrenches ranging in sizes from 3/8 in. to 1-1/4 in. The 11-piece metric set (M950) and the 18-piece metric set range in size from 7 mm to 24 mm. The reversible-ratcheting combination wrenches are available in two sets, comprising one SAE and one metric set. The eight-piece SAE set (E8SRCW) consists of wrenches ranging in sizes from 5/16 in. to 3/4 in., while the eight-piece metric set (M8MRCW) ranges in size from 8 mm to 19 mm.

Wright Tool Online Reader Inquiry No. 872

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Cordless angle grinder features rotating battery pack

Online Reader Inquiry No. 876

Mobile chest provides weather-tight storage for tools

Electric torque control wrench is for general industrial use

Offering 2,200 lb-ft of torque with a 1-in. square drive, the STC30AE electric torque control wrench from Tone has been re-designed with a LED light indicator confirming that the torque setting has been achieved. Special features such as low weight and high accuracy make this tool suitable for industrial use. The wrench comes with a heavy-duty metal case and accessories.

Voltage is 115 V, current is 12 A, power consumption is 1,350 W, torque range is 750 lb-ft to 2200 lb-ft, and weight is 9.5 kg.

McCann Equipment Online Reader Inquiry No. 881

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Metabo has introduced the W18LTX professional-grade cordless angle grinder, complete with a rotating battery pack, making it suitable for grinding and cutting applications in hard-to-reach areas. This costeffective, durable 4-1/2-in. grinder is part of the company’s PowerMaster series of 18-V lithium-ion cordless power tools.

The slim motor housing and ergonomic side handle make it comfortable and easy to use throughout the day. Features include a robust, debris-resistant four-pole motor with easily replaceable carbon brushes, and removable dust filter. It has a no-load speed of 8,000 rpm. The kit comes with two Extreme 3.0 Ah batteries, a 30-min. charger and carrying case. The grinder also is available without the kit.

Metabo

with a belt hook, LED work light, carrying case or bag, charger, and two 18-V lithium ion batteries. Features include an LED work light that illuminates the work area when in use, a comfortable contoured rubber grip, and one-handed operation of the variable speed control trigger and forward/reverse switch.

Panasonic Canada

Moving tools is an easy task using the all-weather mobile tool chest from Snapon Industrial, which provides convenient, secure, versatile and weathertight storage for tools that must be readily moved. Its lid

doubles as a seat when the case is open. The mobile tool chest is designed to be pulled easily by hand, with a wide wheel base and a telescoping trolley-style handle. It comes with sliding drawers that

can accommodate foam cutouts for tool control and accountability. Two configurations are offered: two 2-in. drawers plus six 1-in. drawers, or three 2-in. drawers plus four 1-in. drawers. The chest is available in black, olive, tan and orange.

Snap-on Industrial Online Reader Inquiry No. 882

MRO

Online Reader Inquiry No. 879

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Screwdriver passes evaluation with flying colours

The SwissGrip screwdriver from PB Swiss Tools has been evaluated by the Fraunhofer Institute, a European organization for research in the field of applied science. The Institute examined the screwdriver for ergonomics, functionality, shape and aesthetics. The tests confirmed that SwissGrip screwing tools are safe and simple to use, and possess good functioning and design-oriented qualities.

The screwdriver handle lines of SwissGrip, ElectroTool, Torque Tools, Ratchets and Crosshandle are made of a durable and impact-resistant polypropylene core, and the Santoprene coating is friendly to the skin and provides a softfeeling grip.

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Cordless circular saw battery allows a multitude of cuts per charge

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Cordless power tools stand up to adverse work conditions

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Panasonic Canada has added four 18-V Li-Ion cordless power tools to its Tough IP professional-grade product offering. Featuring dust- and water-resistant technology, the IP56-rated products include a 1/2-in. drill and driver kit, an impact wrench kit, an impact driver kit and a hammer drill/driver kit, all equipped

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The SCW 18-A CPC cordless circular saw from Hilti lets users cut more as they move around a jobsite. Due to corded RPM, base plate design and air flow management, it provides smooth operation. The saw incorporates the company’s Cordless Power Care (CPC) battery sys-

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Machinery & Equipment MRO

December 2011

PT industry gathering focuses on future

BY BILL ROEBUCK

recipient of its Warren Pike Award for lifetime achievement in the power transmission/motion control industry.

Mitch Bouchard, secretary-treasurer, General Bearing Service Inc., Ottawa, ON, was elected PTDA’s president for 2012, and George Rizza, president, Rossi Gearmotor Division, Habasit America, Suwanee, GA, assumed the duties of the PTDA Manufacturer Council chair.

The Summit’s signature event, the Manufacturer-Distributor Idea Exchange (MD-IDEX), brought together existing and potential channel partners to plan for the upcoming year. The program featured over 600 meetings through pre-scheduled appointments and open times.

For the sixth year, the Industry Summit included a Motion Control Showcase, featuring 20 motion control suppliers

with live demonstrations of their latest hardware. The showcase is targeted at members considering expansion into the motion control arena, looking for additional suppliers to support current offerings or who are interested in networking with other market players.

One of the keynote speakers at the event, economist Alan Beaulieu of the Institute for Trend Research, predicted continued growth in the economy over the next couple of years. In the long range, however, he forecast a “major depression” by 2030.

A panel discussion, ‘Effects of Mergers and Acquisitions on The Distribution Channel’, was moderated by Barb Ross of Timken Drives LLC. Distributors and manufacturers were each provided separate, distinct opportunities to network with their peer groups

Photographs by Eric Achilles Cousineau

More than 530 delegates from the power transmission/motion control industry took part in the Power Transmission Distributors Association (PTDA) 2011 Industry Summit in Washington, DC, Oct. 13-15. Including companions and guests, the total attendance exceeded 700.

Attendees came from all over the United States and from 12 other countries, including Belgium, Brazil, Canada, Columbia, France, Germany, Italy, Mexico, Russia, Trinidad and the United Kingdom.

The event offered many opportunities for business networking, industry education and economic insight, as well as various social events. The theme of the conference was ‘CAPITOLizing on Change’.

At the Summit, PTDA named Carlos Ingram, retired vice-president of business systems of Kaman Industrial Technologies Corp., Windsor, CT, as the 22nd

to share ideas, trends, problems and solutions during networking lunches and forums. Distributors heard from Jade West, senior vice-president of government relations for the National Association of Wholesaler-Distributors (NAW) during their luncheon. The Distributor Forum focused on ‘Big Issues for Small Distributors’ such as value-added and fee-based services, and tiered distribution.

Manufacturers heard from Dave Asselin, vice-president, Allied Associations and executive director of the Council of Manufacturing Associations at the National Association of Manufacturers (NAM), during their luncheon. The Manufacturer Forum grappled with issues such as the expectations of distributors with regard to loyalty, demonstrating value in serving OEM customers, and distributor training.

PTDA’s 2012 Industry Summit is scheduled for Oct. 18-20, 2012, at the Hyatt Regency Dallas in Dallas, TX. For more information, visit www.ptda.org.

MRO

1 1. Charlie Banta of Isostatic Industries, Tim Breen of Motion Industries and Doug Savage of Bearing Service Inc. attended PTDA’s Motion Control Showcase. 2. Carol and Cliff Bannon of Climax Metal Products. 3. Steve Varano and Mike Catania of Leeson Electric/Grove Gear. 4. Mitch Bouchard, General Bearing Service, was elected president of the PTDA for 2012. 5. Brian and Karen Short of Kaydon Corporation. 6. Marco De Maria of the Shaeffler Group displayed bearing products from INA, FAG and Barden at the Motion Control Showcase. 7. Kelly Barker of Commercial Solutions and Tom Karch of SKF Canada, with Ken Yamasaki and Mitch Bouchard of General Bearing Service. 8. Loren Kamstra, Jennifer Dorhout and Ed Tullar of Groschopp Inc. 9. David Zoesch of Shaeffler Group USA and

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Wayne Law of Motion Industries. 10. John and Debbie Miles, RotoPrecision Inc. 11. Eric Klein of Lenze-AC Tech demonstrated products during the Motion Control Showcase.

12. Terry Bell of Baldor Electric showed a demo application at the Motion Control Showcase. 13. Keynote speaker Alan Beaulieu of the Institute for Trend Research predicted growth in industrial markets over the next couple of years. 14. Kevin Powers of US Tsubaki Power Transmission, Keith Nowak of MPT Drives and Jeff Lindsay of Torque Drives.

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We see less downtime in your future.

At NTN, we are dedicated to help you get the most out of your rotating machinery.

Our people contribute to this vision every day.

Invite us to roll up our sleeves with you.

Online Reader Inquiry No. 139

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UNMATCHED ENGINEERING EXCELLENCE FROM THE SCHAEFFLER GROUP Spherical Roller Bearings T41D Vibrating screens for grading material and other machinery where vibration stress exists are among the most severe bearing conditions encountered in machinery construction. For a number of years Schaeffler has offered special design FAG E1 spherical roller bearing with specification T41A to accommodate the punishing operating conditions found in vibrating machinery such as: • high loads and high speeds • high radial accelerations • revolving shaft deflections • sliding motion within the bearing In order to prevent fretting corrosion between the bearing bore and the shaft, Schaeffler now offers the same series and design of spherical roller bearings with a thin-layer chromium plated bore (specification T41D). This coating ensures that the displacement ability (floating bearing function) between the bearing and the shaft – necessary

due to thermal influences - is maintained for a long period of operation.

With the addition of thin-layer chromium plating, FAG spherical roller bearings for vibrating screens offer unparalleled operating benefits: • highest load carrying capacity • supports heavy shock loads and radial acceleration • no fretting corrosion • unhindered thermal shaft expansion • prevention of shaft damage • longer service life

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Hydraulic Extractors PowerPull SPIDER Hydraulic extractors PowerPull SPIDER are used where higher extraction forces are required that preclude the use of standard mechanical methods and devices. The 10 available extractor sizes have a range of extraction forces from 40 to 400 kN, covering a very wide range of possible applications.

These devices allow rolling bearings, gears, sleeves and many other shrink fitted parts to be quickly and easily dismounted. In addition, the light weight of the extractors mean that they can be used in virtually any position.

Through Rock-Solid Obstacles The combined technologies of INA and FAG offer the broadest possible range of bearing solutions to guide mining and processing machinery and equipment through the most demanding operating conditions.

From standard bearing products to highly specialized application solutions, including monitoring and maintenance services, INA and FAG commit decades of innovation to optimizing the performance of boring and excavation machinery, hoisting and conveying equipment, grinding mills and vibrating screens.

Operational reliability and cost-effective innovation from INA and FAG – bearing solutions that move the earth.

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If necessary, greater grip depth can be achieved through the use of extra long extraction arms (available integrally if specified, or separately as accessories).

For protection of operators, the extractors SPIDER 40 to 80 have a safety grid. All larger hydraulic extractors are supplied with a transparent, tough safety cover to capture any parts that may fly off under extreme load. All parts under load are made from high quality chromiummolybdenum steel, and an integral pressure control valve prevents overload of the extractor.

For additional information about spherical roller bearings T41D or hydraulic pullers, contact your local Schaeffler representative.

Online Reader Inquiry No. 142

Online Reader Inquiry No. 141

www.schaeffler.us

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