Machinery & Equipment MRO September 2012

MACHINERY AND EQUIPMENT

Rehabilitating old pumps Reducing bearing contamination Time management for maintainers

Vol. 28, No. 4

SEPTEMBER 2012

Profile: 100-year-old firm makes custom tools for maintenance Reports from PTDA Victoria, IDI Vancouver & MMTS Montreal

Rehabilitating old pumps Reducing bearing contamination Time management for maintainers Profile: 100-year-old firm makes custom tools for maintenance Reports from PTDA Victoria, IDI Vancouver & MMTS Montreal

WRENCH TIME Mail Agreement #40069240

Maintaining conveyors in harsh environments

WHAT’S NEW p01 Septl12 MRO CoverREV.indd 1

BEARINGS

PUMPS

CASTERS

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P R O D U C T

SP TLIGHT

Machinery & Equipment MRO

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Spherical roller bearing housed unit is built for rugged long life

Lubricant keeps equipment running in adverse conditions

Lubtect lubricant from the Schaeffler Group provides a reliable supply of lubri-

car steering systems.

Schaeffler Group Industrial Online Reader Inquiry No. 429

Sealing extends life of four-row bearings

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Online Reader Inquiry No. 444

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Timken Blue Brute spherical roller bearing housed units feature housings made of cast steel for durability in virtually any application. Feet ends are machined to the true bore of the housing to help with proper alignment. Six types of primary seals provide the right protection for the particular application, and steel or urethane covers offer secondary seal protection against dirt, dust or high-pressure washdown. Locking mechanism options include standard locking configurations: set screw or eccentric lock collar, or double nut V-lock.

Timken Canada

cant even under critical operating conditions such as swivel movements, low to medium speeds, high loads, and low temperatures. The compound, which essentially comprises a polymer and a lubricant, fills the cavities in the rolling bearing and forms a rigid, porous matrix structure. Due to the permanently uniform distribution of the compound, it is also suitable where bearings undergo external accelerations or where multi-row bearings are fitted in a vertical arrangement. The lubricant can be used for ball, needle roller, spherical roller, tapered roller and cylindrical roller bearings in textile machines. Further applications include truck steering knuckle bearing supports, conveying equipment, woodworking and agricultural machinery, as well as passenger

September 2012

Sealed Type Four-Row tapered roller bearings from Koyo reduce grease usage and contamination in harsh environments, such as in steel mills. The bearings are designed for the work rolls and intermediate roll necks of rolling mills. The Sealed Type Four Row tapered roller bearings extend bearing life and the time between overhauls, and cleaning intervals, by reducing the ability of contaminants to enter the bearings. In addition to reducing overall grease usage, these sealed bearings provide environmental and safety benefits to the workplace.

Koyo Canada Online Reader Inquiry No. 419

The Sign of Quality

Oversize caster is designed to move extremely heavy loads

The Ultra Maxi-Duty (UMD) caster from Hamilton Caster has a load rating up to 40,000 lb per caster. Moving colossal loads that formerly required six or eight casters can now be accomplished with four, simplifying designs and lowering maintenance costs. The series targets heavy equipment and aerospace manufacturers, defence contractors and ship builders. The mounting plate is 14 in. by 14 in. and 1 in. thick.

The main load bearing assembly has two precision thrust bearings for smooth swivelling: one is 13 in. in diameter with a 234,000-lb load rating; the other is 7 in. in diameter and is rated at 100,000 lb. A third, 1-1/2-in. four-point contact bearing completes the assembly.

Hamilton Caster & Mfg. Co. Online Reader Inquiry No. 466

Heat shrink protects irregularly shaped objects

Parker TexLoc PTFE 4:1 heat shrink tubing features a large expansion ratio for superior protection of instruments, cables and other objects from heat, abrasion and chemical hazards in harsh environments.

Operating in temperatures up to 260°C (500°F), the tubing slips easily over objects with protrusions or irregular shapes, yet still provides a snug fit. In addition, the thin wall promotes quick installations while keeping the tubing flexible. It may also be used to repair electrical wiring, fittings, cord, etc.

The product meets specification AMSDTL 23053/12, Class 2 and is supplied in 4-ft lengths. Sizes range from 2 mm (0.078 in.) expanded, up to 31 mm (1-1/4 in.) expanded. Custom sizes, long lengths, colours and samples also are available.

Parker Hannifin Online Reader Inquiry No. 441

Workboot keeps feet dry, comfortable and safe from shocks For almost 100 years, Baldor•Reliance® has developed a reputation for designing and manufacturing the highest quality industrial electric motors available.

Beneath the nameplate of every Baldor•Reliance motor, you will find the best industrial electric motor you can buy.

When reliability counts, accept nothing less than the Sign of Quality from Baldor•Reliance.

• Unmatched Quality • Superior Reliability • Quickest Delivery Available

baldor.com

©2012 Baldor Electric Company

Online Reader Inquiry No. 115

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• Energy Efficient

The Timberland P ro Hy per ion premium hiker boot features an upper built with premium fabric and leather and a waterproof membrane for extreme abrasion resistance and dry feet. The boot also features a mesh lining with Agion antimicrobial treatment for odour control and comfortable feet, as well as a Vibram outsole for durability and traction. A heat-resistant and durable rubber compound offers good slip-, abrasion- and oil-resistance, while Anti-Fatigue technology absorbs shock and returns energy at key zones of the foot to deliver long-lasting, all-day comfort. The workboot with electrical hazard protection meets ANSI Z41PT99, AS F2412-05 and F2413-05 standards to provide protection from open circuits.

Timberland Online Reader Inquiry No. 462

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C O N T E N T S

Machinery & Equipment MRO

September 2012

in this issue Extending pump reliability / 13

Optimizing pump performance with bearing, lubrication and surveillance technologies.

Rehabilitating old pumps / 16

A full-scale pump refurbishment can work wonders and even improve performance.

Selecting bearings for food processing / 18

Meeting environmental challenges to ensure reliability.

p16

Switching from belt drives to gearmotors / 27

departments

Direct drives retrofitted on busy aggregates conveyors reduce maintenance in these harsh weather and environmental conditions.

Editor’s Notebook / 6

MRO on the Road / 37-38

Mr. O, The Problem Solver / 10

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Reports from PTDA’s Canadian Conference in Victoria, the IDI Independent Distributors Inc. annual meeting in Vancouver, and the MMTS show and conference in Montreal.

columns

Industry Events / 12 The Safety File / 28 Supervisory Suggestions / 29

MRO on the Road / 37-38 Product News

What should you do when a Ministry of Labour inspector gives you a Stop Work order?

Product Spotlight / 2

Supervisory Suggestions: Time management tips for maintainers / 29

Environments / 31

These five easy suggestions can help you save time when ordering products.

Wheels / 32

Maintenance 101: Monitoring machinery trends / 30

Stage 5 in an 8-part program: Using condition-based maintenance to cut costs, save time and minimize downtime.

How sealed bearings reduce contamination and grease consumption.

Profile: Gray Tools / 21

Business Briefs / 9

Maintenance 101 / 30

The Safety File: Working on unguarded machinery / 28

The three-barrier solution for bearings / 20

Industry Newswatch / 8

Focus on Harsh Focus on Casters & Focus on Pumps / 33 Focus on Bearings / 34

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100-year-old Canadian company makes custom tools for maintenance that can reduce costs and improve safety.

How oil monitoring helps with hydraulic fluid / 22

editor’s selections

Severe-service conditions and workload stress both affect how well hydraulic fluids protect equipment.

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34% of bearings fail due to contamination, so the use of an appropriate sealing solution is of great importance.

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John Melanson / 20

p35 Cover story: Maintaining conveyors in harsh environments / 24

Here are 14 practical tips for troubleshooting conveyors and preventing critical catastrophes.

Paul Michalicka / 12

Beverage industry conveyor pours on advantages / 26

Motion Canada’s new distribution centres in Montreal and Edmonton have lowered the noise, reduced the maintenance and improved the safety of their conveyors.

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16% of bearings fail because they are whacked directly, 36% fail when equipment is coupled together, and 33% fail prematurely because the wrong grease, or too much grease, is applied.

Cover Illustration by Rui Ramalheiro

Companies often report productivity gains of 3-5% after equipment has been retrofitted for safety.

Simon Fridlyand / 28

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Online Reader Inquiry No. 117

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E D I T O R’ S

N O T E B O O K

Machinery & Equipment MRO

September 2012

Giving back

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t’s been a while since we’ve crossed your desk – our previous issue was June – and so much has happened since then.

Unfortunately, we couldn’t pack all the best relevant news into this issue (but if you’ve subscribed to our weekly e-newsletter or checked out our website regularly, you’ll be fairly up-to-date).

As you might expect, we’ve attended several industry meetings, conferences, trade shows and conventions since our last issue – you’ll read about a few inside. Those meetings got me thinking about how much industry supports good charitable works across the country.

This thought was specifically triggered by the cheques donated to cancer research at the IDI Independent Distrib-

utors Inc. annual meeting in Vancouver (see page 37), the 5K walk taken by spouses of delegates at the Power Transmission Distributors Association Canadian Conference in Victoria (see page 8) and, significantly, the frenzied fundraising activities of representatives of the industry’s distributors and manufacturers, who call themselves the Shaker’s and Maker’s (their apostrophes, not mine).

The Shakers are the industrial distributors and the Makers are the industry’s various power transmission and bearing manufacturers. The group has been around since 2009, and they like to do fun – and good – stuff together.

This year’s activities included dressing

up in drag to attract attention to their fundraising efforts during the PTDA event’s welcome reception. Their costumes – like their senses of humour – were exceptional.

The following weekend – some still jetlagged from redeye flights back to Ontario from Victoria — eight of them were off riding in the two-day, Toronto to Niagara, 2012 Enbridge Ride to Conquer Cancer benefitting The Campbell Family Institute at The Princess Margaret.

No easy task, that – the ride totalled 220 km. But the reward was great. Among individual donations and support from PTDA members and others in the industry, the Shaker’s and Maker’s raised over $46,000! Truly impressive, and every one on that team deserves kudos.

They want to make it bigger next year, so we’ll be providing details and dates in upcoming issues so you can get involved too.

You’d think one event was enough, yet

a whole bunch more Shaker’s and Maker’s got together near the end of August for a fundraising golf tournament in south-eastern Ontario, again with more money going to their Charity Fund.

Don’t these guys ever stop?

My point in telling you these stories is to encourage you, no matter what your job or your position, whether you’re a ‘shaker’ or a ‘maker’ or shop-floor maintainer, to get involved with your own favourite charities. Fun events with colleagues and friends might only raise a few dollars, but every little bit of funding helps those many good causes. And look what can happen when big groups pull together.

Participants in programs like these will tell you that giving back to your community, to your world, does wonders in making you feel good. There are many fundraising events across the country. You’re encouraged to find one and jump on board.

Bill Roebuck, Editor & Associate Publisher

MACHINERY AND EQUIPMENT

MAINTENANCE, REPAIR AND OPERATIONS

SEPTEMBER 2012 Volume 28, No. 4 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

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

BUSINESS 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.

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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. ©2012. 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.

Making bearings since 1921.

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I N D U S T R Y

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Machinery & Equipment MRO

September 2012

Global demand for bearings to reach $96 billion in 2016 Cleveland, OH — Global demand for bearings is projected to grow 7.8% annually to $96 billion in 2016. Unmounted ball bearings will remain the best-selling type of bearing in 2016, followed closely by unmounted roller bearings. Unmounted roller bearings will experience the fastest sales gains in the 2011-2016 period.

CANADA FALLS TO 14TH IN GLOBAL COMPETITIVENESS Ottawa, ON – Canada fell two positions to 14th place in the Global Competitiveness Index 2012-2013, released in September by the World Economic Forum (WEF).

The Conference Board is the Canadian Partner Institute at the WEF’s Centre for

WORLD BEARING DEMAND Millions of Dollars

% Annual Growth

Item

2006

2011

2016

2006-2011

2011-2016

North America

10390

11750

15150

2.5

5.2

Western Europe

11581

13000

15450

2.3

3.5

Asia/Pacific

17721

33050

53500

13.3

10.1

Other Regions

5301

8100

11700

8.8

7.6

44993

65900

95800

7.9

7.8

Total Bearing Demand © 2012 by The Freedonia Group Inc.

The machinery and motor vehicle markets accounted for over 70% of all bearing demand in 2011. However, sales of bearings used in aerospace and other markets will rise faster, boosted by increased output of aircraft, rail equipment, motorcycles, electronic devices and medical equipment in developing nations, as well as by more moderate gains in these same markets in the rest of the world. These and other trends are presented in World Bearings, a new study from The Freedonia Group, an industry market research firm.

The Asia/Pacific region will post the fastest gains of any region between 2011 and 2016 — climbing an average of 10% per year to $54 billion in bearing sales and accounting for more than half of the world total. Demand in China will rise fastest among the major markets in the region, stimulated by rapidly expanding motor vehicle and machinery production, combined with a strong aftermarket in industrial equipment and motor vehicle repair. In 2016, bearing sales to customers in China will account for one-third of the world total, and by 2021 the market will exceed those in North America and Western Europe combined.

Demand for bearings in Japan, the nations of Western Europe, and the US — the largest mature markets — will expand faster than it did during the 20062011 period. In most of these countries, manufacturing activity — especially motor vehicle output — plummeted between 2007 and 2009, before strengthening in 2010 and 2011. Bearing demand followed the same pattern, falling between 2007 and 2009 before turning upward in 2010 and 2011. As manufacturing output continues to recover, gains in bearing demand will be well above those posted during the 2001-2011 period, due partially to the modest levels of sales in 2011.

Growing needs for industrial products and a variety of durable goods in the developing world will aid in the rapid acceleration of bearing sales to original equipment manufacturers operating in Japan, North America and Western Europe.

World Bearings (published 07/2012, 452 pages) is available for US$6,300 from www.freedoniagroup.com.

Global Competitiveness and Performance, and managed the Executive Opinion survey to obtain the candid perceptions of Canadian business leaders.

“Canada is a developed economy and it is at a stage where its capacity to innovate successfully determines its overall success. Canadian businesses must be able to compete on the basis of developing new or improved products, services, models and processes,” said Daniel Muzyka, president and chief executive officer, The Conference Board of Canada.

“Unfortunately, as a country, we are not taking full advantage of our strong economic fundamentals, well-educated workforce and efficient markets to build higher-value-added products and services. Too often, Canada fails to commercialize its good ideas into marketable products and services or capture the value from growth,” said Muzyka.

“More needs to be done — all levels of government, all sizes of business, and all types of educational institutions have an important role to play.”

MULTI-TRADE AND TECHNOLOGY EVENT PUTS SPOTLIGHT ON STUDENTS AND APPRENTICES Ottawa, ON — Skills Canada, a not-forprofit organization that actively promotes careers in skilled trades and technologies, has announced that the United Association of Journeymen and Apprentices of the Plumbing and Pipefitting Industry (UA Canada) has signed on as a Presenting Sponsor of the next three Skills Canada National Competitions.

UA Canada is a multi-craft union whose members are engaged in the fabrication, installation and servicing of piping systems.

“As Skills/Compétences Canada prepares to host the Skills Canada National Competition in Vancouver next year, it welcomes the generous support of UA Canada,” said Shaun Thorson, CEO of the organization.

Industries that depend on skilled trade workers are key drivers of the Canadian economy and contribute over 50% of Canada’s GDP — or over $550 billion, according to Statistics Canada, which also reports

that 24% of Canadian employers are unable to find the right skilled trades talent.

“Events such as our National Competition play such an important role in bringing talent and industry together,” said Thorson.

The 2013 Skills Canada National Competition will take place June 5-8, 2013, in Vancouver. The event brings more than 500 competitors, representing over 40 trades from all provinces and territories, to compete in Canada’s only national, multi-trade and technology event of its kind for young skilled trade and technology students and apprentices.

The event also attracts school groups and young career-seekers who can take part in interactive Try-a-Trade and Technology activities, as well as employers and recruiters, industry associations, labour groups, training institutes and government agencies.

For more information on the next Skills Canada National Competition, visit www.skillscanada.com or call 877754-5226.

INDUSTRY RAISES OVER $46,000 FOR CANCER Victoria, BC — The ‘Shaker’s & Maker’s’, a dynamic group of industry veterans, spiced things up at the welcome reception of the Canadian Conference of the Power Transmission Distributors Association in Victoria in June by cross-dressing on a dare to raise money for The 2012 Enbridge Ride to

tributor and a Maker a manufacturer.)

Also during the PTDA Canadian Conference, spouses of several delegates participated in a 5K walk around the grounds of Victoria’s Beacon Hill Park, with $25 of the spouse/companion registration fee being donated to The Campbell Family Institute cancer research centre.

ICP JOB BOARD LINKS YOUNG PEOPLE WITH INDUSTRIAL WORK Chicago, IL – The Industrial Careers Pathway (ICP) initiative has launched an online job board designed to connect young people looking for career jobs with industrial distributors and manufacturers looking for those same bright people to fill open positions.

The ICP Job Board is located at http:// jobs.idcareers.org and is also available through the Jobs tab at the ICP website, www.industrialcareerspathway.org.

Because wages for wholesale distributor and manufacturing sales reps rank very high for positions that do not require college degrees, industrial distribution careers can be an attractive place for thousands of individuals to work and earn a good living. Jobs for those with technical school and community college, as well as four-year college degrees, are available.

Employers can post open positions to the ICP Job Board at http://jobs.idcareers.org.

PTDA BUSINESS INDEX INDICATES CONTINUED EXPANSION Chicago, IL — The PTDA Business Index indicated the second quarter of 2012 was the ninth consecutive quarter for business growth among Power Transmission Distributors Association members, with a reading of 54.2.

Compared with a reading of 75.4 for the first quarter of 2012, the recently released second-quarter results indicate the

M M

Top: Shaker’s and Maker’s riders (left to right) included Evan Boere of Timken Canada, Sergio Restagno of Canadian Bearings, Francisco Lourenco of Wajax, Brian Burton of Jason Industrial, Jos Sueters of Tsubacki Canada, Paul Meo of NTN Canada (team captain), Shawn McQuire of Tsubacki Canada, and Rod Stelmack of Canadian Bearings. Bottom: A total of 17 women participated in a 5K walk to raise funds for cancer research during the PTDA Canadian Conference in Victoria, BC.

Conquer Cancer benefiting The Campbell Family Institute at The Princess Margaret.

Their fundraising efforts helped the group raise a total of $46,406 (far exceeding their original goal of $25,300). Following the conference, eight riders from the power transmission and bearing industry travelled more than 220 km over two days in an event that raised a total of $18.1 million from almost 5,000 participants.

“It was truly amazing to watch so many people doing the right thing for such a great cause,” said Evan Boere of Timken Canada. “Now that the saddle sores have healed, we look forward to doing it again next year, perhaps with more riders joining the Shaker’s & Maker’s team.” (A Shaker represents a dis-

power transmission/motion control industry is still expanding but at a slower pace than before. Both distributors and manufacturers reported decelerated sales growth in 2Q12.

PTDA members participating in the Business Index expect 2012 to be another year of sales growth with an average forecast of 8%, down from 11% in the first quarter 2012 survey.

T he f ull repor t is ava ilable at www.ptda.org/businessindex. It includes US and Canadian breakout data in addition to historical data.

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

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September 2012

Machinery & Equipment MRO

Business Briefs

Association (PTDA) welcomed a new manufacturer member in the second quarter of 2012. Krown Corporate of Schomberg, ON, manufactures industriNews and views about companies, people, product lines and more. al lubricants, cleaners and coatings for the manufacturing, mining, marine, • Renold Canada, Brantford, ON, a Spungen will join the company as presifood processing, pulp and paper, and raw supplier of precision roller and engineerdent, effective Oct. 1, 2012. Spungen will steel sectors, including a line of ecoing chain and power transmission prodmanage all facets of operations friendly products. ucts, has made the following appointand oversee the expansion of • Acklands-Grainger Inc., ments: Jorge Casallas is district sales the third-generation family Richmond Hill, ON, opened a new manager in Quebec; Darrell Tetreault business. Spungen held leaderdistribution centre in Saskatoon, has the dual role of Western Canada reship roles at a related family SK, in May 2012. The new 122,000 gional sales manager and district sales company, Peer Bearing, for 27 sq-ft facility in Saskatoon, which manager over Saskatchewan, Manitoba years. When the Spungen famemploys 90, includes a 102,000 and Northern Ontario; and Pat O’Connell ily sold the bearing arm in 2008 sq-ft warehouse, along with a is district sales manager in British Coto SKF in Sweden, the compabranch showroom and regional Peer Chain’s lumbia and Alberta. ny had over 1,400 employees. support centre.

Glenn Spungen.

• Ameridrives Couplings and TB • Advantage Sales Network • In other Acklands-Grainger Wood’s, suppliers of industrial coupling Inc. (ASN), Brampton, ON, is news, the distributor appointed technologies, have received ISO 9001:2008 now the sole sales agency representative John Kaul as vice-president and general manager, Western Canada, where he is Certification for Quality Management at for Hitachi Chain for all of Canada and responsible for branch sales and operatheir facilities in Erie, PA, and San MarMexico. For Canadian sales, ASN is retions in British Columbia, Alberta, Sascos, TX. The audit was completed by Unporting to Chuck Briere, Hitachi Maxco katchewan and Manitoba. As well, derwriter’s Laboratories. The Certificate of Ltd.’s national sales manager for Canada.

George McClean has been appointed viceRegistration issued to the Erie and San As of September 2012, ASN will be shippresident and general manager, Eastern Marcos facilities states that they comply ping Hitachi products from its Edmonton, with the requirements of ISO 9001:2008 AB, and Brampton, ON, warehouses.

Canada, and is responsible for branch in the design, manufacture, contract main• In other news from ASN, Dings Comsales and operations in Ontario, Quebec tenance and service of flexible and rigid pany (aka Dings Brakes) has entered and Atlantic Canada. couplings and other related mechanical into a partnership with the rep house to • As well, Acklands-Grainger recentpower transmission devices including unimarket its direct-acting spring set brakes ly launched new and improved features versal joints. The certification also includes in Canada. The Milwaukee, WI, company to its website designed to help customthe distribution and repackaging of kits is a manufacturer of brakes that typically ers navigate to products and solutions (including seals, gaskets and fasteners) attach to motors to stop and hold a load. more quickly and efficiently. Specific used on flexible and rigid couplings. Both Dings has been manufacturing directfeatures include improved ordering companies are owned by Altra Industrial acting spring-set brakes since 1953. Its functionality and enhanced search (the Motion, Braintree, MA. unique design uses a small air gap that product tab now includes over 200 sub• Peer Chain Company, Waukegan, IL, engages the brake, which eliminates categories). To view the site, visit www. a provider of industrial chains and atlinkages and wear points. acklandsgrainger.com. tachments, has announced that Glenn • The Power Transmission Distributors • On Aug. 29, 2012, Siemens celebrated

White paper now online Want to know what it takes to be an Ultrasonic Power User? Power users have a knack for getting the most out of ultrasound technology.

Download the Power User Profiles white paper by Allan Rienstra of SDT Ultrasound Solutions and learn the fast track to an effective ultrasound program. Look for the link to the white paper on the home page at www.mromagazine.com.

its 100th anniversary in Canada, and also marked the inauguration of its new 110,000-sq-ft headquarters facility in Oakville, ON. The subsidiary of German engineering conglomerate Siemens AG started its operations in Canada at the beginning of the 20th century out of a small office in Toronto. The company now employs a total of 4,400 in Canada in 74 locations, including 13 manufacturing and assembly facilities across the country. Sales for Siemens in Canada for fiscal 2010 were $2.3 billion.

• Siemens Canada officially welcomed Prairie West Technical Services into its family in May 2012, hosting an open house at the newly acquired company’s Regina, SK, head office. Prairie West is an electrical service organization specializing in engineering solutions for the utility, industrial, commercial and institutional electrical markets. continued on page 10

MAXIMUM SPEED. MAXIMUM LIFE. MAXIMUM PERFORMANCE.

ANGULAR CONTACT BALL BEARINGS. NSK angular contact ball bearings are designed for the rigorous demands of pump and compressor applications. Our innovative products feature optimized internal geometry to promote increased load ratings and limiting speeds as well as advanced cage design to improve strength and lubricant distribution. High dimensional and running accuracies ensure stable, smooth and energy-efficient operation. For maximum speed, performance and extended bearing life, Think NSK.

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Machinery & Equipment MRO

continued from page 9 • The Timken Company has appointed new leaders within its Bearings and Power Transmission group, reporting to Christopher A. Coughlin, group presi-

Timken’s John Beam, Richard Boyer and Hans Landin (l-r).

dent: John W. Beam is now vice-president for supply chain, Richard M. Boyer is now vice-president of manufacturing, and Hans Landin is vice-president of business advancement.

• Magneto Electric, Mississauga, ON, a provider of electro-mechanical sales and service, has added a new offering to its list of services. It now has six fully trained confined-space technicians to provide installation and repair for equipment in confined and hazardous areas.

“This new certification is about serving our customers better,” says Mike Vassallo, Magneto-Electric president and general manager. “And [it’s] about keeping our employees safe and at the leading edge of their trade.”

• With the anticipated retirement of more than 80 million Baby Boomers over the next 20 years and only 43 million younger workers in line to replace them, the time is fast approaching when recruiting talented individuals will once again be a serious challenge for every business. For the power transmission/ motion control industry, the problem is even more profound as it endures a lack of recognition among young people — as well as a well-publicized skills gap. The Industrial Careers Pathway (ICP) initiative — founded and significantly funded by the Power Transmission Distributors Association’s PTDA Foundation — is taking major steps to ensure the workforce is aware of the satisfying and rewarding careers available in industrial distribution. To help, Bison Gear and Engineering, St. Charles, IL, has

September 2012

stepped up by making a contribution to fund the initiative’s activities in 2012.

ICP is a collaboration of industrial distribution associations working together to bring tomorrow’s North American employees to the industrial distribution channel, develop programs to teach business and distribution basics and create affordable resources for current employee development. For more information or a complete list of donors, visit www.industrialcareerspathway.org.

• Reliable Controls, Victoria, BC, has promoted Chris Gleason to vice-president, sales and marketing, Americas. For the past decade he has had the responsibility of regional sales manager for Eastern USA, providing sales support and distribution development for some 30 Reliable Controls authorized dealers in the region.

• Schneider Electric, Mississauga, ON, has identified a potential non-conformance issue with the bus mounting hardware used with its Square D Masterpact NW Circuit Breakers (800 Amp to 6300 Amp) assembled in North America. This also applies to equipment using these circuit breakers, such as PZ-4, QED-6, QED-2, QEDS, and Model 6 MCC. These circuit breakers may have a non-conforming washer on primary terminal mounting screws. If the washer is non-conforming, there is a risk of low clamp force between the terminal and the breaker/cradle that can result in overheating at the loose connection. The manufacturing periods from March 1, 2012 through June 12, 2012 (Date Codes 12094-12242 inclusive) are the root cause of the potential problem.

Users should contact Schneider Electric Services, Product Support Services, at 1-800-634-8730 or 704-571-6020 with any questions. Refer to Project RC103 when calling. Complete de-energization of the circuit breaker/equipment will be required to update the Masterpact circuit breakers.

Since there is no way to visually inspect the product for the non-conformance, if the circuit breaker is energized, it is recommended that you use thermal scans to check for overheating at the buss connections to the cradle or back of the circuit breaker. Minimize loading as much as possible and monitor the circuit breaker and equipment for overheating until such

time as the equipment can be repaired.

• Tsubakimoto Chain Co., Osaka, Japan (known as Tsubaki), a manufacturer and developer of power transmission products, will acquire Cleveland-based Mayfran International and its affiliated subsidiaries, together forming the world’s largest firm in its market segment. Founded in Cleveland in 1933 as a general industrial engineering firm, Mayfran is a provider of engineered solutions for scrap and coolant management, and material handling systems, for metalworking, recycling, solid waste processing and other applications.

• Miller Electric Mfg. Co., Appleton, WI, has announced the results of live online voting at millerwelds.com for its ‘Nominate a Hero’ promotion. After more than 11,000 online votes were cast, three welders have been voted winners as the everyday welding heroes in the campaign. The winners are: 1) Kay Minto, who has been TIG welding for 28 years.

She is a 70-year-old grandmother living in Eagleville, CA, who finds time to create internationally shown welded art.

2) Carl Offenbacher, who is working with a contractor in Afghanistan assisting with the US military fleet, keeping the armed vehicles safe and on the road with Force Protection. 3) Steven George, who quit his corporate job to move to Fairbanks, AK, to become a welder. He has made a name for himself as a meticulous and quality-conscious welder.

Of course, being a Canadian publication, we were hoping the single Canadian contender would be among the top vote recipients. Joey Gyetvan of Bridgenorth, ON, an instructor at the Canadian Welding Skills College, was nominated because he inspires many welders on a daily basis with his passion and enthusiasm for the craft.

The three winning welders and their nominators will be treated to a Hero’s event at the Miller headquarters in Appleton in September 2012 and receive prize packages of welding equipment and the latest in Miller Arc Armor safety gear. Watch videos from their visit at www.millerwelds.com/hero.

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

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ROMA AD_1/4 VERT PG_3.375 X 4.875 Online Reader Inquiry No. 122

Mr.0 The Practical Problem Solver

Repairing a loose bearing fit on site Problem: One of the things I often saw when I was chief engineer at SKF was the loss of fit between the bearing bore and the shaft or bearing OD and the housing. In spite of a number of noble attempts, there really wasn’t a good way to repair the housing or the shaft. About a year ago, I came across a product line that has continually impressed me and one product in particular that is suitable for bearing seat repair.

Solution: DurAlloy can be used for repairing bearing damage to shafts and housings. The ceramic/polymer Shaft before treatment.

Shaft after treatment.

composite paste is merely applied to the shaft or housing, allowed to cure and then machined to the original OEM specifications.

DurAlloy cures to a hardness of Shore D86 with excellent machinability and no loss of uniformity at the metal-to-composite transitions.

Bearings can be pressed or heatshrunk on according to your normal maintenance practice. Quick and safe, DurAlloy requires no special tooling is non-toxic, non-flammable and has no odour to contend with.

The ‘cold’ repair can even be done with the shaft in place and you needn’t confine yourself to housings and shafts. DurAlloy is a multi-purpose product that will repair almost any metallic surface, from sloppy keyways to scored rams and damaged castings. It can even be drilled and tapped.

Thanks for this tip go to Jeff Malilnowski, P.Eng., MBA, previous general manager of Koyo Canada and former chief engineer at SKF Canada.

He now operates his own company, Strategic Industrial Technology Inc. He can be reached at 519-221-3784 or by e-mail at jeff@strategictech.ca.

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, 12 Concorde Place, Suite 800, Toronto, ON M3C 4J2.

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Machinery & Equipment MRO

September 2012

SKF event dispenses wealth of technical knowledge

BY BILL ROEBUCK

T

he latest information about bearings and condition monitoring tools was among the highlights of topics discussed at SKF’s Technical Press Day, held in Philadelphia in June 2012 and to which Machinery & Equipment MRO was invited.

The event was hosted by Paul Jeppesen, president and CEO of SKF North America, and featured Jon Stevens, vicepresident of solution factories, SKF North America; Matt McCormack, an application engineer at SKF USA; and Canada’s Paul Michalicka, head of Maintenance Products, North America. They discussed SKF’s BeyondZero environmental impact reduction program, the

company’s Solution Factories around the world, recent advancements at the company globally and specifically in the bearing industry, and the best ways to solve machinery maintenance problems.

Of course, we were most interested in sharing SKF’s knowledge in machinery maintenance. “Your maintenance methods may be causing more trouble than you know,” said Michalicka. He opened his presentation by describing the evolution of plant maintenance.

First, there’s ‘run to failure’. “Not repairing machinery until it fails can lead to expensive secondary damage, unplanned downtime and high maintenance costs,” Michalicka noted. Next is

preventive maintenance. “Overhauling machinery regardless of its condition causes excessive downtime and high maintenance costs due to needless repairs and part exchanges,” he said. Then there’s predictive maintenance. “Monitoring the condition of machinery in operation prevents failures and allows repairs to be scheduled and completed costeffectively, only when required.”

Michalicka then covered examples of predictive maintenance technologies.

“Shaft alignment should be done quickly and accurately,” he said, as a mediumsized factory does at least two alignments per month. “Lasers make aligning belts and shafts a flash,” he says, so laser alignment devices are a good choice.

He also recommended the use of a belt frequency meter, because setting the proper belt tension in any belt-driven system reduces energy consumption by optimizing transmission, reduces slip and therefore the noise/comfort complaints of

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Photo: Bill Roebuck

12

Jon Stevens is flanked by Paul Michalicka (left) and Matt McCormack.

users, reduces downtime by minimizing maintenance interventions, and lowers operating costs by extending the life of belts, pulleys and bearings. “A good belt tension will bring you better long-term value for your system and provide improved performance of the whole system by optimizing transmission,” he said.

Because a medium-sized factory has thousands of bearings, the mounting of bearings presents the opportunity for poor maintenance practices, Michalicka said, noting that 16% of bearings fail because they are whacked directly. He added that up to 36% of bearings fail when equipment is coupled together, and that 33% of premature bearing failures are because the wrong grease is used or too much is applied.

Michalicka recommended the use of an induction heater for mounting bearings. “It’s torch me now and pay me later,” he said. “By the time your coffee break is done, the bearing is heated. It also helps save on energy bills.”

Michalicka went on to describe a range of basic condition monitoring hand-held tools that assess temperature, speed, noise and vibration, and detect preventable failures before they occur.

“Thermal imagers bring safety in your day-to-day maintenance work, checking temperatures on any machinery and electrical cabinets without any contact. They also help in identifying heat/cold losses in all types of conducts and insulations, extend equipment life by creating efficient preventive maintenance, reduce operating costs and cut downtime.”

“Thermopens and thermolasers give you a quick temperature indication with or without contact. They instantly help in doing a first diagnosis to identify abnormal temperatures on your critical machinery so you know when to take preventive actions.”

Ultrasonic leak detection is a simple and economical way to identify wastes on fluid conducts, Michalicka added. “It helps in identifying any leakage on refrigerant conducts, gas conducts or air conducts, reduces operating costs when all identified leaks are fixed, improves the efficiency of the whole system, and helps reduce energy usage.”

Visual inspection of any conduct or system that can’t be seen without dismounting is a precious gain of time. Periodic inspections using a video endoscope help extend equipment life, reduce downtime and operating costs, bring better long-term value to a system, improve the performance of the whole system, and improve indoor air quality, he said Michalicka also advised the use of SKF’s Machine Condition Advisor, which detects vibration. “A proper vibration diagnosis helps adjust equipment properly, extends equipment life, reduces downtime by optimizing maintenance interventions, reduces noise/comfort complaints of users, and brings better longMRO term value to the system .

Bill Roebuck is the editor and associate publisher of Machinery & Equipment MRO.

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How design and maintenance can extend pump reliability OPTIMIZING PUMP PERFORMANCE BY APPLYING ADVANCED BEARING ENGINEERING, LUBRICATION AND SURVEILLANCE TECHNOLOGIES.

BY DANIEL THALMANN

I Photos: NKE Austria GmbH

n the general machinery industry, including fluid technology such as pumps, there is a basic requirement of increasing performance and efficiency. That pressure also demands an upgrading and improvement of existing machinery designs, such as pumps, in order to enhance performance and – of equal importance – to cut down on maintenance costs and service efforts.

Bearings are one of the key components in every pump. In larger pumps, rolling element bearing performance may – along

• adequate dimensional and geometric accuracy of adjacent parts • adequate sealing of the bearing arrangement • efficient and effective lubrication, including suitable heat dissipation.

Tips for new pump designs In many cases, experience and a certain kind of ‘engineering tradition’ in a company with already existing pump designs and bearing arrangements is available and is a useful guide. However, for newly designed

Fig. 1 Fig. 3

Fig. 2

Type and size of bearing Choice of specific bearing characteristics in accordance with actual operating conditions

Bearing quality

Efficient and effective lubrication

Design of bearing location

Adequate dimensional and geometric accuracy of adjacent parts

Adequate sealing of the bearing arrangement Correct mounting and adjustment

with the seals – be one of the dominating factors for maintenance and service costs.

Stable and reliable bearing performance is of paramount importance in rotating machines. As rolling element bearings fulfil key functions in rotating machines, a sudden or premature bearing breakdown will significantly affect the performance of a pump or associated equipment, occasionally with catastrophic consequences.

In general, there are several possibilities available to the design engineer and to maintenance personnel for improving design and gaining a benefit from extended service life and prolonged maintenance intervals, respectively.

In any case, a design review or modification requires a careful examination of the existing design and of the actual operating conditions.

Each bearing application can be seen as a complex system of several interacting factors (see Fig. 3). Some of the most important factors are: • correct selection of the type and size of bearing • correct choice of specific bearing characteristics, including tolerances according to given operation conditions • correct mounting and ease of adjustment • realistic design of the bearing location

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Fig. 4

pumps, there are several more possibilities for improving bearing performance.

Achieving longer bearing life: The international bearing industry has developed a new generation of bearings featuring higher the load rating would allow load capacities, yet consumfor gaining up to – theoretiing the same space. An examcally – eight times the life of ple is shown in Fig. 4, illustratthe original product. ing the development step in singleDownsizing bearing arrangeFig. 6 row angular contact ball bearings ments: The same achievement also from the historic design, to the modern brings a second possibility, to downsize a ‘E’ version (featuring Extra capacity). bearing arrangement or shrink the bearAs there is a non-linear but exponening sizes by taking advantage of their intial connection between the load rating creased load ratings. and the nominal bearing life, doubling This yields reduced sizes and thus

Fig. 5

Fig. 1: This pump set uses specially designed single-row angular contact ball bearings. Fig. 2: Different types of bearings are shown. Fig. 3: Factors influencing bearing performance. Fig. 4: The E-version angular contact ball bearing (right) can take up extra capacity compared to a normal bearing. Fig. 5: A cutaway model of a pump with a bearing unit. Fig. 6: Angular contact ball bearings as typically used in pumps.

smaller masses, allowing for building smaller, lighter and more compact structures and pumps.

Re-evaluating existing solutions There are new bearing designs available on the market, including bearing sets designed specifically for the demands of the international pump industry. One of the typical challenges is the increased speed requirecontinued on page 14

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continued from page 13 ments in pumps that require new solutions for the bearing arrangements, too.

Among various modifications of standard bearings, e.g., high-speed angular contact ball bearings using ceramic balls (hybrid bearings) or bearings with hightemperature-resistant plastic (PEEK) cages, there are also specifically matched pairs of angular contact ball bearings available for high-speed applications, (see Fig. 7 and Fig. 8 respectively).

Fig. 1 shows an asymmetrically arranged Thrust Ball Bearing Unit consisting of one 40° angular contact ball bearing and one 15° angular contact ball bearing arranged back-to-back in matched pairs. This allows coping with thrust forces predominately acting in one direction.

Fig. 6 shows a symmetrically arranged radial ball bearing unit consisting of a matched pair of 15° angular contact ball bearings arranged back-to-back.

This unit accepts radial loads.

Fig. 7

Fig. 8

X 2B

Solid brass cage

B r2

r2 15° øD

X

View X

Lubrication groove

Bearing 2

r2

Marking C

r1

15°

15° ød

Solid brass cage

B

Bearing 1 r1

View X 2B

øD

Lubrication groove

Marking C

r1

r2 40°

r1 ød

Figs. 7 and 8 show two versions of NKE PumpSet bearing units, pairs of specifically modified single-row angular contact ball bearings.

Use of advanced lubrication technology Every bearing application resembles a tribological system consisting of the bearing and the lubricant. The lubricant is an element of equal importance in this

consideration. A failure of the lubrication will always terminate the bearing service life and thus cause technical problems in the affected pump.

There are also new-generation lubri-

cants available that considerably outperform older or standard lubricants.

Applying new lubrication solutions or lubricants may thus enhance specific technical features such as the high-speed ability of bearing arrangements, may extend the grease service life, or simply may add to a higher reliability with grease-lubricated bearings.

Use of advanced surveillance technology Countless pumps are used in remote locations. A fair portion of them are just used as standby or backup systems, while other pumps are being used nonstop over long periods of time. In all cases, the pumps fulfil essential tasks; a failure will have significant effects on products and processes.

In many cases, these bearings are subjected to preventive maintenance. That means all wear parts, including bearings, are being replaced irrespective of their actual condition. This is important for field maintenance engineers in order to make sure that there are no bearing breakdowns.

Using modern condition-monitoring equipment allows for centralized condition monitoring, which allows for scheduled and planned bearing maintenance, as there are clear indices provided by the monitoring system warning when a bearing is likely to develop damage.

Such systems, despite their initial cost, provide more detailed information on the bearing condition and thus allow for cutting back on maintenance costs.

Tips for existing pumps For existing pumps, the possibilities are somewhat limited, as there are hardly any design changes that can be performed in the field. However, there are some possibilities for at least cutting down on maintenance costs. One of these possibilities would be the use of condition monitoring as explained above.

Another practical possibility available to the maintenance engineer would be the use of modern lubricants that yield a longer grease service life and thus require fewer re-lubricating intervals.

Bearing manufacturers can assist in developing bearing solutions and can help contribute to optimal bearing and equipment service life, as well as reduced costs. Besides design, maintenance also plays an essential role in maximizing the service life of pumps. Although premium quality bearings are extremely reliable, every care should be taken to ensure their optimal service life.

MRO Daniel Thalmann is the application engineering manager for NKE Austria GmbH, Steyr, Austria. NKE’s Canadian distributor is Global Bear Inc., Dorval, QC. For more information, visit www.globalbear.ca.

Online Reader Inquiry No. 125

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Rehabilitating older industrial pumps

BY JAMES TULK

A full-scale refurbishment can do wonders in bringing a large industrial pump back to its original condition, or even improve its performance, often at a cost that is much lower than a complete replacement.

B

ig industrial pumps – the sort that are used to move large volumes of water or other fluids through industrial processes – need to be dependable and long-lived.

However, even with routine preventive maintenance and periodic overhauls, heavy use over long periods takes its toll and there comes a time when it be-

comes necessary to consider either replacing an aging unit or to undertake a major refurbishment.

To find out more about the potential for giving older pumps a second lease on life, let’s look at two major pump renewal projects carried out by the specialists at KSB Pumps Inc., the Canadian arm of the international KSB Group.

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A rejuvenated steel mill pump nears completion.

Renewal and rejuvenation The first project involved a large (8,000 US gpm at 380 ft TDH) horizontal splitcasing high-pressure pump that was one of three pumps used to provide quenching water for a steel mill. The pump was over 30 years old and had been subject to several routine overhauls involving the replacement of wear rings, seal packings and, at one point, the impeller. However, while this pump was running reasonably smoothly, its overall performance had deteriorated to the point where it was not able to meet the full requirements of the steelmaking process.

A key step occurred when the pump was disassembled in KSB Pump’s Mississauga service centre. “It’s always a surprise when you open up an older pump” warns Gary Zeidler, service manager at KSB. “It’s only when you have inspected all the parts in front of you that you can decide how much work needs to be done.”

In this case, the most significant problem was erosion of casings around the intake caused by internal turbulence and cavitation. A number of non-OEM components had been installed over the years, notably wear rings on the intake side of the impeller that had a square contour that would have disrupted the smooth flow of water in this area. Other replacement parts appeared to be out of spec.

Original service documents that established the correct specifications were provided by Standard Alloys Inc., a KSB partner company that specializes in reverse engineering and the remanufacture of components for older pumps.

The main task was to rebuild the eroded areas on the cast-iron casings.

For each area where significant losses had occurred, a steel matrix was brazed into place and the final contour built up with high-strength ceramic fill.

The entire interior of the casing was refinished with a two-layer ceramic coating. The two layers of ceramic have different colours. This makes it easier to identify areas of accelerated wear in the future, since the lower layer coating will tend to show through in these regions.

The impeller was carefully cleaned and re-balanced. Wear rings were replaced with new units that were contoured to allow smoother intake flows.

The mounting grooves for the wear rings were modified to incorporate a fully-spigotted seating. (This method of retaining wear rings is currently the norm for large pumps, but was not widely used when this unit was originally manufactured.)

Bearings were replaced and seals were renewed with Teflon/graphite-impregnat-

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ed non-asbestos packing material. And, to finish things off, the unit was given a fresh coat of blue enamel. The renewed pump has been placed back in service.

“It isn’t just a case of restoring a pump to as-new condition,” adds Zeidler. “When you look at a machine that has been in service for a long time, you can often spot areas where the original design wasn’t as good as it could have been. Improving these with more up-to-date materials and techniques gets us to a pump that is as good as new or even better.”

“Making major repairs to a large pump involves a wide variety of resources,” points out Mike Blundell, president of Mississauga, ON-based KSB Canada.

“We have made major investments to acquire the necessary equipment and skills under one roof; this makes it possible to do this kind of job in a cost-effective manner.” KSB’s facilities feature a variety of heavy machine tools and a 16-ton overhead crane capable of handling the largest pump assemblies.

Reconfiguring for a new lease on life A more extreme example of improving pump performance occurred earlier when KSB was asked to help with the renewal of boiler feed pumps used in a British Columbia pulp and paper mill. These pumps had been supplied by KSB over 40 years earlier and were still running well.

However, recent changes to plant operations had significantly reduced the amount of high-pressure water required from the pumps. Restrictor plates or valves could be used to reduce the flow, but this would mean a serious loss of pumping efficiency and wasted energy.

So, what to do? The solution proposed

by KSB was the replacement of several impellers and sections of the volute casing with new hydraulic elements designed to match the new flow and pressure requirements. The result was a hybrid new/old pump whose optimal duty point closely matched the new operating conditions.

The bulk of the casings, supporting structures, motor mounts and connecting pipes remained intact, which sharply reduced the overall cost of the rebuild. In this case, because of the age of the pumps, no original replacement parts were available. However, KSB was able to use its international resources to design and manufacture new components that were entirely compatible with the original casings and bearing supports.

Lessons learned These examples demonstrate that major refurbishment of older pumps can be a cost-effective way of extending the useful life of these vital pieces of equipment. A key advantage of renewal over replacement is that it eliminates the need for making major changes to associated infrastructure, such as supports, piping layouts, and even power supplies and control systems. However, the economic viability of a major overhaul can depend on a number of factors, including the amount of damage that has been suffered by key components such as volute casings, the shaft and impellers.

Clearly, a thorough evaluation of the pump condition is required before any repair/replace decision is taken. The limited availability of important spare parts can pose a challenge. For pumps that are several decades old, it’s quite likely that the original manufacturer no longer stocks the appropriate replacement parts. However, well-established manufacturers will often have original drawings and specifications on file.

Moreover, there are a number of compa-

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Machinery & Equipment MRO

nies that specialize in solving problems with older pump components and remanufacturing hard-to-find parts.

Large industrial pumps are rugged pieces of equipment and there are many cases where a full-scale refurbishment can do wonders in bringing a pump back to its original condition – or even improve its performance – often at a cost that is much lower than complete replacement.

The key, however, is to find a service company with trained staff who are not only able to carry out a professional overhaul, but also have the special experience and in-depth knowledge of pump performance that enables them to take advantage of opportunities for alterations that will improve overall performance.

MRO

Above left: Erosion of metal adjacent to the input wear ring can be seen before the pump has been rehabilitated. Top right: Repaired areas on the lower casing are shown post-rehabilitation. Bottom left: A 40-year-old KSB boiler feed pump at a BC pulp and paper mill was reconfigured for reduced flow requirements.

Technology journalist James Tulk wrote this exclusive story for Machinery & Equipment MRO on behalf of KSB Canada. For more information, visit www.ksb.ca.

Online Reader Inquiry No. 481

Increase your operations efficiency and profitability by reducing installation errors, maintenance costs and downtime. The Rexnord® ZAF6000 series bearings and new ZLF6000 large bore bearings are direct drop-in replacements to industry standard SAF bearings.

Pre-lubricated and shaft-ready, these bearings decrease installation and removal time by as much as four times versus SAF models.

And, you can find Rexnord bearings at your local Motion Industries location. Our local sales and service specialists are experts in application and technical support, providing the parts and the know-how you need to stay up and running.

Over 500 locations More than 4 million products Industrial maintenance training courses Call. Click. Visit.

The brands you count on from the people you trust…that’s Rexnord and Motion Industries.

1-800-526-9328 for the location nearest you ©2012 Motion Industries, Inc.

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September 2012

MANY ENVIRONMENTAL

CHALLENGES MUST BE MET TO ENSURE RELIABILITY

T

he food processing industry covers a wide range of product specializations, each with its own environmental characteristics and design challenges. Proper component selection begins with understanding the environmental challenges that your application faces.

These challenges can include high- and low-temperature exposure, humidity, washdown exposure, general corrosion, sea and saltwater corrosion, acid attack, bacteria resistance, small particle contamination and vibration.

Temperature stability: Baking and refrigeration can introduce thermal stresses that can lead to lubricant breakdown, which is responsible for 70%

PUMPS FOR

MUNICIPALITIES

iStockphoto/Thinkstock

Selecting bearings for food processing

of premature bearing failures. Heattreated and specialized ball bearings are highly recommended to reduce the degrading effects of extreme-temperature applications.

Humidity and fluid corrosion resistance: Fluid contamination and post-processing washdown can catalyze rust development, which can lead to food contamination. Stainless steel or specialtyplated bearings are a near-must requirement given the stringent government requirements regarding the operation of food processing lines.

Dry particle corrosion resistance: Dust particles in pharmaceutical and grain processing environments present their own set of challenges. Without optimum sealing protection, these finely sized elements can easily find their way between ball bearings and raceways, slowly corroding the inner bearing surfaces. Superior sealing systems and solid lube grease are ideal for protection against dry particle corrosion.

Vibration stability: Shaker screens and separators are commonly found within dry goods environments and can subject bearings to significant levels of vibration. Bearing units featuring a solid base construction are highly recommended, not only for vibration resistance, but for shock and impact load stability. MRO This article was adapted from NTN Revolutions, Vol. 12-6, Issue 1. For more information from NTN Canada, use the response number below at www.mromagazine.com/rsc.

Online Reader Inquiry No. 483

Mr.0 The Practical Problem Solver

Removing belt-drive flanges

Gorman-Rupp of Canada Limited has been manufacturing pumps, pumping systems and providing superior fluid handling solutions in Canada since 1960.

Our Canadian made, industry leading products are shipped across Canada from our 5,500 square metre Canadian manufacturing facility.

An ISO 9001-2008 Canadian company with a long history of manufacturing excellence, uncompromised performance and industry leading customer service offering the broadest range of pumping equipment to meet the needs of any municipality You will find the..... right pump for your job at Gorman-Rupp.

GRCanada.com Gorman-Rupp of Canada Limited n 70 Burwell Road n St. Thomas, Ontario N5P 3R7 PH: 519-631-2870 n FX: 519-631-4624 n grcanada@grcanada.com ©2011 Gorman-Rupp of Canada Limited. Gorman-Rupp of Canada Limited is an ISO 9001:2008 Registered Canadian Company.

Problem: Some users require the removal of flanges from belt drives for various application requirements.

Solution: The flanges can be removed by evenly heating them with a torch. Larger diameters may require multiple torches to allow even heat distribution to get the flanges hot enough to expand over the flange seat. Heated flanges should be handled carefully and with adequate protection to prevent personal injury.

The heat-shrink method of flange attachment doesn’t provide an easy method for forced removal of the flange. Therefore, the impact removal of the flanges is not recommended, due to potential damage to the sprocket teeth or the flange mounting surface.

An alternate method would be to chuck the part on a lathe and remove the flange seat material.

This tip was adapted from a recent Gates Corporation Belt Tips newsletter.

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, 12 Concorde Place, Suite 800, Toronto, ON M3C 4J2.

Online Reader Inquiry No. 129

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Online Reader Inquiry No. 130

Online Reader Inquiry No. 131

Online Reader Inquiry No. 132

Online Reader Inquiry No. 133

Online Reader Inquiry No. 134

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Online Reader Inquiry No. 135

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Machinery & Equipment MRO

September 2012

The Three-Barrier Solution Sealed bearings are a key to reducing contamination and grease consumption.

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BY JOHN MELANSON, P.ENG

he sight of a heavily contaminated bearing may not involve an emotional reaction for most people, but for many in the maintenance sector, this picture does evoke a sense of concern, since it’s know that 34% of bearings fail due to contamination.

Bearings are exposed to tough conditions

The three barriers to contamination.

in various industries, such as mining, mineral processing, cement, pulp and paper, metals, and other heavy and process industries. Contaminants may vary in type and size, from steam and moisture or other corrosive media, to fine dust or heavy rocks. As such, the use of an appropriate sealing solution is of great importance.

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You’d better cross your fingers if you still depend on washers, locknuts, or other mechanical devices to keep your fasteners tight. Fact is, they do little to prevent fastener loosening — one of the leading causes of catastrophic equipment failure.

There’s a better way to secure fasteners. Use Loctite® threadlockers. You’ll get a solid, dependable threaded assembly that won’t loosen and cause breakdowns. That means more uptime and productivity.

Loctite threadlockers come in a variety of strengths and formats to match your application. They lubricate for easy assembly, seal against leakage, protect from rust and corro- sion, and improve breakloose and prevailing torque strengths – all for about one-third of the cost of mechanical devices. So don’t take chances. Reach for the sure thing. Loctite.

For details and the name of your nearest authorized Loctite Industrial Distributor, call: 1-800-263-5043 or visit www.useloctite.com.

Visit us at Fabtech 2012 and bring or mention this ad to receive a free “4GB Loctite USB Key.”

John Melanson is the engineering manager at SKF Canada.

Except as otherwise noted, all marks used are trademarks and/or registered trademarks of Henkel and/or its affiliates in the U.S. and elsewhere. ® = registered in the U.S. Patent and Trademark Office. © Henkel Corporation, 2012. All rights reserved. AD-128-12

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In applications with harsh environments, and high maintenance costs due to short bearing lifetimes, one way to get excellent sealing is to use the ‘three-barrier solution’. This involves the use of: 1. L abyrinth seals as a primary barrier 2. A grease-filled cavity in the housing as a secondary barrier 3. Bearing seals as the third and final barrier.

It is important to ensure that the primary barrier is grease-purgeable, to ensure that when the housing is relubricated, the old grease (with some contaminants) is purged out during relubrication.

The cavity in the housing should be filled about 70% to 80% with grease to start out with. This will ensure an adequate grease fill to act as a secondary barrier.

A different type of grease than what is used inside the sealed bearing may be used in the housing. Since this grease will purge out (depending on the relubrication interval and amount), it is suggested you use an environmentally friendly grease, to reduce the effect of grease spillage and/or disposal on the environment.

The final barrier is to be the bearing seal itself. A sealed spherical roller bearing is often used in such a case, since these bearings are capable of supporting heavy radial and axial loads, and are suitable for integrated seals due to their non-separable design.

Using sealed bearings virtually eliminates the common incidence of introducing contamination into the bearing by way of installation or relubrication practices, since the bearing is lubricated and sealed at the factory.

Besides reducing contamination in the bearing, and increasing its operating life, there are other advantages of this approach. The grease used in the housing does not have to be chosen based on the NLGI grade or operating viscosity required by the bearing, since the bearing is sealed. The grease leakage from the bearing itself is virtually eliminated (although there can be a small amount of leakage of the grease from the sealed bearing, mostly during initial start-up). Therefore, an immediate savings in grease consumption is experienced, which can add up quickly.

The use of the sealed bearings also makes it possible to consider downsizing the bearings in many applications, since a lower contamination level will result in a higher bearing lifetime, as per the life modification factors used in bearing life calculations (ISO 281:1990/Amd 2:2000).

As an example, the contamination factor of an open bearing in the range of 0.1 to 0.4 may be improved to as much as 0.6 to 0.9 (depending on the size and application). This higher factor contributes to the longer service life and increased uptime of a sealed bearing.

Finally, ensure that when using the three-barrier solution, it is appropriate for your individual case, paying attention to the selection of each part of the assembly.

If you are unsure about any detail, err on the side of caution, and contact your bearing distributor or manufacturer of choice.

Stay clean, live long and prosper. MRO

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Machinery & Equipment MRO

PASS THE WRENCH How custom tools can improve safety and reduce operating costs.

BY ROBERT ROBERTSON

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aced with costly downtime and a tense production manager, the clock is ticking. To make matters worse, a critical tool needed for the repair is back-ordered with purchasing. Now what? Think again if you decide to cobble together a do-it-yourself quick fix from whatever can be found in the shop. Unfortunately, the safety risk and potential for further equipment damage is far too great.

That’s the view of Brampton, ONbased hand tool manufacturer and distributor Gray Tools, which offers more than 6,000 industrial product solutions and operates a plant and two warehouses in Canada. The company’s product catalogues include a wide selection of standard tools, such as master sets, hand sockets and accessories, combination wrenches, screwdrivers and nut drivers, as well as toolboxes and organizers.

Gray Tools can also design and manufacture custom tools to specification for preventive maintenance or repair work.

Frank Dominguez, marketing manager for Gray Tools, encourages MRO professionals to always put safety first and consider using custom tools to get the job done.

“Using the correct tool for the correct job is of paramount importance. I understand there are situations and times when it’s not feasible,” says Dominguez.

“In real life, however, you must protect the user and the investment [in the equipment]. We often see people incorrectly using combination wrenches as hammers or screwdrivers as chisels.

Homemade tools can also be dangerous.

“Leave the creation and manufacture of tools to the people who are experts in this area. We consider torque load, determine the ideal steel hardness and identify the best finish to match the application. Higher quality tools will always shine through. They also enable a business to focus on its core competency, which could offset the time and energy spent going in-house.”

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Custom tools provide an edge Mississauga, ONbased Cummins Eastern Canada LP called upon Gray Tools to help with a challenging production problem on an assembly line.

A turbocharger needed to be turned 120 degrees and accessed at the circlip, while holding the turbocharger itself. Gray Tools’ chief engineer went on site, took measurements and developed a custom locking clamp. With the clamp, Gray Tools reduced the time it takes to “clock the turbo” by six times.

Gray Tools also developed a custom wrench for Cummins. It’s used to remove several huge 64-mm bolts from a generator set gearbox in the field. Traditionally, the Cummins technician would order a 2-1/2-in. combination wrench from Gray Tools, cut off the closed end-side and insert a pipe to create the leverage needed to produce more torque.

Since Cummins is a safety-oriented company, its technicians and management decided there was a need for Gray Tools to develop a custom 64-mm hightorque, 5-ft-long open-end wrench. Gray Tools came up with two prototypes. The selected tool was aptly named the Galezoski wrench in honour of the inventor, Rick Galezoski, a technician with Cummins Eastern Canada.

“Cummins places a great deal of emphasis on safety, so we called Gray Tools and asked if they could custom design a wrench for the application,” says Benoit Parent, M. Eng., general manager, Power Generation Ontario for Cummins Eastern Canada LP. “On a monthly basis, we use the tool to repair gearboxes and it continues to work great for us.”

According to Gary Nuttall, president of Gray Tools, many companies often create their own tools, but this can present

Left: Gary Nuttall, president of Gray Tools. Above left: Gray Tools began operations 100 years ago. Right: (from the archives) This socket wrench catalogue is from 1922. Far right: (from left) Frank Dominguez, marketing manager, Gray Tools; and Gary Nuttall, president of Gray Tools. Bottom: A special set of tools has been created to mark the company’s 100th anniversary.

safety issues. “Cummins recognized the safety concerns of making their own special wrench,” says Nuttall. “They also had seen the benefits of working with us on other customized tools.”

Metric versus imperial measurement can also lead to a common problem.

“Cummins considered using an imperial wrench on a metric nut,” says Gray Tools’ Dominguez. “Sometimes, companies don’t have the exact tool required and attempt to improvise, but often without satisfactory results.”

Ergonomics factor There are instances when companies solely base their buying decision on the tool’s upfront price, but this doesn’t take into account the risk of workers getting hurt. According to Dominguez, ergonomics, especially in terms of stress, fatigue and repetition, also has to be taken into consideration.

“I spoke with one mechanic at a recent mining industry trade show and he told me cheap wrenches hurt his hand. This can be a major issue if you use the tool every day, as heavy equipment mechanics do,” says Dominguez. “If you have a less-expensive tool and it sounds ‘tinny’ or there’s no brand name, warranty or manufacturer contact information, there’s a reason for all of that.”

After properly selecting the required tool (out of the box or custom-made), Dominguez advises it’s equally important for MRO professionals to have an effective storage, theft-prevention and transportation strategy in place. This also takes into account the effective use of organizers, stationary cabinets, mobile toolboxes and tool wall boards.

“If you throw tools in, how will you effectively know where they are? We’re often looking for revolutionary solutions for what is a common basic problem,” says Dominguez. “If you keep your workspace clean, tidy and organized, you’ll know what tool is missing or has been lost. Proper storage solutions with heavy-duty locks can prevent tool loss and theft. Don’t forget your toolbox is an investment.”

MRO Robert Robertson is a Mississauga, ONbased freelance writer. He can be reached by e-mail at robertrobertson@rogers.com.

Online Reader Inquiry No. 486

Gray Tools marks its 100th anniversary On September 12, 2012, Gray Tools celebrated its 100th anniversary. Over the years, the company has manufactured more than two million tools for a variety of industries. Founder Alex Gray started the business back in 1912. To commemorate its 100th anniversary, Gray Tools introduced a limited-edition tool collection and held an employee celebration day.

“We’re excited to build upon the strengths of this 100-year old Canadian icon. We have exciting plans for the future and believe our manufacturing capability gives us a competitive advantage,” says Gary Nuttall, president of Gray Tools. “Customers regularly turn to us to see if we can design a special tool for them. We manufacture in Canada, so we can do this quickly. It’s something no one else seems to be doing.”

Top: Gray Tools In May 2012, Gray Tools announced that Nuttall, along founder Alex Gray. with marketing director Frank Dominguez, had purchased the Bottom: Gray Tools company from Alex Gray, who was the third-generation owner current chairman, of Gray Tools from 1969 to 2012. He will remain with the orgaAlex Gray III. nization as chairman.

According to Nuttall, it was essential for Gray Tools to stay privately owned and keep close personal relationships with customers, as well as for the new owners to share the same Gray family values that have spanned decades. He also says the ownership change ensures continuity within the company, and it has answered succession planning questions that periodically came up from customers.

“Alex Gray wanted to find somebody who had the same value structure in terms of customer service, product quality and dedication to manufacturing in Canada,” says Nuttall. “Gray Tools is a company with a great heritage, products and people.

We now have at least 25 years of succession planning in place for the company.

“We’re in the second year of a five-year business plan. There’s no change and we’re continuing with what we started. Our employees and customers know what we’re doing. We’ll focus on new markets in Canada and increase our presence globally.”

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September 2012

How oil-monitoring helps with hydraulic fluid The proper types of protective hydraulic fluids are required to deal with workload stress or severe-service conditions.

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n today’s business environment, even the smallest details can provide a company with a competitive edge.

Choosing what type of fluid to use in hydraulic equipment can make the difference between productivity and inefficiency, between profit and loss.

Although general manufacturers may not have to face severe environmental conditions, there are other factors to consider that can make or break the fluid you use,

Above: Auto Mats and Accessories has unique chalsuch as hours in service, intensity of lenges. Right: An oil-monitoring program used with equipment operation, pressure dehydraulic fluid can extend equipment drain times. mands and temperature levels. Many manufacturing plants are often in continuous operation, striving to meet critnies need advanced protection to keep hyical deadlines. That kind of workload on draulic systems up and running,” says industrial machinery requires hydraulic Marc Bouchebl, hydraulic oil category portfluids that protect equipment and help folio manager, Petro-Canada Lubricants. eliminate unscheduled downtime.

“Whether it’s rugged working conditions The right fluid plan or a relentless production schedule, compaDavid Moore, plant manager for Auto Mats

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and Accessories, Dalton, GA, knows first-hand the importance of selecting the right hydraulic fluid to suit specific business demands. Auto Mats and Accessories specializes in producing all-weather, automotive floor mats.

In this line of business, injection moulding machines play a vital role in melting and injecting the vinyl that is used to produce automotive mats. This plant, like many others, presents unique challenges.

“It takes about three hours to start the extruder, heat it up and get the vinyl flowing freely,” says Moore. “We keep our machines running all the time because it is such a nightmare to get them back up once they have been shut down. Having additional downtime because of lubrication change-outs is a cost we don’t want to face.”

The role of oil monitoring Mike Smith of Whitfield Oil, a Petro-Canada Lubricants distributor based in Chickamauga, GA, did a side-by-side comparison of the competitive products available for the equipment at Auto Mats and Accessories. He also arranged a schedule of regular oil analysis to determine when the machines would need servicing.

“With Hydrex AW, we extended drain intervals to two times what we experienced with other products,” says Moore. “The cost savings have been a tremendous benefit.”

Every machine is different and so are the conditions in which they operate.

“With varying factors across the board, it doesn’t make sense for every business to follow the same drain intervals,” says Smith. “Using an oil-monitoring program helps to better understand the oil, conditions and best practices, and also helps save money by safely extending drain intervals until they are actually necessary.”

With equipment being pushed to the limit for hours on end, day after day, often in harsh conditions, it is becoming increasingly important that companies use top-quality hydraulic fluids that can both persevere and perform.

“A regular review of hydraulic fluids is something many maintenance and purchasing managers often overlook,” says Bouchebl. “Yet failure to evaluate can result in the use of a low-quality fluid with a short service life that requires frequent top-ups or change-outs. The resulting downtime and repairs can increase maintenance costs, slow production and ultimately reduce profit margins.”

Oil monitoring programs, such as Petro-Canada Lubricants’ Lubri-Test, are lowcost, preventive maintenance programs used to evaluate the condition of lubricants and equipment on a routine basis. The program monitors oil properties such as viscosity, oxidation levels and metals content to help detect abnormal equipment wear and unwelcome contaminants like dust, dirt and water. Oil monitoring programs can be used to help extend drain intervals until they are actually necessary.

“By reviewing the performance of their hydraulic fluids, many companies have been able to reduce unscheduled downtime, improve equipment reliability and extend equipment life,” says Bouchebl. “The results of reduced maintenance costs and improved equipment performance help build a stronger bottom line.”

The tougher the job, the stronger your hydraulic fluid needs to be. If you haven’t analyzed your oil in a while, now is a good time to assess whether you’re getting the best performance and protection possible. It’s a relatively easy way to meet the extreme demands on your equipment and your business.

Online Reader Inquiry No. 480 MRO

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Online Reader Inquiry No. 138

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September 2012 Photos courtesy Belterra Corp.

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HERE ARE A DIRTY DOZEN PRACTICAL TIPS (PLUS TWO BONUS ONES) FOR TROUBLESHOOTING AND PREVENTING CRITICAL CONVEYOR CATASTROPHES IN HARSH

Crazy Conveyors ENVIRONMENTS

BY CARROLL MCCORMICK

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onveyor systems, particularly those used in mining industries, are under constant attack by dusty, abrasive or corrosive materials such as coal, bitumen, iron ore or potash. Operators often push them to deliver beyond their design capacity specifications, causing more wear and tear. As well, straightforward maintenance tasks are frequently not done, leading to premature failure of components and production downtime.

The following maintenance tips are distilled from conversations with three specialists from Delta, BC-based Belterra Corporation, which services and sells conveyor system products and improvements: Bob Collins, territory manager/ solutions specialist; Jim Halloran, projects division manager; and Mike McInnis, mechanical maintenance services division/technical specialist.

Tip 1 As a rule, conveyors should be inspected while in operation. Watching and listening can reveal a lot about the condition of a conveyor. McInnis shares some symptoms. “Very loud squealing and or grinding noises are most often the result of failed or failing bearings. They could be in pulleys, but more often than not, they are failed idlers. They are quite easy to locate.

“Slapping or even banging noises are quite often related to failed idlers in the return strand that cause the belt to jump and then slap down. These noises can also be caused by pulleys, possibly in the take-up, that are worn out or round or are out of balance. They cause the belt to jump or whip in the system.”

It is usually quite obvious what is causing that problem and the cure is usually straightforward: replace the component that is causing the problem. “Prompt attention can save extra money,” Collins warns.

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Fig. 2

“When an idler fails, it makes the bearings of the next idler work that much harder, which will cause that idler to fail also.”

Tip 2 A dirty conveyor is arguably the largest cause of component wear and failure, including idlers, head and tail pulleys, bend and snub pulleys, and conveyor belts. Dirt does not accumulate randomly, so where it piles up provides clues symptomatic of particular problems. If root causes are not found, the problems will persist.

In most cases, the conveyor should be thoroughly cleaned before attempting to determine what is causing a problem.

This makes it easier to see where waste is building up, McInnis says. “This will aid in your efforts to determine if the issue is the result of a problem in direct proximity to the build-up, or if it is happening somewhere else on the system and being carried there by the conveyor belt and deposited.

“Taking the time to investigate these issues thoroughly, which can in many cases be done without interrupting production, will — in most cases — result in less downtime and lower costs to resolve the issue.”

Tip 3 You observe material building up on the return idlers or directly below them, perhaps on the floor or on a system below the conveyor. “This may be the result of poor cleaning of the belt, or a chute that won’t allow the material to clear the transfer point fast enough. As a result, material is being dragged back on the system in the return stand, on the carry side of the belt or the top cover,” McInnis suggests.

A chute problem can be caused by overloading the conveyor, that is, exceeding its design specifications, but the solution to this problem will not be found in a mechanic’s toolbox. This requires reducing the amount of material being con-

veyed or rebuilding the transfer point to handle the extra volume.

A cleaning problem can be solved by adding more cleaners to the belt, or possibly by properly adjusting existing cleaners.

Tip 4 “It all boils down to effective cleaning of the belt,” Collins counsels.

Effective cleaning at the head end reduces carry-back, means less build-up on the rollers, produces better tracking and results in less wear and tear on rollers. If your conveyor has belt cleaners, maintain them properly, he says. If it has none or perhaps just one cleaning blade, consider adding more.

“One blade was thought to be good 25 years ago. Three blades are considered better now,” Collins adds. A pre-cleaner at the head end of the conveyor will remove about 75% of the product from the belt. A secondary cleaner will remove 15%-20% of the remaining product. A tertiary cleaner will often give the belt

the final wipe needed to remove the balance of the product.

Tip 5 Your new cleaners are installed, adjusted and working well. Then the weather takes its annual turn for the worse, and so does the effectiveness of your new cleaners. Snow and ice can turn belt cleaning into a significant issue, McInnis observes, where one cleaner may work in favourable conditions, but several may be needed when the weather becomes aggressive.

“Secondary cleaners with carbide tips dramatically improve cleaning. They have the ability to remove ice, snow and very wet material in a very effective manner. When installed correctly, they can do this without damaging the belt.

They will reduce carry-back and damage to other conveyor components.”

Tip 6 It is winter and you are transporting wet material. The belt cleaners are not working any more, the wet product is find-

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September 2012 Photos courtesy Belterra Corp.

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Fig. 3

Fig. 4

Fig. 1: A new chute and conveyor system, ready for headache-free action.

Fig. 2: Finding the leak in this transfer point first requires that it be thoroughly cleaned.

Fig. 3: Designing and building a better transfer point might require outside expertise.

ing its way to all the return rollers and material is building up and freezing. Rollers are getting encapsulated with frozen material, the belt is wandering and there is no roller grip. The cause of this mess is obvious, but what can you do?

Chipping off the frozen material is one option. Another is to install a de-icing spray system at the tail end of the conveyor, behind the load zone. “Spray chemicals like glycerin-based products, potassium acetates and calcium chlorides can be recommended for different conveyed material. They can also help material move up an incline that would normally slide back on a frozen belt,” Halloran says.

Tip 7 You notice abnormal wear of return idlers or on snub and bend pulleys, abrasion of the bend and snub pulley covers, and maybe even belt-tracking issues. The poor tracking can be caused by uneven pulley cover rubber wear and all of the above problems can be caused by poor belt cleaning. Collins recommends tapping the cleaner manufacturer’s engineering department for advice on applications and product installation locations.

McInnis adds, “Do your homework to ensure you get the correct cleaner for your conveyor system and the material you are dealing with. Is the material dry or wet, is it abrasive, or are there chemical characteristics in the material that require the use of stainless steel components? Proper mounting locations and adjustments as per the manufacturer’s instructions will determine the success of these components.”

And for long-term satisfaction, Collins insists, “You can have the best cleaner on the market, but if it isn’t properly inspected and maintained, it’s all for naught.”

Tip 8 You observe that the conveyor belt is wearing a notch through the conveyor’s skirt board, some distance away from the load zone and tail end of the conveyor. The problem may be poor tracking on the return strand at the tail pulley, resulting in

side-loading of the belt, which causes the tracking to get progressively worse as it travels down the system.

“The solution to this problem is to add a belt trainer on the return side of system close to the tail,” McInnis suggests. “It correctly aligns the belt feed on the tail pulley and lets the belt be loaded in the centre.

This is a relatively simple and inexpensive solution to an apparently significant problem.” Whether a maintenance department can add a belt trainer depends on its experience and training on speciality conveyor components, he adds.

Tip 9 You’ve installed belt cleaners yet you still have carry-back, but on the bottom cover of the belt. McInnis suggests, “This can be the result of many different things, such as a leaking load zone, material becoming airborne at the transfer point and then settling on the returning belt below, or a poor transition point that allows the material to spill off the edge of the belt.”

Inspect the system while it is operating, but take your time: the leak or spill area could be quite small and hard to recognize. Study whether the material has time to settle on the carry side of the belt before it leaves the transfer point and/or containment zone, or whether the belt is not centred on the system as it enters the transfer/load zone.

If a belt is making a poor transition from a trough section to a flat section as it engages the flat tail pulley, a seal might leak. Extending the tail-box at the back of the load chute closer to the tail pulley will allow for a seal on the flat part of the belt.

Tip 10 You decide to purchase and install some new components. But did you take time to corner the vendor to learn how to take care of them? Collins observes, “I’ve seen where products get a bad name because a company puts in a nice product, but didn’t show the maintenance people how to maintain it.

Fig. 4: A maintenance inspection would have caught this broken idler.

“I’ve seen belt damage because an edge seal bar wasn’t flipped over to give it a second life or an impact bar wasn’t replaced after the UHMW polyethylene wore out. I spend a lot of time with my customers making sure they know, for example, by putting on stickers that tell them what the spring tension is.”

Vendor websites offer literature for downloading on the installation and maintenance of products like belt cleaners, load zones and belt trainers.

Tip 11 You notice a torn belt and perhaps other problems, but an inspection suggests nothing to your eyes and ears.

Consider then, the possibility that someone has knocked the conveyor out of alignment with a piece of heavy machinery, but not reported the incident to the people in a position to resolve it. This can cause big problems.

“What people sometimes don’t understand is that when these issues go unresolved, they can result in system failure, a torn belt, etc. These resulting problems are quite often considerably more costly than the initial repair would have been.

Downtime can quite often far outweigh the cost of repairs,” McInnis says.

Halloran adds, “Usually it is the structural bent supports holding the conveyor up that get damaged. Some customers will install extra protection walls, cement barriers or beams to avoid damage.”

Tip 12 One minute your conveyor is working like a charm and the next it looks like it’s been savaged by Tasmanian devils. Halloran says, “It isn’t just machinery that can knock a conveyor or components out of line. If a huge piece of tramp metal gets through your system and down a chute, it can tear out the belt and jam into idlers or knock them out. It can even go into pulleys and throw ev-

erything out of alignment. The solution is to install a belt magnet at a strategic location in order to remove this metal before it causes damage.”

Bonus Tip 13 Fugitive material at a transfer point has been a headache. You have even brought in a man with a shovel to keep the area clean. Not only is this time-consuming, it is not safe to do this around a moving conveyor. The problem is also causing maintenance headaches and is affecting production efficiency.

Halloran could spend hours discussing inefficient transfer point design, but he suggests checking this first: “Transfer points are often designed with the steel skirt boards right at the edge of the belt.

If the belt is mistracking, it will wander right out of the seal and dump fugitive material on the floor or ground. The belt should extend past the skirt board.”

Bonus Tip 14 You decide to tackle a problem with excessive dust at a transfer point. Here, however, you might need to call in the experts to do some redesigning. Halloran hints at the challenge you might be facing if a poor transfer point design is the cause of your problem: “The amount of dust created in a transfer point depends on a number of factors, including the nature of the material carried, the height of drop onto the belt, and the speeds of loading and unloading belts.

A key to controlling this airborne dust is to increase the volume of the containment zone. This will slow down the velocity of airflow. We also install internal rubber dust baffles, which help decrease the airflow and the amount of escaping dust.” MRO Montreal-based Carroll McCormick is the award-winning senior contributing editor for Machinery & Equipment MRO. Online Reader Inquiry No. 485

Online Reader Inquiry No. 139

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Machinery & Equipment MRO

Beverage industry conveyor pours on advantages In its new Montreal distribution centre, Motion Canada looked for ways to reduce noise, eliminate maintenance and improve safety with its conveyors.

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otion Industries’ two new Canadian distribution centres have no bottling lines, but that didn’t stop the industrial distributor from adopting a conveyor solution widely used in the bottling industry, where the system’s low-friction components have proven to reduce operating costs.

Designed by a Montreal-based OEM, the new flat-top conveyors use System Plast chain and Browning gear drives from Power Transmission Solutions, a division of Emerson Industrial Automation.

The ultra-low-friction conveyor has delivered a range of advantages, including low noise, compactness and low energy use.

According to Tom Sawyer, Motion Canada’s distribution centre director, the conveyor is much quieter than roller conveyor, vastly improving the work environment, and it has proven very reliable, conveying totes without the drift that

Left: The conveyor systems use six Browning premium-efficiency gearmotors with gearboxes assembled on site. End caps on the motors and bearings protect the rotating shafts. Above right: The flat-top conveyor is much quieter than roller conveyor and demonstrates the plastic chain’s advantages beyond a bottling/washdown environment, where it is often used.

Right: Motion’s two systems include 180-degree turns in a 6-ft radius, measured on the outside of the conveyor, a compact arrangement that is almost impossible using roller conveyor without transfer tables or pushers.

can occur on a gravity roller conveyor. He emphasizes the new conveyor demonstrates the plastic chain’s advantages beyond a washdown environment.

Motion Canada opened its two new distribution centres (DCs) in August 2011, one in Edmonton and another in Montreal, replacing its single centre in Montreal and nearly quadrupling its size to 100,000 sq ft with the new facilities.

Both facilities have a conventional layout, with shipping and receiving on opposite ends of the building, and shelved inventory in the centre. The shelves branch off at right angles to the shipping conveyor, which runs down the centre of the layout to a 90-degree turn and then to a 180-degree turn leading to five shipping lanes, each for a specific Canadian province.

“Our two DCs serve our 70 branches in Canada, and we also ship some product directly to customers,” Sawyer explained.

“We pick 2,000 to 2,400 lines per day for our branches, and each line may consist of many pieces of a specific product. Our warehouse management software consolidates orders from the branches so our pickers, using radio-frequency (RF) scanners, can efficiently pick in the same zone for multiple accounts.

“The product is regrouped in shipment, and a given branch may have several hundred lines going to it every day.

We also pick about 200 orders per day for direct shipment to customers.”

Motion Canada’s prior DC used a twolevel gravity and powered roller conveyor. In the new facilities, the company looked for ways to reduce noise, eliminate maintenance and improve safety.

Motion teamed with a Québec-based OEM to design its DC conveyors. It was decided that the best product for the application was the flat-top System Plast convey-

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Online Reader Inquiry No. 140

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or, using XPG chain and Nolu S wear strips. This combination has a coefficient of friction of just 0.16, reducing energy consumption about 25% compared to standard acetal chain and UHMW-PE wear strips.

The XPG chain is also rated for 607 lb, adequate for the 50-lb maximum tote weight handled at Motion’s facilities.

“This type of belt proved ideal for a compact system layout,” Sawyer explained. “For example, we did a 180-degree turn in a six-foot radius, measured on the outside of the conveyor. This is almost impossible with roller conveyor without transfer tables or pushers. Each of our systems includes a section of about 40 ft of accumulation conveyor with a cleverly designed surface that minimizes load and energy use.

“We use the accumulation section to spot-check our totes for picking accuracy.” Automatic sorting to the shipping lanes is planned for 2012, using scanners and pushers, with manual sortation being used in the short term.

The new conveyor systems use six Browning 575-volt premium efficiency gearmotors, with the gearboxes assembled on site at Motion’s Montreal DC, which is home to the company’s largest assembly shop in North America. End caps on the motors and bearings protect the rotating shafts. The conveyor requires no compressed air in its accumulation zones, and reduces maintenance with the elimination of belt-driven rollers.

“We’ve been surprised by the low noise level of this system, which enhances the workplace, and the conveyor has proven highly reliable,” Sawyer added.

“The totes are more secure on the chain than on rollers — much less likely to drift. The chain will actually realign totes slightly, and it easily transports them 175 ft to the first turn. We are quite pleased with the outcome and the results of the installation.”

MRO An interactive page-flip version of the System Plast catalogue is online at www.emersononlinecatalog.com. Printed copies can be ordered at www.emerson-ept.com.

For other information, visit www.EmersonIndustrial.com.

Online Reader inquiry No. 489

12-09-07 8:24 AM

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Machinery & Equipment MRO

Switching from belt drives to gearmotors A CHANGEOVER FROM SHAFT AND BELT DRIVES TO DIRECT DRIVES FOR THE CONVEYORS AT THIS BUSY AGGREGATES PLANT HELPED TO CUT COSTS AND REDUCE MAINTENANCE EXPENDITURES.

in

many gravel pits, stone-crushing plants and similar operations, motive power for conveyor belts is provided by shaft and belt drives. Until recently, this was the situation at the gravel plant of NorStone AS in Tau, located in the southwest region of Norway. Three years ago, NorStone, a subsidiary of HeidelbergCement AG, decided to change to geared motors.

This option promised lower investment costs and increased operational reliability, along with better process security. Reduced energy consumption thanks to higher efficiency was also anticipated.

NorStone is Norway’s largest producer of gravel products. The company supplies aggregates for concrete and asphalt, pipe cover gravel for coastal regions, and other special products. Each year, NorStone’s production facilities altogether produce over 6.6 million tonnes of gravel products in various sorts and quality classes.

The demand is large, and even with its present annual production capacity of 2.3 million tonnes of material, the Tau plant can scarcely meet the demand. This makes it especially important to ensure that the plant is operational as much as possible and to minimize unplanned downtime.

Familiar advantages plus increased reliability Geared motors are actually not new in gravel pits. Direct drives of this sort were commonly used in the 1980s, but in subsequent years many plants changed to belt drives because spare parts for these drives were always quickly available, while manufacturers and suppliers of geared motors were unable to offer stocks of spare parts with the same good availability.

“We have found that service and spare parts for geared motors are now available to us very quickly. We hold some parts in stock ourselves, and for all of the rest we have complete trust in Nord Drivesystems as a supplier,” explained Ivar Ullestad, maintenance manager at Tau, as the reason for going back to the former solution.

“This allows the known advantages of drive solutions with geared motors to be fully exploited. In particular, direct drive leads to higher reliability, which means less downtime and therefore less lost production time. Another important aspect is that less maintenance is necessary. In addition to

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reducing maintenance costs, this increases safety in the plant,” added Ullestad.

Measurably less wear Working conditions are a significant factor in such considerations. “You have to bear in mind that we work outdoors all year round. Most of the locations for the conveyor belt drives are open and unprotected. Due to the harsh weather conditions in the west of Norway, with wind, rain and sleet, as well as the dusty and rather unpleasant environment at the site, we try to minimize repair and maintenance times for our maintenance staff.”

The Tau plant runs seven days a week, 24 hours a day, in shift operation.

The 168 production hours include 16 hours of scheduled maintenance. The plant is only shut down for the winter break. During this break, annual maintenance inspection and overhaul tasks are performed in two to three weeks.

The direct drives have contributed to a distinct increase in reliability, amounting to approximately 4.5%, in the past three years. “We are very satisfied with this trend. With the change from shaft and belt drives to direct drive with geared motors from Nord Drivesystems, in the first place we eliminate the aspect of belt wear, which is considerable. Furthermore, no water or dust can enter the drive mechanism. This means that the decision in fa-

Top left: Due to the harsh weather conditions, with wind, rain and sleet, as well as a dusty and rather unpleasant environment, the aggregates plant tries to minimize repair and maintenance times for its maintenance staff.

Top right: The NorStone plant used to have many excavation belts such as the one shown, with a shaft and drive belt connected to two 55-kW motors. By contrast, the refurbished belts are equipped with geared motors, such as the combination of a gear unit and 90-kW motor.

Bottom left: NorStone’s Tau plant produces 2.3 million tonnes of material annually.

Bottom right: A worker installs a new gearmotor drive on the Tau plant’s conveyor system, which operates in severe conditions. Here, a 15-kW drive with a geared motor is fitted on a belt below the crushers.

vour of compact, robust geared motor units yields clear advantages and has therefore proven to be an intelligent move,” summarized Per Thu, production manager of the NorStone plant.

The direct drives brought more than just higher reliability and reduced financial and labour expenditure for maintenance activities. The relative investment costs for purchasing new gear units also proved to be lower.

Replacing a complete package, consisting of a shaft-type gear unit along with belt pulleys, belts, a shed, belt cover and a motor, turned out to be more costly than purchasing a comparable geared motor. As a series of periodic gear unit replacements was anyhow in the works, a comprehensive switch from shaft and belt drive to direct

drive was a logical choice for Ullestad.

He is currently working to standardize drive components. “With a staged cutback in drive systems for the conveyor belts, we are standardizing aspects such as motor size, shaft size and drum diameter in order to limit diversity and thereby simplify maintenance, stock management and service. We are also developing backup solutions, which among other things involves keeping components in stock ourselves,” according to the maintenance manager.

MRO This article was prepared by Getriebebau Nord GmbH & Co. KG, Hamburg Germany. For more information from Nord Gear Canada, visit www.nord.com.

Online Reader Inquiry No. 482

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Online Reader Inquiry No. 141

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12-09-07 8:24 AM

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September 2012

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BY SIMON FRIDLYAND

DO YOU WORK ON

UNGUARDED

MACHINERY? WHAT SHOULD YOU DO WHEN A MINISTRY OF LABOUR INSPECTOR GIVES YOU A STOP WORK ORDER FOR UNGUARDED MACHINERY?

order as soon as possible.

The easiest and simplest way is to place a box around the machine, in some cases with a padlock attached. When the inspector comes to withdraw the order, there is seldom a problem. The machine is safe!

However, can you operate this machine? Can you clear jams without completely locking out and tagging out the machine? Can this machine be productive so that you can compete? The answer is no.

Therefore, such a box will not last long, and because it is so inconvenient and slows production to a halt, it often will be removed. We see this scenario time after time. The result is wasted money, a reduction in productivity, increased liability and total frustration with the process.

Should the MOL inspector come back and notice the removal of the box, additional orders and penalties will definitely apply. If convicted of an offence under the Act, an individual can be fined up to $25,000 and/or imprisoned for up to 12 months. The maximum fine for a corporation convicted of an offence is $500,000.

Should, a very serious accident or fatality take place, criminal charges under Bill C-45 may apply. This may mean life imprisonment and an unlimited fine.

So what should one do when the MOL issues a stop work order? You need to get in touch with a professional engineering firm specializing in machine safety compliance issues. In selecting such a firm, you need to make sure that they are capable of the following: • The engineering firm that designs the safety solutions for machine guarding issues must produce a positive Pre-Start Health and Safety Review report (PSHR), assuming full responsibility for the content of the report.

• Hazard assessment must be a part of any PSHR report, especially one dealing

©iStockphoto/Thinkstock

he Ontario Ministry of Labour recently reported that its safety inspectors conducted more than 60,000 visits to workplaces from April through to December 2011.

The inspectors visited 32,467 workplaces, for an average of two visits per workplace, and the inspectors issued 103,965 compliance orders.

Were you one of the companies cited for non-compliance? Could it happen in your own province?

An inspector’s enforcement action depends on the type of violation. If an inspector observes a violation of the Occupational Health and Safety Act, the inspector may issue an order for compliance. There are three different types of orders.

1. Time-based order — compliance must be achieved within a time frame determined by the inspector in consultation with the employer and worker representative (where there is one).

2. Forthwith order — efforts to achieve compliance must begin immediately and be completed before the inspector leaves the operation; or 3. Stop work order – used when an inspector finds that the contravention is an immediate danger or hazard to the health or safety of a worker (e.g. unguarded machinery that is being used).

A stop work order will be withdrawn upon compliance being achieved.

In machine guarding situations, when a stop work order is issued, the equipment cannot be operated and there is a natural desire by the employer to deal with the stop work

with machine guarding issues. Some reports do not include a hazard assessment and it is therefore impossible to assess the electrical circuitry architecture of the machine to establish the degree of safety redundancy necessary.

• Conclusive statements. Some reports do not have any conclusive statements or recommendations to achieve compliance. The report may just indicate noncompliance issues based on a simple physical examination of the machine.

Drawings, which show the architecture of the electrical circuitry, are sometimes not examined. When selecting a provider, specify that a conclusion is to be part of the report.

• Multiple disciplines. The majority of PSHR providers specialize in one discipline only. However, owners and employers have to make sure that all issues of concern, such as with mechanical, electrical, pneumatic and hydraulic systems, will be addressed by the provider. Therefore, a firm with multi-discipline capability should be given consideration.

• Liability insurance coverage. The owner and employer should clearly specify the insurance coverage expectations, including general liability (minimum $5 million), professional errors and omissions (minimum $2 million), and WSIB insurance.

• Design and advice. This is the most important criteria. When selecting an engineering firm, one needs to make sure that such help is available.

When it comes to system design, particularly on older existing equipment, the devil is in the details. This is why the chosen engineering firm must take the time to involve your operators and the maintenance and engineering staff in the solutions-development process.

The first step in the process is the development of the Solution Technical Requirements. This is an intensely consultative stage where all parties brainstorm and agree on how the safety solutions should look, work, behave, cost, etc. This is the basis for all further design and build efforts.

Needed services must include design and project management capabilities.

The safety design that leads to productive and compliant machinery usually incorporates electrical/electronic devices such as light curtains, scanners and interlocks, as well as a reliable control system.

Compliant designs must meet the requirements of the CSA/Z432- Safeguarding of Machinery Standard. When machinery is designed correctly, the Standard allows entry into the protected envelope of the machine for adjustments and clearing up jams without locking out the machine. This does not apply to major overhauls or when equipment goes through regular maintenance.

Safety and productivity are two sides of the same coin only when used correctly. The most productive ways of operating a machine can be discovered during brainstorming in the solution development process and then locked in by using machine guarding arrangements.

Companies often report productivity gains of 3-5% after equipment has been retrofitted for safety, so it is possible to turn a liability into productivity. MRO 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.

Online Reader Inquiry No. 487

Online Reader Inquiry No. 142

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12-09-07 8:26 AM

S U P E R V I S O R Y

THESE FIVE SUGGESTIONS CAN HELP YOU SAVE TIME BY COORDINATING NEW AND OLD IDEAS

Machinery & Equipment MRO

©Huntstock/Thinkstock

September 2012

TIME MANAGEMENT TIPS FOR OPERATIONS & MAINTENANCE

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S U G G E S T I O N S

shop for and order supplies, keep track of how much you’re spending, and integrate your order process.

4. Multi-task; it can be fun, or at least easy. Standing in line: Use your smartphone to check e-mails or review and approve the orders in your in-box. On the job site and need a product: Use your smartphone to search for products. Websites that offer eCommerce to provide features such as real-time product availability can answer questions such as: Do they have it?

Where can I get it? How can I get it?

5. Don’t start from scratch every time you start a new project. Do you perform the same task over and over again? Then, create a shortcut. Use online tools on distributor websites like personal lists that let you create reminders for specific items that you order frequently. You can use your personal lists to quickly place orders, share your lists with people working with you, and keep a record of your previous purchases for fast accounting later.

Regardless of whether it is a hammer, computer or smartphone technology, a tool is not helpful unless it to works the way you need it to work. Combine your resources to customize how you shop, buy and have products delivered — whether you use mobile web, a website, a printed catalogue, or meet in person with a distributor’s local branch sales representative..

MRO For more information, visit www.acklandsgrainger.com.

A

ccording to Forrester Research, in the US alone, there were nearly 100 million smartphones by the end of 2011. New mobile technology is changing how people control the information that is important to them.

Here are five tips from industrial distributor Grainger, to help you think about how to make technology work for you and, most importantly, help you put time back into your day and efficiently manage your work.

1. Technology should work the way you work. In January this year, 51% of Americans used their cell phone to go online, and it can be expected to be a similar percentage in Canada. By 2014, more people will find information online using cell phones rather than desktop computers.

You’re likely to be part of that trend. If so, you can take advantage of new mobile websites that improve your access to critical features on a distributor’s website, no matter your location – job site, truck, plant floor, garage or maintenance shop.

The latest mobile web platforms and enhancements make online experiences faster, easier and more personal.

2. Don’t put things off; get answers when you need them. Today, most operations and maintenance professionals spend less time at their desks than in the past. To be the most effective, make sure you have access to resources where you need them, when you need them.

For some, that may mean starting to shop in the office on a distributor’s website, then working with a partner who wants to use a printed catalogue as they have done for decades, or being in the field alongside associates and using a mobile phone to find the right product and ordering it on the spot. Your resources should be interactive as well. Online features like ‘click to chat’ can provide immediate answers to help complete projects quickly.

3. One minute of set-up equals hours of time saved. Forrester Research also says businesses can save $10-$20 per order when they automate purchasing processes.

Online ordering offers an efficient way to

p28-30 MRO Sept12 Columns.indd 29

Online Reader Inquiry No. 143

12-09-07 8:26 AM

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Machinery & Equipment MRO

September 2012

Monitoring Machinery Trends BY PETER PHILLIPS

How condition-based maintenance allows maintenance departments to do only the right things, minimizing spare part costs, system downtime and the time spent on maintenance.

This is the fifth set of activities in an eightstage program on achieving world-class maintenance. Stage 4 was described in the April and June 2012 issues of Machinery & Equipment MRO. Stage 5 examines the field of trend management.

TYPES OF MAINTENANCE MAINTENANCE APPROACH

if

you have been following our Maintenance 101 column, you know we have been covering the basics of world-class maintenance. The steps that we’ve been exploring in this and the past several issues have been guiding us towards a new way of looking at how we do equipment maintenance.

The days of doing a high percentage of reactive maintenance compared to a low percentage of preventive maintenance have sailed into the sunset. Many companies are building skilled maintenance teams that rely on reliable equipment history, parts management and effective preventive maintenance practices. They use breakdown analysis to correct failures, root cause analysis to study problems, and continuous improvement methods to create more reliable equipment.

Maintenance personnel are expected to embrace new technologies, using computers for their CMMS programs and electronic tools to measure and control maintenance systems. As we progress with these technologies and our maintenance skills improve, we are ready to move on to the next step of world-class maintenance, Stage 5 — trend management.

Trend management is the study of equipment condition using indicators to tell us how the equipment is performing.

nance, involves duties carried out by machine operators. These basic maintenance routines help to maintain the equipment.

Operators are trained to do equipment lubrication and visual inspections.

TBM is about preventive maintenance tasks that are completed based on the passage of time, such as scheduled activities like weekly, monthly, quarterly and annual preventive maintenance routines. These maintenance jobs are the typical work orders that maintenance staff perform.

As the maintenance team progresses through to a goal of world-class maintenance, they are ready for the more ad-

PLANNED

PM Preventive Maintenance

AM Autonomous Maintenance

UNPLANNED

BM Breakdown Maintenance

CM Corrective Maintenance

CBM Condition-based Maintenance

TBM (Periodic) Time-based Maintenance

Continuous

In this article, we are going to explore equipment trending using conditionbased maintenance.

A typical maintenance approach (see chart) entails Planned and Unplanned Maintenance. Planned maintenance is further broken down into Preventive Maintenance (PM) and Corrective Maintenance (CM). CM are those repairs waiting to be planned and completed. PM is further subcategorized into Autonomous Maintenance (AM), Time-Based Maintenance (TBM) and Condition-Based Maintenance (CBM).

CM entails repairs that have been identified during preventive maintenance activities and work requests submitted by operators and supervisors. Maintenance tags are a part of corrective maintenance that was discussed in Finding the Weak Points (June 2012 issue, p. 20).

AM, a subset of Preventive Mainte-

Intermittent

vanced forms of predictive maintenance.

Condition-Based Maintenance offers maintenance staff the opportunity to engage in a different approach to maintaining the condition of the equipment. Briefly, CBM means ‘maintenance when the need arises’. Maintenance is performed after one or more indicators show that the equipment is going to fail or that the equipment performance is deteriorating.

Basically, by observing the state of the equipment, the maintenance department can determine the equipment’s health and act only when maintenance is actually necessary.

CBM can either be continuous or intermittent. In either case, CBM relies on the fact that the majority of failures do not occur instantaneously, but develop over time. We can use the analogy of a pothole in a road. It starts off as a very

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small blemish in the pavement, but over time and if left unattended, it develops into a large rut. The same happens to equipment; a small bit of deterioration develops into a catastrophic failure over a period of time.

CBM involves recording some measurements that give an indication of a machine’s condition, for example, the rise of the temperature of oil in a gearbox, or the increase of vibration in a bearing housing.

However, condition-based maintenance is not purely a high-tech tool to be used by highly skilled maintenance people. Operators who work with equipment every day can listen to their machines and identify changes in noise levels, vibration and temperature. These indicators are warnings that something is not right. Maintenance staff can then carry out an investigation to identify the exact problem.

Of course, listening to the equipment operators is a relatively new concept. For many decades, operator reports of equipment problems were ignored. This created a culture where operators did not bother to report the things they heard, smelled or felt while operating their machines. Now, the direction is to train highly skilled operators not only to report issues but also to help maintain the equipment through Autonomous Maintenance.

So what are the advantages and disadvantages of condition-based maintenance?

Advantages • Maximizes equipment availability.

• Some forms of inspection use human senses and can be effective and inexpensive.

• Allows shutdown before severe damage occurs.

• Cause of failure can be analyzed.

• Maintenance can be planned to make the repair.

• Labour can be organized.

• Spares can be assembled.

• Some CBM tools are very basic, such as temperature and pressure monitoring.

• Decreases maintenance costs.

Disadvantages • Vibration monitoring, thermography and oil analysis require specialized equipment and training, or the work needs to be contracted out to external specialists. In both cases, there is a significant cost involved.

• A company must carefully choose the correct technology.

• A period of time will be required for trends to develop, before the machine condition can be assessed.

These disadvantages are being outweighed by the cost of maintaining equipment as condition-based monitoring instrumentation becomes cheaper and more reliable. The cost of breakdowns and the effects they have on the ability for a company to supply its customers are driving the use of more advanced predictive maintenance practices. With better tools for analyzing condition data, maintenance personnel today are more able to decide when it’s the right time to perform maintenance.

Ideally, Condition-Based Maintenance will allow maintenance departments to do only the right things at the right times, minimizing spare part costs, system downtime and the time spent on maintenance. As a result, maintenance people will become more engaged in the performance of the equipment and the maintenance department overall. It’s a win-win combination.

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.

12-09-07 8:26 AM

P R O D U C T

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N E W S

September 2012

What’s new for severeservice environments t

Conveyor bearing’s multi-level barrier protects against extreme conditions

Online Reader Inquiry No. 432

For bearings and metal parts that are exposed directly to humid or corrosive environments, NKE Austria GmbH offers a special galvanic coating that provides cost-effective protection against corrosion. The new and improved coating SQ171E is even thinner and provides longer-lasting protection against corrosion than the previous version. The coating

protects bearings and components in applications including material handling, agricultural machinery, chemical and pharmaceutical industries as well as compressors and pumps. As the photo shows, even after a neutral salt spray test, the coated part (in front) does not show visible traces of corrosion. The uncoated reference part (behind) shows traces of rust.

The SQ171E coating can be used for standard or special bearings as well as for all metal parts that are exposed to wet or corrosive environments. Even machined surfaces such as races can be coated with SQ171E. The coating provides protection against water, condensation and slightly alkaline or acidic cleaning agents. Compared to stainless steel, the coating is more cost-effective, yet offers better anticorrosion protection.

Global Bear Inc. Online Reader Inquiry No. 475

IR thermometers withstand hostile environments

t

New special coating protects bearings against corrosion

Online Reader Inquiry No. 437

Built for the harsh conditions faced by technicians i n ele c t r ic a l, ser v ic e, HVAC, process, industrial a nd facilities maintenance applications, the Fluke 62 Max and 62 Max+ infrared thermometers are dust, water and drop resistant. They can survive 3 m (9.8 ft) drops to wood floors, are IP54 rated to withstand rain, splashing liquids, dust and dirt, and are small enough to carry comfortably on a tool belt all day. The 62 Max has a distanceto-spot ratio of 10:1 and measures temperatures from 30°C to 500°C. The 62 Max+ has a distance-to-spot ratio of 12:1 and measures 30°C to 650°C. Both operate on a single AA battery.

Fluke Electronics Canada Online Reader Inquiry No. 434

Radial shaft seal protects wind turbine drivetrain bearings

SKF reinforced all-rubber HSS radial shaft seals provide protection against contaminants and extended service life for large-size bearings in wind turbine drive-

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Metallic coating helps assure long-term motor operation

Lenze Americas has introduced an OKS coating for its Lenze geared motors and

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MadeEasy_MRO_7x2.25.indd 1

Hand cleaner makes light work of tough soil environments

Gojo Cherry Gel pumice hand cleaner, a heavy-duty hand cleaner with pumice scrubbers, quickly cleans the heaviest dirt while leaving skin feeling refreshed.

Its pleasant cherry fragrance eliminates soil odours and leaves hands smelling clean. It is pH balanced for skin comfort.

The cleaner features a gel formula that spreads evenly and clings to hands and arms for tough cleaning power on heavy dirt, grease and oil. It also provides a quick, easy and complete rinse. It is available in portable 6-fl-oz and 10-fl-oz squeeze bottles, 1/2-gal and 1-gal pump-top bottles, and the Pro TDX dispensing system in 2,000-ml and 5,000-ml sizes. The rugged dispenser uses Sanitary Sealed refills to help ensure that the soap is safe from contamination.

Gojo Online Reader Inquiry No. 464

trains. The seals are designed for easy installation or uptower replacement during planned maintenance procedures. Their minimal space requirements allow for smaller and lighter bearing housings, potentially reducing turbine weight. They integrate SKF Duratemp hydrogenated nitrile rubber, which can accommodate imperfections in the mating housing surface. Available in solid and split versions, the seals can be equipped with an optional SKF Springcover, specially engineered to keep the spring in the correct position.

SKF Canada

t

The SKF Three-Barrier Solution for conveyor applications exposed to extremely harsh conditions comprises a bundle of environmentally friendly products designed to increase bearing reliability and extend service life without the use of solid lubricants, auxiliary seals or large quantities of grease. The conveyor solution consists of four interrelated components: factory-sealed and upgraded SKF Explorer performance-class spherical roller bearings, optimized split pillow block housings, PosiTrac Plus type seals for the housing, and 60% to 80% grease fill inside the housing. The bearing is lubricated, sealed and mounted inside the housing, which is then internally greased and sealed. This creates three barriers of protection for the bearing during operation. The solution suits operations in the mining, cement and aggregates, steel, forestry, and pulp and paper industries, among others.

SKF Canada

gearboxes for the packaging market.

The metallic coating withstands extremely harsh ambient conditions, such as UV rays, temperature, humidity, salt-spray, oil, solvents, fuel and acids, which can cause corrosion on motor surfaces and wear down components. The coatings can be applied to the motor and/or components depending upon the degree of protection required in the enduser application. OKS-G (primed) and OKS-S (standard paint) coatings provide protection in indoor installations in heated rooms with air humidity up to 90%. The OKS-M paint is for use in indoor installations in unheated rooms or in a protected outdoor installation with air humidity up to 95%. These powderthin coatings offer good corrosion resistance without adding weight or size to the motor and its components, and do not change the product’s dimensions or surface properties.

Lenze Americas

Machinery & Equipment MRO

Online Reader Inquiry No. 431

Stainless steel shock absorbers have long service life

ACE Controls has introduced a series of long-life application shock absorbers.

These V4A stainless steel absorbers are suitable for many industry uses, such as packaging, food processing, medical, marine and more. They also come with a protective cap made of PTFE Teflon, which protects the complete damping system against harmful environmental agents. Energy capacity ranges from 20 Nm/cycle to 3,400 Nm/cycle (175 in.-lb/ cycle to 30,000 in.-lb/cycle), weight capabilities from 0.9 kg to 42,500 kg (2 lb to 93,600 lb) and thread sizes from M14 by 1.5 up to M64 by 2.

Vickers-Warnick Online Reader Inquiry No. 435

Bearing material can handle high loads in dirty or wet conditions

Self lubricating, low-maintenance Vesconite Hilube bushings and wear plates require no grease. Developed to solve wear problems in unlubricated and dirty applications, these long-life, low-friction products can be used dry or underwater, including in sea water. Typical applications include earth-moving equipment bear-

Build a complete picture of your environment with IRPhotoNotes™ Color alarms highlight problem areas

ings, mining machinery on surface or underground, long-life pump line shaft bearings, heavyduty truck suspension bushings, and dirtresistant bushings for grabs, tail lifts and material handling. They are ideal for high loads with precision clearances in dirty or wet conditions.

Vesconite Online Reader Inquiry No. 436

Mast hose is built to withstand harsh environments

Parker Hannifin’s Parflex Over-TheSheave thermoplastic hose for mast hose applications is built to weather harsh environments and continuous flexing with a high level of contact strength between the layers of core, braid and jacket. The company’s bonding process creates projections on the outside of the core that ex-

tend up into the braid, while the jacket material is forced down into the braid from the outside. Parflex 53DM Duramax hose meets or exceeds SAE 100R18 and the 55LT hose meets or exceeds SAE 100R7 specifications. These hoses and the H6 hose feature a minus 70°F low temperature, and the H6 hose is rated as high as 250°F. Wire-reinforced options are available. Sizes range from 3/16 in. up to 1 in. and all of these hoses are available in a single, twin or multi-line design.

Parker Hannifin Online Reader Inquiry No. 430 MRO

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New from Fluke: Our easiest-to-use thermal imagers ever. IR-OptiFlex™ delivers point-andshoot imaging with full IR-Fusion capabilities.

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Online Reader Inquiry No. 145

12-02-04 11:05 PM

12-09-07 11:51 AM

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P R O D U C T

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Machinery & Equipment MRO

September 2012

What’s new in heavy duty casters and wheels

Online Reader Inquiry No. 472

The antimicrobial compound used in Albion Prevenz wheels is designed to suppress the growth of a variety of destructive and odour-causing microbes, including bacteria, moulds, mildew and fungi. The active ingredients neutralize the ability of microbes to function, grow and reproduce. As it is an integral part of the wheel material, not a surface coating, the compound lasts the functional life of the wheel and helps reduce wheel decay and deterioration. The wheels are available in a variety of diameters, from 3 in. to 10 in., and rated for loads from 300 lb to 2,500 lb. Applications include scientific and research,

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Bestway offers a full line of stainless steel casters for all common applications where steam cleaning and cleanliness are a must. The company has introduced the SSLD, SSLE and SSLS series casters, incorporating its double ball kingboltless technology, all of which can be customized to suit specific needs.

Various models are available with capacities from 250 lb to 3,500 lb. This heavy-duty stainless caster can stand up to punishing towline and shockload applications in such areas as cheese factories, slaughter houses, poultry and fish plants and hospital carts.

Bestway Casters & Wheels

Colson Caster has added a brake option to its low-cost Encore Dolly line of swivel casters. Crafted to move dollies, food service carts and stock carts easily and silently, the brake is formed with a durable zinc-plated finish, and locks both the wheel and swivel simultaneously when easily engaged by foot action. The series’ easy-rolling and non-marking grey TPR wheel is fitted with a plastic thread guard that also serves as an integrated spanner bushing. All models have a 1-1/4-in. tread width and are available in 3-in., 3-1/2 in., 4 in. and 5 in. wheel diameters with load capacities tested from 180 lb to 260 lb.

Colson Caster

Antimicrobial compound helps keep wheels sanitary and bacteria-free

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Stainless steel caster line is for use in hygienic applications

Caster brake option locks wheel and swivel for added safety

WHAT VIBRATION PENS

Online Reader Inquiry No. 467

medical and healthcare, pharmaceutical, chemical, food processing and clean room environments.

Albion Online Reader Inquiry No. 469

Corrosion-resistant nylon wheel can bear extra-heavy loads

Hamilton Caster’s Nylast wheels are designed for high-capacity applications in corrosive and sanitary environments. With a tensile strength of 11,000 psi and resistance to both moisture and many chemicals, these wheels are an alternative to steel for ex-

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Reader Inquiry No. 146

5/28/12 8:04:14 PM

LYNN COMPANY LTD., 470, St-Alphonse St, Thetford Mines, QC CANADA G6G 5V2 Tel.: 418 338-4501 • Fax: 418 338-4504 • www.lynnco.ca • info@lynnco.ca

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SINCE 1951

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ROTOFLUID • Inline or V-Belt

ROTOFLUID CA • Controlled Extra Soft Starts

ROTOGRID • Drop in Interchange

ROTORIGID • Supports Complete Drive Base

Online Reader Inquiry No. 147

motors

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MaxMotion

MaxMotion

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Online Reader Inquiry No. 471

Wide range of wheels, casters suits many applications

— Quality motors for every application

All-in-One 56C Frame JM-JP Close MaxMotion Stainless Steel MaxMotion MaxMotion w/removable feet Coupled Motors Motors Availability * Expertise *1HP Warranty Three * Phase, to 50HP * 1HP to 300HP All-in-One 56C Frame * Expertise JM-JP Close* NEMA Premium * Availability * Availability * Expertise * Warranty * Warranty * Complete product benefits at www.motors.mep.ca * Warrantyfeet * w/removable Coupled Motors Efficiency Motors* Availability * Expertise Complete productComplete benefits at www.motors.mep.ca 1-877-812-7788 Complete product benefits product at benefits www.motors.mep.ca at www.motors.mep.ca

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Darcor KP (kingpinless) double- and triple-wheel casters combine high load capacity, low starting and swivelling forces, quiet operation and a choice of wheel sizes and materials, all at a competitive cost. The easy movement helps reduce workplace injuries and increase productivity. Designed for loads up to 6,000 lb, the casters come in 6 in. or 8 in. diameter, in solid elastomer, for normal conditions, or neoprene for uneven floor surfaces and debris. In applications where height is an issue, the casters deliver a 1/2-in. height advantage for 8-in. wheels, and 2.5 in. of clearance for 6-in. wheels.

Darcor Casters

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MaxMotion

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Online Reader Inquiry No. 465

Ro-Ma manufactures aluminum wheels with polyurethane tread using its Inter Lock process, which seals the tread to the aluminum core, thereby preventing separation. Its swivel and rigid casters range in capacity from 110 lb to 34,000

Three Phase, MaxMotion 1HP to 50HP MaxMotion MaxMotion MaxMotion MaxMotion MaxMotion 1HP to 300HP All-in-One 56C Frame JM-JP Close NEMA Premium Three Phase, Three Phase, 1HP to 50HP 1HP to 50HP 1HP to 300HP 1HP to 300HP w/removable feet Coupled Motors Efficiency Motors All-in-One 56C Frame JM-JP Close JM-JP Close NEMA Premium NEMA Premium All-in-One 56C Frame MaxMotionfeet MaxMotion w/removable feet w/removable Coupled Motors Coupled Motors EfficiencyMaxMotion MotorsEfficiency MotorsMaxMotion 1HP to 300HP NEMA Premium Efficiency Motors

ensure consistent quality. The wheels are often mounted in Hamilton’s stainless steel casters due to their shared corrosionresistant properties.

Hamilton Caster & Mfg. Co.

High-load caster keeps rolling smoothly

New Expanded ROTO-Coupling Range

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tremely heavy load applications. They find application in the chemical, food and heavy manufacturing industries. The Nylast material is formulated with finely divided particles of molybdenum disulphide to enhance its load-bearing capability while maintaining the impact resistance inherent to nylon. The face, sides and bore are CNC-machined to precision tolerances to

lb. As an example, the extra-heavy-duty Serie 7 offers up to 17,000 lb capacity and features a hot-forged ASTM 1045 steel MaxMotion zinc plated finish and is kingpinless.

1/3HP to 20HP Ro-MaSteel Casters & Wheels Stainless Motors Online Reader Inquiry No. 473 MRO Obtain free additional information about

* Availability * Expertise * Warranty * any of these items by using our online reader reply card at www.mromagazine.com/rsc.

Online Reader Inquiry No. 148 Complete product benefits at www.motors.mep.ca 10/7/10 2:27:26 PM

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What’s new in pumps Pump is designed to boost pressure in inline applications

Thermoplastic pump series delivers long service life

Hayward Flow Control has introduced the T-Series Webster thermoplastic pumps.

Manufactured using a single, non-coupled motor/impeller shaft with a PTFE shaft seal, the line of vertical sealless immers-

Online Reader Inquiry No. 446

Modular waterjet pump is built for easy portability

Jet Edge has introduced the iP3650 modular waterjet intensifier pump. Designed for ease of portability, the 36 KSI (kilopound/sq in. or 2500 Bar), 50-hp pump features a modular design that makes it easy to move into tight spaces, such as small passageways, ship engine rooms and ballast tanks. It produces up to 1.8 gpm (6.8 l/m) of 36 KSI (2500 bar) ultra-high pressure water for precision cutting, cleaning and surface preparation applications, and includes three modules with lifting eyes. The modules, which can be stacked to save

Online Reader Inquiry No. 149

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Diaphragm rupture sensor allows for safe fluid handling

Suitable for use in chemical processing applications, the All-Safe DRM (Diaphragm Rupture Management) sensor from All-Flo detects any diaphragm failure in a diaphragm pump. The system provides two layers of protection. A sensor installed between the PTFE overlay and the backup diaphragm detects a leak if the PTFE overlay becomes compromised. A second sensor is installed in the air section itself. Should both diaphragms become compromised, this sensor will detect fluid in the air section. Both sensors can be configured to take a variety of actions should a leak be detected, such as turning on a warning light, sounding an audible alarm or triggering pump shut-off. The electronic connectivity probes complete a circuit and alert the external sensor panel, which can be easily wall-mounted and is housed in a NEMA-rated polycarbonate enclosure.

All-Flo Pump Co. Online Reader Inquiry No. 449

space during operation or storage, are linked together by hydraulic hoses and electrical cables, allowing for 10-ft (3-m) separation of the modules from each other.

Jet Edge

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Online Reader Inquiry No. 445

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The KSB Movitec models are easy-to-install pumps for a wide variety of applications where pressure boost is needed, including water supply/treatment, hot and cold water recirculation, condensate transport, and boiler feed and desalination systems based on reverse osmosis.

The pumps come in a range of sizes (up to 90-mm pipe diameter) and feature heads of up to 249 m and flow rates as high as 90 cm per hour. Stainless steel hydraulic elements ensure long service life and good pumping efficiency. A wide range of fluids is readily handled, including water, acidic and alkaline solutions, alcohol, vegetable oils and petroleum products.

KSB Pumps

ible pumps is available from 1/3 hp to 1-1/2 hp with standard and washdown motors and in voltages of 115/230 and 208230/460. Features include CPVC pump head and impeller, 303 stainless steel shaft material and extended shaft sleeve.

Options include GFPP or PVDF pump head and impeller assembly, inlet screen, in-tank filtration, impeller trim variations, explosion-proof motors, 575-V motors and S-J type electrical cord. Typical applications for this versatile pump series include chemical processing and transfer, metal plating, waste and water treatment and mining.

Hayward Flow Control

Machinery & Equipment MRO

Online Reader Inquiry No. 448

Water pressure sensor helps maintain pump efficiency, minimize service calls

Used to measure water booster pressurization in pipelines and tanks and serve as part of monitoring and control systems, AST water pressure sensors use Krystal Bond technology and a one-piece, thick diaphragm design that keeps hazardous

materials from penetrating the sensor diaphragm.

The sensors can be constructed in a choice of wetted materials such as 17-4PH and 316L stainless steels and nickel alloys to handle all types of water, and can be packaged with high-level voltage, current and frequency outputs. Units are available with a variety of process connections (NPT, SAE and BSP threads), various electrical connections (cable, DIN, Eurofast and Deutsch) and in sealed-gauge pressure ranges to protect electronics from water conditions.

American Sensor Technologies Online Reader Inquiry No. 447 MRO

Online Reader Inquiry No. 150

12-09-07 11:51 AM

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Machinery & Equipment MRO

What’s new in bearings t

App puts bearing assistance at the user’s fingertips

Rexnord’s free Bearing Mobile Pro iPhone app allows customers and distributors easy access to technical data and assistance for bearings, anywhere and at any time.

This user-friendly app, which is supported by the Apple iOS platform, is suitable for anyone who purchases commercial-grade bearings. It offers technical information with more than 17 data points for Rexnord roller, ball and cylindrical bearings, the ability to interchange competitive manufacturer products to the appropriate Rexnord solution, instant answers

Press forward button to prompt e-mail screen Interchange between Rexnord brands Over 17 unique technical fields are prompted

to critical job site questions, the ability for users to immediately share information via email, and direct access to live support via e-mail and phone.

Rexnord Online Reader Inquiry No. 421

Upgraded spherical roller bearing offers longer life, runs cooler

Engineered for enhanced durability, Timken’s spherical roller bearing offers an 18% increase in capacity, resulting in a 75% design life improvement over the company’s former spherical roller bearing offering. The bearing is designed to run cooler in heavy-duty applications subject to high temperatures. Features include optimized internal geometries for

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Radial insert ball bearings and housing units withstand rough conditions

Schaeffler offers a comprehensive modular system of INA X-life radial insert ball bearings and housing units. Operating with quiet-running efficiency, these products offer long life and simplified mounting operations with low maintenance outlay. The use of Corrotect N surface coating greatly enhances corrosion protection, rating life has been increased by up to 15%, and the standard operating temperature range has been extended to 180°C for some series. The seal system comprises an outer cap, seal lip and inner cap designed for nearly all operating and environmental conditions. The product line includes over 230 series ranging from 10 mm to 120 mm in diameter.

Schaeffler Online Reader Inquiry No. 428

increased load-carrying capability and lower operating temperatures, improved lubricant distribution and positive roller guidance, and positive hydrodynamic contact for better roller/cage interaction.

The bearing is available with a stamped

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Place advance orders by scanning this QR code, visiting www.ptda.org/Order5th or call +1.312.516.2100 or e-mail ptda@ptda.org Channeling the Power of Industry

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Online Reader Inquiry No. 442

Bearing catalogue contains a wealth of practical information

NKE Austria has published the fifth edition of its General Catalogue, containing more than 1,000 pages of comprehensive

There’s only one

• New chapter on technical and engineering data for easy reference

Online Reader Inquiry No. 151

steel or machined brass cage.

Timken Canada

information for industrial distributors as well as engineers and designers. Available free of charge in print form or as a download from www.nke.at/catalogue, the catalogue contains NKE’s updated product range of standard bearings. The technical section includes information on bearing selection and on handling, mounting and dismounting, lubrication and tolerances. The product section contains product tables and model-specific details for each product group. This edition contains additional technical data, such as service life calculations, fatigue limiting loads and thermal speed ratings.

NKE/Global Bear Inc. Online Reader Inquiry No. 424

Data sheet details high-load slewing ring bearings

Kaydon HS Series slewing ring bearings, offering high load and thrust capacity, are featured in a data sheet from Kaydon Bearings Division. The data sheet can be downloaded at http://www.kaydonbearings.com/downloads.htm#other. The bearings provide four-point contact in deep groove gothic arch raceways and feature about twice the load capacity of the company’s RK Series bearings (up to 139,900 ft-lb) in the same envelope. Suitable for medium- to heavy-duty applications such as cranes, aerial lifts, digger derricks, chute swivels, lift truck rotators, and industrial turntables, they are available with internal gearing, external gearing or no gearing. Outside diameters range from 500 mm to 1,200 mm (20 in. to 47 in.).

Kaydon Bearings Division Online Reader Inquiry No. 423

12-09-07 11:51 AM

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Machinery & Equipment MRO

Kilian Manufacturing has developed a line of ball bearing housed units for the tough washdown conditions in food pro-

film, which promotes effective lubricant performance and reduces heat generation and wear. A special heat treatment process reinforces bearing hardness, toughness and dimensional stability.

SKF Canada Online Reader Inquiry No. 426

Gearbox solutions keep wind turbines running smoothly

Online Reader Inquiry No. 463

Angular contact ball bearing features high-strength brass cage

NSK HPS angular contact ball bearings with a brass cage are designed for highspeed, long-life, low-vibration and quietrunning applications. Features include an optimized internal design, high load ratings, increased limiting speed, highstrength ball guided brass cage, high dimensional and running accuracy, and narrow axial clearances or preloads range. The universal facing allows easy handling and installation. The cage material is dedicated to the application: polyamide for standard applications, L-PPS for screw compressors, and machined brass for API pumps.

NSK Online Reader Inquiry No. 420

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Self-aligning roller bearing line is upgraded for enhanced performance

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Timken offers a broad range of cylindrical roller bearings starting at 65 mm (2-1/2 in.) inside diameter. The single-row EMA Series bearings feature a onepiece brass cage with a full-milled pocket design. This landriding cage, which, unlike roller-riding cages, minimizes drag on the rollers, improves lubrication flow and reduces heat generation.

The increased cage rigidity allows for more rollers on larger sizes, and proprietary roller profiles and surface finishing allow for smoother-running operation.

Timken Canada Online Reader Inquiry No. 427

is available in a variety of types and sizes and can be used in a range of equipment and applications.

SKF Online Reader Inquiry No. 422 MRO

cooling water, scale and chemicals all contribute to a tough operating environment. To combat these challenges, the bearing contains a graphite mixture that eliminates the need for grease relubrication, delivering reduced maintenance and downtime and eliminating the cost and environmental consequences of conventional greasing programs. It

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. 425

Bearing operates in hightemperature environments

The Drylube bearing from SKF is designed for use in equipment that is repeatedly subjected to high temperatures in environments such as bakeries, food processing facilities, mills or foundries.

Product surfaces can reach temperatures as high as 900°C, and operating speeds of equipment such as continuous caster foot rolls used in the heavy milling industry can be as low as 5 rev/ min. In addition, the effects of

Online Reader Inquiry No. 152

CRANES & HOISTS • MARINE DECK EQUIPMENT • CONVEYORS • WINCHES

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This is a QR Code ... the smart-phone scannable code used by companies like Air Canada, PR Newswire and the New York Times to generate reader interest and link print copy to the Internet.

Just use one of many free reader apps on any smart-phone platform, including iPhone, BlackBerry and Android, then click. MRO Magazine has full QR-capability ...we can create codes, host landing pages, track usage and create QR-unique ad and advertorial content just for smartphone users ... an excellent way to reach the tech-savvy and early-adopter demographic. MRO Magazine can create QR codes which can be positioned like display advertising, within editorial copy or added to your existing ad creative…as well as custom products like mailers, pressuresensitive labels and promotional literature. Contact Nick Naunheimer, Publisher, MRO Magazine, at 416-510-6868 or nnaunheimer@mromagazine.com for more details.

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While the motor is running with power engaged, an electromagnet within the brake pulls back the pressure plate, allowing the friction discs and motor shaft to rotate freely.

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The family of SKF Explorer performanceclass, bearings product line has been expanded to encompass the range of upgraded selfaligning roller bearings, including spherical roller bearings, CARB toroidal roller bearings, and spherical roller thrust bearings. The bearings feature advanced steel processing technology, which strikes a balance between hardness and toughness for improved wear resistance. This enables the bearings to run longer, particularly under difficult operating conditions. Compared with previous versions, the upgraded Explorer bearings can provide up to twice the service life under harsh conditions where poor lubrication or high contamination levels exist.

All of these bearings feature optimized internal geometry to reduce friction, wear and heat generation, and withstand heavy axial and/or radial loads. Manufactured to close tolerances, the rolling elements deliver good load distribution and run more smoothly with less vibration compared to earlier versions of the bearing. Enhanced cages improve guidance of the rolling elements and maximize the effects of the lubricant to help reduce operating temperatures and extend lubricant life.

The bearings incorporate an advanced surface finish to reduce friction and enhance formation of a hydrodynamic

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cessing and packaging operations. NoRust housed units feature corrosionproof 303 stainless steel components for extended life, and resist steam and continuous temperatures up to 250˚F. The thermoplastic housing and stainless steel bearing insert together stand up to a wide range of common corrosives and contaminants. Specifically designed for moderate loads and speeds, the units are resistant to acids, alkalis, solvents, detergents, oils and other chemicals.

Altra Industrial Motion/Kilian

Timken has newly developed main shaft and gear drive solutions for wind turbines. Its wear-resistant roller bearings for wind-energy applications are designed to reduce wear problems, including micropitting on main-shaft spherical roller bearings, and micropitting, smearing and brittle flaking on wind turbine gearbox cylindrical bearings. The UltraWind pre-loaded tapered roller bearing has superior stiffness to manage the motion of the main shaf t a nd rotor and also contains raceway profiles designed to control maximum stress levels. The company’s planetary bearing solutions include cylindrical roller bearings, the semi-integrated planet-pac and the fully integrated flexpin bearing. These solutions combine planetary pins, bearing raceways and planetary gears in various combinations to help achieve lean, compact and reliable wind turbine gearbox design.

Timken Canada

Cylindrical roller bearing has high load capacity, long service life

• THEATER STAGE EQUIPMENT • ELEVATORS • MINING CONVEYORS • SATELLITE EQUIPMENT •

Corrosion-proof bearing withstands rigours of washdown environments

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Online Reader Inquiry No. 153

12-09-07 11:51 AM

Online Reader Inquiry No. 154

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IDI focuses on ‘giving back’

Vancouver, BC — The 2012 annual meeting of Mississauga, ON-based IDI Independent Distributors Inc. took place at the Sheraton Wall Centre in Vancouver, BC, June 12-15. The event saw the group’s members gather together for the 31st year to share in the distribution of the financial benefits that IDI has brought to them.

IDI surpassed the $6 million mark in sales for its 94 shareholder members, comprising both purchase totals and IDI Connects rebates.

A great turnout was in attendance for IDI’s special outing events, which included a Jet Equipment and Tools Pioneer head office tour and the annual golf tournament, which took place at the beautiful Furry Creek Golf & Country club – claimed to be BC’s most scenic golf course.

The meeting also offered the opportunity for members and distributors alike to be able to get together and take part in multiple networking sessions to develop business relationships and opportunities.

IDI, as a group, started a program to “give back” in 2006, through the creation of the IDI Charitable Foundation, said president Scott Bebenek. It began with a modest $5,000 donation to two charities.

Since that time, members have begun to get involved by making donations through the IDI Foundation, and the results, said Bebenek, “are very gratifying.” In the past six years, the Foundation has raised over $101,000 for numerous Canadian charities.

MRO

Montreal show targets new products

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8 1. John Morrison of IDI with Jim Diachuk from Nachi Bearings.

2. John Fanjoy receives a cheque for the Ride to Conquer Cancer from IDI president Scott Bebenek.

3. John Morrison of IDI (left) with Dave Strutt Jr. from Ontario Belting. 4. Kelly Barker from Commercial Solutions with Scott Simpson of SB Simpson. 5. Member appreciation awards were presented to Northern Metallic Sales, Source Atlantic, Outil Pac

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and Charles Jones Industrial for support of IDI’s programs. 6. The recipients of the largest bonus for buying through the IDI group were recognized at the event.

7. Kathy Ramage from Triton Automotive receives a cheque for the Ride to Conquer Cancer from Scott Bebenek. 8. IDI’sScott Bebenek (left) and John Morrison flank Rob Inglis of Charles Jones Industrial, IDI member of the year.

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BY ERIC ACHILLES COUSINEAU

Machinery & Equipment MRO Photos: Eric Achilles Cousineau

M R O

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BY ERIC ACHILLES COUSINEAU

Montreal, QC — MMTS 2012, the Montreal Manufacturing Technology Show, which took place at Place Bonaventure in Montreal, was billed as Quebec’s best manufacturing trade show and conference.

The three-day event began May 14 and offered a variety of keynotes and speakers on several current hot topics in industry. The opening speaker was Larry Smith, well-known from his days as a fullback with the Montreal Alouettes and later president of the team. A networking reception was also held and an Interactive Town Hall featured a panel discussing the Deloitte Quebec Manufacturing Study.

MMTS also presented a special New Products Program with the participation from 50 exhibitors, with the aim of making companies aware of how technology is shaping the way people do business.

MRO

3 1.

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The aisles at Place

Bonaventure were crowded with visitors during MMTS. 2.

Marc-André Hudon (left) with Jean Denis, Henkel Canada.

3. Dan Roy (left) with John Romeo, Summit Industrial Products. 4. Jean-François Geissel demonstrates a grinder at the Walter Canada exhibit.

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Online Reader Inquiry No. 155

12-01-16 9:43 PM

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September 2012

Victoria venue attracts PTDA delegates

BY BILL ROEBUCK

Photos: Eric Achilles Cousineau

Victoria, BC — The Power Transmission Distributors Association (PTDA) held its 2012 Canadian Conference June 7-9 at the Fairmont Empress in Victoria, attracting 46 distributors and 139 manufacturers from the power transmission and motion control industry. Including companions and guests, the registration list totalled 220.

The conference began with its third annual Industry Showcase, which featured tabletop exhibits by PTDA’s manufacturer members. The opening day also included a golf outing at Bear Mountain Golf Resort.

The opening keynote address was provided by Vancouver-based economist and author Michael Campbell, who spoke about the Canadian economic outlook and thriving in a tough environment.

Also speaking was Ryan Berlin of Urban Futures, who discussed the changing demographics of Canadians.

Two market briefings were presented on the mining industry and the aboriginal community. As well, delegates heard an update on the Industrial Careers Pathway

initiative and learned about a new ICP Job Board to link industrial distribution employers and candidates (visit www.industrialcareerspathway.org and click on Jobs).

The closing keynote speech was presented by science journalist and author Dr. Bob McDonald, host of CBC Radio’s Quirks & Quarks and a regular science commentator on the CBC News Network. An avid sailor and motorcyclist, McDonald had moved from Toronto to Victoria a year earlier. He spoke to the group about the impact of clean energy and how it is good for business.

Several delegate companions participated in a Walk for Cancer benefitting The Campbell Family Institute at The Princess Margaret. As well, a group of eight bike riders from the industry participating in the Enbridge Ride to Conquer Cancer raised a large amount of funding at the conference — with several of them dressing in drag during the announcement (for more details, see Industry Newswatch on page 8).

The next PTDA event is its Industry Summit, set for Oct. 18-20, 2012, in Dallas, TX. For details, visit www.ptda.org. MRO

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13 1. PTDA golfers enjoy the view at BC’s Bear Mountain Golf Resort. 2. Sophie Bobbie of PTM Industries, Ajay and Neera Bajaj of Rotator Products, and Tamara Somerville of Posi Lock Puller. 3. Sean and Hellen Hickey of Lafert North America, with Carol and Cliff Bannon of Climax Metal Products. 4. Barbara Ross of Timken Drives LLC with Tom O’Brien of RalphsPugh Company. 5. Opening keynote speaker Michael Campbell. 6. Ted Chislolm of BDI and Kevin Haffey of NSK. 7. Ann Arnott, PTDA’s executive director, with Adrian Trotman of Wajax Industrial Components. 8. Jim Miernicke of Canadian Bearings, Tom Karch of SKF Canada, and Don and Bev Latham of Belterra. 9. Frank Mascia of Timken Canada with Marc Joanis of Wajax Industrial Components. 10. Jeff Lunn of AIT Canada, Otto Gerum and Dan Rasmussen of Schaeffler Canada, and Shawn Grant of Martin Sprocket and Gear. 11. Angie and Tony Bisante of RBI Bearings, with Pierre Bouchard of General Bearing Service. 12. Sandy and Denis Dryburgh of Nord Gear. 13. Closing keynote speaker Bob McDonald.

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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. 156

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MRO Ad_June_2012_Mining_Focus_Schaeffler 5/15/2012 7:35 AM Page 1

From Extraction to Finish Processing — We Do It All As the acknowledged bearing specialists to the mining and processing industry, Schaeffler has spent decades developing products designed to optimize the performance of mine operations. From standard bearings to the most highly specialized application solutions, INA and FAG brand products from Schaeffler are specifically engineered to thrive in some of the harshest operating conditions on (or under) the earth. Some highlights of our expansive portfolio: • Large-bore spherical roller bearings for dragline & shovel applications • Special bearing designs for off-highway motorized wheel applications • Split spherical roller bearings for super-fast bearing replacement in hard-to-reach locations • SuperTac II taconite seals with multiple labyrinths to ensure contamination stays out • High-capacity cylindrical roller bearings for vibratory applications • The revolutionary WiProM with FisNet portable condition monitoring device (so advanced, it fits inside our signature yellow carrying case!)

Schaeffler also offers its exclusive X-life series of products whose optimized roller geometries and raceway finishes are so precise, their service life far exceeds the conventional standard - as much as 70% in the case of our cylindrical and spherical roller bearings.

Rock on.

Superior-quality products.

Comprehensive reliable solutions. www.schaeffler.ca Online Reader Inquiry No. 157

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12-09-07 11:51 AM