Machinery & Equipment MRO December 2015

MACHINERY AND EQUIPMENT

30

Getting the right angle in shaft alignment

19 8 5 - 2 015

How to deal with v-belt drive troubles Conveyor maintenance tips from an expert builder

Vol. 31, No. 6 1

DECEMBER December 2015

Food plant puts focused improvement to work Why bearings with brains will change the future of condition monitoring

STORED MOTORS USE OUR GUIDE TO ENSURE THEY REMAIN READY TO RUN

Mail Agreement #40069240

WHAT’S NEW NEW POWER TRANSMISSION MOTORS & DRIVES & POWER TOOLS WHAT’S BEARINGS DRIVES HARSH HAND ENVIRONMENTS

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P R O D U C T

SP TLIGHT

Machinery & Equipment MRO

Energy efficiency module enables compressed air savings

The MS6-E2M intelligent energy efficiency service module monitors and regulates such operating parameters as air flow and pressure automatically.

The unit helps reduce the consumption of compressed air by cutting off its flow in stand-by mode. Also, any pressure drop it detects in the piping system is notified to the plant control system.

Measured values for flow rate, air consumption and pressure can be called up at any time, making it possible to determine whether a plant is consuming more air now than a year ago, how much air is needed for a production batch, whether the pressure is correct-

ly adjusted and what the pressure and flow rate were at the time of a machine breakdown. The user can quickly adapt the module to each installation via a manual input device or Profibus. With a simple connection of sensors to a PLC, the module is an easy retrofit on older equipment.

Festo Canada www.festo.com

Mild parts-washer cleaner promotes worker health and safety

AluStar 100 is a mild, long-lasting alkaline cleaner for cleaning and degreasing aluminum in automated and ultrasonic parts washers. Containing built-in foam and corrosion-inhibitor pack-

ages, the product leaves a low-residue finish, allowing it to meet strict cleaning requirements. It cleans and degreases effectively in hot parts washers at lower temperatures, generating substantial energy savings. Formulated for sensitive materials, it can be used for mechanical parts washing and degreasing of aluminum and other non-ferrous alloys. In addition, it is VOC-free, non-flammable, and phosphate-free.

Bio-Circle Canada www.biocircle.com

Welder’s optional digital meter gives operator more precise control

December 2015

setting monitoring welding amperage.

With this meter, the welding operator can quickly identify both preset and welding amperage levels, allowing them to be confident they are within specified parameters. Delivering up to 280 A of output power, the portable 41-lb machine can be easily moved around the shop or at a jobsite. The series, which is suitable for welding pipe and plate in power plant construction, petrochemical construction, maintenance and repair, and shipbuilding applications, comes standard with a 6-ft power cable and is compatible with Miller wireless remote control solutions.

Miller Electric www.millerwelds.com

The stick and TIGcapable CST 280 series welder is available with an optional digital meter for precise control when pre-

The New Standard in Large Motors

Cloud-based laser shaft alignment system offers wireless connectivity features

With Rotalign Touch, the cloud-based laser shaft alignment system with touchscreen and integrated mobile connectivity, alignment is no longer a static snapshot. A dynamic parameter for machine condition monitoring, it measures and tracks the alignment condition over time to help identify machine issues early on.

Using Alignment Reliability Center 4.0 software, users can connect to the cloud to send alignment tasks in real time to a Rotalign Touch mobile device anywhere in the world. The capacitive glove-enabled touchscreen enables the user to tap, swipe and drag, just like a smartphone or tablet. In addition, voice control allows for hands-free operation. This rugged system features a strengthened glass screen and tough housing.

Pruftechnik www.pruftechnik.com

Bearing cage extends life of wind turbine cylindrical roller bearings Whether you pump it, compress it, blow it or convey it, Baldor Large AC GPM motors are the perfect choice for your application. Available in low voltage or medium voltage configurations, Baldor Large AC GPM motors are inverter ready and in stock for fast delivery.

• Low & Medium Voltage • Modifications Available

And, if you need a general purpose motor modified with optional features to fit your exact specifications, you can count on Baldor Large AC GPM motors to set the new standard in performance with the fastest turnaround in the industry.

• In Stock & Ready to Ship

baldor.com

• Designed for Safe Operation

479-646-4711

©2015 Baldor Electric Company

Online Reader Inquiry No. 115

Download a QR reader app and scan this code for more information. http://esp.to/wNxjg7

Schaeffler’s FAG high-capacity cylindrical roller bearings for wind turbine gearboxes incorporate a sheet steel cage, which ensures low friction and provides sufficient space for an additional roller element in the bearing, due to very narrow crosspieces. The cage comprises two cage rings lying one inside the other and joined together. The crosspieces of the inner cage guide the roller elements. At the same time, these retain the roller elements in the bearing, even when the bearing ring is removed. This means that the bearing is much easier to mount, as no separate device is required to help prevent the roller elements from falling out. In addition, the special geometrical shape of the cage pockets improves lubricant flow, which reduces friction and prevents damage to the bearing.

Schaeffler Technologies www.schaeffler.ca MRO

Online Reader Inquiry No. 116

4

C O N T E N T S

Machinery & Equipment MRO

in this issue

30

December 2015

19 8 5 - 2 015

Getting the right angle / 25

Basic procedures assure reliability of stored motors / 12

Methods differ among small and large motors and for short- or long-term storage.

To align a shaft, moving a combination of both machines can give you the best option with the least amount of correction.

p12

departments Editor’s Notebook / 6 Industry Newswatch / 8 Business Briefs / 10 Mr. O, the Practical Problem Solver / 10 MRO On The Road / 11 Maintenance 101 / 30 Product News Product Spotlight / 2 Focus on Power Transmission / 27 Focus on Motors and Drives / 28

p26

Focus on Hand and Power Tools / 29

Monitoring and evaluating bearing distress / 26

Take a forensic approach to diagnose the root causes of bearing problems and to help prevent future troubles.

Conveyor maintenance: Between a rock and a hard place / 16

‘Build ‘em oversize and build ‘em tough’, says a veteran conveyor manufacturer. And then take care of maintenance!

columns

editor’s selections ‘ Machines with heavy rotors and long frames require more frequent rotation to prevent shaft distortion caused by rotor sag. Some machines may need rotation weekly.’

Chuck Yung / 12

Mr. O, the Practical Problem Solver / 10

How to select an industrial sealant.

MRO On The Road / 11

Successful meeting held by EASA’s Western Canada chapter.

‘ Make regular visual inspections.

Replace broken parts. Often, when I go to a site, there are broken parts, spillage … with spillage, all of your mechanical components can be buried. The rollers don’t roll as they should, bearings are full of dust and you will probably have tracking problems.’

Simon Rouleau / 16

‘ Often the first indication of a belt problem shows up when a machine operator notices unusual noises or smells coming from the area of the drive.’

p16

Paul Dzsudzsak / 20

Get rid of troubles with v-belt drives / 20

p30

If you’re having drive problems, an entirely new belt drive is likely to be much less costly than one downtime incident.

Putting ‘focused improvement’ to work / 30

Bearing with brains / 22

How revolutionary smart bearing technology will underpin the creation of intelligent machines and be a new tool in maintenance for condition monitoring.

Maintenance 101: Organizations like this Ontario food plant, that follow a systematic process, have tremendous success and will use it over and over again to improve their operations.

p22

‘ We know that bearings rarely fail in service under normal operating conditions due to factors such as subsurface fatigue. Instead, the cause of failure is usually misuse or neglect.’

Filippo Zingariello / 24 For the record

We got a bit ahead of ourselves in the previous issue, calling it Vol. 31, No. 6 on both the cover and the masthead, but in fact, the November issue is No. 5. You’re now reading No. 6, the final issue in our 30th anniversary year.

Special supplement

Cover Louis-Paul St-Onge © Thinkstock

Some readers will have received a copy of the December issue of Maintenance, Réparation et Opération along with this issue.

This French-language version of MRO Magazine is distributed twice a year to 5,000 readers in Quebec.

Extending the Bearing Life Cycle Help your bearing achieve its maximum service life

» SKF EasyPull mechanical puller TMMA series

» SKF Machine Condition Indicator The SKF Machine Condition Indicator is a robust, battery-powered machine vibration/ temperature monitoring device that reliably warns about impending machine failures, without the need for expensive hard wiring and electrical power supply.

More at www.skf.ca/MCI

Equipped with spring-operated arms and a solid design, the patented SKF EasyPull is one of the most user-friendly and safe tools on the market. Ergonomically designed, the spring-operated arms enable the user to position the puller behind the component with just one movement. The SKF EasyPull is available in mechanical and hydraulically assisted versions, as well as complete kits with a tri-section pulling plate and a puller protection blanket.

By applying the right maintenance practices and using the correct tools in all stages of the bearing life cycle, you can considerably extend your bearing’s service life and thereby increase plant productivity and efficiency.

Learn more at: http://goo.gl/FdpfJs

» Portable Induction Heater TIH030m The heater combines high heating capacity with portability. Placing the induction coil outside the heater’s housing allows the heating of bearings weighing up to 40 kg.

The heater is equipped with thermal overheating protection to reduce the risk of damage to the induction coil and the electronics. In addition to temperature mode, the TIH 030m is equipped with a time mode for heating components other than bearings.

Having the right tools makes it easier to get the job done - but your team also needs to know best practices to get the job done right!

Check out our training programmes.

Learn more at http://goo.gl/3mdwTh

» Shaft Alignment Tool TKSA 11 The SKF TKSA 11 heralds a new generation of shaft alignment tools. Using mobile devices, the instrument intuitively guides the user through the whole alignment process. With a focus on the core alignment tasks, the TKSA 11 is designed to be a very easy-touse instrument that results in accurate alignment and is especially suitable for entry level shaft alignment.

Talk to your SKF Authorized Distributor for more details and pricing.

» SKF Long-range Automatic Lubricant Dispenser TLMR series A single point automatic lubricator designed to supply grease to a single lubrication point.

With a relatively high pressure of 30 bars, this lubricator can operate at long distances providing optimum results with difficult-toreach and unsafe lubrication locations. With a wide temperature range and robust design, the TLMR lubricator is suitable for operating conditions with various levels of temperature and vibration.

» SKF SYSTEM 24 Single Point

Automatic Lubrication

a single point automatic lubrication system that continuously delivers precisely measured amounts of lubricant to desired points via a gas-driven pump. SKF SYSTEM 24 units are supplied ready-to-use straight from the box and filled with a wide range of high quality SKF lubricants. Tool-free activation and time setting allows easy and accurate adjustment of automatic lubrication flow.

The SKF SYSTEM 24 is ideal for lubrication points difficult to reach manually, or where there are a large number of lubrication points where manual greasing would be less effective.

Online Reader Inquiry No. 117

6

E D I T O R ’ S

N O T E B O O K

Machinery & Equipment MRO

December 2015

Turning over a new leaf Y

ou may have read in my previous Editor’s Notebook that this is the final issue for which I’ll be responsible for the editorial content and direction as Editor and Associate Publisher. Due to an acquisition earlier this year by Annex Publishing & Printing of several magazines published by Glacier Media – which previously owned MRO – several changes are afoot.

The next issue you receive will be edited by Rehana Begg, who has been the editor of Plant Engineering & Maintenance (PEM) magazine, which will cease publishing and be amalgamated into MRO. She is also the editor of

Resource Engineering & Maintenance (REM) magazine. Begg has more than 16 years of editorial experience and has managed a variety of B2B and consumer publishing projects and events. She holds a master of journalism degree from Ryerson University and a certificate in project management from the University of Toronto.

There are other changes in the works for the magazine, including resizing MRO from its current ‘tabloid’ size (16 in. tall x 11 in. wide.) to a new size that will be 12 in. tall and 9 in. wide. This should be good news for the many readers we’ve surveyed over the years who told us they felt MRO was cumbersome, although we’d held fast to the big size because we liked the fact it was difficult to lose sight of on a desk, lunchroom table or workbench,

and because of the large amount of ‘real estate’ available on each page to advertisers.

The new size will also mean there will be more physical pages in each issue – about double the current number, which should allow for an expansion of the range of content provided.

Commenting on the amalgamation of PEM into MRO, Begg says, “I believe that we share a number of traits – we are devoted to quality editorial content, a passion for the industry and a deep and enduring respect for those who are engaged in it. I look forward to the challenge of ensuring the new format meets the evolving needs of our audiences.”

MRO will continue to publish a special French-language edition for its Quebec audience twice a year, and you’ll also see some online-only, industry-specific initiatives coming from the team, as well as other developments.

For me, this has been an exciting magazine to work on for the past three decades, despite its ups and downs as the industrial economy waxed and waned. I am reassured that it will be in good hands with Begg co-ordinating the editorial content. I know she will appreciate your feedback, and if you have some suggestions for stories you’d like to read, don’t hesitate to e-mail her at rbegg@annexweb.com.

Meanwhile, if you’d like to reach me with comments or feedback, please send an e-mail to my personal e-mail address, broebuck@sympatico.ca.

Thanks to everyone – all of our readers, those involved in the magazine and those in the MRO industrial aftermarket – for your support over the decades. I expect 2016 should be an interesting year for all of us. MRO Bill Roebuck Editor & Associate Publisher

MACHINERY AND EQUIPMENT

MAINTENANCE, REPAIR AND OPERATIONS

DECEMBER 2015 Volume 31, No. 6

Established 1985 www.mromagazine.com www.twitter.com/mromagazine EDITORIAL Bill Roebuck, Editor & Associate Publisher 416-510-6749 broebuck@mromagazine.com Mark Ryan, Art Director Contributing Editors Carroll McCormick, Peter Phillips BUSINESS Jim Petsis, Publisher 416-510-6842 jpetsis@mromagazine.com Jay Armstrong, Sales Manager 416-510-6803 jarmstrong@mromagazine.com Tracey Hanson, Account Coordinator 416-510-6762 Beata Olechnowicz, Circulation Manager 416-442-5600 x3543 bolechnowicz@annexbizmedia.com Tim Dimopoulos, Vice-President Annex Business Media tdimopoulos@canadianmanufacturing.com Mike Fredericks, President & CEO Annex Business Media Machinery & Equipment MRO is published by Annex Business Media Inc., 80 Valleybrook Dr., Toronto, ON Canada M3B 2S9; tel. 416-442-5600, fax 416-510-5140. Toll-free: 1-800-268-7742 in Canada, 1-800-387-0273 in the USA. AWARD-WINNING MAGAZINE

Subscription rates. Canada: 1 year $58.95, 2 years $94.95. United States: 1 year $85.95. Elsewhere: 1 year $87.95. Single copies $10 (Canada), $16.50 (U.S.), $21.50 (other). Add applicable taxes to all rates.

On occasion, our subscription list is made available to organizations whose products or services may be of interest to our readers. If you would prefer not to receive such information, please contact us via one of the following methods – phone: 1-800-668-2374, e-mail: privacyofficer@businessinformationgroup.ca, fax: 416-442-2191, mail to Privacy Officer, 80 Valleybrook Dr., Toronto, ON Canada M3B 2S9. © 2015. 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.

Publications Mail Agreement No. 40065710. 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 Dr., Toronto, ON Canada M3B 2S9.

PEMAC

We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund of the Department of Canadian Heritage.

Online Reader Inquiry No. 117

Online Reader Inquiry No. 118

8

I N D U S T R Y

N E W S W A T C H December 2015

Toronto – The latest RBC Canadian Manufacturing PMI survey, for October 2015, pointed to another downturn in overall business conditions, with output, new orders and employment all declining since the previous month, which also set a record low. Moreover, new export sales dropped for the first time since April, with survey respondents noting that weaker global economic conditions had weighed on new business volumes.

Meanwhile, input costs rose at a sharp and accelerated pace in October, which placed pressure on operating margins and contributed to a further slight increase in factory gate charges.

The

A monthly survey, conducted in association with Markit, a global financial information services company, and the Supply Chain Management Association (SCMA), the RBC PMI offers a comprehensive and early indicator of trends in the Canadian manufacturing sector.

Adjusted for seasonal influences, the RBC Canadian Manufacturing PMI posted 48.0 in October, down from 48.6 in September and below the neutral 50.0 threshold for the third month in a row.

Moreover, the latest reading signalled the sharpest rate of deterioration since the survey began in October 2010.

“Heightened global economic uncer-

NEW SURFOX

RBC Canadian Manufacturing PMI™ RBC PMI: Manufacturing sector dips to record low in October 58.0 HIGH: 56.9

57.0 56.0 55.0 54.0 53.0 52.0 51.0 50.0 49.0

LOW: 48.0

48.0 Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apri May Jun Jul Aug Sept Oct

Manufacturing index dips to a new record low

2010

2011

2012

2015

The latest manufacturing index reading signalled the sharpest rate of deterioration since the survey began in October 2010.

The intellectual property rights to the RBC Canadian Manufacturing PMI provided herein is owned by Markit Economics Limited. Any unauthorised use, including but not limited to copying, distributing, transmitting or otherwise of any data appearing is not permitted without Markit’s prior consent. Markit shall not have any liability, duty or obligation for or relating to the content of information (“data”) contained herein, any errors, inaccuracies, omissions or delays in the data, or for any actions taken in reliance thereon. In no event shall Markit be liable for any special, incidental, or consequential damages, arising out of the use of the data.

Purchasing Managers’ Index™ and PMI™ are trade marks of Markit Economics Limited, RBC use the above marks under licence.

tainty and ongoing energy price weakness continues to weigh on the Canadian manufacturing sector, as indicated by October’s record-low reading of 48.0,”

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Machinery & Equipment MRO

said Craig Wright, senior vice-president and chief economist, RBC. “As we move toward the end of the year, we expect that a strengthening US economy and weaker Canadian dollar will fuel demand for Canada’s exports, resulting in a shift to positive growth territory.”

The headline RBC PMI reflects changes in output, new orders, employment, inventories and supplier delivery times.

A faster reduction in manufacturing output levels was the main factor contributing to a drop in the headline index during October, as new business volumes decreased at a slightly slower pace than one month previously. Manufacturers linked the survey-record fall in production levels to a combination of weaker underlying demand and efforts to reduce their stocks of finished goods. Reflecting this, the latest data indicated the sharpest decline in post-production inventories since the survey began five years ago.

At the same time, manufacturers pared back their input buying for the fourth month running in October, which contributed to the fastest fall in stocks of purchases in the survey history.

Overall volumes of new work decreased slightly in October, but the rate of decline eased since September and was broadly in line with the average so far in 2015. That said, for the first time in six months, manufacturers reported a decrease in export sales. Meanwhile, backlogs of work were lowered again during October, reflecting a general lack of pressure on operating capacity.

Canadian manufacturers indicated a modest reduction in their payroll numbers during the latest survey period, thereby continuing the trend seen throughout much of the year to date.

“The lack of spending by Canada’s oil and gas sector, and weak economic conditions abroad, made October a very tough month for Canada’s manufacturing sector. October saw the sharpest fall in manufacturing production in at least five years, and the overall performance of the sector has dropped to yet another record low,” said Cheryl Paradowski, president and chief executive officer, SCMA. “Despite these challenges, we see evidence that employers have tried to limit job cuts as much as possible through initiatives like work-share arrangements, and want to retain their staff in anticipation of future growth.”

YOUTH HAVE PERCEPTION OF SKILLED TRADES CAREERS THAT IS INCORRECT, SAYS STUDY

Online Reader Inquiry No. 119

Ottawa – Though parents and youth say they believe career opportunities in the skilled trades to be limited, the Canadian Apprenticeship Forum (CAF-FCA) has published a new national report indicating the opposite is true.

I N D U S T R Y

9

N E W S W A T C H

December 2015

Machinery & Equipment MRO

With insights and observations from 754 certified journeypersons across Canada, The Benefits of a Skilled Trades Career: Journeyperson Perspectives and Experiences sheds new light on career progression in the trades. Journeypersons point to benefits, including good pay, interesting work, full-time employment and the job satisfaction that comes with building or creating something.

Based on a national survey with tradespeople at various stages of their career, 50% of respondents reported making more than $80,000 annually.

“In recent surveys to gauge parent and youth understanding of the skilled trades, we were disappointed with the perception that skilled trades careers are ‘dead-end jobs’,” said Sarah Watts-Rynard, CAFFCA’s executive director. “This study reflects a much different reality, one of broad opportunity both in the trades and in related occupations. Tradespeople often transition into different fields, including teaching, training, management and business ownership. We need to share that story with young people.”

When asked what a skilled trades career brought him, one respondent said, “I would question the notion that front-end programs, like degrees and diplomas, are equivalent or superior to an apprenticeship as they often lack the most critical component — social interaction in the context of the workplace. No one ever learned how to be a senior executive at school. They learned it at work.”

The survey found that the majority of journeypersons valued their Red Seal endorsement because it made them more employable and enhanced their labour mobil-

ity. Many had also become mentors themselves, expressing satisfaction in becoming leaders who promote a positive work environment, model good safety practices and facilitate team collaboration.

These findings will support conversations with youth, parents and educators, and be included in future updates to CAF-FCA’s career awareness resources.

The watch enables miners to report any injuries or safety incidents in real time to operators at the surface.

NEW SMARTWATCH HELPS MINERS ID DANGEROUS ISSUES Toronto – The new MineSafe Smartwatch is a tool to help miners identify and respond to potentially dangerous issues. It has been launched by Illumiti, in collaboration with the SAP Co-Innovation Lab and Vandrico Solutions Inc. The watch enables real-time communication between miners underground and their support team on the surface.

Using real-time data and analysis software, mining companies can quickly identify and predict potential hazards, notify employees of dangerous situations, identify worker locations in an emergency, and provide safety guidance to workers in an automated fashion.

The MineSafe Smartwatch combines proactive features that can enhance worker awareness of safety issues with immediate response features that can

assist both miners and topside responders in the event of an emergency.

“Our watch leverages Wi-Fi and sensors in the mine to provide mine workers with greater situational awareness, facilitate communications and accelerate evacuations,” said Lorraine Howell, vicepresident of R&D for Illumiti. “Using our worker tracking feature, the mining company can quickly identify the location of each miner in real time from the surface during an emergency, enabling safety teams to quickly locate missing team members. Localized evacuation messages can also be sent based on worker location in the mine.”

Some key features of the Smartwatch include: • Worker location tracking: Tracks individual worker locations and enables regular check-ins.

• Real-time incident reporting: Enables miners to report any injuries or safety incidents in real time to operators at the surface who can take immediate action.

• Proactive real-time communications: Automatically send safety procedures to workers step by step – and record whether or not procedures were followed.

• Automatic alerts: Using sensors set up within the mine, detects potentially hazardous conditions resulting from gas leaks, smoke or seismic movements and provides immediate alerts to workers in the danger zone through audible, visual and vibrating alarms.

• Among the greatest benefits of MineSafe is the ability to facilitate distress calls.

“Mine workers can use a one-touch distress call feature to send an urgent notice to the surface. The surface system

is designed to send immediate alerts to key personnel and emergency responders based on the type of incident being reported – which can enhance response time and reduce risk to other workers,” said Gonzalo Tudela, CEO at Vandrico.

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

OCTOBER SAW FEWER PEOPLE WORKING IN ‘OTHER SERVICES’ LIKE REPAIR & MAINTENANCE Ottawa – After four months of little change, employment increased by 44,000 (+0.2%) in October, bringing the number of people employed in Canada to over 18 million for the first time. The unemployment rate declined by 0.1 percentage points to 7.0%.

Compared with 12 months earlier, employment was up 143,000 (+0.8%), with all of the gains in full-time work. During the same period, the total number of hours worked grew by 0.7%.

In October, more people were employed in public administration, wholesale and retail trade, as well as accommodation and food services. On the other hand, employment decreased in the ‘other services’ industry, natural resources and utilities.

There were 8,900 fewer people working in ‘other services’ such as repair and maintenance, as well as personal and laundry services. In the 12 months to October, employment in this industry was down by 13,000 (-1.6%). MRO Industry Newswatch is written and edited

by Bill Roebuck. Visit our website for the latest news and more-detailed versions of the items here.

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BALL BEARINGS

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Online Reader Inquiry No. 120

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TECHNICAL SERVICES

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I N D U S T R Y

N E W S W A T C H

Machinery & Equipment MRO

December 2015

Business Briefs

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

• North Vancouver, BC – Gordon Lindemere, the founder in 1953 of a successful Delta, BC-based bearing and power transmission distributor, Industrial Equipment Company Ltd. (IECO), died earlier this year, MRO Magazine has learned. Lindemere was CEO and president of the company for 49 years, establishing 19 branches across Alberta and British Columbia, as well as two fabrication and machine shops, and subsidiaries in the United States and South America. IECO, which rose to become a C$35-million business, was named Power Transmission Distributor of the Year in the 1990s by Machinery & Equipment MRO magazine. Lindemere sold the company in October 2002 to the Canadian subsidiary of Applied Industrial Technologies, Cleveland, OH, for about C$18 million. He died in North Vancouver at the age of 90, on May 16, 2015, of natural causes.

• Vancouver, BC – Safety products supplier the JET Group, Vancouver, BC, has acquired Sellstrom Manufacturing Co., Schaumburg, IL, a US brand of PPE (personal protective equipment) safety products. The acquisition broadens JET’s Canadian safety portfolio by adding several categories of professional PPE products to complement its existing Pioneer and Ranpro safety apparel, and PeakWorks fall protection brands. It also offers the JET Group a solid safety foundation with significant opportunities for expansion and growth within the United States and globally.

• Fort Smith, AR – Baldor Electric Company recently promoted Ryan Fitts to director of quality. He is responsible for leading and directing Baldor’s Corporate Quality pro- Ryan Fitts is gram with a focus on Baldor’s director addressing customer of quality. concerns, particularly around lead times, on-time delivery and root causes of product quality issues. Fitts joined Baldor in 2011 as a member of the Lean Core Team. Since that time, he successfully led the project team that established the 210 motor plant in Fort Smith, AR, and most recently, he was the company’s director of logistics. He is a Lean Flex-Flow Master and a Six-Sigma Black Belt.

• Mississisaua, ON – Ringball Corporation has been appointed the Canadian distributor for grease lubricator manufacturer Pulsarlube, based in Elk Grove Village, IL. The agreement includes the complete product line of the Pulsarlube electrochemical, electromechanical and mechanical lubricators. With five Ringball branches and its network of authorized distributors from coast to coast, the partnership provides local inventory, low shipping costs and fast shipping times.

For more information, visit www.ringball.com or www.pulsarlube.com.

• Chicago, IL – The Power Transmission Distributors Association (PTDA) has named John Masek, senior vice-president, Bearing Service Inc., Livonia, MI, as the 25th recipient of its Warren Pike Award for lifetime achievement in the power transmission/motion control (PT/MC) industry. Masek received the award, named for PTDA’s co-founder and

John Masek received PTDA’s lifetime achievement award.

first president, at the association’s Industry Summit in Chicago in October 2015.

The award was established in 1984 to honour individuals who have demonstrated outstanding, continuous, long-term support of PTDA and the PT/MC industry, and is only presented when an individual’s achievements merit this prestigious recognition. More information is available at ptda.org/WarrenPikeAward.

• Chicago, IL – In another award given at the PTDA’s Industry Summit, Elizabeth (Liz) Moon of Kaman Industrial Technologies Corp., Bloomfield, Liz Moon CT, was presented with received the 2015 Wendy B. Mc- PTDA’s Wendy Donald Award, awarded B. McDonald Award. to honour the memory of Wendy B. McDonald, one of the power transmission/motion control industry’s true pioneers. The award, presented by the PTDA Foundation, acknowledges a woman who has established herself as a critical contributor to her company’s success and has affected positive change within the power transmission/motion control industry. In her comments, Moon advised other women in the field to heed the advice of Wendy B. McDonald herself, who said, “Don’t forget who you are.

You have to have a lot of common sense and a sixth sense for people.” Moon credited Mrs. McDonald as paving the way through the world of industrial distribution before her. For more information, visit ptda.org/WBMcDonaldAward.

• Pittsburg, CA – Bishop-Wisecarver Group (BWG), a woman-owned family of companies that offer guidance solutions, contract specialty manufacturing and mechatronic-based engineering services, has signed an agreement with T RACE, an established European supplier of linear guides and telescopic slides. Through this strategic partnership, BWG will be able to service a wider range of motion applications by offering a more expansive product line to meet diverse requirements.

T RACE’s headquarters and production facility are located in Aicurzio Milan, Italy, and the company maintains a German, branch in Burscheid (Düsseldorf).

• Espelkamp, Germany – After almost 50 years in the management of the Harting Technology Group, Dietmar Harting (Dr.-Ing. E.h.) handed over the position of chairman of the board to his son Philip Harting on October 1, 2015. Dietmar Harting nevertheless remains a member of the company group’s board as a personally liable partner and will focus on matters concerning “the future and new technologies,” he said. The Harting Technology Group is a global supplier of industrial connection technology for the

Philip Harting (left) succeeds his father, Dietmar Harting, as chairman of the board.

three lifelines of power, signal and data, with 12 production sites and subsidiaries in 42 countries.

• Wayne, PA – The Fluid Sealing Association (FSA) has appointed Jeff Bernthisel, general sales manager at EGC Enterprises Inc., Chardon, OH, and Carl Jones, packing market specialist at W. L. Gore & Associates Inc., Coraopolis, PA, to its board of directors. FSA is an international trade association whose members are involved in the production and marketing of a wide range of fluid sealing devices primarily targeted to the industrial market. For details, visit www.fluidsealing.com.

• Montreal, QC – Wajax Industrial Components has been named the exclusive national distributor of Apparel Solutions International (ASI) safety clothing, offering access to apparel with Flame Resistant (FR) Wajax now and Arc Flash (AR) rat- distributes ings. The FR and AR Canadian-made products distributed safety clothing. under the Sirius Specialized Workwear brand meet multiple industry safety standards such as CSA Z462-12 & NFPA 70E. They are produced at the ASI corporate facility in Edmonton, AB. • Atlanta, GA – For distributor Genuine Parts Company, sales for the third quarter ended September 30, 2015, decreased 2% to $3.92 billion compared to sales of $3.99 billion for the same period in 2014 (all figures in US dollars). Net income for the third quarter was $188.0 million compared to $190.5 million recorded for the same period in the previous year. Sales at Motion Industries, the company’s Industrial Group, were down by about 4%, which basically represents the underlying decrease for this business, as a 1% contribution from acquisitions was offset by an equal currency headwind.

• Cleveland OH – Motion and control technologies manufacturer Parker Hannifin Corp. saw major weakness in its main markets – including 13% lower sales in its industrial segment – in reporting results for its fiscal 2016 first quarter ended September 30, 2015. Fiscal 2016 first quarter sales were $2.87 billion, compared with $3.27 billion in the prior year quarter (all figures in US dollars). Net income was $195.0 million compared with $280.2 million in the first quarter of fiscal 2015. “Despite ongoing headwinds from a strong dollar and further weakness in key end markets that pressured sales, we delivered adjusted segment operating margins of 15.3%.” said chief executive officer Tom Williams.

• Toronto – Omron Automation and Safety Canada has moved its Canadian headquarters to new offices in Consilium Place, a Toronto East business complex, with facilities that better reflect how Omron does business in the 21st century.

“Our old building was designed for the way Omron did business in the 1990s, with full warehouse and office space for a large marketing and support staff,” said general manager Peter Brouwer. “Now that we operate as a Pan-American business, we needed to consolidate certain business functions to provide uniform service and support to meet customer needs.” In anticipation of the move, Omron moved its warehouse services to KWE – Kintetsu World Express (Canada) Inc., in Milton, ON, to integrate import/export activities with order handling as a way to shorten delivery time and improve customer responsiveness. MRO Industry Newswatch is written and edited

by Bill Roebuck. Visit our website for the latest news and more-detailed versions of the items here.

Mr. 0, The Practical Problem Solver

Selecting an industrial sealant

Problem: With so many products to choose from, making sure you select the proper sealant is especially important. Selecting the wrong industrial sealant, or applying the correct sealant in the wrong manner, can have serious consequences.

Solution: Keep the eventual application of your sealant in mind, and also make sure it has the following characteristics: • Stability over a wide temperature range – Once fully cured, highquality sealants perform across a wide range of temperatures. The best sealants can withstand temperatures ranging -65°C to 315°C. Select a sealant that functions reliably at temperatures outside the performance range to accommodate unexpected temperature changes.

• Weather resistance and chemical stability – UV rays, radiation and weather can cause low-quality sealants to crack, crumble and become brittle, compromising the seal over time. Look for sealants with good resistance to these and other erosive factors. Also, some organic sealants react to atmospheric pollutants or chemicals much like iron reacts with water to produce rust. Use a sealant that does not readily degrade after prolonged contact with common elements and industrial chemicals.

• Good bond strength – Good sealants provide durable adhesion to a wide variety of industrial materials.

• Electrical properties – If electrical properties are a concern, be aware that some organic sealants are less well-suited to applications where they may be exposed to electricity; in such instances, a silicone sealant may be a better option.

• Low flammability – In fire conditions, some sealants are more burnresistant than others. Silicone sealants, in particular, are especially reluctant to burn.

This issue’s tip came from Ross Noel, a senior applications engineer at Dow Corning.

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Machinery & Equipment MRO

Successful meeting held by EASA’s Western Canada chapter

Saskatoon, SK – The annual general meeting of the Western Canada Chapter of the Electrical Apparatus Service Association (EASA), held at the Delta Beesborough in Saskatoon in September 2015, drew about 70 attendees, including EASA International chairman Mike Dupuis and Region 8 (Canada) director Brian Larry.

Seminars held during the meeting included: CSA C392, Testing of Electric Motors During Refurbishment, and C391, Testing of Synchronous ThreePhase Machines; a session on succession planning comparing an interest-based approach to a value-based approach, and a discussion of valuations and financing options, provided by Rod Wolfe of BDC Subordinate Financing Group; an update on the EASA accreditation program

by Ken Lipinski of Green Motors Practices Group; and a technical session by Douglas Martin of SKF Canada on hybrid rolling element bearings and how they compare to all-steel insulating (Insocoat) bearings.

The event’s trade show included exhibits from Baldor Electric Canada, Brook Crompton, Diagnalysis Inc., Electro-wind Supply Inc., Green Motors Practices Group, Guspro Inc., ICC International, MEP Drives, Mersen Canada, Nidec Motor Canada, Swiger Coil Systems, Teco-Westinghouse Motors and WEG Canada.

“The Saturday evening dinner cruise was a huge success as we had a private sailing on the Prairie Lilly on the North Saskatchewan River,” reports Eddie Sandboe, secretary of the chapter and president/general manager of GPR Industries (1994) Ltd., Grand Prairie, AB. His company celebrated its 50th anniversary in 2015.

Awards presented during the event included the Elliot Creelman award, given for 2015 to Thomas Garnall of Edmonton.

Chapter president Rene Robertson reported total membership is currently at 67, including new member CDM ElectroMech Technical Services of Regina. Robertson said that the SAIT (Southern Alberta Institute of Technology) program to support the electro-mechanical system trade, established last year, “was full, with 14 apprentices.” He also noted that EASA Accreditation has been achieved by chapter members Beaver Electrical Machinery of Burnaby, BC, and GMR Electric Motors of Saskatoon (GMR was the first Canadian shop to obtain this status).

International chairman Mike Dupuis, shop manager at Morrish Electro Me-

chanical Co. of Windsor, ON, said EASA’s theme this year is ‘E3’ – for Educate, Experience, Engage. “It means that members can be more successful when they educate, experience and engage using the services and resources provided by the association.” He cited the safety and vibration webinars as examples.

Dupuis also provided an update on EASA’s Accreditation program. “There are currently 27 Canadian members that have applications in for the program,” he noted.

Region 8 director Brian Larry of Larry Electric Motor Service Ltd., Peterborough, ON, said that the next International Convention is coming to Canada. It will take place in Toronto, June 12-14, 2016.

For more details about EASA’s Western Canada chapter, visit the website at www.easawesterncanada.com. MRO

Photos courtesy Eddie Sandboe

BY BILL ROEBUCK

Eddie Sandboe, secretary, EASA Western Canada Chapter; Mel Hitchings, vice-president, EASA Western Canada Chapter; Brian Larry, EASA Region 8 director; Mike Dupuis, EASA International Chairman; and Rene Robertson, president, EASA Western Canada Chapter.

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Brian and Diane Larry, Simon Morris and Peter Liston enjoy the dinner cruise on the Prairie Lilly.

EASA’s tabletop trade show offered exhibits from 13 companies.

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December 2015

Basic procedures assure reliability of stored motors Methods differ among small and large motors and for short- or long-term storage.

BY CHUCK YUNG

EASA’s Chuck Yung.

Photo: EASA

Maintenance experts need to ensure replacement motors are ready to run when needed by preventing problems caused by improper storage.

Photo: Haltinner Thomas, Thinkstock

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owntime is costly, so it pays to have spare motors for critical applications. But unless they’re stored properly, those spares may not perform reliably when needed.

Storage requirements generally depend on motor size and expected length of storage, so some measures may be impractical for smaller, readily available motors. The following recommendations cover most cases, but factors like heat, humidity and ambient vibration may dictate different schedules or procedures. It’s also important to recognize that some long-term storage procedures must be undone before the motor is placed in service.

TYPE OF WINDING

MINIMUM INSULATION RESISTANCE

Form-wound coils (PI)

10-minute insulation resistance / 1-minuteinsulation resistance should be greater than 2.0.

Random-wound coils (DA)

1-minute insulation resistance / 30-second insulation resistance should exceed 1.25.

Table 1. Dielectric absorption ratio recommendation.

Short-term storage Whenever possible, store motors indoors in a clean, dry area, placing horizontal machines horizontally and vertical motors in a stable vertical position. Whether the motors will be put in service within a few weeks or a few years, it’s important to protect them from ambient vibration (more on this later).

Condensation can form inside the motor if the storage area isn’t climate controlled. To avoid this problem, use space heaters (supplied or added) to keep motor windings 5-10°C (10-20°F) above the ambient temperature. (For other ways to prevent condensation, see the section on special care for windings later in this article.)

If outdoor storage is necessary, protect the motor with a waterproof cover (e.g., a tarp), allowing breathing space at the bottom. Never wrap a motor tightly in plastic and place it in the sun; temperature extremes plus humidity can cause condensation inside the motor.

Outdoor storage also requires preventive measures to keep out rodents, snakes, birds or other small animals that could damage the motor’s insulation system. If insects are prevalent, keep them from blocking ventilation or drain openings by loosely wrapping the motor and covering all openings.

Long-term storage and larger machines Protection of bearings, windings, shafts and other machined surfaces is essential for above-NEMA size machines and all motors slated for long-term storage.

Shafts and other machined surfaces. Coat shafts and other exposed machined surfaces with a viscous rust/ corrosion inhibitor (e.g., LPS2, Techtyl 502C or RustVeto) to protect them throughout the storage period. In humid and rainy/snowy environments, ask your service centre to paint as much of the motor’s interior surface as practical, and to coat the windings with an appropriate fungicide in tropical environments.

(Note: If a protective coating is applied to sleeve-bearing surfaces, the machine must be dismantled to remove it before the motor is placed in service.)

Bearings – rust and corrosion.

Completely fill the bearing cavities of grease-lubricated motors with compatible grease to prevent rust and corrosion staining that can occur if moisture collects between the balls and races.

Fill the reservoir of oil-lubricated motors to maximum capacity after situating them in storage. If possible, add enough oil to cover the bearings without overflowing the stand tube or labyrinth seal.

The oil should contain rust and corrosion inhibitors. Water is heavier than oil, so draw an oil sample from the drain every three months and check for moisture.

Tip: Never move a motor with oil in the reservoir. If oil sloshes over the stand tube, the combination of surface tension and capillary action may continue to siphon oil from the chamber. In other words, careless handling with oil in the motor can create a slow, continuous leak.

Before putting the motor in service, always drain and replace the oil (drain it, move it, then refill it).

Bearings – ambient vibration. Motors can be damaged by vibration even when they aren’t rotating. Proximity to rail lines, busy roads, and/or production floors can all contribute to the ambient vibration. (One mill countered the effects of ambient vibration from nearby machinery by storing motors on worn-out conveyor belting.) Over time, even lowlevel vibration can damage bearings while they’re stationary – causing false brinelling, for example.

False brinelling is damage along the bearing race that corresponds with the positions of the rolling elements. Initially it may appear slight or even invisible to the naked eye, but it progresses rapidly when the motor is placed in service (see Figure 1). When a newly installed motor seems fine initially, but the bearings become noisy within a few hours or days, false brinelling is a likely culprit. Corrosion staining can also result if moisture collects between the balls and races.

Shaft rotation. Rotate motor shafts at least monthly during long-term storage to prevent false brinelling and inhib-

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it corrosion by redistributing lubricant on machined surfaces. Larger, two-pole machines require more frequent attention than smaller (NEMA-frame) machines.

Machines with heavy rotors and long frames require more frequent rotation to prevent shaft distortion caused by rotor sag. For instance, some machines rated at approximately 1,500 hp (1,100 kW) and larger may need rotation weekly. As an extreme example, power plants typically keep very large turbine generators rotating slowly at all times to prevent sag. While it’s uncommon, the rotors of very large critical machines can also be removed and suspended vertically to prevent sagging.

Tip: Stop the keyway at a different o’clock position each month. Rotate the keyway position of all shafts in five-hour increments – e.g., 12:00 in September, 5:00 in October, 10:00 in November, and so on. This makes it easy to see if a motor

December 2015

Figure 1. False brinelling corresponds to the spacing of the bearing’s rolling elements. In this case, it started as non-rotating vibration during shipping or storage. Photo: EASA

was missed. It also puts the rolling elements in a different orientation each time and avoids rocking the rotor back and forth between just two positions.

Special care for windings. Motor windings must be kept clean and dry to prevent insulation degradation. If the storage area isn’t climate-controlled, keep the winding temperature above the

dew point to prevent condensation inside the motor. As mentioned earlier, this is usually accomplished by keeping the winding 5-10°C (10-20°F) above the ambient temperature with space heaters (supplied or added). Another option is to use the windings as a resistance heater by supplying low-voltage DC or singlephase AC voltage (8-12% of rated).

Alternatively, you can lower the dew point of the storage area with a dehumidifier. The dehumidifier option is far less expensive than air conditioning.

Measure the insulation resistance (IR) of the winding(s) before placing the motor in storage and just before putting it in service – even if the motor will be idle only a short time. That way, any decrease in IR can be addressed before the motor is installed. For motors in long-term storage, take IR readings annually, correcting them to a standard temperature.

Tip: Attach a data card to each motor

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and record the IR, temperature and date of each test.

For form coil windings, conduct a polarization index (PI) test in addition to the IR test. PI test variables skew results for windings with lots of exposed conductor surface area, so use the dielectric absorption ratio (DA) test for random windings and DC armatures (see Table 1).

If the windings need to be cleaned and dried, take IR and PI readings again before returning the motor to storage. Disregard the PI ratio if the IR is greater than 5,000 megohms (refer to the IEEE 43 standard).

Carbon brushes. DC machines, wound-rotor motors and some synchronous machines have carbon brushes. For long-term storage, lift the brushes away from the commutator/slip rings to prevent a chemical reaction. Leave the springs in the relaxed state, when practical, to avoid weakening them.

Placing the motor in service To ensure reliable operation, perform the following when removing the motor from storage: • Remove any dust or dirt and inspect the motor.

• Measure the IR with a megohmmeter and compare the temperature-corrected reading with the one taken before the motor was placed in storage.

• Drain oil-lubricated motors before moving them; refill the reservoir after installation.

• For grease-lubricated motors, purge excess grease by running the motor at least 10-20 minutes with the drain plug removed.

• If there is any moisture in the grease, the bearings probably have sustained rust damage and should be replaced.

• If the motor was stored for several years, the grease has probably hardened, and the drainpipe will be plugged with dried grease. In that case, it’s best to dismantle the motor, clean out the old grease, and repack it with fresh grease.

• If the motor has been subject to vibration while in storage, inspect the bearings and replace any that are damaged before installing the motor.

• After installing and aligning the motor, but before coupling it to the load, document uncoupled baseline vibration levels; check the vibration levels again after the motor has been in service a week or two.

• For motors with rolling element bearings, evaluate the vibration spectra for indications of bearing fault frequencies.

• For large machines where shaft sag is a consideration, performing vibration analysis during startup is critical to avoid catastrophic damage.

High-cost machines obviously justify the cost of rigorous storage procedures more than inexpensive, readily available motors. What’s not always apparent is that some ‘small’ motors are equally important to production. To assure a quick return to reliable operation after a failure, obtain replacements for all critical applications and store them as described in this article. MRO Chuck Yung is a senior technical support specialist at the Electrical Apparatus Service Association (EASA), St. Louis, MO. EASA is an international trade association of more than 1,900 firms in 62 countries that sell and service electrical, electronic and mechanical apparatus. For more information, visit www.easa.com.

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Between a rock and a hard place

‘ Build ‘em oversize and build ‘em tough’, says a veteran conveyor manufacturer. And then take care of maintenance!

BY CARROLL MCCORMICK

Every conveyor is custom fabricated for Simar-Dacon’s clients.

conveyors, plus as many feet of walkways, and staircases, supports, etcetera, for Construction DJL’s $12-million, 500,000 and 600,000-tonne capacity aggregate plant in St-Philippe, QC, about 40 km south of Montreal. DJL is a division of Eurovia (Vinci group).

“We spent most of 2014-15 working for DJL. It was our biggest project ever,” Rouleau says. That says something, considering the photos in the hallways and offices of some pretty massive machines, and the fact that one of his clients operates nearly 150 of his conveyors in a single plant.

Conveyor innovations Now that the DJL contract is all but fulfilled, Rouleau is ready to rock with some new contracts. But that is not what we talked about that day in his boardroom.

We talked maintenance. We discussed some of the unusual specifications of the DJL job that Rouleau found sufficiently compelling to add to his list of signature practices.

Take hot-dip galvanizing, for example.

Simar-Dacon had galvanized small parts before, but nothing on the scale that DJL specified for all the new aggregate plant’s conveyors and support structures.

Aside from it simply being easier to send the parts out to be galvanized than to sandblast, prime and then apply two coats of paint (DJL’s original specification, which it then changed), Rouleau explains some of the advantages of galvanizing that make it a viable alternative to painting. “It is a very good thing for everybody, especially in Quebec. It also makes the [structures] easier to handle than painted ones. Just [transporting] in the winter can sandblast structures. We shipped to Alberta once and everything was sandblasted. We had to repaint them.”

Rouleau also notes that galvanizing all that DJL equipment cost no more than had they been painted.

Rouleau also likes another DJL speciContinued on page 18

‘Galvanizing makes the structures easier to handle than painted ones. Just transporting in the winter can sandblast structures. We shipped to Alberta once and everything was sandblasted. We had to repaint them.’

Shop talk: From left to right: Simon Roy, junior engineer, David Marchand technician, Simon Rouleau, engineer and owner, Roch Pellerin, welder.

A plasma cutter at work.

Photos: Carroll McCormick

C

onveyors have it rough. Often overworked and under-maintained, this is why Simon Rouleau, owner of Beloeil, QCbased Simar-Dacon believes in building them extra tough and sized for tomorrow’s needs, not just today’s.

“Build it strong, and with 25 per cent more capacity than what is requested,” are two of Rouleau’s commandments. In his two decades designing and building conveyors of all shapes and sizes, he has come to some firm conclusions about their construction and maintenance. His cup of wisdom is not full, though; he is happy to incorporate new ideas into his production and design repertoire.

Simar-Dacon began as Dacon Conveyors, which was founded in 1984. Rouleau joined the company in 1995, became president and owner, and in 1998 renamed it Simar-Dacon. Rouleau’s clients can be found in industries such as quarries, mines, recycling, pulp and paper, sugar and fertilizer, and in countries as far away as Pakistan and Australia.

Company products include fixed and mobile belt conveyors and radial stackers, chain, screw and drag conveyors, bucket elevators, shuttle conveyors and ship loader conveyors. And because every conveyor is a custom product, SimarDacon also designs and builds conveyor supports and hoppers.

A staff of 14 carries out the design and fabrication work in a 20,000 sq-ft (1,858 sq-m) facility about 20 minutes east of Montreal. There were, unfortunately, none of his brightly-painted conveying machines to study when I visited, but an arcing water jet cutter was making its spooky warbling sound, beefy trusses waited for part-mates, a painter painted, a welder welded and a five-ton overhead crane awaited its next command. A forklift operator zipped plastic-wrapped conveyor hoods into a cube van.

This tranquility was more the eye of a storm than a slow period, though. SimarDacon has just come off nearly two years of building 3,600 ft (1,100 m) worth of

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‘By using hydraulic belt tensioners, there are three fewer pulleys and less maintenance, because there are six fewer bearings.

And you don’t need to grease them. There is no need to guard the area where the pulleys are, and there is no spillage.’

Continued from page 16

Conveyor components in the paint room.

Hoods protect conveyors from the weather, and reduce maintenance. This Simar-Dacon conveyor system is galvanized, not painted.

Photos: Carroll McCormick

A mobile radial stacker, fabricated by Simar-Dacon. The red urethane rollers are manufactured by sister company Plasthane.

This hydraulic tensioner replaces the more common gravity tensioner, and requires less maintenance.

fication for its new plant: hydraulic belt tensioners. Unlike gravity belt tensioners, hydraulic tensioners simply pull on the tail pulley to make the belt taut. They are only appropriate for conveyors over about 250 ft (76 m) long, but when they can be used, they are better, Rouleau says.

“There are three fewer pulleys and less maintenance, because there are six fewer bearings. And you don’t need to grease them. There is no need to guard the area where the pulleys are, and there is no spillage. Now, knowing that we can do it this way, as long as we have room at the end of the conveyor, about 12 to 14 ft [3.74.3 m], we will definitely go this way.”

DJL also specified a belt configuration called, in French, a “retournement bande.” In it, the belt is twisted 180 degrees after the head pulley and then twisted 180 degrees back just before the tail pulley. A conveyor needs to be at least 300 ft (91 m) long to do this, and it costs more, but the advantages are interesting.

“I told a client recently that if he wanted this, he wouldn’t have any spillage, nor does the guard around the return roller fill up and cause damage. There is no accumulation of dirt or ice over the return roller in the winter. And [subsequently] you don’t have a tracking problem with your belt,” Rouleau explains.

Coloured rollers fill shelves in the corner of the boardroom. Made of urethane, they are products of a sister company Rouleau bought in 2008, called Plasthane. It manufactures urethane guide rolls and belt scrapers. “Since we bought the company, we have developed many urethane parts. We use urethane because it doesn’t damage the rubber belts.

It is the sturdiest material that can come in contact with belts without damaging them,” Rouleau says.

This year Plasthane began manufacturing magnetized urethane liners, a quick-install alternative to abrasion-resistant steel overlays. “The idea is to protect chutes. Their function it is similar to hardox, a special steel plate that is very hard and good protection against abrasion. The magnetized urethane liners take only seconds to install, even if they cost somewhat more. You’d be surprised at how strong the magnets are. It takes

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80 pounds of pull to remove a square foot of urethane liner,” Rouleau says.

Conveyor maintenance tips Inevitably, we alight on maintenance issues. What practices can Rouleau, as a manufacturer, recommend? Here are some, in no particular order: Use standard components on the market. “Try to work with standard bearings. Many companies come to us, trying to sell us their models of bearings and reducers, but they are not standard. I stick with bigname components in the market.

“I also suggest to clients to have a heavy-duty design. You can go on the market and buy bended steel frames, but we use C-channel, heavy-duty frames. If something hits the conveyor, it will resist the forces more. If a conveyor goes out of square, the belt will not track properly.”

Rouleau also recommends conveyor hoods – popular purchases from SimarDacon by customers and competitors alike. “Hoods reduce maintenance. They reduce the accumulation of snow, dirt and rain. They protect belts from the sun. They protect the whole mobile part of the conveyor. They also help keep dust inside.”

Rouleau also likes to build some additional capacity into his conveyors. “If someone asks me for a 600-tonne conveyor, I will build it larger. Eventually they will need the extra capacity.” And, he adds, “I always try to have six inches from each edge of the belt with no material on the belt. If not, and you have mistracking, you will have spillage.”

Finally, he broaches the oft-ignored topic of inspections, repairs and cleaning.

“Make regular visual inspections. Replace broken parts. Often, when I go to a site, there are broken parts, spillage … with spillage, all of your mechanical components can be buried. The rollers don’t roll as they should, bearings are full of dust and you will probably have tracking problems. There are some industries where the maintenance is so low that the ends of the conveyors are buried. Keep the conveyors and loading points clean.” MRO Montreal-based Carroll McCormick is the award-winning senior contributing editor for Machinery & Equipment MRO.

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sive downtime and production losses?

Then you need to pay more attention to maintenance.

To perform a check on drives in your plant, always start with safety – follow prescribed procedures regarding ma-

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more quickly than they should when excess slippage occurs.

Poor drive maintenance isn’t always a personnel issue – often drives are not easily accessible or production requirements dictate that equipment just isn’t available for routine maintenance checks by maintenance staff.

Often the first indication of a belt problem shows up when a machine operator notices unusual noises or smells coming from the area of the drive or, worst case, the machine stops running suddenly. One advantage of belt drives is that they can be monitored while running by looking at them and listening to them.

When you’re removing the guard from the drive, inspect it for damage or a build-up of dust or other foreign material on the expanded metal to ensure proper ventilation. An internal temperature increase of 10°C in the v-belts can cut the belt life in half, so good ventilation is critical (Fig. 2) Next, inspect the belt or belts on the drive. Look for cracks and glazing on vbelt sidewalls. Some wear is normal for a v-belt drive that has been in operation for some time, but if the sidewalls are glazed and worn down, or if there are large cracks that go almost through the belt, then it is time to replace the belt. With synchronous (timing) belts, look for badly worn, cracked or missing teeth (Fig. 3).

While inspecting belts, it’s also a good time to inspect the sheaves or pulleys for wear or damage. As a rule of thumb, V-belt sheaves should last roughly between three and five belt changes. Worn sheaves will not transmit horsepower efficiently to the belt sidewalls, resulting in loss of speed and excess wear on the belts themselves.

While you’re doing your inspection, you can smooth out any nicks and burrs you find by using emery cloth.

Sheave gauges are available from your belt supplier and can be used to show sheave wear (Fig. 4). Even without a gauge, if you can feel the wear in the groove, it is time to change the sheave.

Usually the smallest sheave in a drive is the one that will show the most wear. A

Photo: Sourced by Paul Dzsudzsak

B

elt drive slipping? You’e paying for electricity that is not producing any product for you — or it is not moving the proper amount of air. Do you have belt drives that seem to ‘eat’ belts, causing exces-

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Fig. 1: Always begin belt drive work with lockout/tagout (LOTO).

F O C U S

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December 2015

Machinery & Equipment MRO

Fig. 2: Guards need to be kept clean to ensure proper ventilation of the belt. worn $100 sheave will ‘eat’ hundreds of dollars’ worth of v-belts. With synchronous or timing belt pulleys, gauges aren’t necessary, as you can see the wear.

If the belts appear to be in good condition or you are installing new belts, tension them to the recommended settings. If you have this information in your maintenance database or in machine manuals, you can follow that. If not, charts for tensioning belts are available online from most manufacturers.

Simple tension gauges are also available from your belt supplier and these can make this job easy and accurate (Fig. 5). V-belt drives are efficient when installed and maintained properly – as high as 98% efficiency. As v-belts wear and stretch, however, that number drops drastically if tension isn’t adjusted accordingly.

Before you tighten everything back up, it would be a good idea to check alignment now. A straight edge, steel tape measure or even heavy string can be used to make sure the sheaves or pulleys are aligned with each other. Many maintenance departments now have more sophisticated laser alignment tools available as well.

Sometimes, in spite of your best efforts and following all of these procedures, you will have a drive that goes through too many belts.

At some point, changes in ratio may have been wanted in order to increase or decrease the output speed, so someone may have changed one of the sheaves to change the speed. Maybe a 15-hp motor that was on the shelf in the maintenance storeroom was installed when the 10-hp motor on the drive failed. Or could it be that a machine that used to run only one shift per day for five days is now running 24/7? Changes like these can greatly affect belt life.

A properly designed and maintained belt drive should give a minimum of one year of belt life on a tough application – and even more on less-demanding applications. If you aren’t satisfied with the life of belts on a drive, your supplier can help – a drive analysis and

Fig. 4: Usually the smallest sheave in a drive will show the most wear.

redesign may be necessary to eliminate the excessive downtime and production losses. An entirely new belt drive is likely to be much less costly than one downtime incident.

V-belt drives are reasonably efficient when all the components are new and

Fig. 5: Use a tension gauge to help maintain belt efficiency.

care is taken to properly tension and align the drive at installation. More efficient options are available if energy savings are the goal and in many jurisdictions, there are government/utility incentives to change from v-belts to synchronous belt drives. If you are going

through too many v-belts on an application, this would be a good time to consider making a change. MRO Paul Dzsudzsak is with J/E Bearing & Machine Ltd., Tillsonburg, ON. For more information, visit www.je-bearing.com.

REAL STORIES. REAL SOLUTIONS. We’re problem solvers.

We do what it takes to help our customers get the job done.

“ Nicole Pelletier Account Manager Acklands-Grainger Innisfail, Alberta

Acklands-Grainger eCommerce Solutions

Photos: Sourced by Paul Dzsudzsak

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D R I V E S

Convenience, Control & Improved Processes

There’s always a way to fix something.

It may not be the conventional route, but there’s always a solution.

“

There are plenty of reasons why businesses adopt eCommerce solutions like time savings, cost savings, and enhanced order management. Even though some businesses may be slow to adopt new technologies, today’s eCommerce solutions can adapt to even the most complex purchasing processes.

Account Manager Nicole Pelletier knows this firsthand and recognized that her customer would save huge amounts of time with an eCommerce solution. But for many reasons, the customer was reluctant. A natural-born consultant, Nicole enabled the customer to see for himself that eCommerce was right for his company.

It was a matter of showing the customer the benefits, not telling the benefits.

Get the full story of how Nicole solved this problem, as well as other examples of Acklands-Grainger team members finding solutions, by visiting:

Fig. 3: On synchronous belts, worn, cracked or missing teeth are easy to spot.

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M O N I T O R I N G

Machinery & Equipment MRO

December 2015

Photos: SKF

Maintenance worker uses SKF’s Marlin I-Pro, part of a system that helps automate inspections.

Bearings with

BRAINS How revolutionary, smart bearing technology will underpin the creation of intelligent machines and be a new tool in maintenance for condition monitoring.

Filippo Zingariello.

D

BY FILIPPO ZINGARIELLO

efining an intelligent machine is no easy task. In the early days of computing, it was thought to be a computer whose answers to questions were indistinguishable from those of a human being. In this sense, the word ‘machine’ was taken to mean ‘computer’. If you search for ‘intelligent machine’ on Google, you’ll still find lots of futuristic work in this vein.

The McGraw-Hill Dictionary of Scientific & Technical terms defines it like this: ‘A machine that uses sensors to monitor the environment and adjust its actions to accomplish specific tasks in the face of uncertainty and variability’.

Cited examples include industrial robots equipped with sensors and selfguiding vehicles that rely on vision rather than painted lines.

Within engineering, we think of an intelligent machine as a mechanical system that can take care of itself: a machine capable of accurate self-diagnosis that can quickly communicate its condition to an operator so that the

problem can be resolved as soon as possible. It could be anything from a highend car to a complex machine on a factory floor. This is the subtext to ‘uncertainty and variability’: as well as reacting to changes in its environment, an intelligent machine must look after itself, so that it can continue to work at maximum efficiency.

This is not to suggest that an intelligent machine is maintenance-free – that really is a futuristic dream – but it uses its in-built intelligence to detect potential problems and streamline maintenance intervals and procedures.

All mechanical parts are prone to failure, of course. The trick is to detect this proactively, as part of a planned condition monitoring regime, and take action in advance, rather than waiting for the machine to fail and then spending time and money repairing it.

Intelligent machines will rely on several critical factors. The most important, by a long way, is information.

Without data, there can be no intelligence or diagnosis. This data needs to

be gathered, transmitted for analysis, and processed, which, in turn, requires sensors, data transmission and computing power. At SKF, we already have extensive experience in all these areas, and are ready to take it to the next level.

Building in sensors The immediate answer might at first simply appear to be enhanced condition monitoring, adding an array of sensors to a machine in order to read its vital signs, then transmit them over WiFi to a central point. But a far more effective solution now exists in the shape of SKF Insight: it collects and transmits process data independently from inside the very heart of a machine using a fundamental engineering component: the bearing.

SKF Insight turns a simple bearing into a diagnostic powerhouse, by embedding into it a tiny, self-powered wireless sensor that transmits real-time information about process conditions. It takes condition monitoring far beyond what was previously possible. The technology, launched in Hanover in 2013, required three years of intensive research, including making the sensors smaller, overcoming power generation challenges and developing unique packaging for the sensors and electronics.

Conventional condition monitoring detects the early signs of failure by measuring vibrations caused by changes on the bearing’s surface. But this means that damage has already begun to occur.

Rather than identifying this deterioration, SKF Insight detects the conditions that cause bearing failure before they can have an effect, and makes this information instantly available to operators.

Miniature electronic circuits, powered by the motion of the bearing itself, transmit this process data via a wireless link.

There is no need to supply external power.

This makes the technology supremely unobtrusive, because there are no wires ‘in’ to provide power, or wires ‘out’ to deliver the signal. This means it will work in places that would previously have been impossible. Just imagine trying to take signals out of a rotating gearbox, for example: it would be a complete mess, with entangled wires everywhere. With SKF

Insight, signals can be taken from anywhere, and we are already developing solutions in challenging applications in wind turbines and steel manufacturing.

We developed SKF Insight because we know that bearings rarely fail in service under normal operating conditions due factors such as subsurface fatigue. Instead, the cause of failure is usually misuse or neglect: insufficient lubrication, for example, or running the bearing under conditions outside those originally specified. Insight’s embedded sensor measures the critical parameters that cause early bearing failure, such as lubricant contamination, or temperature, allowing operators to take corrective action while the machinery is still operating.

The direct result is that expensive, disruptive failures are avoided, which reduces the total cost of asset ownership and extends machine operating life. It also makes it simpler for engineers to gain a far more detailed appreciation of the varied causes that can affect the calculation of bearing life.

By applying sensors directly within the bearing, SKF Insight identifies the risk of failure before even microscopic damage occurs.

SKF algorithms and diagnostics can identify duty excursions, lubricant contamination and lubrication problems, allowing operating conditions to be modified, and so avoid damage before it occurs.

By integrating SKF Insight with asset diagnostic and bearing health services, we can send information on actual operating conditions to cloud servers for remote diagnostics, enabling a better understanding of the risk of future damage and failure.

Rethinking maintenance SKF Insight gives maintenance engineers a powerful new tool to keep machinery in prime condition, giving them capabilities way beyond traditional condition monitoring. It means that maintenance can be carried out at exactly the right time (we can even call it ‘adaptive maintenance’), rather than being guided by a strict schedule that is unrelated to the actual condition of the machinery or its components.

Continued on page 24

When he reduced costs by 13% with a new RTU, he wasn’t just saving money.

He was setting a precedent.

Once you start seeing the benefits of our incentives for upgrading to high efficiency RTUs, you will want to look into making other parts of your building like ventilation, chiller and building automation systems more efficient too.

When you do, you’ll be joining thousands of organizations across Ontario who are already enjoying the savings that our programs deliver.

Take a look at their stories and our incentives at

saveonenergy.ca/business

Subject to additional terms and conditions found at saveonenergy.ca. Subject to change without notice.

OM Official Mark of the Independent Electricity System Operator.

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M O N I T O R I N G

Machinery & Equipment MRO

December 2015

Photos: SKF

Continued from page 22

Looking into the future, we’ll see the joining of bearings and condition monitoring.

All mechanical parts are prone to failure.

The trick is to detect this proactively, as part of a planned condition monitoring regime, and take action in advance, rather than waiting for the machine to fail.

Cutaway view of bearing shows sensor module in green.

The intelligent wireless technology inside the bearing allows bearings to be configured in smart networks, which communicate via wireless gateways. The gateway can be local to the machine or to the plant.

System information is provided to the customer for analysis using SKF @ptitude Analyst, or sent via the SKF cloud to a remote diagnostic centre. From here, dashboards and reports can be supplied

to the plant operator, machine manufacturer, SKF or any other authorized person with Internet access. The inclusion of SKF in the list of ‘recipients’ is an important one, as its assistance in gathering and interpreting the data will be vital thanks to the deep bearing and machine knowledge existing in SKF. Because the bearings are self-contained, they can be used right in the heart of a machine, where it was previ-

ously impossible to embed sensors. This is a huge step forward in real-time condition-based maintenance, and provides a vastly improved understanding of the operating environment. Having such a deep knowledge of operating conditions – in real time – could even make it possible to upgrade a machine, extending its life or power rating beyond its initial specification.

The sensors communicate through each

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other, and the wireless gateway, to create a ‘mesh network’, providing both machinewide and plant-wide information.

SKF Insight makes condition monitoring more widely applicable, especially where it might previously have been considered impossible. Because of this, it is being tested in industries including wind power, rail and steel manufacture.

Tough conditions SKF Insight also offers huge potential benefits to industries like wind energy, where the cost of maintenance is astronomical. In some offshore wind applications, changing the main bearing on a wind turbine is so expensive that it undermines the business case for building the turbine in the first place. Used here, intelligent bearings could monitor loads and lubrication conditions in service, giving plenty of time to prevent the development of damaging process conditions.

We are already working with customers to develop SKF Insight for wind turbine monitoring. It measures dynamic bearing information in the true operating state, then wirelessly communicates it to remote monitoring centres or local maintenance crews. The solution being considered will monitor bearing speed, vibration, temperature and lubrication. Most importantly, it can be retrofitted, so could enhance the operational potential of both new turbines and the many thousands that are already in operation worldwide.

A similar solution, further in the future, is being developed for wheel end bearings in the rail segment. These critical components are normally changed at set intervals, regardless of their condition. SKF Insight creates a cost-effective way of collecting condition monitoring data so that service bearing life, and change-out intervals, are determined based on actual, rather than predicted, operating conditions.

The ability to monitor and transmit information on operating conditions will bring about a revolution in bearings, in terms of maintenance planning, total cost of ownership and maximizing machine efficiency. Bearings have long been considered the heart of rotating machinery. Now, by imbuing them with intelligence, SKF Insight makes them the brain as well. It goes beyond traditional condition monitoring, into what might be called ‘future reliability’ – identifying potential problems before they occur, and taking immediate corrective action.

SKF Insight is already being put to work in high-end applications such as wind turbines. But consider the machine that we spend most of our time with: the car. Think about all the problems that could be avoided with this kind of advance intelligence, and you can see why the technology embodied within SKF Insight is truly a revolution – joining both bearings and condition monitoring. MRO Filippo Zingariello is director of global strategic development at SKF. For more information, visit www.skf.com.

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A L I G N M E N T

Getting the right angle

December 2015

Machinery & Equipment MRO

To align a shaft, moving a combination of both machines can give you the best option with the least amount of correction.

BY JOHN LAMBERT

on the graph, we can draw a green line (Fig. 2) from one outbound foot to the other (Foot 1 to Foot 4). We draw the line through the point where the shaft intersects the foot plane. This green line is now our target line.

Now if we view these outbound feet to be the locked pair, we can see that in order to achieve our alignment, we will have to move the inbound feet up. In this case, the driven (stationary) unit has to go up 0.003 in. (3 thou) at Foot 2 and the driver (moveable) unit has to go up 0.010 in. (10 thou) at Foot 3. Now that’s a lot less work than the first option and it gets you out of the base-bound issue.

Can this move cause other issues? The answer is yes, but let’s continue with the analysis before we make the move. We can see that the front foot of the pump has to go up 0.003 in. (3 thou). If we want to find out how much of an angle we will be introducing by lifting the pump/pipe flange up, we will use the rise-over-run principle. If we divide 3 thou by the distance between the machine’s feet (16 in.), we get 0.1875 per in. of angle that we will be introducing to this machine. If we multiply that by the distance across the pipe flange, which let’s say is 7 in., we would be lifting it up 0.0013 in. (1.3 thou), which is very little indeed.

Once we are satisfied with our analysis stage, we take action and make the move. But this is only one option; if we draw our line from Foot 2 through to Foot 4, we could tilt the pipe flange down instead.

The point is that you have options when moving machine units and very often a small amount of angle can make a big difference. You need to be able to see and understand this when you analyze the results of your measurement.

Understanding dial indicator shaft alignment methods as well as graphing or plotting helps you see the whole view – the bigger picture. This is why organizations like the American Petroleum Institute (API), which has produced its own pump and motor installation standards, highly recommend that tradesmen who use laser systems to align shafts be fully conversant with dial-alignment methods.

Now a good laser system will give you different boltbound and base-bound options, such as the examples in Figs. 3, 4 and 5.

In Fig. 3, we lock the inbound feet of the stationary (pump) and the inbound feet of the moveable (motor) in the vertical plane. If we were base-bound, this would be a good option because we can add shim.

In Fig. 4, we lock the outbound feet of the stationary (pump) and the outbound feet of the moveable (motor) in the vertical plane. If we were base-bound, this would not be a good option because it’s asking us to take shim out, and there is no shim to take out.

In Fig. 5, we lock the outbound feet of the stationary (pump) unit and the inbound feet of the moveable (motor) unit in the vertical plane.

If you look at the different options, you can see the amount of angle you are introducing to the machines – in this case, 1.5 thou per inch with each option. Multiply this by 7 in. (distance of the pipe flange face) and you get 0.0105 in. Yes, 10.5 thou. Can the pipe handle that much?

The way to find out is to measure it; using the right style of laser system, you can actually measure the effects of pipe strain – but that detail is for another article.

Remember, the optimum move is the one that meets your needs the best, but if we were base-bound, option one (Fig. 3) would work the best.

Finally, documentation is a basic requirement for a machine’s history file. It is also being strongly requested by companies after an alignment is finished. So don’t short-change the job. Finish it off by capturing this important information and don’t forget to include your graphs in the documentation. MRO John Lambert is the principal of Benchmark Maintenance Services, Pickering, ON. For more information, call him at 1-800-598-1117 or visit www.benchmarkpdm.com.

Fig. 1.

Fig. 2.

Fig. 3.

Fig. 4.

Images: Benchmark Maintenance Services

W

hen we think of shaft alignment, we usually think of one machine being the stationary and the other machine being the moveable.

The normal preference is to use the driven unit (i.e., a pump) as the stationary and the driver (i.e., a motor) as the moveable. The reason behind this is that you don’t want to create pipe strain by moving the pump. Makes sense right?

For some who don’t think beyond this, it limits their options. The reality is that you can move either machine and in fact, in the case of say, a diesel engine that is driving a generator, it’s the driven unit that is normally chosen to be the movable. However, very often, moving a combination of both machines will give you the best option with the least amount of correction.

During a three-day MAAD Training Machinery Installation program that my company developed, we can demonstrate this combination move during the reversedial indicator shaft alignment section. MAAD is an acronym for Measure, Analyze, Act and Document, and that is the process we promote during the training. This training covers it all, from nuts and bolts to the geometric measurement of the base. We train participants in shaft alignment using dials and laser systems.

An organization that recently participated in the program had asked that we include both rim and face, and reverse-dial methods of shaft alignment, as well as laser alignment, which we accommodated.

One benefit of using the reverse-dial alignment procedure is that we can use the graphical method to calculate the necessary machine corrections. The graph is a pictorial view of the machine’s shafts, and is drawn to scale.

If we set up a graph and draw the machine’s shaft and leave out the dial-plotting points, you would have something like Fig. 1. The black solid lines represent each of the machine’s shafts plotted from the dial indicator readings (not shown). The red lines represent the plane of the machine’s feet (the adjustment points). The dashed line is a target line for traditional alignment graphing/plotting.

We are showing the vertical plane only and the scale we are using is such that going across the page, each small box in the graph paper is equal to 1 in. Moving up and down, each small box is equal to 0.001 in. (1 thou).

The stationary machine is on the left and as you can see, we have 16 in. between the feet. It is drawn in the traditional manner – sitting in a level plane.

The moveable machine is on the right and its position is based on the dial reading taken from each shaft. However, for simplicity we are not showing the plotting points.

You can see we have 18 in. between the machine’s feet and the shaft is low at foot 3 (F3) but high at foot 4 (F4).

Now imagine that we are base bound – a common problem in the real world. There is no shim under the back feet (F4) and based on this graph, it is telling us that we must lower the back feet by 10 thou. The problem is, however, that we cannot lower the machine if there is no shim to take out.

So we have measured the misalignment and now we can use the graph to help analyze the base-bound issue.

Remember, the goal is simply to have these two shafts as one. We need to move one or both to be opposite to each other, in line – the technical term is collinear, to be inline in both the horizontal and vertical planes.

Because of the base-bound issue, the traditional option is to lift the stationary machine up by equal amounts to be higher than the moveable machine – in this case above 0.010 in. (thou), which is the high point. You would then readjust the moveable machine into alignment. However, this is a lot of work and you will be fighting the pipe if the stationary machine is a pump, so you are better off looking for an alternative option.

The fact is that there is more than just one option. The stationary/moveable method means that the stationary feet are locked, and usually fixed in position. However, you can choose which feet to lock in any combination so you can achieve your goal of collinear shafts. To see this

Fig. 5.

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Machinery & Equipment MRO

December 2015

Phtoto: Thinkstock/Lagereek

By taking a forensic approach to plain bearing failures, the operator can uncover and correct systemrelated problems.

Monitoring and evaluating bearing distress

Take a forensic approach to diagnose the root causes of bearing problems and to help prevent future troubles.

B

earing health can be monitored through the use of infrared temperature measurements, vibration and acoustical signals, and oil analysis. Failure mode analysis by itself

is especially useful in diagnosing root causes of problems after the damage is done.

Through the prudent use of temperature and vibration monitoring equipment, routine oil analysis, lubrication

system evaluations and machine operational performance reviews, bearing distress may be identified and evaluated before catastrophic failure occurs.

Being able to properly identify damage resulting from improper installation, pitting, fatigue, abrasion and corrosion is the key to diagnosing the root causes of bearing problems. Here are the critical things to look for.

False brinelling: Caused by vibration resulting in movement of the rolling element against the raceway in stationary bearings. Damage appears as linear or elliptical wear marks in the axial direction at each ball position. It can be controlled by eliminating axial movement and using lubricants containing solid additives.

True brinelling: Appears as indentations in the raceway at the same interval spacing as the balls. It will result in increased bearing vibration and can lead to fatigue failure. It is different from false brinelling in that the indentations are not just surface marks. True brinelling is caused by severe impact to the bearing, such as by dropping it or striking it with a hammer. Static overload can also be a cause. Proper installation will cure most causes of true brinelling. Paying attention to static load ratings is important too.

Misalignment: Appears as a wear path not parallel to the raceway edges.

This can be caused by many things, most commonly bent shafts, improperly aligned shafts or improper installation.

It’s best fixed by properly aligning shafts and through good installation practices, including use of precision locknuts.

Fretting corrosion: Characterized by micromotion between parts where the fit is just short of tight enough. The corrosion appears as brown rust, usually between the housing and the outer ring or the shaft and the inner ring. It can be prevented by assuring proper fit upon installation. Fretting corrosion can also affect shaft and hub and spline shaft connections. In these applications, the use of solid lubricants can cure the problem.

Contamination: Raceway and/

or rolling elements will bear slight indentation marks in a random pattern. Contamination will often lead to early spalling failure. It is caused by dust or dirt particles or other abrasive substances introduced from the environment, a contaminated work area or a contaminated lubricant. Clean tools, work areas and lubricants will solve the problem. Keep bearings in the original package until it’s time to install them.

Normal fatigue (spalling failure): Indicated by pitting of the raceway or rolling element surfaces. Progressive wear results in increasing vibration and leads to bearing failure. It’s caused by excessive preloading, tight inner ring fits and excessive load. Normal fatigue is also the mode of failure for the 10% of bearings that operate for their calculated service life.

Additional preventive maintenance In addition to the previous checks, the oil should be examined and other operational data should be noted.

Oil analysis: A quick visual examination of the oil and oil filter may be all that is required to determine that a problem exists. A thorough oil analysis can provide useful data to assist in diagnosing bearing or machine distress. As a minimum, the following should be supplied: particulate density, particulate breakdown, viscosity, water contamination and chemical breakdown.

Operational data: Another important source of diagnostic information is unit operational data, such as: period of load or speed changes, recent maintenance, performance of related machinery and vibration data/analysis.

In a perfect world, hydrodynamic bearings theoretically have an infinite life.

Equipment operators know that their world is far from being perfect. By taking a forensic approach to plain bearing failures, the operator can uncover and correct system-related problems and ultimately increase machine availability and output, thereby decreasing costs. MRO The article has been adapted and edited from Dow Corning Corp.’s Smart Lubrication Tips newsletter.

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P R O D U C T December 2015

Machinery & Equipment MRO

What’s new in mechanical power transmission Torque limiting coupling helps decrease maintenance costs and downtime

Eaton’s Airflex torque limiting coupling provides increased torque and an automatic slip detection system. Designed to withstand high torque spikes found in grinding mills and heavy-duty variable frequency drive applications, the coupling uses automatic reset and re-engage and automatic wear compensation to help safeguard expensive driveline components. It is available in a wide range of sizes, from 51 in. to 76 in., with a torque range capacity of 2.5 mil in.-lb to 12.1 mil in.-lb on grinding mill applications of 4,000 hp and above. Torque settings remain constant throughout the service life, requiring no periodic adjustments, lubrication, calibration or other preventive maintenance.

Eaton Canada www.eaton.com/AirflexTLC

Compact motorized lead screw range offers small footprint, easy maintenance

Thomson precision-engineered motorized lead screws combine a hybrid stepper motor and lead screw in one compact envelope, offering reduced power consumption, low noise, long battery life, and increased load capacity without increasing installation footprint. Taper Lock technology enables quick connection/decoupling of the lead screw and the stepper motor. Available in rotating screw and rotating nut configurations, they come in standard and high-precision variants and have a wide range of standard options. NEMA frame sizes between 11 and 23 can be selected with various lead screws available in metric and imperial sizes. Stepper resolutions range from 0.00398 mm (0.00016 in.) to 0.127 mm (0.005 in.) and the NEMA 23 variant delivers a maximum axial thrust of up to 890 N (200 lb).

Thomson Industries www.thomsonlinear.com

Large-bore shaft collars, flange mounts are built for heavy-duty equipment

Stafford largebore shaft collars for heavy-duty drive system applications are offered in one- and two-piece clamptype configurations with smooth round, square, hex and threaded bores. These fully split collars are available in a variety of materials with bore sizes up to 12 in. I.D. and can incorporate keyways and slots on the bore, tapped mounting holes, spanner wrench holes and other features on the face or O.D. They can incorporate multiple and extra-large screws for extreme applications. Flangemount shaft collars also are offered in large sizes and can incorporate drilled and tapped mounting holes in any pattern, along with other customer-specified modifications. Applications include construction equipment, processing and mining conveyors, and energy applications.

Stafford Manufacturing www.staffordmfg.com

Torque limiter offers full adjustment, alarm triggering, corrosion resistance

A suitable substitute for friction type torque limiters, the fully adjustable Zero-Max H-TLC torque limiter has consistent and repeatable disengagement features, can withstand corrosive environments and operates dependably in temperatures ranging from minus 40°F to plus 180°F. It operates on a spring-loaded convex pin and detent design that reacts to overloads in the system. Available in models to handle torque from 4 in.-lb up to 500 in.-lb, there are six H-TLC sizes and two models in bore sizes from 7 mm through 25 mm (0.250 in. through 1.000 in.). All are bidirectional. Applications include a wide range of machinery, including food processing, packaging and printing systems.

Zero-Max www.zero-max.com

Simple rubber washer prevents shaft collars from getting stuck on shafts

The Elasto-Ring washer, for use with U-Clip quick-release shaft collars, installs by hand with no tools required. It snaps onto the end of the collar, and, when the collar is in place, is positioned against the spool flange, between the flange and the collar. If back pressure starts to build, it is largely absorbed by the washer, which flexes against the collar. This effectively cushions the collar and prevents a significant buildup of back pressure. The quick-release feature assures fast, easy, one-handed removal of both collar and washer. The washers are

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available in the same 10 sizes as U-Clip collars for use on shafts with diameters ranging from 8 mm to 35 mm. Made from durable, heat-resistant rubber, the washers are long-lasting and will not deteriorate from heat generated by friction coming from the rotating spool flange.

Amacoil/Uhing www.amacoil.com

Company accelerates expansion of electric automation business

Festo’s expanded electric automation portfolio includes 25 mechanical axes and 550 motor combinations, creating a potential one million-plus configurations of different systems. The EXCM planar surface gantry is a compact, electro-mechanical drive, a ready-to-run handling system with two servo drives and a controller that comes fully assembled, suitable for desktop applications such as dispensing, screwing in, bonding and testing, as well as simple pick-and-place tasks. In addition, the CMMO-ST closed loop servo controller can serve as a positioning control-

Dual actuator brake for hoisting systems can be retrofitted

A dual-action head assembly has been developed for the line of Wichita Clutch AquaMaKKs watercooled brakes that provides both failsafe parking and precision tension braking capability in one unitized assembly. The brake provides accurate torque control for constant tensioning in heavy-duty continuous slip tension applications such as drawworks and other hoisting systems. The assembly can be retrofit onto existing pneumatically controlled 25 and 36 size units. Spring-set and tensioning functions can be either pneumatically or hydraulically operated with fewer parts for simple installation and maintenance, and a shim design that makes it easy to maintain.

Adjustment for wear is easily accomplished by removing shims without any unit disassembly.

Altra Industrial Motion www.wichitaclutch.com/aquamakks.asp

Torque limiter’s remote-reset feature keeps production running

The Autogard 820 remote-reset torque limiter allows users to reset the device from a distance, eliminating hands-on labour requirements and reducing downtime by anywhere from minutes to hours in heavy-duty industries such as energy, metal processing, mining, aggregates, automotive, food processing and pulp and paper. The remote-reset feature enables the torque limiter to be reset from anywhere onsite or offsite with the touch of a button, flip of a switch or click of a mouse. The device can be installed independently or as a retrofit upgrade to existing units.

Rexnord Canada www.rexnord.com/autogard

Hygienic design gearbox line offers different levels of protection

Wittenstein’s Alpha brand has introduced a line of gear reducers for washdown and corrosion-resistant applications. These multi-level protection solutions are designed to meet technical requirements in different industries, different machines and axis at different price levels. Designed to meet 3-A, FDA and EHEDG standards, the 316L series stainless steel IP69K-rated hygienic design gearbox offers the highest corrosion protection. For medium corrosion protection for regular cleaning, the stainless steel- and nickelplated inline and right-angle portfolio, with 300 series stainless steel output configurations, protect the gearbox from cor-

ler for stepper motors or for managing the company’s expanded EPCO electric cylinder family. Like the EXCM, the CMMOST can be ordered as complete package with a single part number and configured using any web connection.

Festo Canada www.festo.com/cms/en-ca_ca/

rosion while ensuring reliable performance. With similar corrosion resistance characteristics to 400 series stainless steel, these food-grade lubricated gearboxes can be washed down and can be located close to, or above, open food.

Wittenstein North America www.wittenstein-us.com/ MRO

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Machinery & Equipment MRO

December 2015

What’s new in motors and drives Ammonia compressor motor helps keep facilities cool 24/7

Baldor’s Reliance ammonia compressor motors are open drip-proof, cast iron designs. Motors are available in ratings of 150 hp to 1,000 hp in low-(460-V) and medium- (2,300-V/4,160-V) voltage configurations with a 1.15 service factor at 40°C ambient temperatures. Designed for minimal energy consumption, low-voltage ratings up to 500 hp meet Premium efficiency levels defined by NEMA in table 12-12. Conversion bases are available for all frames for easy adaptability for drop-in replacement. These reliable motors are suitable for cold storage facilities, among other applications.

Baldor/Reliance www.baldor.com

Decentralized servo drive offers full integration

The Sinamics S120M compact, ready-to-connect motor with integrated drive offers users the option of moving the motor inverter outside the control cabinet and directly onto the motor, thereby reducing both cabinet space and required cooling. The decentralized axes are connected back to the central components in the cabinet via a hybrid cable and the AM600 adapter module. The pre-assembled hybrid

Compact right-angle hypoid gearmotor fits into tight spaces

An addition to the PowerStar right-angle hypoid gearmotor product line, the 712 series allows for the same performance advantages as the larger PowerStar series designed into a smaller package. Offering the ability to meet most industrial requirements, the compact series has standard 0.5 in. hollow bore output shaft size with metric sizes coming soon, three standard AC motors (115V single phase, 115/230V dual voltage/dual frequency and 230V 3-phase inverter duty) and 14 standard gear ratios ranging from 10:1 to 240:1. Custom options also are available. This is a viable gearmotor for small conveyors, food and beverage equipment and small industrial applications where saving space is crucial.

Bison Gear and Engineering

Over 450 models in DC drive line-up

www.bisongear.com

Standardized AC system drive saves on maintenance

Washdown motor completely sealed to prevent ingress of liquids

The Extreme Duck motor’s completely sealed design The NXP standardized AC system drive ensures that liquids do not is based on the NXP and common DC bus penetrate the motor in any products, which include a large variety of mounting position. Features include nonmodules in a wide power range. Available wicking lead wires that are coloured and in various IP ratings and featuring CE numbered for easy identification during and UL certifications, the product range installation, standard dual voltage and dual is well-suited to heavy industries such as rotation, upgraded encapsulation process pulp and paper, and metals and marine, that ensures complete filling of the motors where round-the-clock activity is required, and curing of the epoxy encapsulation, all leaving little time for maintenance work. stainless steel exterior, nameplate The drives are configurable via a number information permanently etched into the of options for added flexibility. The frame and corrosion-resistant coating configuration tool software allows applied to the rotor. Installable in all customers to save their own configurations mounting positions, the motor is designed and try out different options before for use in food processing and other purchasing. The wide range of preapplications where motors are exposed to engineered options includes supply units, frequent washdown, common cleaning and fieldbus interfaces and inverter modules. sanitizing chemicals and high humidity.

Vacon Leeson Electric www.vacon.com www.leeson.com 15_1051 Shelf w_Brute_DEC Mod: September 18, 2015 2:01 PM Print: 09/30/15

All Sprint Electric DC drive products and ancillary items are available from stock, allowing users to source the drives they need without having to suffer a lengthy lead time. The product lines include a wide range of DC motor control, with over 450 models covering both onephase and three-phase, regenerative and non-regenerative DC motor applications, together with field controllers, digital slip ring motor controllers and external thyristor stack controllers. The product offering includes the compact, powerful, flexible and easy-to-program PLX DC drive in current ratings between 12 A and 2,250 A at up to 690 VAC, and the XLV range of DC motor controllers rated from 2 A to 12 A and suitable for use on DC supplies up to 48 V. The full range of products covers analogue DC drives from 2 A up to 330 A, digital DC drives from 12 A up to 2,250 A and digital slip ring motor controllers from 12 A to 1,680 A. MDA Controls www.mdacontrols.com

Variable frequency washdown drive is for use in harsh environments

Trans-Power V-Drive NEMA 4X/IP66 variable frequency drives are designed to withstand daily washdown and protect against dirt, dust and liquid. In addition, these space-saving drives are available with an integrated power disconnect for a decentralized mounting solution, allowing reduced component 11:11:15 AM costs. pageThe 1 v7drives’ default

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COMPLETE CATALOG

1-800-295-5510 uline.ca

cable contains all encoder and power cables and serves multiple axes through a daisy chain connection. This single-cable solution reduces the number and length of cables and is easily expanded for additional axes. Typical applications include packaging, printing, glass, textile, and other processes where machinery and production lines require multiple servo axes in a spacerestricted environment.

Siemens Canada www.usa.siemens.com

settings feature 14 quick-start parameters suitable for most applications, while up to 50 parameters can be input manually via the optional V-Stik, a small, Bluetoothcompatible device that allows for rapid copying of parameters between drives. For optimal drive performance, a V-Drive can be combined with a Trans-Power motor.

Kaman Industrial Technologies www.transpower.com/drives/

Brushless DC motor/control package offers versatility

For use where high torque, high speed, quiet operation and low maintenance are needed, the Groschopp robust and economical brushless DC motor and control package has been designed for optimal operation. The brushless DC motors provide high power density in a compact design, while the closed loop controls are designed to deliver commutated power and variable speed control, maintaining good speed regulation over a wide range of loads.

Motor features include 2,600 rpm to 3,800 rpm, 1.8 in.-lb to 10.8 in.-lb torque, 1/7 hp to 1/3 hp, and aluminum frame.

Features of the controls include closed loop speed regulation, line and low voltage, chassis mount and NEMA 4X enclosures, and analogue and digital.

Holding brake, foot mount and IP66 are available as options.

Groschopp www.groschopp.com/products/

Lubricatedfor-life right angle gear drive comes in many sizes and models

Crown smooth-operating right angle gear drives feature lubrication for life with Beacon 325 premium-grade grease and heat-treated AGMA Class 10 spiral bevel gears for maintenance-free, highperformance operation. These quietrunning drives feature long-life, precision-hardened and -ground ball bearings handling speeds up to 2,000 rpm, and internal gears that are permanently mounted to the shafts with locking pins. They are pre-lubricated during assembly, then completely enclosed in a heavy-duty anodized aluminum housing. Standard two- and three-way models are available with 1:1 and 2:1 speed ratios in shaft diameter combinations of 3/8 in., 1/2 in., 5/8 in. and 3/4 in. Temperatures for the grease range from minus 50°C to plus 120° C without evaporation. The wide range of applications includes food processing, packaging and material handling systems.

Zero-Max www.zero-max.com MRO

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P R O D U C T December 2015

Machinery & Equipment MRO

What’s new in hand and power tools Impact driver delivers speed and access in tight corners

Delivering 600 in.-lb of torque for fast, reactionless fastening, the M12 1/4-in., 12-V hex right-angle impact driver features a 3.6-cm (1.4-in.) head diameter for easy access in close quarters and a fast driving speed of 2,425 rpm. The extended paddle switch enables operation from multiple grip points and the recessed forward/reverse switch minimizes accidental actuations. To protect the user’s work surface, the tool also features a non-marring rubber ring around the head. It comes with a RedLithium battery pack, multi-voltage charger and carrying case, and also is available as a bare tool.

Milwaukee Tool www.milwaukeetool.com

Pliers protect staticsensitive equipment from electrostatic discharge

is hardened for long life, while the nutdrivers are precision-formed and -hardened for heavy-duty workloads. Doubleinsulated tool kits are available as a 25piece Journeyman set that includes all tools and a knife, Volt Sensor, fuse puller and tool roll case, a Standard 17-piece set, a Basic nine-piece set, a Screwdriver-only nine-piece set, and a Nutdriver-only seven-piece set.

Ideal Industries

Electrostatic-discharge-safe precision pliers use ergonomically friendly handles to safely dissipate static and help eliminate the dangers of electrical arcing during work on static-sensitive components, making them suitable for use on aircraft, avionics components and other sensitive instruments that are prone to building up static. The tool’s lap joint with screws allows good control of the holding torque and assures the user of sufficient threads, while the low-profile nut design increases accessibility. Plier halves are hot forged and then ground to achieve an accurate fit. They are offered in 13 types.

Snap-on Industrial

www.idealind.com

www.snapon.com/industrial

Well-balanced metal impact wrench designed for user comfort

The ergonomic CP7736 series of 1/2-in. metal impact wrenches delivers durability, power and user comfort. The series also includes the CP7736-2 model, which includes a 2-in.-long anvil attachment. The impact wrench is highly durable, with a twin hammer mechanism providing a working torque of 69-770 Nm (51-568 ftlb) and a maximum torque of 900 Nm (670 ft-lb). It features three power settings in forward, and full power in reverse. In addition, its robust steel motor and aluminum housing withstands the tough workshop environment.

Chicago Pneumatic

Preset torque screwdriver prevents bolts from being under- or over-tightened

An upgrade to the Mountz cam-over torque screwdriver technology, the TLS Pro preset torque screwdriver series improves the ergonomic experience for the assembly operator and was engineered to enhance the user experience during the fastening process. Offering the same performance, quality and torque results as the old TLS screwdriver, the durable TLS Pro features improved lightweight, twotouch design, grip and feel, and reduced operator fatigue. ESD-compliant models are available.

Mountz www.mountztorque.com

www.cp.com

Versatile bolt cutters deliver more power with less effort Insulated tool line boosts electrical safety

Offered individually or in multi-piece sets, Ideal’s line of insulated screwdrivers, nutdrivers, pliers and cutters meet ASTM F1505-01 and IEC 60 900 standards, as well as comply with OSHA 1910.335 regulations and NFPA 70E standards. Each tool is UL and VDE listed and certified to 1,000 VAC. Cutters and pliers, engineered for toughness and durability in harsh work environments, feature high-carbon steel jaws with induction-hardened cutting edges and serrated gripping surfaces.

The screwdrivers feature a tempered blade that is finished with black oxide and

Lightweight magnetic drills provide safe way to drill large holes

The redesigned Icecut 100 and Icecut 200 magnetic drills include the addition of the Accudrill pressure indicator and material and thickness detector.

Redesigned for heavy-duty applications, the Accudrill safety amp meter prevents the motor from overloading and overheating. These lightweight drills will not start when the magnetic holding power is insufficient to secure the unit to the workpiece and operate safely. The compact and portable Ice-

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Four lightweight models expand strap wrench line

Powerlink bolt cutters, designed to stand up in the harshest working environments, have a double compound action system and feature durable centre cut blades and high-performance steel handles that provide strength and power for each cut. The precision-ground, induction-hardened cutting blades make the bolt cutters easy to use on various materials, such as bolts and screws, chain, strapping steel, tire chains, wrought iron, and more. Designed to stand up in the harshest working environments, these durable tools are available in 18-in. and 24-in. handle lengths, cutting up to 9/32 in. and 5/16 in. HRC 48 materials, respectively.

H.K. Porter

Lowell has added four lightweight aluminum models to its line of strap wrenches.

Specs for the four wrenches include handle lengths that range from 6 in. to 24 in.

Strap lengths range from 17 in. to 54 in., and custom lengths are available. Capacities range from 2 in. to 12 in., torque limits range from 20 lb-ft to 330 lb-ft and weights range from 1/8 lb to 2-5/8 lb. Designed for use in industrial, construction, water and high line-utility work, the tools make it possible to turn any shape without scratching, denting or crushing.

Applications include loosening and tightening oddly shaped and frozen fittings, machine and vehicle oil filters, small handwheels, PVC pipe, knurled fasteners and knobs, and turned shafts.

Lowell

www.apexhandtools.com/brands/hkporter/

www.lowellcorp.com

cut 100, built for off-site drilling, weighs 22 lb and features 850 W and 600 rpm. Engineered for heavy-duty applications, the Icecut 200 weighs 27 lb and operates at 300 rpm and 600 rpm, allowing users to cut small and large holes with precision. Pairing of these magnetic drill units with the company’s line of annular cutters and Icecut cutting lubricants ensures the fastest drilling time and maximum life of the core cutters.

Walter Surface Technologies www.walter.com

Lightweight drill driver packs powerful punch in small package

The lightweight, compact Bosch DDB181 18-V 1/2-in. basic-duty drill driver measures just 7.1 in. long and weighs only 3 lb. Especially effective in tight spaces, it has two speed settings and a soft, ergonomic grip. It offers 350 in.-lb of maximum torque and fast drilling at 1,300 rotations per minute for both wood and metal applications. Features include 20 clutch settings and a motor brake for precise screw driving, 1/2-in. tool-free auto-lock chuck, a variable speed trigger for accurate speed regulation, and an LED light to illuminate dark work spaces. A 1.5Ah battery is included, but the tool also works with any Bosch 18-V lithium-ion battery. The DDB181-02 kit comes with a charger, bag and two 1.5Ah batteries.

Bosch www.boschtools.com

Slim-design torque wrench is for applications where space is limited

The UltraSlim torque wrench is designed to provide a robust, high-performance bolting solution in tight spaces. Featuring a lean, stepped-width design, the compact tool can easily be mounted over bolts in narrow-access applications. Few moving parts allow for quick maintenance in the field, while a fast-release drive unit enables easy exchange of cassettes with no tools required. For increased versatility, the bi-hexagonal cassette design allows twice as many positioning points on a nut or bolt. A topmounted straight handle facilitates safe and easy access to hard-to-reach fasteners, and an optional angled handle also is available. All torque wrenches are CEATEX declared for use in explosive environments, and are shipped complete with a calibration certificate, helping to ensure accuracy and traceability.

Enerpac www.enerpac.com

Fastening tool line for light industrial use is expanded

The expanded Apex Geta line of fastening tools includes a wide variety of screwdriver bits, magnetic bit holders, magnetic sockets, nutsetters and extensions available in various sizes and dimensions, including Torx, Phillips, Square, Torq-Set and slotted insert and power screwdriver bits.

Suitable for fast-paced construction, light industrial assembly, and general maintenance and repair applications, the products are machined from high-grade alloy steel and heat-treated to provide a longlasting, non-brittle toughness.

Apex Fastening Tools www.apextoolgroup.com MRO

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Machinery & Equipment MRO

December 2015

Putting

‘focused improvement’ to work Organizations that follow a systematic process like that presented here have tremendous success and will use it over and over again to improve their operations.

BY PETER PHILLIPS

W

e were back at the food manufacturing facility in Ontario last month, Peter Phillips. where we talked about our progress of purging and organizing the parts and equipment storage areas. We talked about expanding the Focused Improvement project to another piece of equipment that directly affects the operation of the equipment on which we originally started making the improvements.

You may remember the two pieces of equipment we referred to in the previous column are called the Tray Loader and the Bagger. The tray loader loads the cookies into trays and then the trays follow a series of conveyor belts to the Bagger. The Bagger loads the full tray of cookies into a bag, ready to be packed into cartons for the customer.

We had created a tally sheet for the operator to record the equipment faults on the Bagger. We had divided the machine into its major components and asked the operators to tally the faults. From this data, we identified the faults that caused the most stoppages and waste. The tally sheets indicated the tray carousel was the biggest problem.

Further investigation showed the trays of product coming from the tray loader caused the majority of these faults. So we studied the tray loader in August and we made some modifications in September, which we promised to write about this month.

But first, I want to talk about Focused Improvement (FI) and what it should mean to us in manufacturing.

The reason I say this is because FI is a cultural change within an organization and requires the entire organization to understand the concept of continually looking for ways to do things better and more efficiently, which of course results in higher levels of productivity, both in labour and equipment effectiveness.

Once people understand, have the commitment and become focused to follow through with FI activities, they need a method to use to help with their improvement efforts.

FOCUS PDCA is an improvement methodology that many organizations use to guide their improvement efforts. It’s simply a formalized process of activities to perform to get to the end result.

So what does FOCUS PDCA mean? It is an acronym for an approach to problem-solving. FOCUS is for Find, Organize, Clarify, Understand and Select. PDCA means to Plan, Do, Check and Act. Let’s start with FOCUS. Find a process or identify a problem that needs improvement. Problems are pretty easy to identify. Just think about the chronic complaints you get or those things that simply frustrate you at work. In our case, we identified through our tally sheets that the trays coming from the tray loader caused problems at the Carousel of the Bagger Organize a team that understands or works with the process or problem. The team consists of people who know the process well and can speak to what works and what needs changing. In our case, we talked with the operators of the equipment and we selected maintenance

personnel who had the most experience with the tray loader and its issues.

Clarify the knowledge. Clarifying the knowledge of the process can help to ensure there’s agreement on what the real issues are. Every person who walks through the process, or who experiences the problem, sees things from a little different perspective. This makes it important to clarify the knowledge from every perspective.

In our case, we worked with the tray loader operators and process operators to understand where the majority problems were coming from. We documented those issues and displayed the major ones on the Focused Improvement board for everyone to see.

Understand the process variations. There are variations in every process. The trick is to discover what causes the variations so you can minimize the peaks and valleys.

What our team did here was to study the major problems and follow those issues to determine if they could be resolved. One of the major issues was the alignment of the cookies on the incoming conveyor belt and how the variations of different products caused the alignment to change.

Select a solution to test. Have the team determine what solution you’d like to test and create a goal for the improvement. In order to correct the cookie alignment, our team sat down to determine where some easy tests could be performed to determine if we were on the right track. In this case, we fabricated cardboard dividers that were securely taped to the machine to see if extended dividers would separate the cookies to allow them to be more aligned with the tray loader.

PDCA (Plan, Do, Check, Act – and repeat) is up next.

After there’s an understanding of the problem and you have selected a solution, it’s time to implement the PDCA steps.

Plan the improvement effort. You do this by creating an action plan for team members to implement. Creating an action plan requires identifying all the necessary tactical steps, assigning accountability or responsibility for each step, and creating a timeline for completion.

This action plan document is what you use to monitor progress and hold team members accountable for achieving objectives. Our team members were assigned the responsibility to use the tally sheet to record problems and downtime and to daily weigh the waste that came from both the Tray Loader and the Bagger. This way we could measure the results of any changes we implemented.

Do the plan. You do this by completing the steps in the action plan and holding people accountable for assigned steps and timelines. This is the most critical step in the entire improvement process. If people do not follow through with the Do, the plan is nothing more than a piece of paper.

Here we created graphs and reports daily to show the day-to-day performance of the two machines. After our cardboard divider tests were completed, we fabricated and installed permanent stainless steel dividers.

Check the results to see whether the improvement efforts truly made a difference. Here we had our baseline data showing the downtime and waste prior to our improvement efforts as a measure of our progress. We collected the same data after the improvements to compare the before and after results. This determined whether the efforts resulted in our goal to reduce downtime and waste.

Cardboard dividers were fabricated and securely taped to the machine to see if extended dividers would separate the cookies to allow them to be more aligned with the tray loader.

After the cardboard divider tests were completed, stainless steel dividers were fabricated and installed.

Photos: Peter Phillips

This issue’s column continues an ongoing analysis of a current project aimed at improving maintenance operations at an Ontario food plant.

The PDCA cycle was repeated, this time using floating dividers that would move the cookies on the conveyor. Because the dividers could float on the belt, the cookies did not jam up, which they would do if the dividers were in a fixed position.

Act on those results. If the improvements worked, write a procedure, train the people who work with the process, and continue to monitor. Our results were very positive and showed a significant improvement in waste reduction. We took pictures and wrote procedures to clean and re-install the new guides.

If the improvement effort didn’t work or if you observe other changes that can improve overall results, then you go through the process again. Repeat the cycle – that is how continuous improvement works.

Although the new dividers were successful, we knew we could align the cookies better before they got to them.

We repeated the PDCA cycle using some floating dividers that would move the cookies on the conveyor; because the dividers could float on the conveyor belt, the cookies did not jam up, which they would do if the dividers were in a fixed position.

The FOCUS PDCA method really works. It is not new – the process has been around for many years. Many companies use it to different degrees of success. The organizations that follow the systematic process presented here have tremendous success and use it over and over again to improve their processes.

Does your organization have a system to improve its processes? MRO Peter Phillips of Trailwalk Holdings, a Nova Scotiabased maintenance consulting and training company, can be reached at 902-798-3601 or by e-mail at peter@trailwalk.ca.

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