Machinery & Equipment MRO October 2015

MACHINERY AND EQUIPMENT

30

Solving cylinder mounting problems Selecting pumps for hygienic applications

19 8 5 - 2 015

Fast fault finding for machinery Vol. 31, No. 6

OCTOBER/NOVEMBER 2015

New Quebec aggregates plant has safety built in How rotating machinery condition monitoring saves time and money

THE FUTURE OF

HYDRAULICS Get ready for Version 4.0

Mail Agreement #40069240

WHAT’S NEW

FLUID POWER

TEST & MEASUREMENT

LUBRICATION

2

P R O D U C T

SP TLIGHT

Machinery & Equipment MRO

up an optimal maintenance schedule. The tags, from Balluff, are highly durable and can be mounted anywhere on a tie rod, on any side of the cylinder. Reading and writing to the tag is simple and allows nearly any RFID reader the ability to read the tag. Software templates have been developed for use with Balluff’s M-series mobile RFID reader.

Milwaukee Cylinder www.milwaukeecylinder.com

RFID tags for maintenance save time and aggravation

Designed for easy identification and maintenance tracking of tie rod cylinders, Milwaukee Cylinder’s RFID tags come pre-loaded with cylinder identifying information and maintenance kit information, allowing for simple preparation of maintenance activity. Once maintenance is complete, the date and work comments can be recorded to the tag, making it easy to track a cylinder’s history and set

Pump’s inline design saves space

Compact and versatile Etaline R pumps combine the low-maintenance features of the Eta family of singlestage centrifugal pumps with an inline design that makes them suitable for pressureboosting duties

in HVAC systems, cooling circuits, water supply and industrial heat recovery systems. The pumps are available in five sizes, for pump diameters from 150 mm to 350 mm. A variety of casing material, impeller materials and seal types are available that withstand temperatures as high as 140°C. Maximum flow rate is 1,900 cu m/hr, with heads of up to 97 m. When maintenance work is required, seals, wear plates and motors can all be replaced quickly and efficiently without removing the main casing from its connecting pipes.

KSB Pumps

October / November 2015

and Marine Grade products. It provides good coverage, especially for touch-ups and equipment maintenance. Designed for use in severe industrial environments, anti-seize compounds protect metal parts from rust, corrosion, galling and seizing. These lubricants ease assembly and disassembly of slip-fit and threaded joints, reduce friction and wear on critical operating equipment, and protect against high temperatures, heavy loads, chemicals and fluids.

Henkel www.henkelna.com/industrial

www.ksb.ca

Brush-top packaging simplifies application of anti-seize lubricants

A compact package featuring an easy-touse, screw-on brush-top applicator is designed for one-hand, precise dispensing of Loctite anti-seize lubricants. This 7-oz brush-top tube is currently available on Copper-Based, Silver Grade, Heavy Duty

Cutting wheel’s narrow-crown technology reduces costs, increases working life

The First Name in Power Transmission

Walter has extended its product portfolio of narrow-crown technology to all 4-1/2-in. and 5-in. Zipcut, Zip+, Zip Stainless and Zip ALU cutting wheels. The Type 27 narrow-crown technology incorporates an improved, refined metal cladding in the centre hub, which allows operators deeper cutting depth. This technology extends the life of the cutting wheel, allowing for more cuts per unit, and reduces annual costs in wheel consumption and wheel changeover. The narrow crown combines the extended life of a flat Type 1 wheel with the extra stiffness of a depressed centre cutting wheel, while the metal cladding prevents contact with the work piece, which increases workers’ safety when cutting into metal.

Walter Surface Technologies www.walter.com

Interactive software helps monitor health of ultra-complex machines

Baldor•Dodge® power transmission products offer reliable service and low maintenance to help reduce your total cost of ownership. Our innovative bearings, gearing and power transmission products have solved the toughest applications for over 130 years.

Our technical sales team can help you with the most challenging applications, and our worldwide distributor network ensures immediate delivery.

• Unmatched Quality • Superior Reliability • Improved Uptime

When it comes to PT solutions, Baldor•Dodge is the first name in power transmission. baldor.com

• Quick Delivery

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/wo8AN5

Omnitrend Center is a powerful software suite for Pruftechnik’s condition monitoring systems: Vibguard, Vibroweb XP, Vibronet Signalmaster and the Vibxpert family. Easy measurement configuration, data management, archiving, analysis and reporting are bundled in one software platform. The software, available in single-user or client-server versions, is ready for cloud solutions, and provides such aids as knowledge-based machine templates, and online and offline device managers. With its tree-based asset management structure, users can quickly orientate themselves through the measurements. Features include dynamic band alarming of overall values, 3D-FFT waterfall diagrams, statistical algorithms for trend prognosis and trend smoothing.

Easy multi-stage drive modelling for linear or planetary gearboxes enables efficient and accurate analysis. The interactive reporting tool allows findings to be shared with the relevant departments and third-party post-processing or CMMS software tools. MRO Pruftechnik www.pruftechnik.com

Online Reader Inquiry No. 116

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30

C O N T E N T S

Machinery & Equipment MRO

in this issue

October / November 2015

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Maintenance safety is built in at aggregates plant / 13

A new rock crushing plant in Quebec is safe, durable and very maintenance-friendly.

p13

How ships save time and money / 22

Critical monitoring of key components in rotating machinery such as pumps, motors and compressors eliminates the need to carry out certain maintenance routines.

p23

departments Editor’s Notebook / 6 Industry Newswatch / 8 Business Briefs / 10 Mr. O, The Practical Problem Solver / 12 Maintenance 101 / 30 Product News Product Spotlight / 2 Focus on Test & Measurement / 24 Focus on Lubrication / 25 Focus on MRO Components / 26

Fast fault-finding for machinery / 23

Quality engineering documentation proves to be a technician’s friend in the field.

columns

Selecting pumps for hygienic applications / 16

Mr. O, the Practical Problem Solver / 12

Various pump designs have individual advantages, but a simple solution for the job – the internal gear pump – can result in higher reliability and reduced maintenance.

Winning reader reveals the most-used books on his company’s maintenance reference shelf.

p30

The future of hydraulics / 20

Hydraulics 4.0 will bring us completely autonomous systems that will monitor and service themselves.

editor’s selections

‘ The pan feeders and conveyors have direct-drive motors. DJL wanted one assembly, a direct drive.

It eliminates the need for belts, guards and safety issues. No tensioning issues, no breaking belts.’

Richard Paquette / 13

‘ Hydraulic systems will gradually become even more intelligent. They will be selfmonitoring by using highperformance sensors, and maintenance will not be carried out during downtime, but dynamically.’

Professor Josef Kurfess / 20

‘ Condition monitoring is a valuable prediction tool. By catching events early, we can replace a bearing at a cost of around US$500, rather than spend between $5,000 and $25,000 on a new electric motor.’

Mike O’Rourke / 22

p21 Dealing with cylinder mounting problems / 21

Pay attention to the load-carrying capabilities of fluid power cylinder mountings to prevent their misapplication, or you could end up with premature cylinder failure, serious machinery problems or safety issues.

New maintenance programs are working well / 30

Maintenance 101: A problem-reporting program using an incentive, a focused improvement project for specific machinery, and spare parts storage organization are helping to solve old problems for this Ontario food plant.

Cover

Dmitry Kalinovsky (kadmy) Thinkstock Images

‘ After a year of using EPLAN database-centric engineering software exclusively, the entire control panel design/build process had become roughly 200% faster, with an even greater degree of improvement in the quality of the finished product and its documentation.’

Kris Morris / 23

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 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.

» 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.

Online Reader Inquiry No. 117

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E D I T O R ’ S

N O T E B O O K

Machinery & Equipment MRO

October / November 2015

After three decades, time for a change I

t’s been a good run – 30 years. Three decades ago, I became the founding editor of Machinery & Equipment MRO magazine, never intending, way back then, to hang around so long. In this business, 30 years is an extraordinarily long time to be the editor of any magazine. Yet while various other staff members came and went, I stuck it out – mainly because I really enjoyed the job and the people I met through working on the magazine.

I knew a bit about the field of maintenance, repair and operations (MRO) from my early days working in industry, before I went back to school to become a journalist. I had studied engineering

earlier (it was electronics, but in hindsight, it should have been mechanical).

Work-wise, I’ve been a draughtsman, making drawings for repair work to be done on glass-making furnaces. I’ve been an electrical construction and maintenance apprentice for one of Hamilton’s huge steel mills. (My right shoulder is still lower than my left from carrying around my surly journeyman’s massive and insanely heavy wooden toolbox, with its thick leather strap slung over my straining shoulder.) Somewhere in there I was also an oceanographic technician, working on wave-tossed ships in the Bay of Fundy, hauling up giant tide-measuring instruments for checking and repair.

Later, sitting at a desk doing writing and editing was just as interesting to me as those challenging jobs, although my working life was certainly a lot more tame. As an editor, I’ve worked on magazines in the fields of foodservice, electronics, construction, finance, computer technology, manufacturing and even automotive.

This particular magazine would not have become the success it is without the founding publishers having a great idea they believed in, and without the help of readers, maintenance consultants, distributors, suppliers and vendors of various MRO products and services. And, of course, there are the many advertisers who helped make this a viable business.

So why am I once again reflecting on the past here in this column? Well, it is the magazine’s 30th anniversary year, so it’s a good opportunity to look back. But it’s also the end of an era for me personally, as I’ll be handing in my MRO edi-

tor’s hat at the end of the year and moving on to other interesting ventures.

Looking back, I can’t think of better work for me than sourcing and compiling interesting content that helps readers in their jobs, writing and rewriting to make the paragraphs clear and understandable, helping create compelling layouts that combine useful text and graphics, writing headlines and captions that grab attention, and managing the production phase of creating each edition of the magazine. On top of that, there’s the newspaper-like action of writing daily news for MRO’s website and producing its weekly electronic newsletter.

It’s a busy job. And in 2016, it will be someone else’s work. Next issue, I’ll tell you about some other changes in the works for next year, and introduce you to the incoming editor. MRO Bill Roebuck Editor & Associate Publisher

MACHINERY AND EQUIPMENT

MAINTENANCE, REPAIR AND OPERATIONS

NOVEMBER 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 Melinda Marasigan, Subscription Enquiries 416-442-5600 x3548 Tim Dimopoulos, Vice-President Annex Business Media tdimopoulos@canadianmanufacturing.com Mike Fredericks, President & CEO mfredericks@annexweb.com Machinery & Equipment MRO is published by Annex Publishing & Printing 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.

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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. 118

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I N D U S T R Y

N E W S W A T C H

Machinery & Equipment MRO

October / November 2015

Photo: Thinkstock

Repair and maintenance services industry earned $25.5 billion in 2013 Alberta had the largest share of operating revenue in the electronic and precision equipment, and commercial and industrial machinery and equipment repair and maintenance services industry.

The

Ottawa – The repair and maintenance services industry earned $25.5 billion in operating revenue in 2013, generating an operating profit margin of 9.3%, according to a new report from Statistics Canada.

This segment is composed of two main industry groups, says the research organization. The first industry group, automotive repair and maintenance services, accounted for 59.1% of the combined operating revenue. The second group, which includes electronic and precision equipment, and commercial and indus-

NEW SURFOX

trial machinery and equipment repair and maintenance services, made up the remaining 40.9%.

This second group earned $10.4 billion in operating revenue and had $9.2 billion in operating expenses, which resulted in an operating profit margin of 11.8%. Cost of goods sold represented 34.8% of operating expenses, followed by salaries, wages, commissions and benefits at 32.4%.

Among the provinces, Alberta (40.3%) had the largest share of operating revenue in the second industry group, mainly as a result of services provided to the oil and gas sector. Firms in Ontario earned 22.2% of operating revenue of this industry group, followed by Quebec (13.8%) and British Columbia (12.4%).

MANUFACTURING INDEX HITS LOWEST POINT IN FIVE YEARS Toronto – Canadian manufacturers indicated further deterioration in overall business conditions during September

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2015, with output, new business and employment levels all falling since the previous month, according to the RBC PMI for September. Weaker demand conditions resulted in lower input buying and greater efforts to streamline inventories, while backlogs of work were reduced at the fastest pace since April.

Moreover, the latest survey pointed to stagnating export sales, despite support from exchange rate depreciation against the US dollar. At the same time, input prices increased at a robust pace amid widespread reports of rising costs for inputs purchased from abroad, but factory gate charges picked up only slightly over the month.

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.

At 48.6 in September, down from 49.4 in August, the seasonally adjusted RBC Canadian Manufacturing PMI registered below the neutral 50.0 threshold for the second month running. Although the index only pointed to a moderate downturn in overall business conditions, the latest reading was the lowest recorded in the five-year survey history.

“Overall conditions in the Canadian manufacturing sector continued to deteriorate in September due to underlying economic conditions, including renewed downward pressure on the price of oil.

Weakness was primarily concentrated in Alberta and British Columbia, with the rest of Canada’s PMI levels registering above neutral and remaining in expansion territory,” said Craig Wright, senior vice-president and chief economist, RBC. “Despite persisting challenges in the oil and gas sector, we expect the strengthening US economy to boost Canadian exports and business conditions over the balance of the year.”

“September was a very tough month for the manufacturing sector in Canada,” said Cheryl Paradowski, president and chief executive officer, SCMA.

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Toronto – Unable to find candidates with the skills they need, many employers are struggling to fill in-demand positions. A total of 50% of employers feel there is a shortage of skilled workers in Canada, according to a new survey from CareerBuilder.ca.

The survey also found that three in 10 employers (29%) currently have positions in their organization that, on average, stay open for 12 weeks or longer. Of those with extended job vacancies, 75% say the vacancies have adversely affected their firm.

The national survey was conducted online on behalf of CareerBuilder.ca of more than 400 hiring managers across Canada in June and July 2015.

“Companies nationwide are feeling the

Photo: Thinkstock

For more information, visit: walter.com or contact your Walter representative

Online Reader Inquiry No. 120

Employers say there are not enough students graduating in in-demand fields.

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Machinery & Equipment MRO

lenges, many employers are taking matters into their own hands and training workers on the job; 46% of employers say they have hired a low-skilled worker and trained him/her for a higher-skill job within their firms in the past two years.

When asked how this practice has affected their firms, employers cited the following benefits: Increased employee motivation, 50%; Improved employee loyalty, 47%; It enabled us to be more competitive, 46%; It enabled us to meet department goals, 41%.

DC DRIVES MARKET TO GROW 2.5% ANNUALLY TO 2020 Vancouver, WA – The global DC drives market will grow from an estimated value of US$2.1 billion in 2015 to around $2.3 billion by 2020, with a compound annual growth rate of 2.5% from 2015 to 2020, according to MarketsandMarkets.

A DC drive is an electrical device used to regulate the speed of a DC motor by controlling the input voltage and/or am-

Photo: Sprint Electric

effect of a skills gap, from lower morale to higher retention rates to a loss of revenue,” said Ryan Lazar, managing director of CareerBuilder Canada. “Our findings indicate, however, that taking proactive efforts to train and reskill workers can go a long way in overcoming these challenges. While we still have a long way to go, the more we can identify the root of these challenges, the more opportunities we will find to bridge this gap.”

Morale, productivity and retention are among the victims of extended vacancies, according to employers. When asked how extended job vacancies have adversely affected their firm, employers cited the following results: Work does not get done, 31%; Lower morale due to employees shouldering heavier workloads, 26%; Delays in delivery times, 24%; Lower quality of work due to employees being overworked, 23%; Employees are less motivated, 23%; Loss in revenue, 22%; Declines in customer service, 20%; Higher turnover because employees are overworked, 19%; Employees making more mistakes, resulting in lower quality of work, 14%.

When asked what they think is causing the skills shortage, employers offered the following opinions: Not enough graduating in in-demand fields, 52%; Lack of interest in required fields, 48%; Employers and candidates have different expectations, 41%; Entry-level jobs are becoming more complex, 37%; Lack of funding in necessary training, 36%; Rapid changes in technology, 34%; Increased competition for candidates, 33%.

In an effort to overcome these chal-

Rising electricity prices, along with increased demand for electricity and energy, is currently driving the DC drives market.

perage to the DC motor. It also rectifies the AC power input into DC feed for the motors. Its primary advantages are increased energy savings and reduced motor wear.

Rising electricity prices, along with increased demand for electricity and energy, is currently driving the DC drives market. In addition, the high potential of DC drives to reduce energy consumption and enhance efficiency of the system provides a huge opportunity for retrofit applications in the manufacturing industry. DC drives also help prolong the service life of the motor systems, further reducing the associated operational costs.

Leading players in DC Drives market include ABB Ltd. (Switzerland), Siemens AG (Germany), Schneider Electric SE (France), Rockwell Automation (US) and Mitsubishi Electric (Japan).

The oil and gas industry is the largest user of DC drives among all industries. DC drives are mostly used to control the speed of pumps and compressors used in the oil and gas industry. Other industries covered in this segment are water and wastewater, power generation, building automation, food and beverages, metals and mining, and chemicals and petrochemicals.

The report has been segmented on the basis of application, type, insulation type, voltage level and region.

The report, DC Drives Market by Voltage (Low and Medium Voltage), by Power Rating (Low, Medium, and High Power),

by End-Use Industry (Oil and Gas, Water and Wastewater, Power Generation, Building Automation, and Others), and

by Region Global trends and forecast to 2020, is available at the website at www.marketsandmarkets.com.

BC GETS MORE LAWS TO IMPROVE WORKPLACE SAFETY AFTER MILL FIRES Victoria – Recommendations from inquests into two sawmill explosions have prompted the British Columbia government to introduce legislation it says will improve safety in the workplace.

The ministry responsible for jobs and labour says Bill 35 will require employers to immediately report all fires and blasts that could seriously injure workers.

Bill 35 adds to workplace-safety legislation introduced earlier this year, and calls on employers to specify meaningful participation for worker and employer representatives in accident investigations.

Other changes would allow WorkSafeBC to proactively assist workplace health and safety committees in resolving disagreements over health and safety matters.

Seven recommendations aimed at the government came out of the inquests into the blasts – at the Babine Forests Products Mill in Burns Lake and at the Lakeland Mills sawmill in Prince George.

Both explosions happened within months of each other in 2012, killing four men and injuring dozens of other workers. The Canadian Press MRO Industry Newswatch is written and edited by Bill Roebuck. Visit www.mromagazine.com for the latest news and longer versions of items here.

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Online Reader Inquiry No. 121

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TECHNICAL SERVICES

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Business Briefs

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

Users with a smartphone can show an engineer what a problem looks like.

• Elgin, IL – Harting now offers live support through its free VideoCall an Expert service, developed as part of its commitment to supporting its customers in all phases of their projects. It is available at HartingVideoCall.com or through the Harting US website (the US operation will also handle Canadian requests).

Customers are able to call from their Apple or Android devices or through their computers. Customers can ‘Schedule a VideoCall’ to select a time in the future or ‘VideoCall an Expert Now’ to set up a face-to-face meeting with one of Harting’s field applications engineers within minutes. The service will help reduce downtime by eliminating the difficulty of explaining challenges over the phone. “If an engineer has an issue, they can use VideoCall to show the problem to one our field application engineers and get help in real time, saving them time

and headache while increasing productivity,” said Jon DeSouza, president and CEO of Harting Inc. of North America.

• Wood Dale, IL – Thomson Industries Inc., a manufacturer of mechanical motion control solutions, has released a new educational video that provides step-bystep instructions on how to properly lubricate linear bearings and guides. The video is the latest in an ongoing series of multimedia content from Thomson intended to maximize performance, reduce lifecycle costs and extend the life of highprecision linear motion technology. “Any system with moving parts will eventually wear out, but understanding the role of lubrication and characteristics of the lubrication itself can help linear guide users make the most of their automation investment,” said Jeremy Gong, global product manager at Thomson. To view the full video, visit www.thomsonlinear .com/website/com/eng/design_tools/ techtips.php.

• Pittsburg, CA – Bishop-Wisecarver Group (BWG), which offer guidance solutions, contract specialty manufacturing and mechatronic-based engineering services, celebrates its 65th anniversary this year. As a company formed in 1950 to manufacture truck accessories, to a growing business today that provides linear and rotary motion product lines,

October / November 2015

BWG says its focus on motion, innovation and quality have remained constant.

BWG’s heritage comes from its founder, Bud Wisecarver, who has spent more than 80 years designing and innovating products that help industries work more efficiently. His patented products can be found in multiple industries, including bottlers, pharmaceuticals, textile plants and semiconductors. Leveraging this innovation, BWG now houses one of the most expansive range of linear and rotary motion product lines that can withstand harsh environments with excessive debris and water, to clean room and low noise environments that require specialized equipment. While Wisecarver is still inventing for the company, his daughter, Pamela Kan, took over BWG leadership as president in 2000. For a view of BWG’s 65-year anniversary, visit www2.bwc.com/history.

• Burnaby, BC – Motion Canada, a distributor of industrial MRO replacement parts, has released a new MiHow2 video that shows how to avoid jamming the bearing at one end when replacing bearings in a pillow block housing. The goal of the video series, developed by the company’s parent, Motion Industries Inc.,

Video shows how to avoid jamming bearings.

Birmingham, AL, is to provide instruction to viewers to help them with their practical applications. ‘How to Maintain Bearing and Pillow Block Centers When Replacing Bearings’ was filmed with the help of Schaeffler, a Motion Industries supplier. The video can be viewed at the www.mihow2.com website under the MiHow2 heading.

• Dorval, QC – Global Bear Inc., a stocking distribution specialist for precision bearings and power transmission products, has hired Michael Gulas to lead the company’s OEM activities. Gulas has previously worked with Emerson, BC Bearing Engineers and Oilless Corp., “a background that makes him well-suited for the challenge,” says Global Bear CEO Harold Benz. For details on the company, visit www.globalbear.ca.

• Mt. Prospect, IL – NTN Bearing Corporation of America has launched NTN e-Knowledge, an online educational platform that allows users to complete a series of training modules at their own pace and at any time of the day. The eKnowledge platform is the newest component of NTN’s educational offerings and is designed to educate industry personnel on basic bearing knowledge and NTN nomenclature. For details, visit the training page at www.ntnamericas.com.

• Chesapeake, VA – Sumitomo Machinery Corporation of America (SMA) has launched a microsite containing interactive tools to help customers navigate and match its new product packages to different applications. Earlier this year, the company introduced its Shield360° family of food and beverage protection packages, developed to with-

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stand environments ranging from general industrial to high-pressure washdown applications. Using the site, visitors can obtain high-level information about each package.

• North Canton, OH – The Timken Company has completed its previously announced transaction with American Industrial Partners to acquire the Carlstar Belts business. The business, a North American manufacturer of belts used in industrial, commercial and consumer applications, markets the brands Carlisle, Ultimax and Panther, among others. The belts business further diversifies the company’s portfolio beyond engineered bearings, bringing customers an expanded offering of mechanical power transmission products and services. In addition to belts, the Timken power transmission portfolio includes gearboxes, housed unit bearings, chain, couplings, lubrication systems and a variety of industrial services, which are marketed under industrial brands including Timken, Philadelphia Gear, Drives and Interlube.

• Pickering, ON – Benchmark Maintenance Services Inc. (Benchmark PDM) has moved to a new location, not far from its previous spot, says company founder John Lambert. “The move was spurred on by the popularity of our MAAD (Measure, Analyze, Act and Document) training program,” he says. “We will now have a larger training facility with a warehouse in the back, which will be used for the MAAD Training Centre.

This will allow us to fit more people in the classroom section and also give us space for more training rigs for real-

Machinery & Equipment MRO

world application set-ups. The new address is 1845 Sandstone Manor, Unit 14, Pickering ON L1W 3X9. For more information, visit http://benchmarkpdm.com.

• Tillsonburg, ON – J/E Bearing and Machine Ltd. has taken delivery of the newest addition to its machine shop, a DMG DMF 360 Linear 5-Axis. The machine is the latest DMF 360 Linear 5-Axis generation and the first one to be bought in Ontario. This is J/E’s first 5-axis machining centre and it will be doing everything from production to custom large 5-axis machining with its 141in. X travel. “We are excited about the recent growth J/E has experienced and what this machine represents. It shows our dedication to continuous improvement, innovation and a commitment to our customer base,” said Rozon, J/E’s

A new machining centre was installed as part of the company’s growth.

There’s no subsTiTuTe for hard work...

plant manager. For details, visit http:// bit.ly/1MXn4r7.

• Delta, BC – Intercon Enterprises Inc. reports that Druseidt electrical products are now available to North American customers. In business before 1890, the Druseidt electrical company, based in Germany, is well-known overseas. The Druseidt line targets OEMs, MROs and distributors in the electrical and power generating industries.

• Montreal – Montreal-based Ficodis has completed the acquisition of Fixaclous, Centre de l’outillage Granby, a company specializing in the sales and repair of pneumatic staple and nail guns, as well as power tools and equipment.

Founded in Granby in 2000, Fixaclous will become the sixth Ficodis point of sale in Canada.

• Fairlawn, OH – ContiTech, a worldwide manufacturer and distributor of rubber products for a variety of applications, has introduced a new marketing campaign, called Ability, for a variety of services and product lines for North America. “ContiTech’s acquisition of Veyance Technologies earlier this year gave us a unique opportunity to give our customers ‘more’,” said Anthony DiGiacobbe, marketing communications director for ContiTech NAFTA. “It was important that only the name would change – not the products. That ‘more’ idea was that [customers] would now have more innovation, more engineering, a bigger portfolio of products, a larger network, all ‘more’ to help [them] take their business to the next level – regardless of the industry.” For further information on this strategy, visit http://addmoreability.com.

• Montreal, QC – Walter Surface Technologies, a global supplier of surface treatment technologies, has appointed Chester Collier, senior vice-pres- Chester ident of global distribution, to se- Collier nior vice-president and general manager of the company’s Bio-Circle North America division. Collier has held progressively senior positions with Walter over the past 35 years. For more information about the company, visit www.biocircle.com.

• Seneca Falls, NY – Goulds Pumps Inc., a business of ITT, has won an arbitration against DXP Enterprises Inc. for violating a 2010 distribution agreement and has served notice to DXP to terminate the agreement. In the award, dated Sept.

17, 2015, the arbitrator found that DXP’s acquisition of B27 LLC on Jan. 2, 2014, was a substantial breach of the distribution agreement and that Goulds Pumps had good cause to terminate the agreement. Goulds Pumps also served notices to terminate on DXP’s subsidiaries, including Austin & Denholm Industrial Sales (Alberta) Inc. of Edmonton. New distributors will be appointed.

• Cleveland, OH – Applied Industrial Technologies is expanding in Canada with the opening of a new distribution centre in Quebec City, QC. The 22,000 sq-ft facility stocks more than 10,000 MRO products, including bearings, power transmission products, fluid power components, industrial hose, tools, chemicals, lubricants and more. The new facility, located at 6600, boul. Pierre-Bertrand Nord, Quebec, QC G2J 1S7, is adjacent to Applied’s service centre in Quebec.

Continued on page 12

...noThing works harder Than a visit www.

maxxworx .com for all the hard facts

I n n o vat I o n b e y o n d t h e o r d I n a r y

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Machinery & Equipment MRO

October / November 2015

Continued from page 11

• Elgin, IL – Harting has developed a Roadshow Truck that will travel across North America showcasing its Demonstration truck is connectivity solu- touring for a year. tions. The truck will display industrial and small-form industrial connectors, cable assemblies, board-level connectors, backplane assemblies, industrial Ethernet switches, and Harting’s industrial RFID solution. The purpose of the roadshow is to support the engineering community with the industry knowledge it needs in its daily tasks. The Harting Roadshow Truck started its year-long tour on Sept. 18 in New York City and visited Toronto on Oct. 21. The tour will continue through Canada and the US. Check out the schedule at the website www.hartingroadshowtour.com.

• Stockholm, Sweden – Atlas Copco

Compressors Canada, a provider of sustainable productivity solutions, has acquired Air Repair Sales and Services Ltd. of Moncton, NB, which distributes, services and rents compressors and accessories. “This acquisition fits us nicely as it enhances our access to the market in eastern Canada,” said Nico Delvaux, president of Atlas Copco’s Compressor Technique business area. “It gives us an opportunity to expand our regional coverage through an experienced and well-trained staff that serves a loyal customer base.”

• Hamilton, NJ – Posital-Fraba, a manufacturer of motion sensors for industrial applications, has joined the Motion Control & Motor Association (MCMA), a trade group serving the global motion control and motor industry. “The MCMA is a great fit for us,” said Christian Fell, head of Posital in North America. “Our sensors are widely used in industrial automation and motion control systems and we are

very pleased to be participating in a group dedicated to promoting the use of automation technologies.” The MCMA (www.motioncontrolonline.org) was formed in 2015 through the merger of the Motion Control Association (MCA) and the Small Motors Manufacturers Association (SMMA). It is headquartered in Ann Arbor, MI, and has over 200 members.

• Kenosha, WI – Snap-on has joined forces with the L.S. Starrett Co. to create the newest addition to Snap-on’s series of technical education certification courses – Precision Measurement Instruments (PMI). The goal of the PMI Certification course is providing students and technicians with a robust understanding of the fundamentals of precision measurement instruments. The course contains six modules, each contributing to a combined total of 32 hours of instruction. Enrollees in the course will use Starrett measuring devices in a practical learning environment.

We Create

Real Innovation With a full line of power transmission drive systems, Continental ContiTech strives for industry-leading innovations to provide you with the most advanced solutions available.

• New York, NY – Crane maker Terex is merging with Finnish rival Konecranes in an all-stock deal that creates a company with a combined US$10 billion in 2014 revenue. The new company is named Konecranes Terex PLC and has headquarters in Westport, CT, and Finland.

• Mississauga, ON – iS5 Communications has appointed Specialized Power Solutions. Burnaby, BC, as its manufacturer’s representative in the British Columbia and Alberta markets to promote its integrated service and solutions and its intelligent Industrial Ethernet products designed to be used in the harsh environments.

• Wayne, PA – Affiliated Distributors (AD), a $31-billion contractor and industrial products wholesale buying/marketing group, has set up a new division, AD Canada Plumbing & Heating, through a merger with Canaplus Limited Partnership of Toronto, a buying group for independent Canadian wholesale distributors of plumbing and heating supplies and related products. Beginning Jan. 1, 2016, the 23 current members of Canaplus will become the founding members of AD’s newest division, AD Canada Plumbing & Heating. These members operate more than 250 branches across Canada.

This is AD’s seventh merger since the group’s founding in 1981 and its third within Canada. AD completed mergers with Canadian electrical groups in 1993 and 2012. MRO Industry Newswatch is written and edited by Bill Roebuck. Visit www.mromagazine.com for the latest news and longer versions of items here.

Mr. 0 The Practical Problem Solver

What’s on your reference shelf?

In our June issue, we asked readers to send us a list of the most-used books on their maintenance reference shelf.

The names of those who entered were placed in a draw to receive a book they didn’t already have from the Mr. O Practical Problem Solver reference shelf.

The winner is Richard Foucher, lead reliability technician at Mondelez Canada’s Montreal Bakery in Montreal, QC. The favourites on his shelf are the Mechanical Reference Handbook and the Electrical Engineering Pocket Handbook, both published by the Electrical Apparatus Service Association (EASA), and Pocket Ref by Thomas J. Glover.

In return, we’re sending Mr. Foucher a copy of the his choice of our books, the Maintenance Engineering Handbook by Lindley R. Higgins, along with a bonus book, because he’s a reliability technician – a copy of The Little Black Book of Reliability Management, by Daniel T. Daley.

Mr. O sends out our thanks to Mr. Foucher and to everyone who participated.

The trademarks displayed in this banner are the property of Continental AG and/or its affiliates. Copyright © 2014 ContiTech AG. All rights reserved.

For complete information go to: www.contitech.de/discl_en

Richard Foucher’s favourites from his company’s reference shelf.

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13 Machinery & Equipment MRO

A soon-to-be-installed external hand crank will allow hammer adjustments to be made while the worker’s hands remain at a safe distance.

Overview shows Construction DJL’s automated aggregate plant in St-Philippe, Que., while still under construction. The project was started in October 2014 and was completed a year later.

MAINTENANCE SAFETY IS

ALREADY BUILT IN

This new rock crushing plant in Quebec is safe, durable and very maintenance-friendly. BY CARROLL MCCORMICK

All photos by Carroll McCormick

M

uch thought and accumulated wisdom has gone into the design and construction of the new automated aggregate plant that Construction DJL commissioned this fall at its StPhilippe, Que., quarry: good access, ease of equipment disassembly, durability, maintenance planning, spares lists and more. But above all, DJL built its $12-million plant to be safe.

“With our company, our goal is to go to zero accidents,” says Julien Antech, lead, plants and quarries, Construction DJL. Part of the strategy to achieve this was to build in stringent safety features that respect both Quebec and European regulations (DJL is a subsidiary of the global transport infrastructure company Eurovia, based in France.

“This will be the first plant in Quebec where we apply the same standards of France, Germany and elsewhere in Europe,” Antech says.

The plant will process 500,000 to 600,000 tonnes of limestone rock a year into aggregate.

One approach to safety is to prevent accidental contact with rotating equipment, e.g., belts, pulleys, shafts and roller ends, regardless of how out-of-the-way they may appear. To this end, DJL built bright yellow-painted steel guard boxes that enclose all such equipment. They

are easily visible, even from a thousand feet away.

This should be a self-evident precaution, but many plants in North America lack such basic protection against getting caught in rotating machinery. Because they are not standard accessories, says François Lussier, operations advisor, DJL. “We had to modify and put on the security screens ourselves.”

Making everything accessible by foot Intentional contact with machinery falls under another DJL rule guiding the plant’s design. Wherever access is required in the normal course of maintaining and operating the plant, those places must be accessible on foot. No portable ladders. No lifts. No cranes. “It is part of the plan that we must make everything in the plant accessible by foot. This was a discussion we had with our mother company,” Antech says.

To this end there are thousands of feet of walkways and staircases. Every conveyor – there are 3,600 ft of them – has a walkway running along its length and right around the end for inspecting the motors. “Many plants do not have walkways or protection at the motors.

But here in Quebec the safety norms are very strict,” Antech says.

A yellow-painted ladder up the side of the Fisher Industries air separator

gives out onto walkways, for easy maintenance access to motors and other equipment.

On either side of the huge screens, built by crushing and screening equipment manufacturer KPI-JCI, and supplied by Candiac, Que.-based Manuquip, are several storeys worth of staircases and walkways. Here is another safety feature: by turning a wheel much like the steering wheel on a racing yacht, a large steel chute rolls away easily to reveal the screens. Instead of crawling around inside the screener, maintenance workers simply roll back the chute and reach out from staircases to work on the screens.

Near the control house, a staircase gives out onto a wide platform running around the secondary and tertiary crushers, also built by KPI-JCI. The cover over the secondary crusher is open the day I visit, revealing four hammers (fat steel bars weighing 400 lb apiece) that rotate at 550 rpm on a drum to blast tumbling rock to bits. Normally, setting the gap is done by reaching inside the crusher, but DJL had something safer in mind: a hand crank safely mounted outside the crusher to make the adjustments.

In another smart example of reducing risk and headache, tidy jib cranes are permanently installed beside the crushers for lifting out the hammers. This makes unnecessary the more typical, involved scenario where a crane would have to be brought in to do the job.

For simplicity and better safety, the plant is divided into five coloured lock-out zones; all equipment is divided among the five zones.

Easy lockout-tagout solution Instead of setting up an elaborate breaker lockout system, with its attendant scores of padlocks, keys and procedures, DJL opted for a quite elegant safety solution. The plant is divided into five colour zones: green, blue, yellow, red and purple. Every piece of equipment belongs to one of these zones. Each piece of equipment has a coloured plate attached to it that identifies the zone it belongs to.

In the electronics rooms – which actually are air-conditioned shipping containers – all of the electronics gear in the cabinets is colour-matched to the equipment they control. Each piece of electronics that controls a piece of equipment; e.g., ‘Conveyor HC2 7.5HP’ has its own coloured plate. Instead of locking out the equipment breaker by breaker, the electronics technician need only perform one lockout to disable an entire zone. Five lockouts, five zones. It’s simple and procedurally very error-resistant.

“When, [for example] you want to [work on] the green zone, you put your lock on the green zone, and you will be sure that nothing in the green zone will start,” Antech says.

The St-Philippe quarry has some 50 years of reserves in it. DJL wants this plant to last for at least 30 years, and to that end has insisted on ease of maintenance and low life-cycle costs. Take, for example, the structures that support all of the machines and conveyors, built by Simar-Dacon, in Beloeil, Que. DJL specified that they all be galvanized steel.

Continued on page 14

Julien Antech, here checking his phone with the aggregate plant in the background, oversaw the construction of the $12-million facility.

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Continued from page 13 Staircases and walkways give maintenance crews easy access to all parts in the plant.

Users turn the big wheel to roll away the chute for easy and safe access to screens.

Plant-wide, brightly coloured guards warn and protect workers from rotating machinery.

Galvanized is longer-lasting and lowermaintenance than painted steel.

Simar-Dacon also built the conveyors, which have many low-maintenance features. The D50 conveyor belts can take a bigger load and are longer-lived. “[They have] close to three times the normal abrasion resistance in the market,” says

Richard Paquette, chief executive officer and majority owner of Manuquip.

Paquette’s company developed the maintenance program for the plant.

The conveyors have CEMA D6 idlers, which have bigger shafts, bigger bearings and larger diameters, for longer life.

The screw take-ups for tightening the

belts have stainless steel screws with copper nuts, to prevent galling.

Conveyors that are longer than 250 ft have hydraulic tensioners, which are not only easier to use, but eliminate three pulleys and six bearings apiece. This translates into fewer potential failures and replacement purchases. All of the 50

hp-plus conveyor drives have ceramic lagging head pulleys. They slip less and require less tension. As a result, the bearings last longer.

The pan feeders and conveyors have direct-drive motors. “DJL wanted one assembly, a direct drive. It eliminates the need for belts, guards and safety issues.

No tensioning issues, no breaking belts,” Paquette explains.

There are 66 motors in the plant.

Manufactured by WEG and Baldor, they, and a lot of other equipment, will benefit from a plant-wide dust collection system that begins with the galvanized-steelsheet-covered conveyors and ends with a Fischer Industries air separator. “[This] should increase durability of many components due to less dust contamination and better heat dissipation,” Paquette says. Less dust build-up on pulleys and idlers will also reduce tracking problems.

Speaking to the KPI-JCI equipment that Manuquip supplied – crushers, screens, and some mobile stacker conveyors – Paquette lists lower-maintenance features that include automatic grease systems on the horizontal shaft impactors, the direct drive motors, impact beds at transfer points to reduce shock, and rock beds in the chutes.

Rock beds are shelves built right where pouring rock would normally hit the chute sides. Instead of administering that punishment, the pouring rock hits the rock that piles up on the shelves, thus protecting the chute walls.

Establishing the maintenance program One of Paquette’s jobs has been to develop the maintenance management program for the plant. It includes gathering up all manufacturers’ specs for service intervals, types of grease, oil, etc.; pulling together a maintenance book, a maintenance library and parts catalogues for each piece of equipment; and entering the scheduled maintenance in the automation and control system.

“The [Electro Kingsey] automation system includes features that flag maintenance, but it is not a computerized maintenance management system,” Paquette notes.

Manuquip also prepared the spare parts list for its machines, and worked out with DJL what parts to keep, how many and where. As for the maintenance scheduling, Paquette wrote a preliminary short-term maintenance plan for the plant start-up, with a complete plan to follow within 30 days of start-up.

In short, DJL applied its experience in building and operating plants to come up with a plant that is safe, durable and maintenance-friendly. Says Paquette: “This plant has the highest standards of any plant in Quebec. It is unique.” MRO

Online Reader Inquiry No. 124

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

Online Reader Inquiry No. 125

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Selecting pumps for hygienic applications Various pump designs have individual advantages, but the simplest solution for the specific job can result in higher reliability and reduced maintenance.

T

October / November 2015

Hygienic pumps come in various designs, such as this internal gear pump model.

BY JOHN H. HALL

Timed lobe and circumferential piston pumps The most widely used hygienic rotary PD technologies are timed lobe and circumferential piston pumps. These use two pumping elements, each on its own shaft, connected by a set of timing gears external to the pumped liquid. The driver shaft is connected to the motor, and the timing gears turn the driven shaft as the driver shaft rotates.

The advantage is that the pumping elements (rotors) rarely touch, which allows use of soft materials like stainless steel that could gall (cold weld) on contact. The key disadvantages are that: 1) the timing gears are housed in an oil or grease-lubricated gearbox that requires frequent lube changes, 2) each shaft requires its own shaft seal (seal

failure is the most common cause of pump downtime), and 3) setting the timing and end clearance during a rebuild can be a maintenance headache, usually requiring shims (assemble, measure, disassemble, shim, reassemble, measure, repeat), consuming precious time.

Timed twin-screw pumps Another timed-pump technology is the twin screw pump, which substitutes screws for rotors. A unique advantage is that it offers the ability to run at very high speeds on CIP solutions, often up to 3600 rpm, which develops sufficient velocity that a separate CIP pump may not be required. Normal operation is usually at much slower speeds to handle the product.

The disadvantage is that to CIP you need a variable-speed, variable-frequency drive (VFD) with a significantly higher horsepower motor to operate at high speeds than you would need for normal operation, which may be at only 10% or less of the CIP speed. Operating the VFD system at very low speeds to handle the product results in poor energy efficiency and shorter motor life. Operating the pump at very high speeds to CIP results in shorter seal and bearing life.

Progressive cavity pumps Another popular technology is the progressive cavity (PC) pump, which has a single, helical-shaped rotor turning within an elastomeric stator, creating cavities that continually shift from the suction end to the discharge end.

Advantages include only one shaft seal, the ability to gently handle abrasive slurries and large solids, and the ability to multi-stage to develop ever-higher pressures, if needed.

Key disadvantages include: 1) elastomeric particle shedding into the product when the pump is run dry, 2) high cost of stator replacement, and 3) the difficulty of in-place disassembly for CleanOut-of-Place (COP) or post Clean-InPlace inspection due to the extremely long footprint.

Peristaltic pumps Peristaltic or hose pumps feature an elastomeric hose that is compressed by rollers to create continuously moving fluid cavities. Key advantages include single-use capability on smaller pumps for ultra-clean pharmaceutical and biopharmaceutical products, and the ability to handle large solids with larger diameter hose pumps.

Key disadvantages include: 1) frequency and cost of hose and coolant replacement, commonly up to seven times per year, 2) potential for cross-contamination of pumped product and coolant when the hose ruptures, and 3) no jacketing capability to melt ambient-temperature solids like chocolate.

Internal gear pumps An internal gear pump is one in which the rotor gear (connected to the driver shaft, which is connected to the motor), turns the driven gear (idler) in the pumped liquid, so no timing gears are needed. The idler gear rotates on a fixed shaft (idler pin) mounted to the pump head. The gears unmesh on the suction side and spaces between the gear teeth carry liquid from the suction to the discharge side, where the gears then mesh to expel the liquid.

Advantages compared to timed pumps include only one shaft seal, no timing gears or lubrication, and ease of maintenance (no shimming). Advantages vs. PC and peristaltic pumps include short-term run dry capability without particle shedding, easy in-line or 90° porting, and ease of in-place disassembly for COP or postCIP inspection.

Disadvantages compared to both timed and PC/peristaltic pumps include the inability to pass large solids (like whole fruits) and limited differential pressures (150 psi/10 bar).

The top six reasons, then, to consider hygienic internal gear pumps versus other types of rotary PD pumps include: 1. Only one shaft seal. It was demonstrated several years ago in a survey of pump repair shops that shaft seals, specifically mechanical seals, are the single largest cause of pump downtime and maintenance. If a pump has two seals instead of one, it essentially doubles the odds of failure, not to mention the cost of replacements. If a pump is cleaned-outof-place, it also speeds up disassembly and reassembly time by a third compared to pumps with two seals. If you’re cleaning 10 pumps a day, that adds up.

2. In-line or 90° mounting. No other hygienic pump offers the option of 90° ports for mounting directly under tanks, or opposite ports for simple in-line mounting. That means you can insert a pump anywhere along a length of straight pipe.

Opposite port pumps also give you the capability of vertical orientation, which allows complete self-draining prior to cleaning, and is required for EHEDG (European Hygienic Engineering & Design Group) certification.

3. No oil to change. Internal gear pumps use sealed antifriction bearings with foodgrade grease and require no re-lubrication. Pumps with timing gears and bearings in a lubricated gearbox usually require oil or grease changes at least four times per year, or more in humid, washdown environments. It is said that one drop of water in a quart of oil will destroy its lubricating properties, and these gearboxes allow humid air into the gearbox through the breather or oil seal as it cools down, causing internal condensation and lube failure.

Continued on page 18

Side view of an internal gear pump.

Peristaltic pump.

Side view of a timed differential piston pump.

Timed twin screw pump.

Images: Viking Pump Inc.

he Hydraulic Institute has classified more than 30 unique types of rotary positive displacement (PD) pumps, each providing different features and benefits.

Fortunately for the food and beverage, pharmaceutical/ biopharm and personal care product industries, many of these pumping principles are available in hygienic versions.

Faced with these many choices, it’s up to each of us to find the right balance of performance, reliability, cleanability, maintenance, capital cost and operating cost to suit our own facility’s needs.

One pump technology that has recently become available in hygienic versions is the internal gear pump. It is a rotary PD pump, meaning that with every rotation of the shaft, the pump draws in and then displaces the same volume of liquid.

That gives it some big benefits, including: • Easily adjustable flow rates using a variable speed drive, since the flow is directly proportional to the speed of the motor • Flow independent of changes in system pressure, enabling accurate metering into batches • Reversible direction of flow to strip the line of product, reducing waste and reducing water and chemical usage during Clean-In-Place (CIP) applications • Ability to handle a wide range of viscosities, from milk to peanut butter • Minimal product degradation due to shear, because shear forces are proportional to pump speed, and rotary PD pumps can be operated at very low speeds to minimize shear • Smooth flow and high efficiency (compared to reciprocating pumps, for example), which improves accuracy of flow meters and reduces splashing when discharging into tanks or packaging To illustrate the differences between internal gear pumps and other hygienic rotary PD pumps, we need to look at the technologies employed.

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Continued from page 16

Shaft seals, specifically mechanical seals, are the single largest cause of pump downtime and maintenance. If a pump has two seals instead of one, it essentially doubles the odds of failure.

4. Same pump for COP or CIP. Designed for ease of disassembly and reassembly in-place, internal gear pumps feature a front-removable rotor and idler, shaft seal and casing for COP. Yet the same pump can be configured to be completely CIP-able. Pumps with EHEDG certification for in-place cleanability have been rigorously tested and validated for in-place cleanability. For processors that COP today, but are considering CIP in the future, this means they can use the same pump for either, while many other

Progressive cavity pump.

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pumps require factory modifications for CIP, if they can be made CIP-able at all.

5. Fast, easy end clearance adjustment – no shimming. Clearances are adjusted on rotary PD pumps to optimize the performance based on the viscosity, to prevent rotor/casing contact due to expansion from high temperatures, and to compensate for wear over time. Internal gear pumps enable easy end clearance adjustment by rotating the threaded rear bearing housing. Rotate it clockwise until the rotor contacts the head, then back it off counter-clockwise a set distance per 0.001 in. of clearance required, and lock it down with set screws. This takes about five minutes.

Timed pumps must be timed to ensure that their pumping elements never actually contact each other, often using shims, which are also used to set end clearances. This process usually takes several hours, in which a pump is assembled, measured, disassembled, shimmed, reassembled and measured, and sometimes that process has to be repeated to get it just right.

6. Dimensionally interchangeable with existing gear pumps. There is a large installed base of internal gear pumps from several manufacturers handling low-hazard foods like edible oils and personal care intermediates that comply to an unofficial dimensional standard set long ago by the market leader.

Hygienic internal gear pumps also fit that standard, and are available with ANSI-compatible flange ports to drop into these low-hazard applications, or with hygienic ports for higher-hazard liquids like dairy.

As hygiene requirements become more stringent, replacement of ‘industrial’ pumps with hygienic pumps will be commonplace on even low-hazard oils and chocolates.

In conclusion, it’s up to each facility to match the right pump to the job. Internal gear pumps are not for everything, but they do excel in many applications, including edible oils, chocolate and peanut butter; sugars, sweeteners and confectionary; and jams, jellies, sauces and pastes. In the pharma and personal care world, they are especially well-suited to syrups and ointments, lotions and creams, and hair care products, to name a few.

Timed lobe, circumferential piston and twin-screw pumps are excellent performers, but their overly complicated design is overkill if you are not pumping large solids or if you don’t need differential pressures exceeding 150 psi (10 bar).

Consider a simpler solution – internal gear pumps – for those easy applications.

Similarly, progressive cavity or peristaltic pumps may be a great choice for slurries of whole berries, but for strawberry jelly or jam, an internal gear pump offers benefits in terms of higher reliability and reduced maintenance. MRO John H. Hall is the senior product manager with Viking Pump Inc. For more information, visit www.pumpschool.com.

Online Reader Inquiry No. 127

His decision to cut energy costs by 70% with LED high bay lighting was a great idea.

And a great start.

Once you start seeing the benefits of our incentives for LED high bay lighting, you’ll want to start upgrading your motors, fans, pumps and compressors to higher efficiency systems as well. 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.OMOfficial Mark of the Independent Electricity System Operator.

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October / November 2015

Are you ready for Hydraulics 4.0?

Hydraulic seals are becoming more application-specific and being developed in line with their intended use.

The future of hydraulics includes completely autonomous systems that will monitor and service themselves.

BY PROF. JOSEF KURFESS

S ketch anticipates future applications for hydraulics.

Photo: ULM University

Images: Trelleborg Sealing Systems

Prof. Josef Kurfess, Ulm University.

O

In this review, Professor Josef Kurfess from Ulm University in Germany outlines why hydraulic systems still have an important part to play in the industrial world of today and tomorrow.

ver the past 40 years, hydraulic systems have been continually deemed a dying technology – if not pronounced dead altogether. And these views don’t seem all that farfetched in light of the on-going energy efficiency debate and the apparent cure-all: electric drive systems. Perhaps the ‘dinosaurs of drive technology’ are truly at an end. Yet

they keep coming back and are more sustainable than ever – all thanks to consistent, systematic thinking.

Hydraulics form the core technology behind many industrial companies and many of the applications we see in our daily lives. Whether it’s at home or at work, whether it’s in mobile or stationary applications, life as we know it wouldn’t be possible without hydraulic systems.

One source: your partner for pumps, valves and service KSB is your single source for all pumping needs.

Our pump experts help ensure the best possible solution for every job, no matter if it’s selecting a new pump, stocking up on spare parts, or remanufacturing a long-service veteran.

Ask us how you can benefit from our exceptional products, advice and service on your next project.

KSB Pumps Inc. info@ksbcanada.com . www.ksb.ca You can also visit us at: www.ksb.com/socialmedia

Our technology. Your success.

Pumps ■ Valves ■ Service

Online Reader Inquiry No. 129

Sluices wouldn’t open or close properly, construction vehicles wouldn’t function correctly, cable cars wouldn’t run, and most machines would no longer manufacture things.

In the same vein, no theatre stage would rotate, no harvesting machine would work quickly and precisely, and trucks couldn’t unload their goods. Personal and professional life would become a lot less convenient.

That said, there have been many attempts over the past 40 years to replace hydraulic systems with other technologies. That’s because, apart from their undisputed advantages, hydraulic systems and applications were considered coarse, clumsy, and only really of any use in rough industrial settings. They were also deemed inefficient energy hogs prone to leakages.

In recent years, the energy debate has ferociously challenged hydraulic systems, and more and more electric solutions have tried to take on the leading role.

Some have even predicted that hydraulic systems would share the same fate as the dinosaurs.

But these dinosaurs are coming back.

A multitude of innovations, developments and enhancements are seeing hydraulic systems and applications improve considerably – and sustainably. There’s no end in sight.

Is there evidence of this? Our university of applied sciences has established an endowed chair for oil hydraulics and our competence centre for hydraulics now has 17 member companies – clear indications of a renaissance. That’s because one thing is certain: hydraulic systems are strong, robust, and they work more reliably than most comparable technologies.

And little by little, they are regaining ground lost in the battle. The reasons for this are quite clear.

Hydraulic systems are becoming more intelligent. Thanks to new ways of thinking and development approaches that focus on systems, hydraulic technology is becoming more efficient, versatile and precise. By integrating high-performance electronics and control software, hydraulic systems are constantly becoming more ‘intelligent’. All the while, the software also ensures that increasingly complex systems are becoming easier to operate. And that’s not all – the focus on systemic factors is reaching out into more and more areas.

Controls. The limits to how far we can stretch the mechanical production of control blocks are being eradicated, but when we do reach the limit, software can help us go further – for example, when balancing oscillations at specific operating points. Control valves are becoming even more precise and faster. Oils and fluids are also advancing further. It’s

quite conceivable to develop fluid sensors that detect wear, and report when a part should be exchanged.

Seals. Seals are becoming more application-specific and being developed in line with their intended use. They will reconcile the two opposing objectives of minimizing friction while maximizing sealing performance. This is giving rise to trendsetting sealing systems that can be connected or switched off, such as the Turcon Roto L system developed by Trelleborg Sealing Solutions. Such developments are paving the way for systems that we are already seeing in use, like a tire pressure system that allows for variable tire pressure and which can be adjusted while the system is running.

Autonomous systems are feasible.

Hydraulic systems will gradually become even more intelligent. They will be selfmonitoring by using high-performance sensors, and maintenance will not be carried out during downtime, but dynamically. Depending on the state and load of the hydraulic system, reports will be displayed indicating required maintenance or when to change components or fluids.

All of this will be accompanied by the highest possible energy efficiency and even greater overall efficiency. And this isn’t even taking Industry 4.0 into account. Quite conceivably, completely autonomous systems will exist in the future. These will monitor and service themselves – more like Hydraulics 4.0.

All of this bolsters the undisputed advantages of hydraulic drives: No other drive system is as powerful and as robust. The ‘dinosaurs of drive technology’ might just outlive everything else.

Competence through cooperation.

The Kompetenzzentrum Hydraulik is a privately funded centre of excellence for hydraulics at Ulm University of Applied Sciences. It was established to promote the qualification of young talent as hydraulics specialists. The centre, sponsored by the chamber of commerce and industry in Ulm (IHK Ulm), will receive over one million euros from its sponsoring companies over the next five years. Each of these companies will also delegate a representative to sit on the advisory board to define core tuition and work activities.

Trelleborg Sealing Solutions is contributing sealing and bearing technology information to the course on ‘Hydraulic Fluids and Seals’. Practical examples and visits to the companies, including the testing facilities at Trelleborg Sealing Solutions, complement theoretical work.

The hydraulic courses are proving popular and interest in the lectures – which are available online as webinars – is growing steadily. MRO For more information, visit the website at www.trelleborg.com.

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Machinery & Equipment MRO

Dealing with cylinder mounting problems Pay attention to the load-carrying capabilities of fluid power cylinder mountings to prevent their misapplication, or you could end up with premature cylinder failure, serious machinery problems or safety issues. BY TED GROVE

F

luid power cylinder manufacturers generally offer a huge assortment of cylinder mounting styles, which is extremely handy for the machine designer. All too often, however, in their haste to finish their projects, the designers fail to consult the application information sections of the cylinder catalogue they are using and end up selecting the most convenient but perhaps the least serviceable mounting for their application.

This oversight can result in improper operation of the machine, premature failure of the cylinder or even catastrophic failure of the cylinder or machine, perhaps threatening the personal safety of employees.

Pneumatic cylinders, because of their lower pressures, can generally be used at full pressure, regardless of mounting.

Medium and heavy-duty hydraulic cylinders, in some mounting styles, may not be used at full rated pressure.

Cylinder mountings are generally classified into three groups: Group 1 – straight-line force transfer with fixed mounts, which absorb force on the cylinder centre line; Group 2 – pivot force transfer, which absorbs force on the cylinder centre line but allows swivelling in one plane; and Group 3 – Straight line force transfer with fixed mounts, which do not absorb force on the centre line.

Group 1 includes front and rear flange mount as well as tie rod mount cylinders.

Selection of front or rear mounting should be based on whether the cylinder will be used primarily in compression or tension. In compression, the back end of a single-rod cylinder is pressurized. Using a front mount will put undue tension on the tie rods and mounting bolts and generally result in derating the maximum permissible pressure for the cylinder.

The same logic can be applied to tension loading with rear-mount cylinders.

Group 2, pivot force cylinders, will normally allow for misalignment in one plane only. The use of spherical bearings in single lug rod and cap clevis mountings will allow for minor misalignment in the second plane. Rear clevis and rear trunion cylinders should only be used in shorter stroke applications. In long-stroke applications, the entire weight of the cylinder will be supported by the rod bearing, causing undue wear and damage, especially when extended. Judicial use of stop tubes in the cylinder to prevent full extension can help a little but the best solution is to use a mid-cylinder trunion positioned to optimally balance the load.

Group 3 cylinders are generally described as side-mounted cylinders. They include side lug, end lug, side tapped, and end angle mountings. All of these mountings produce an off-centre or twisting motion to the cylinder structure, which may cause leaks and premature bearing failure. They are, however, convenient to use and when needed, the side lug design should be selected if possible. The welded or bolted connection points of end lug and end angle mounts will be severely stressed by the rocking action of the end caps and may fail. End-mounted side connections should be avoided in all but the lightest of applications The off-centre twisting motion can also create structural problems in the

machine. The machine base, to which the cylinder is side-mounted, must be strong enough to withstand the resulting eccentric loading without flexing. Any movement of the machine structure at this point will tend to amplify the cylinder misalignment.

Be careful when selecting cylinder mounts. By being competitive in offering a wide range of cylinder mounts, the cylinder manufacturer may be doing himself and his customer a disservice. More emphasis must be placed on the de-rating factors or load-carrying capacities of various mountings to prevent their misapplication.

Having said this, however, does little to

solve the problem. The onus, as usual, rests on the shoulders of the user. The use of a little common sense and mechanical intuition, as well as referring to the cylinder manufacturers’ engineering recommendations when designing a machine, can save you a lot of grief later on. MRO For our 30th anniversary this year, we’re occasionally publishing top-rated articles from our previous editions. This article first ran in November 2000, when author Ted Grove, a widely experienced fluid power trainer, was the corporate training manager for Wainbee Ltd., Mississauga, ON. He has since retired.

Cylinder technology is evolving. Milwaukee Cylinder has a new RFID solution for easy identification and maintenance tracking of tie rod cylinders. The RFID tags come pre-loaded with cylinder identifying and maintenance kit information. Maintenance comments can be recorded to the tags.

Photo: Milwaukee Cylinder

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Machinery & Equipment MRO

October / November 2015

How ships save time and money W Critical monitoring of key components in rotating machinery such as pumps, motors and compressors eliminates the need to carry out certain maintenance routines. hen the Overseas Shipholding Group Inc. (OSG) launched its new generation of liquefied natural gas (LNG) carriers, it also introduced a condition monitoring system to support the smooth operation of each of these innovative vessels.

With the job of transporting LNG around the world, the new carriers have to maintain the highest levels of operational performance and meet stringent safety standards. The four gas-carrying giants, Al Gharrafa, Tembek, Al Gattara and Al Hamla, which form the company’s LNG fleet, each have a carrying capacity of up to 216,000 cbm (cubic metres) and use onboard reliquefaction to reduce gas losses. At the time of construction, in 2007 and 2008, these ships were the largest and most sophisticated LNG carriers afloat.

OSG’s Mike O’Rourke, fleet manager, LNG Fleet, explains that all of the ship’s

equipment, main engines, propellers and steering systems are duplicated to ensure failsafe operation.

To give an idea of the amount of rotating machinery on board, each vessel is propelled by two slow-speed diesel engines. Plus, each ship is equipped with an on-board reliquefaction system to handle the boil-off gas, liquefy it and return the LNG to the cargo tanks. This equipment allows the carrier to deliver nearly all of the cargo to the customer.

This system ensures that LNG losses are minimized, which produces economic and environmental benefits.

On long journeys using conventional LNG carriers, there can be significant losses. To avoid this, each vessel has complex, computerized systems and a heavy-duty, high-voltage electrical system comprising a number of generators, which are required due to the power demand of the reliquefaction plant.

Critical monitoring of key components in rotating machinery such as pumps,

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Critical monitoring in done on key components in shipboard rotating machinery.

The use of condition monitoring helps the OSG reduce the costs associated with unplanned maintenance.

Photos: SKF Group

motors and compressors on each vessel is provided by SKF. The use of condition monitoring helps OSG reduce the cost associated with unplanned maintenance.

An important benefit in using the SKF condition monitoring system is that it has helped OSG achieve class approval from the leading certification body for the industry, DNV. “This has given us exceptions to the need to carry out certain maintenance routines, thus saving both time and cost,” says O’Rourke.

This avoids the need to periodically strip down machinery, which possibly could take the LNG carrier out of service for a significant period of time and add considerably to the cost of operation.

Early detection of a potential bearing failure can ensure that maintenance schedules are optimized, it can reduce the need for maintenance in general and cut associated costly maintenance work.

“Condition monitoring is a valuable prediction tool. By catching events early, we can replace a bearing at a cost of around US$500, rather than spend between $5,000 and $25,000 on a new electric motor,” O’Rourke points out.

The condition monitoring system consists of three elements: An SKF Microlog portable data collector/analyzer, SKF@ptitude Analyst software and sensors. SKF has considerable experience in developing maritime condition-based maintenance programs. “For each vessel in the OSG fleet, SKF carries out regular monitoring of 225 onboard machines with a total of 3,020 readings being taken over all the units,” explains Steven Tyrer, contract manager at SKF UK. “For critical equipment, data is collected on a weekly basis,” he adds. The sensor readings are divided into several distinct types: - Velocity (mm/sec), which detects problems such as out of balance and misalignment - Acceleration (g), which detects problems such as gearbox and lubrication issues, and

- Enveloped acceleration (gE) SKF technology for detecting bearing condition and damage.

To gather this data, engineers use the SKF Microlog CMXA 51-IS, an intrinsically safe, rugged and portable, handheld instrument specifically developed and certified for use in hazardous environments. The instrument, accelerometers and cables are all certified IS (Intrinsically Safe) for use in Zone 0, Zone 1 and Zone 2 areas.

This monitoring is recorded to determine the trend related to the vibration levels, for example, and this information builds up a picture of how well the equipment is performing and can predict possible future failure. Early detection of potential problems gives more time to plan and organize maintenance.

As Tyrer explains, “We can notice degradation in components months before it becomes critical. In this way we can keep an eye on when action is required and also optimize the operational life of a component.” Regular reports from SKF keep OSG updated on machinery status so that remedial actions can be planned during regular maintenance.

SKF’s condition monitoring system plays its part in keeping OSG’s advanced vessels operating at peak performance, while meeting the class requirements of DNV to ensure they can keep delivering LNG without the need to carry out additional maintenance routines. MRO OSG is a diversified energy transportation group with a fleet of more than 100 International Flag and US Flag vessels.

Incorporated in 1969, OSG has headquarters in New York, with offices in Quebec City. For details, visit www.osg.com.

SKF is a global supplier of bearings, seals, mechatronics, lubrication systems, and services that include technical support, maintenance and reliability services, engineering consulting and training.

For more information, visit SKF Canada at www.skf.com/ca.

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Fast fault finding for machinery W

Labels help technicians find what they need quickly.

Fleet vehicles stand ready for the Neutron Factory Works field team of electricians and automation technicians.

Quality engineering documentation proves to be a technician’s friend in the field.

henever Kris Morris went out on service calls around the BC Lower Mainland, one thing would always make his day. Often, he’d find poor electrical schematics for equipment he was summoned to troubleshoot, even for systems his company had built.

But sometimes, Morris, until recently automation and panel shop manager for Neutron Factory Works, came across schematics for foreign-made machinery that had been done in EPLAN Electric P8, which is design automation software for electrical engineering. Those schematics were precise, detailed, professional-looking and made servicing that equipment easier and faster.

Later, to upgrade Neutron’s in-house design capability, Morris resolved to switch to EPLAN from the CAD programs being used. The added productivity quickly paid for the switch.

“I come from a maintenance/service background and not from an engineering background,” said Morris. “I would get frustrated every time I saw a product we made that had no wire labels, no drawings. I was always happy when I saw a machine had nice EPLAN drawings.

Bingo! I could read the schematics, I could find stuff real quick.

“I wanted us to put out schematics like that … for the quality, reliability, ease of troubleshooting.”

Neutron is an industrial contractor providing refrigeration and other services to manufacturing and processing facilities. Fast, around-the-clock service is Neutron’s calling card, even when the

Images: Neutron Factory Works

Neat cables make for easier servicing of equipment.

Planning view using EPLAN software.

customer is a fishing boat in port with a refrigeration issue and an extremely tight schedule. Lost production and spoilage costs can mount by the minute, which puts a premium on the availability of accurate engineering documentation to help technicians locate the source of the problem as quickly as possible.

Stored records easily updated In the field, the printed documentation that came with the machine or system can become torn, smudged or otherwise unreadable, even go missing. CAD drawing programs cannot archive project documentation. Keeping a digital record of a CAD project usually involves multiple, incompatible file formats; updating such a project can take days, if it’s done at all.

By contrast, database-centric engineering software like EPLAN archives projects in one format, and can revise them in a fraction of the time. Small changes can be applied in minutes. If it chooses, an OEM can maintain a version that reflects all significant life-cycle maintenance actions such as upgrades, add-ons or parts substitutions. An added convenience: EPLAN documentation can be exported as PDFs to a technician’s iPad for on-site viewing.

A growing part of Neutron’s business is serving as a ‘full life-cycle partner’ for customers – designing and building their electrical, mechanical, refrigeration and automation systems and then servicing them. Most builds are custom, one-off installations. The design automation features and database architecture of computer-aided engineering (CAE) software like EPLAN are key to

producing high-quality engineering data and production outcomes.

Neutron used AutoCAD or Constructor software previously to create schematics. For Morris, who recently joined Siemens, another EPLAN user, using those previous drawing programs at Neutron “was just slow and cumbersome and you wouldn’t get all the information out of it [that was] needed to make us more efficient.”

Physically assembling panels would begin with a rough placement of components. A lot of time-consuming adjustments then had to be done before the job was finished.

“Things were constantly shifting. I made it a personal rule that with every wire I connected to anything, I left a really big loop, so I could always move stuff around.”

Morris said he now can make EPLAN drawings much faster than when using the old software. They are more precise, with great detail and specificity, which leads to correct placement of components the first time.

In the CAD environment, he added, generating labels for a typical control panel used to be a manual process that could take four hours or more with a 5% data-entry error rate. Now, labels for the same size project are generated automatically by the CAE in about 20 minutes.

Faster panel design and assembly Morris estimates that after a year of using EPLAN exclusively, the entire control panel design/build process had become roughly 200% faster, with an even greater degree of improvement in the quality of

Online Reader Inquiry No. 132

the finished product and its documentation. Neutron is making good use of baseline automation features such as auto-connect, automatic error correction and automatic cross-referencing. That’s usually enough for most companies to repay an EPLAN investment within a year.

Even greater savings can be obtained by embracing EPLAN’s potential in areas like content standardization and data sharing. Using its macro-generation capability and archiving potential, many users build up libraries of project templates and macros, covering commonly used components, circuits, even entire subassemblies.

Parts macros can be imported from vendor websites or via the EPLAN Data Portal, a powerful free search tool. The latter is an integral part of EPLAN CAE products and allows users to locate and import master data sets for over 520,000 components from over 85 manufacturers.

The larger a company’s library of templates and macros, the faster projects are completed. Neutron is creating parts macros for recurrent usage items like controls and transformers, and content macros for motor control circuits and more. The CAE is readily scalable, helping the company pursue larger projects than it had undertaken previously.

“EPLAN allowed us to build and deliver consistently high-quality products reliably, on time and on budget,” said Morris. “I wanted to create this culture where this is what we are known for and what every Neutron customer expects.” MRO For more information about Neutron Factory Works, visit www.neutronfactoryworks .com; for EPLAN, visit ww.eplanusa.com.

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What’s new in test and measurement AC measurement standard offers precision, wide range of capabilities

The 5790B AC Measurement Standard is an AC voltage and current measurement or transfer standard designed for the most demanding calibration applications. It combines the accuracy expected from a thermal transfer standard with the ease of use of a digital multimeter, and is designed to meet the complete AC voltage, current and wideband verification requirements of the Fluke Calibration 5730A, 5720A, and 5700A multifunction calibrators, 5522A, 5502A, and 5500A multi-product calibrators, plus other calibrators, amplifiers such as the 5725A and 5205A/5215A, transfer standards and AC voltmeters. The 5790B can make direct, absolute or relative current measurements with current shunts without needing to make any calculations.

The interface allows users to input and save characteristics and coefficients such as shunt serial numbers and calibration constant values to automate the ACI-toACV conversion calculations.

Fluke Calibration www.flukecal.com/5790B

Thermal imaging camera family for Android phones is expanded

Two models have been added to Ogpal’s ThermApp thermal imaging camera for Android phones.

The Therm-App TH device, dedicated for thermography applications, allows professionals to take accurate temperature measurements captured on high-resolution thermographic photos and videos and immediately transmit them via e-mail, messaging or file-sharing platforms. Features include full radiometric capability, multiple colour palettes, video and sound recording, as well as efficient reporting and data analysis.

Additional features include touchscreen

Compact high-voltage digital insulation resistance tester is multi-featured

Designed for high-voltage testing, Megger’s BM5200 rugged and compact, battery-powered 5-kV digital insulation resistance tester is for use in the maintenance, electrical manufacturing, railway/railroad, industrial/manufacturing and raw materials processing industries. Safety features include CAT

Monitoring program for torque vibration helps protect rolling mill drives

Emerson’s torque-amplification analysis program for precisely measuring the true torque loads and vibration frequencies experienced by rolling mill drives is part of a program to help mills process tougher alloys, increase output with thicker slabs or higher speeds, protect against cold-end slabs, or mitigate torsional vibration. This program combines computer modelling of complex drives with true torque measurements to determine the actual torque amplification factor (TAF) on the drive, incapabilities, round-the-clock connectivity, ongoing application updates and more. Applications include temperature measurements of electrical installations, buildings, HVAC, insulation, plumbing and veterinary, among many others.

The second model, Therm-App Hz, is a high-end solution for security, safety and other night/outdoor applications.

Through its higher 25-Hz frame rate, it delivers smooth thermal images, especially when the user or the targets observed are on the move, using a variety of interchangeable lenses ranging from 6.8 mm to 35 mm.

Opgal Optronic Industries www.opgal.com

stead of inferring it from motor current readings. Solutions are engineered that reduce TAF and torsional vibration using alterations of coupling stiffness, improved overload protection, resilient couplings and other strategies. TAF data capture and analysis can be a temporary service or it can be integrated with a mill’s CSI6500 condition monitoring system as an ongoing service.

Emerson www.emersonindustrial.com

Motor circuit analyzer provides system health status report on the spot

Offering a complete electric motor health analysis in minutes, the All-Test Pro 5 motor circuit analyzer tests all types of motors, including induction, synchronous, AC, DC, brushless DC, servo and wound rotors, as well as single-phase motors.

The health of all motor components is evaluated, including induction windings and rotors, DC field windings and armatures, and field and rotor coils in synchronous motors. Single- and threephase transformers, pole and pad

III 600 V rating, a high-voltage warning indicator, an external voltage display after IR test, automatic discharge of reactive loads and high-quality test leads. This fully automatic, IP40-rated digital IR tester features five preset test voltages ranging from 250 V to 5,000 V, a maximum resistance range of 1 teraohm, multiple operating modes including insulation, polarization index, as well as varied timed test, and a single rotary switch for easy operation. In addition, the compact unit features a user-settable insulation resistance test timer with a range to 20 minutes, selectable DC or AC voltmeter functions ranging from 25 V to 600 V, as well as a guard terminal that minimizes surface leakage current.

Megger www.megger.com

mounted, also can be evaluated with this portable, lightweight device. Features include storage capacity for more than 650 tests, on-screen guidance, trending and reference testing, and the ability to perform testing from distances of 1,000 ft from the motor control centre, for inaccessible or hard-to-reach motors. Test results are easily uploaded.

All-Test Pro www.alltestpro.com

Portable assessment kit helps avoid costly spindle downtime

The SKF spindle assessment kit measures and interprets key spindle operating data to help users detect developing problems before they can escalate. Designed for use after a spindle is assembled and installed in a machine tool, the kit can help validate performance indicators.

It includes a spindle test module providing nine condition tests, balancing module and RUCD (Run Up Coast Down) module and comprises a portable Microlog analyzer, acceleration sensor, laser tachometer, dial gauge with gauge stand, belt tension gauge and a spindle-specific software package preconfigured to convert measured data into intuitive green-amber-red colour-coded results. Features include lightweight ergonomic design, extended battery life, easy-operation function keys, and rugged and water-resistant design.

Step-by-step instructions are included.

SKF Canada www.skf.com/ca/en/

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Compact infrared camera series makes thermal imaging affordable

The easy-to-use, lightweight Omega OSXL-EX series compact infrared cameras (made by FLIR) have three views, thermal, visible and MSX imaging featured on their high-resolution colour LCD display.

The MSX thermal images clearly reveal problems from sources of energy loss, moisture intrusion and structural issues to overheating electrical and mechanical equipment. This cost-effective thermal imager series offers camera choices to meet the most demanding applications. Features include 2% accuracy, radiometric jpg file format, swappable lithium ion battery with four-hour life, spot measurement mode, simultaneous storage of IR/visual/MSX images, picturein-picture image and a temperature range from minus 20°C to plus 250°C (minus 4°F to plus 482°F). MRO Omega www.omega.ca

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What’s new in lubrication Lubricant line can offer energy-efficiency benefits

ExxonMobil’s machine shop lubricants are formulated for performance and energy efficiency. The line includes: Mobil DTE 10 Excel series of high-viscosity-index, shear-stable, anti-wear oils for hydraulic systems; Mobil SHC 600 synthetic circulating and gear oils that deliver good equipment protection; Mobil SHC Gear fully synthetic industrial gear oils that help enhance equipment performance, and deliver good oxidation resistance and low-temperature fluidity. All products offer potential energy efficiency benefits.

Exxon Mobil

Transmitter enhances lubrication flowmeter series

Universal Flow Monitors has added the LL, SN and MN series transmitters to its lubrication flowmeter line. These variable-area meters have compact, noncontact, magnetically coupled transmitters as an alternative to alarm switches. Easy to install, operate and maintain, the meters monitor the rate of oil flow to keep gears, bearings, drills and mills functional in the processing industries for flows ranging from 5 gph to 70 gpm. The SN vane-style meters are designed for

for the lubrication to pass through to a felt pinion, which disburses lubrication onto either the pinion or the rack.

Wittenstein North America www.wittenstein-us.com

Portable lubrication system goes almost anywhere

A mobile lubrication system from the IFH Group provides storage and dispensing of lubricants, cutting oils, bearing oils, hydraulic fluids, transmission fluids and engine oils for plants requiring lubrication

flows from 0.5-20 gpm; the MN vanestyle meters are for flows from 10-70 gpm; and the LL piston-style meters are for flows from 0.25-20 gpm. All of these meters can be used when local flow indication and mechanical flow switching or 4-20 mA transmitters are desired.

Universal Flow Monitors www.flowmeters.com

maintenance at multiple locations over a large area. The system, which is delivered on a pallet, can be placed in the bed of a heavy-duty pickup truck for easy mobility anywhere within a plant. It includes two 50-gal. and two 25-gal. steel containers with PVC sight gauges. Air-operated piston pumps on top of each container provide a 5:1 pumping ratio, and filters remove any dirt or small particulates. The system includes retractable hose reels with metered dispensing control handles.

A large steel tool box with cabinets under-

neath the reels provides convenient storage of tools, greases, rags, etc. MRO The IFH Group http://ifhgroup.com

www.exxonmobil.com

Lubricant provides both water spray-off and wear resistance

Dow Corning’s Molykote G-1502FM synthetic bearing and gear grease has been formulated to simultaneously resist water washdown and spray-off and help prevent wear and corrosion, minimizing both grease loss and wear scar. Offering long service life at wide service temperature ranges in water-rich environments, the product is designed to reduce costs and extend equipment life. It delivers effective results even at low speeds.

Dow Corning www.dowcorning.com

Lubricant complies with food safety standards

Sprayon’s NSF-H1rated food grade lubricant line features 12 lubricants developed specifically for the food processing industry. Consisting of high-quality foodgrade base-stocks, including synthetics, renewable oils and silicones, these lubricants feature heavy load pressures, good resistance to water washout, low flammability ratings and wide temperature ranges. They meet the formulation hygiene requirements for the use and handling of lubricants that may come into contact with food, cosmetics or animal feed products during manufacture or processing.

Sprayon www.sprayon.com

Lubrication system keeps rack and pinion systems running smoothly

Wittenstein has developed a complete lubrication system, specially designed to work with any type of rack and pinion system, that ensures these systems are running smoothly with long service life. The lubricator supplies a preset quantity of grease to the felt pinion and guarantees a constant film of lubrication on the rack and pinion. Multiple components make up the lubrication system. The lubrication canister, which comes in two sizes, houses the lubrication. To this is attached a sensor kit, which notifies when the lubrication is running low. The lubrication flows from the canister to the mounting shaft through a plastic hose connection. The mounting shaft contains holes that allow

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- REPRESENTATIVES IN CANADA Southern Alberta, Saskatchewan & Manitoba: Robin Tetrault / Summit Agencies Ltd. / 403-236-8655 / robin@summitagencies.ca Northern Alberta and Saskatchewan: Peter Liston / Summit Agencies Ltd. / 780-406-7462 / peter@summitagencies.ca British Columbia: Brian Weihs / Summit Agencies Ltd. / 604-329-7848 / brian@summitagencies.ca Southeastern Ontario: Mechanical Sales Co. / 2199 Dunwin Dr. / Mississauga, ON L5L 1X2 / 800-263-7226 Southwestern Ontario: RJ (Richard) Seguin / Mechanical Sales Co. / 800-263-7226 / rjs@mesaco.com Northern Ontario: Gord Jopling / Mechanical Sales Co. / 800-263-7226 / gordj@mesaco.com Quebec and the Maritimes: Lydia Oosterbaan / Mechanical Sales Co. / 800-263-7226 / lydiao@mesaco.com Online Reader Inquiry No. 134

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What’s new ...

in products, systems, components and accessories for machinery and equipment MRO (maintenance, repair and operations).

Bulkhead mounted housing offers IP67-rated immersion protection

Harting’s Han B IP67 bulkhead provides IP66 and IP67 protection for virtually the same price as a comparable IP65-rated connector. In the locked state, the housing’s protection allows for temporary full immersion in water, as compared with the IP65-rated housing, which is only hose proof. A special flange protects the gasket seal, preventing water from penetrating the connector, while the circumferential collar also

prevents the seal from sliding inwards or outwards. Seal stability provides additional protection against water ingress. The housing is compatible with all standard Han hoods and housings, and can be configured with any Han insert or module. Suited for applications in extreme conditions such as wind turbines, construction cranes, railway and marine installations, it comes in sizes 6B, 10B, 16B and 24B and fits the same standard cut-out dimensions for the existing Han housing portfolio.

Harting Canada www.harting.ca

DON'T LOSE YOUR BEARINGS!

Pre-start inspection training improves safety in mining

An interactive and virtual tool from Immersive Technologies has been introduced to ensure effective and consistent training and assessment of operators on machine inspection routines. The PreStart Inspection tool trains and assesses mining personnel on the correct identification and actions to be taken in relation to equipment issues. This training tool allows operators to demonstrate competency when real-world training is not possible and where mistakes are costly if undetected. The interactive environment

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Advanced Technology Control Large LCD & User Panel for Easy Programming Unrivaled Output Pressure of over 850 PSI Positive Displacement Pump for Precise Lubrication Up to 8 point Lubrication

Remote Installation up to 6 m away on high vibration areas Innovative Design for Better Protection of Your Equipment ONLY Lubricator in the World with Auto- Lockout System

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Online guide provides interactive instruction for bearing mounting

The Schaeffler mounting toolbox is a webbased information guide on how to professionally install rolling bearings. Users can learn about what tools and fitting aids are needed, and short video sequences demonstrate how these are used. The virtual plant home screen serves as the main user interface, allowing fast interactive navigation. The toolbox provides details of tools and accessories, and demonstrates the benefits of correctly mounted rolling bearings, such as longer operating life and reduced unplanned downtime. The virtual plant contains three pillars – mounting/dismounting, aligning, and lubrication. Subtopics are displayed as drawers in the pillars and can be opened by clicking with the mouse. These contain the tools and fitting aids that are shown in the demonstration videos. The user is also given an insight into the different mounting methods, as well as general safety guidelines and preparations.

Schaeffler Technologies www.schaeffler.ca

Hose reel withstands abusive and demanding environments

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enables a trainee to control the movement around the simulated machine, and in and around an object or component. Trainees can examine lubricant inspection panels and all other inspection items in life-like detail, then be assessed on the understanding and level of accuracy at conducting inspections.

Immersive Technologies

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“Leak-Free” fittings

The stainless steel T series hose reels from Coxreels has been expanded with the addition of six models for a current total of nine models. This variety of hose sizes and hose length capacities meets the demand for heavy-duty industrial-grade truckmount hose reels. The spring-driven reels, made of high-quality electro-polished stainless steel with stainless steel fluid paths, offer clean, non-corrosive performance in many applications, such as food-grade washdown, chemical processing, marinas, water treatment, petrochemical and medical services. They feature an extra-large chassis with dual pedestal-style design and the company’s Super Hub that provides triple-axle support to reduce vibration and strengthen the structural integrity of the reel.

Coxreels www.coxreels.com

Visit our website for FREE samples!

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Valves, manifolds, transducers suit many applications

Ode Valve Canada’s series of two-way and three-way high-quality affordable solenoid valves, manifolds and pressure transducers have been designed for a wide variety of applications. Multiple AC and DC coil voltages are available and housed in a NEMA 4 enclosure with brass or 316 SS valve bodies. Pressure ratings range from 0 psi to 1,450 psi and

P R O D U C T October / November 2015

maximum temperature to 360°F. The company offers NSF-certified products with all valves being CSA/UL approved, including CRN approval for Canada.

Ode Valve Canada www.odevalve.com

Rod clamp enables cylinders to retain load on failure

The Amlok hydraulic series RCH rod clamp provides power-off clamping of rods and shafts. Actuated by a spring/collet mechanism and unclamped by hydraulic pressure, these units are designed to clamp components after the motion has stopped and to hold the position securely as long as the forces do not exceed the table values. Since the locking of the rod clamp is accomplished mechanically and unlocked by hydraulic pressure, loss of hydraulic pressure to the clamp will cause the unit to lock. The mountings have been designed to apply to standard heavy-duty NFPA-style MF1 cylinders, and the standard housing can be mounted to any machine structure or be custom-designed to suit a particular application. The clamps are designed for locking reciprocating motions only. Special units are available for both rotating and reciprocating motions.

Hennig www.hennigworldwide.com

High-torque, flange-mounted servo motor brake line is expanded

Nexen has expanded its Eclipse line of high-torque servo motor brakes to offer more than 140 variations of spring-engaged, air-released servo motor brakes. The line includes flanges ranging from 57 mm (2.25 in.) to 265 mm (10.43 in.) square and shaft diameters from 6.35 mm (0.25 in.) up to 48 mm (1.89 in.). This range of sturdy, low-inertia brakes is designed for all major servo motor models up to 20 hp, and is used in a diverse range of industrial applications including packaging machinery, food production, machine tools, conveying systems, CNC machining centres, automotive production equipment and woodworking. Features include torque of 2 Nm to 125 Nm, NEMA 23, 34, and 42 frame sizes, high torsional rigidity, long facing life, true zero backlash, and speeds up to 10,000 rpm.

Nexen Group www.nexengroup.com

Pressure transducer designed for test and measurement applications

Setra Systems’ AccuSense model ASL high-performance, lowrange industrial pressure transducer for the accurate measurement of air or other clean gases is designed for applications such as leak detection systems, test stands, wind tunnels, laboratories, and research and development. It offers accuracy at <±0.07% full scale over low differential pressure ranges of 0 to 2.5 in. W.C. to 0 to 1 PSID, while its thermal error is <±0.25% FS. The accurate outputs over this temperature range reduce the need to thermally isolate the transducer from the application. The device’s zero and span settings may be accurately set through the use of the SecureCal accessory, which makes for secure and stable zero and span adjustments in the field.

Alpha Controls & Instrumentation

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Dual-range torquemeter measures low running/ high load torque

The MCRT 88700V series dual-range torquemeters from S. Himmelstein accurately measure torque even if the ratio of peak to average torque is high. Such conditions occur when starting, stopping or reversing high inertia loads, during torsional oscillations, and in diesel and single-cylinder engine/compressor drivelines. The torquemeters have a low range that is 20% of its high range. Three simultaneous analogue outputs can be individually set to 5 V or 10 V at each range full scale.

Overrange is 150% to 300% and mechanical overload is 200% of the high range and 1,000% of the low range. Digital output of torque, and speed and power with option Z, is available over the resident RS232 serial port.

S. Himmelstein

timize maintenance and facilitate component lifecycle assessment on overhead lifting equipment. The service features continuous data collection to provide customers with a clear view of crane usage, allowing overhead crane maintenance to be planned according to actual usage. It can be used in any heavy-duty overhead crane application in which manual crane monitoring is difficult. When the safety alerts feature is added to the standard reporting service, a focused selection of safety-related data is produced and issued by email and/or SMS soon after an overload or overheat event occurs. Usage data is collected from the crane through a remote connection and compiled into web views and customer reports that are available through a secure online customer portal, which offers easy access to the historical data of the crane.

Konecranes http://en.konecranes.ca/

www.himmelstein.com

Durable clamp meter stands up to hostile conditions

Remote monitoring and reporting service collects data on crane usage

The Truconnect remote monitoring and reporting service from Konecranes is designed to enhance safety, op-

Des-Case has launched a line of desiccant breathers called Extended Series. The series of four variously sized breathers addresses a number of industrial needs, bringing greater protection and productivity to tank farms, wind turbines and large gearboxes, as well as to applications in both high-humidity environments and remote locations. They are durable, sophisticated filters for industrial lubricants, removing dirt and water from the headspace of equipment. Featuring higher airflow, more moisture adsorbing desiccant, check-valve technology and longer life, the line builds on past models and combines the materials, design and high air flow of the company’s standard breathers with the check-valves of its hybrid breathers. The oil mist-reducing feature, added to more than double the desiccant of the company’s other disposable breather products, helps prevent contamination.

Des-Case http://descase.com

The Fluke 320 series true-rms clamp meters, a line of tools engineered to produce noise-free, reliable measurements in the toughest environments, has been introduced by Fluke. Designed to be long-lasting and easy to use, the Fluke 323, 324 and 325 clamp meters are suitable for rugged, all-purpose use in residential, commercial, HVAC/R and light industrial electrical applications. Features include a slim, ergonomic design for comfortable all-day use; a large, easyto-read display; and CAT III 600 V/CAT IV 300 V safety ratings. The 324 and 325 models offer a backlit display for easy viewing, contact temperature readings from 10°C to 400°C (14°F to 752°F) and capacitance measurements from 100 to 1,000 microfarad. The 325 model also offers DC current measurements up to 400 A, frequency measurements from 5 Hz to 500 Hz, and a Min/Max function.

Fluke Canada www.fluke.com

Long-lasting desiccant breather extends oil and equipment life

Feature-rich insulation tester is for twisted copper cables

The Megger MIT410-TC2 and MIT430TC2 insulation resistance and continuity testers have been designed for use within the telecommunications industry. The model MIT430-TC2 offers extensive results-storage capability for later recall and Bluetooth download capability for wireless transfer of stored results to a PC. The instruments allow the user to determine the condition of the insulation of the twisted copper cable pair, which could cause problems for services such as voice, video and data or VOIP. The MIT410-TC2 offers insulation testing up to 500 V and 100 G-ohms, the MIT430TC2 up to 1,000 V and 200 G-ohms. Features include analogue arc and dual digital display, CAT IV 600-V rating, TRMS and DC voltage measurement, continuity testing at 200 mA or 20 mA down to 0.01, Pass/Fail limit alarms, and PI/DAR and timer function. A soft canvas carrying bag with shoulder strap and rugged snap hook to attach to a tool belt, and a test lead set are included.

Megger

Moving energy made easy

www.megger.com/cae/

MACHINERY AND EQUIPMENT

Free MRO Product

Literature Guide 2015 SMALLEY CATALOGUE NOW AVAILABLE FROM ROTOPRECISION The 2015 Smalley Engineering and Parts Catalogue use features 140 pages of part tables, engineering guides, design information and expanded part offerings for over 10,000 standard parts available, including WAVE SPRINGS and RETAINING RINGS. The catalogue also contains information about metric wave springs (including the ES Spirolox Aerospace series), Hoopster® rings, linear springs, and details for custom spring and ring design up to 120” (3,000 mm) with No-Tooling-Charges™. It is an ideal resource for engineers and product designers.

Move cables and hoses with ease with the Triflex® R system from igus®. Modular, flexible, and available as a fullyharnessed ReadyChain® system with cables, connectors, and accessories.

Learn more at igus.com/TriflexR

Contact: RotoPrecision Inc. Phone: 1-800-232-1985 Email: applsupport@rotoprecision.ca More information: www.rotoprecision.ca

www.alphacontrols.com Online Reader Inquiry No. 138

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P R O D U C T

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ing 5 lb. or less and measuring less than 9 in. in length. An auxiliary handle offers 23 positions and a tongue-andgroove locking structure. Features include Durashield housing, all-metal gearbox and optimized four-pole motor.

Both drivers are offered in a kit with two 4.0 Ah FatPack batteries, charger and carrying bag. The addition of an optional 5.0 Ah FatPack adds 25% more runtime.

Bosch Power Tools www.bosch.ca/

Cutback brush performs three tasks in one step for cost and time savings Spherical washers optimize bolt mounting of machinery

SKF Spherical Washers optimize bolt mounting of machinery and bolted equipment by integrating unique design features promoting ideal performance in industrial, marine, and all other heavy-duty bolted joint applications. The all-spherical two-piece washer automatically adjusts under compression to compensate for up to four degrees of angular deviations.

This creates an exact parallel plane between the inner face of the bolt head and inner face of the nut to distribute the load evenly over the entire inner contact surface areas. Any need for on-site machining (spot facing) to achieve parallelism is eliminated. The washers ultimately serve to reduce the likelihood of bolt relaxation by distributing bolt tension evenly, retaining proper bolt tension by preventing bolt bending, and keeping bolts straight as intended. The extended length of the spherical washer allows for the use of longer bolts, resulting in additional bolt clamping length and elongation in the bolt.

SKF Canada www.skf.com/ca/en/

Ergonomic preset torque screwdriver prevents improper tightening

The Mountz PSE is an ergonomic pre-set torque screwdriver for production applications where over-torque conditions are not tolerated. Built with a cam-over design, this accurate tool prevents a fastener or bolt from being under- or overtightened. When the tool reaches its preset torque value, the mechanism disengages from the drive, thus limiting the torque applied. Also, the thrust bearings ensure that the torque setting is independent of any end load applied by the operator. Manufactured to meet or exceed the accuracy and repeatability requirements of ISO6789: 2003, the company offers various PSE torque driver models that range from 0.7 ozf.in. to 120 lbf.in. The screwdrivers feature a tamper-proof internal adjustment, have no external adjustment scale and must be pre-set using a torque tester. They are designed for a variety of industries, such as medical, aerospace, semiconductor, electronics and communications.

Mountz www.mountztorque.com

Drill drivers pack power in compact package

Bosch Power Tools has introduced the 18-V heavy-duty DDH181X drill and HDH181X hammer/drill drivers, designed for control, power and durability. Both tools feature Active Response Technology, which allows professionals to tackle high-torque applications efficiently and effectively, while reducing the risk of dangerous kickback. Both tools are compatible with all Bosch 18-V lithium-ion batteries and are well balanced, weigh-

Osborn’s heavy-duty 114-knot cutback brush removes excess coating on pipe ends quickly, efficiently and cost effectively, and is used for angled removal of three or more layers of coating from pipe ends. Made with ultra-high-density AB wire, the large-diameter brush cleans the pipe edge, removes the pipe coating and grinds the coating angle, all at one time. The brush is available in custom arbor hole/keyway dimensions.

Osborn

Linear speed control option can fix different speed in each travel direction

A linear speed control option for Model RG rolling ring linear drives has been introduced by Amacoil/Uhing. Normally, the drive moves on a driven shaft with linear speed being adjustable via a pitch control lever located on the drive unit.

The option lets users fix a specific linear travel speed in one or both directions of travel. The fixed travel speed is achieved using set screws that Amacoil inserts into the drive housing. No adjustments to motor speed or controls are necessary.

Based on application needs, the company will work with customers to determine custom settings for the set screw speed control option. The option is inexpensive and is easily retrofitted to existing Uhing linear drive set-ups.

Amacoil www.amacoil.com

www.osborn.com/

Ball valve line for lead-free press systems has various configurations

Viega has introduced a line of ProPress Zero Lead ball valves for its ProPress systems manufactured from material specifically designed for lead-free press systems.

Made from the company’s silicon-bronze alloy, the line includes press by female, press by hose and two additional lines of press by press end configurations. The valves are forged, providing a strong valve body, and are constructed with double stem seals, which provide years of leak free-operation. The Smart Connect feature helps installers easily identify unpressed fittings during pressure testing. Certified to ASME A112.4-2004 and NSF-61G in sizes from 1/2 in. to 2 in., the ball valves are suitable for use with ProPress fittings in copper for potable water applications. Installers have a choice of stems in the press by press configuration ball valves, either Eco Brass or 316 stainless steel.

The Viega Group

Axial excluder seal is for wind industry

Designed especially for the wind market, SKF’s HRC1 axial excluder seal addresses the harsh conditions that wind turbine main shafts face. Benefits of this rugged

Quality Reliability Efficiency

www.skf.com/ca/en/

Non-kinking hybrid polymer hoses are easy to work with

Gates’ water hose and whip air hose will not kink or curl. The hybrid polymer water hose has heavy-duty nickel-plated fittings and spring guard and comes in multiple sizes. Features include lightweight and extremely flexible construction, zero memory, which allows it to lay completely flat, superior bend radius and easy coiling after use, and high abrasion and chemical resistance. It is kink resistant, even under pressure. The whip air hose will reduce wear and tear to help prolong air hose life. Features of this hose include 1/4-in. male ball swivel and 1/4-in. female NPT fitting, zero memory and superior bend radius. It is available in 2-ft, 4-ft and 6-ft lengths. MRO Gates Canada www.gates.com

BRECOflex CO., L.L.C. is the pioneer and world leader in the polyurethane timing belt industry. We offer our customers a wide range of timing belts, drive components, metal pulleys and accessories designed and manufactured with the highest priority given to quality and precision.

Whether you are looking for a standard product from our inventory or a custom design tailored to your requirements, your application can benefit from our perfectly matched timing belt and pulleys. Without fast response and quick delivery even the best drive solutions are ineffective. We take pride in our rapid customer response time and industryleading product delivery.

www.viega.com

For additional information regarding our products and technical support services, visit our website at: www.brecoflex.com or call 732-460-9500.

Pressure-control regulators useful in fuel industries

The RHPS Series high-flow, pressure-reducing and back-pressure regulators from Swagelok are designed for applications in the chemical/petrochemical, oil and gas, power, biopharmaceutical, semiconductor and alternative fuels industries. These regulators are constructed of 316L stainless steel for line sizes up to 4 in., and provide a variety of options.

Pressure-control products include pressure-reducing regulators, with both spring-loaded and dome-loaded models, designed for general industrial applications; back-pressure regulators, available in both spring-loaded and domeloaded models, designed for general industrial purposes; and specialty regulators, including products designed specifically for pharmaceutical applications.

Swagelok www.swagelok.com

seal include extended service life and contaminant protection, helping wind farm operators reduce the risks of contaminant-related bearing failures and unplanned downtime, repair and lost productivity. The seal is manufactured from H-ECOPUR, an SKF-developed polyurethane material with good abrasion resistance and tear strength. Available in solid and split executions, it also features a steel band clamp with a fast-lock mechanism for easy up-tower installations.

SKF Canada

ISO 9001 CERTIFIED COMPANY

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New programs

After: Organized spare parts means less time is spent searching for them, thus reducing downtime.

WORKING WELL

A tag reporting program using an incentive, a focused improvement project, and parts storage organization are helping solve problems for this plant.

BY PETER PHILLIPS

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

W

e are working on progress reports about how we are doing on our projects at the plant. We have made two visits since our last article about this project (June 2015, page 20), one visit in August and another in September. Improvements have accelerated forward since the completion of the new packaging line and employees have had more time to focus on the projects we have started there.

The Tag Program has continued to bear fruit as operators report various equipment problems, which are then addressed by the maintenance department before they become failures. This has significantly improved the uptime and reduced product waste. Operators write the issue on a preformatted tag and attach one copy to the equipment near the problem area, and hang the other portion on the tag display board. The maintenance planner collects the tags every morning and creates work orders to investigate and repair the problems.

Tag reporting incentives have been put in place to encourage even more participation. Employees can earn credits towards purchases at the plant’s employee store.

Photos: Peter Phillips

Before: In many plants, looking for the part you need can be like going on a scavenger hunt.

The more problem tags they put in, the more credits they can earn. Ideas like this keep the momentum going and give employees a reason to report equipment and process issues.

The Focused Improvement Project has expanded to another piece of equipment that directly affects the operation of the equipment on which we originally started making improvements.

These two pieces of equipment are called the Tray Loader and Bagger. The tray loader loads the product into trays and then the trays follow a series of conveyor belts to the Bagger. The Bagger loads the tray and the product into a bag so it is ready to be packed into cartons for the customer.

The Bagger was our original Focused Improvement Project and during our August visit, we created a Problem Tally Sheet for the Bagger, where operators could record the number of equipment faults during their shifts.

We divided the machine into its major components and asked the operators to tally the faults on a list. From this data, we identified the faults that cause the most stoppages and waste.

The tally sheets indicated the tray loader carousel to be 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 that we will write about in our next column.

As you may remember, we also are working on the equipment spare part inventory areas. The area you see in the ‘before’ picture here is not unlike that in many other plants we visit. Finding the part you need can often turn into a scavenger hunt. We all know that time spent looking for parts prolongs downtime on equipment.

This plant has a continuous processing line, so when equipment fails to operate, product is off-loaded into waste bins. Downtime causes significant losses. Downtime and waste are recorded on every packaging line and reviewed every morning at the management meeting.

Monthly and yearly production goals are set for each line, so downtime plays a big role in plant efficiencies.

A plan to purge and organize the parts storage areas has been formalized and I will write about some of the results next time.

These projects have taken a great deal of time to plan and implement. They will consume many more manhours and commitment from the people at the plant. On top of these projects, personnel are involved in their daily responsibilities that ensure the plant runs as smoothly as possible. Let’s not forget the many meetings that take place to plan new products, quality meetings, management meetings and so on. The projects that we have asked them to do are one more thing on their plate.

We visit a lot of manufacturing and processing plants.

We hear and see what people need to do every day to ensure product leaves the shipping dock. So our hat goes off to the personnel at this plant. They truly want the plant to run better and to improve the quality of their working lives.

There’s an old saying, ‘plan your work and work your plan’. These dedicated people do their best to work their plan every day. 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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Schaeffler Introduces a Genuine Breakthrough in Condition Monitoring: WiProM is the industry’s first truly cost-effective diagnostic tool for analyzing the performance of vital plant equipment such as motors, pumps and generators. WiProM’s portable design allows for quick and easy deployment, while the proprietary FisNet wireless network transmits the data to a monitoring center (yours or ours) for analysis.

Real Solutions - Real Savings When a customer faced the daunting task of performing end-ofwarranty inspections on scores of gearboxes and generators, Schaeffler was called upon for a solution. A permanent online monitoring system was deemed cost-prohibitive, and the facility was not staffed with highly trained data analysis experts.

Armed with a single yellow carrying case containing a WiProM diagnostic unit, Schaeffler experts set about the task of analyzing factors such as meshing of gears and generator performance. Within three weeks, Schaeffler was able to provide condition monitoring data that has, so far, saved the customer over $1 million.

We rest our (yellow) case.

Need more details? info.ca@schaeffler.com www.schaeffler.ca ©2015

Superior-quality products.

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