BSC Sustainability Solutions Catalogue

ENERGY SAVING

WATER ENERGY SAVING SAVING

ENVIRONMENTAL WATER SAVING

ENVIRONMENTAL

Sustainability Solutions for Australian Industry SOLUTIONS

SOLUTIONS SOLUTIONS

www.bsc.com.au

SOLUTIONS SOLUTIONS

SOLUTIONS

Australian owned since 1921

F

ormerly known as Bearing Service Pty Ltd and established in 1921, BSC is the premier and most experienced Bearing and PT product distributor in Australasia. Proud of its Australian

owned heritage, we are primarily engaged in the supply of Bearings and Power Transmission products. Today, BSC employs around 300 permanent staff and operates over 40 branches in all states around Australia.

The BSC product range is the largest of its type and is supported by a large distribution network of more than 100 computer-linked branches and authorized distributors to ensure that our broad stock range is available in all areas throughout Australasia

including PNG, New Caledonia, Fiji, Solomon Islands, etc.

Comprehensive bulk stock and accounts are managed using an IBM AS400 server platform.

Over the years BSC has built a reputation as a respected supplier of quality products and services. Since 1995 BSC has been licensed as a Quality Endorsed Company (QEC4475) and regularly audited and certified by SAI Global Limited to comply with the requirements of AS/NZ ISO 9001:2000 for the procurement, warehousing, distribution and sale of a wide range of bearings, power transmission and associated products.

www.bsc.com.au 2

INDEX

Sustainability Solutions for Australian Industry

Sustainability Solutions for Australian Industry

INDEX Energy Management

BSC understands our responsibility to the environment and our customers, and sustainability has been an important part of our company policy for many years. Our commitment to sourcing technically advanced products across our product range from world class manufacturers has been our response.

Motors 4 Variable Speed Drives 8 Engineering Services 11 Gear Boxes 17 Belts 19 Water Management TS Flat Chain AESSEAL Water Management

25 26

Environment Management

In today’s environment with soaring energy

Bearings 27

prices it is essential for companies to reduce costs in order to remain competitive. This has prompted BSC to put together a range of products with potential energy saving initiatives and ideas.

BSC’s new Sustainability Catalogue will not only save you money with smart product choices and energy saving initiatives and ideas but will also be helping our planet. Selecting products from this range will significantly reduce your energy consumption or water usage or simply using environmentally friendly products.

“

We won’t have a society if we destroy the environment.

Margaret Mead

www.bsc.com.au

3

Industry Information

MOTORS

Energy Wise Electric Motors Published - ecoBiz Queensland

H

alf of the world’s electrical energy goes toward

Improve performance with a VSD

powering electric motors.

A Variable Speed Drive (VSD) is an electrical device that

To improve energy-efficiency in your workplace, ensure

controls power to the motor, and is suitable for inconsistent

electric motors are suitable for the tasks they perform. The best

loads. Rather than continuously running at full speed, the VSD

way to identify potential energy savings is to work backwards

varies the motor speed to meet the energy needs of the load.

from the task the motor performs to its power input.

While a VSD can cost more than the motor, it can achieve

A smaller motor may provide sufficient power for a specific task

energy savings of up to 50 percent a year. VSDs provide best

and cost less to run. If feasible, install a time switch to control

energy savings when applied to a motor-driven centrifugal

the length of time the motor operates. Alternatively, install a

pump.

calendar time switch to prevent motors running on days when

There are cheaper alternatives to VSDs. Multi-speed motors

not in use, such as when your workplace is closed.

can be used with two or more pumps running parallel systems.

Does your motor match your needs?

One motor is used for the base load, and the second is used

Consider three basic factors when assessing motor suitability: 1. Consider total life costs when buying an electric motor, including purchase price, installation and operating costs.

If you invest in an energy-efficient motor your business will save more over time.

2. High Efficiency Motors (HEM) are about two to four percent more efficient than standard electric motors, and offer lower operating costs and reduced energy consumption.

The initial investment will be greater, but it only takes about two years to recoup the additional costs in energy savings.

HEMs produce less heat, reducing air-conditioning costs and providing a cooler work place. They maintain high efficiency over a wider range of loads and have a greater thermal tolerance.

It is important to match the HEM to its application as these motors operate at a slightly higher full-load speed than standard motors. This means that centrifugal loads, including pumps, fans, and compressors, can be affected by higher speeds and negate energy savings. This may involve replacing an existing motor with a smaller one, trimming impellers on pumps or changing gear or pulley ratios.

3. Consider the size of the motor. Companies often buy an oversized motor to cope with unexpected peak loads or to allow for process expansion in the future. As a result, hundreds of motors used in industrial applications are grossly oversized. Motors are most efficient when operating at full load, and installing a smaller motor, which operates at full load, will greatly improve the operating efficiency.

4

only during peak load times, offering improved reliability and providing a back-up if one motor or component fails.

Maintaining your motors • Check that drive belts, chains and couplings are in good condition and are adjusted in accordance with the supplier’s recommendations.

• Check for motors that are running hot, as this is a sign of energy loss. Use an infrared non-contact thermometer to measure the temperature of the motor casing (investigate if it is 60 degrees or higher).

• Check alignment, as parts in a misaligned motor will be susceptible to wear more quickly, reducing both the motor’s service life and efficiency.

• Record data for each motor to assess if it is running unnecessarily. Record the motor’s application, the nominal power (in kW) from the motor identification plate and how the motor is controlled.

• Replace a motor rather than rewinding it. Although rewinding is popular, efficiency is reduced by up to three percent each time a motor is rewound, leading to lower operating efficiency than the nameplate efficiency. If a motor burns out, the best solution is to review your load needs and purchase a highefficiency motor to match that load.

MOTORS

Sustainability Solutions for Australian Industry

ENERGY SAVING

ENERGY SAVING

SOLUTIONS

SOLUTIONS

W22 E3 Motor Reduce energy loss and save money.

Completely interchangeable with lower level

noise level. The fan provides greater amounts

Based on state-of-the-art technologies which

efficiency motors (eg MEPS2) and designed

of air to cool the motor and the fan cover with

reduce carbon foot print from manufacturing,

to comply with standard EN 50347 for ‘kW to

its aerodynamic outline is designed to avoid

to installation and on-going use, the W22 range

frame’ ratios. The W22 E3 has a flat efficiency

recirculation of air (loss of performance) and to

of E3 High Efficiency motors will reduce your

curve: from 75% up to 100% of load the high

better direct the airflow over the motor fins.

operating, inventory and maintenance costs,

efficiency is kept constant for maximum

The ageing of the insulating material is directly

whilst helping you achieve carbon emission

energy saving in applications where the motor

proportional to its operating temperature –

targets.

has been oversized.

the optimised cooling system of the W22 E3

The new generation W22 E3 super long life performance advantages including reliability, life, energy efficiency, reduced noise and vibration levels, extended lubrication intervals, standardisation and flexibility. The W22 motor

provides outstanding heat dissipation and

TYPICAL EFFICIENCY CURVE OF W22 LINE EFFICIENCY (%)

High Efficiency Motor encompasses many

100

eliminates hotspots by providing a uniform temperature distribution throughout the frame.

OH&S regulations call for reduced noise levels.

90

It is possible to meet the lowest noise levels

80

60 70 80 90 100 110 120 130 PERCENT OF RATED OUTPUT

comes in two design variants either meeting the requirements of AS1359.5 High Efficiency

Constant efficiency area

E3 levels or exceeding them with a Super High

on the market simply and economically as the W22 limits noise to 80Db(A) at 1 metre from the motor without compromising flexibility.

An electric machine’s lifespan is governed by its

Efficient model.

insulating material operational hours. H Class

W22 E3 super long life High Efficiency motor

The optimised cooling system of the W22 E3

insulation is standard in W22 E3; providing a

designed to exceed the requirements of MEPS3

composed of fan, fan cover and motor frame is

design life of up to 3.35 times that of standard

high efficiency levels are among the most

designed for optimum balance of airflow and

F Class insulated motors. This super long life

efficient motors in the world. In fact the W22

COST BREAKDOWN OF MOTOR

E3 can reduce energy losses by between 10%

maximizes product serviceability and results in a significant reduction in materials spend – from reduced replacement to providing a

For the life of the motor, the purchase cost can

$220

solution enabling plants to halt the practice

be as low as 2% of the total cost of ownership.

The payback period for a W22 over a standard efficiency motor can be less than 7 months depending on the operating hours. www.bsc.com.au

COST

and 40% compared with other typical motors.

$225

of rewinding – universally identified as a

$215

significant contributor to lowering motor

$210 IE1 Energy Cost

Purchase Cost

IE3

efficiency levels.

Maintenance Cost

5

MOTORS

W22 E3 Motor (Continued)

COMPARISON BETWEEN W22 AND MEPS EFFICIENCY LEVELS 98

EFFICIENCY (%)

97 96 95 94 93 92 91 ENERGY SAVING

SOLUTIONS

37

ENERGY SAVING

SOLUTIONS

45

75

90

110 132 160 200 250 315 355 KW

W22 Top Premium Efficiency

Minimum High Efficiency Level

W22 Premium Efficiency

Minimum Efficiency Level

motors are fitted with WISE insulation which

information on Optimal Flux® please refer to

recognized to be one of the major driving

permits them to be operated by VSD – the

the section in this catalogue on the CFW11.

forces for energy efficiency because it can

WISE system is composed of Class H wire

Insulated bearings are expensive and, like any

adjust motor output to best suit load needs.

(200C), enhanced insulation materials and a

load carrying rotating or sliding product, are

However, voltage spikes from the PWM

solvent-free resin. When used with a VSD, our

subject to wear which eventually requires

waveform can have harmful effects on the

innovative WISE® insulation will deliver years

replacement. W22 E3 motors can be fitted with

motor winding, leading to premature failure

of reliable operation. Operating the W22 with

a non-drive end shield where the bearing hub

of the insulation system. This worsens as

WEG’s CFW11 VSD, the patented Optimal

is insulated. This component doesn’t wear and

switching frequency is increased. All W22 E3

Flux® will provide further savings. For further

guarantees longer operating hours.

CASE STUDY

The use of Variable Speed Drives (VSD) is

Quarrying Application

REDUCTION

Total Design Life Materials & Energy Saving

The outcome for the customer:

of over $451,170

• Reduction in energy consumption of

A major BSC quarrying customer in Victoria recently worked

321 T pa

223,778kwh per annum

with BSC’s Engineering Services to identify site improvement

• Reduction in CO2 emissions of 321 tonnes per annum

opportunities that would enhance reliability, reduce ongoing

• Nett reduction in energy costs of $31,329 per annum

materials spend associated with replacements and rewinding and deliver significant energy consumption reduction. Quarry environments are tough and require mining class rated motors.

Following the survey and analysis, Engineering Services identified a number of areas throughout the quarry where a progressive change-out to the Super Long-Life High Efficiency mining specification motor range would provide significant benefits to our customer.

6

55

• Increased motor life of 335%.

MOTORS

Sustainability Solutions for Australian Industry

The DE end shield has a patented design with

are achieved through patented end shield

most operating environments, as there is no

fins and reinforced structure that increases heat

design and reduced bearing temperature rise.

longer any need to carry motors of varying IP

dissipation, ensuring low bearing operating

W22 E3 motors are IP66 rated – the highest

ratings in inventory.

temperatures. This results in extended

Ingress Protection rating against solid objects

lubrication intervals and subsequently lower

such as dust and the highest Ingress Protection

maintenance costs and reduced TCO as

against water (powerful jetting) other than

lubrication intervention relies upon personnel

totally immersible motors. This IP rating allows

and equipment. In the W22 E3 design,

for standardisation of motors throughout, in

CASE STUDY

extended lubrication intervals of up to 126%

Premium Efficiency Motor Audit – Food & Beverage Industry

REDUCTION

6600 T pa

Energy consumption reduction equivalent to over

At a glance:

$400,000 per annum

• Reduction in energy consumption of 4.6 million kwh per

BSC’s Engineering Services was asked by one of our major

annum

national customers, a multi faceted manufacturer with

• Reduction in CO2 emissions of 6,600 tonnes per annum

production plants in most States throughout Australia,

• Increased motor life of 335%

to conduct a detailed audit of electric motor applications with a view to identifying opportunities to reduce energy consumption and increase reliability.

• No more rewinding costs • IP66 standardisation opportunity

Utilising our Super Long Life High Efficiency motor range BSC was able to provide an attractive solution which would provide very significant savings.

www.bsc.com.au

7

VSD - Variable Speed Drives

ENERGY SAVING

ENERGY SAVING

SOLUTIONS

SOLUTIONS

CFW-11 VSD WEG CFW-11 variable speed drive for

Improve Efficiency and Save Energy

Optimal Flux®

all industries.

The CFW-11 VSD provides the ability to directly

When working on Heavy Duty loads with

Using state of the art technology, the CFW-11

control motor speed and motor torque

constant, or high, torque requirements

variable speed drive is designed for control of

to meet the process requirements. More

throughout a wide speed range, the patented

three-phase induction motors. CFW-11 utilises

importantly the CFW-11 improves efficiency by

Optimal Flux® provides the most cost effective

precise sensorless vector control or closed

saving energy when controlling motor speed.

and energy efficient solution. Optimal Flux®

loop vector contol and since it is designed

Operating a centrifugal pump or fan with a VSD

automatically minimizes losses within the W22

for operating on either Normal or Heavy

will provide high energy savings negating the

motor negating the need to oversize the motor

Duty loads, it can be used in a wide range of

need for throttling control. Power consumed

to meet the torque requirements, and negating

applications such as:

by a pump is proportional to the cube of the

the need for a separate forced cooling system

• pumps

speed. Comparing the two operating points

on the motor (further reducing the size of the

• fans

shown in the graph below, VSD control shows

installation).

• air compressors

remarkably lower power consumption for the

Optimal Flux® can reduce motor temperature

• refrigeration compressors

same flow. A flow-on benefit of VSD control on

rise by up to 11% which can increase motor

• converyors

centrifugal pumps is reduced pressure within

winding life by over 200%.

• ball mills

the system. (See below)

• mixers • crushers • palletizers Normal duty provides 110% overload for 60 secs every 10 minutes and 150% overload for 3 secs every 10 minutes. Heavy duty provides 150% overload for 60 secs every 10 minutes and 200% overload for 3 secs every 10 minutes.

Head (m)

H1

TYPICAL Q-H CURVES FOR A CENTRIFUGAL PUMP C

H2

Flow reduced by throttling

A

ENERGY SAVED

• hoists

Flow reduced by speed control

B

With rated ambient temperatures of 50°C and maximum ambient temperature of 60°C (up to frame size D), the CFW-11 is robust enough for the most arduous conditions.

8

FLOW Q1 CHANGE

Q2

Flow (m3/h)

Sustainability Solutions for Australian Industry

VSD - Variable Speed Drives

Reduce the cost of the installation

Oriented Startup reduces time to configure

An often overlooked aspect of a VSD is the

the drive by providing the minimum required

installation where costs can be incurred. The

parameters necessary to control a motor. The

CFW-11 has features that can reduce the cost

default configuration of the CFW-11 is suitable

of the installation.

for most applications out of the box. The

The design of CFW-11 allows the heatsink to be mounted external from a panel, reducing the temperature rise within the electrical cabinet and reducing the cost of ventilation and

intuitive keypad and menu structure makes a programming manual almost redundant.

Navigating the keypad is as simple as navigating a mobile phone. (See right)

cooling. The internal components of the CFW-11 are protected by an IP54 seal ensuring reliable operation.

Automatic control of the speed of the heatsink fan reduces the power consumed by the VSD providing lower energy usage in favourable ambient conditions.

With application functions such as Multipump for multiplie pumps systems, crane, winder, and a SoftPLC for customising, additional time and equipment is not required for specific applications. (See right)

www.bsc.com.au

9

VSD - Variable Speed Drives

CFW-11 VSD (Continued)

TYPICAL BRAKING TORQUE x SPEED GRAPH (FOR 10HP / 7.5 kW MOTOR DRIVEN BY A CFW-11)

Braking Torque (%)

100%

TB1 ENERGY SAVING

ENERGY SAVING

0 0

SOLUTIONS

20%

100%

200%

SOLUTIONS

Dynamic Braking Torque Curve Optimal Braking Torque Curve DC Braking Torque Curve

In applications where braking is required,

ambient temperature rating, and has high start

typically braking resistors are needed. These

torque/overload torque.

resistors are an additional cost and take up

BSC can also provide other WEG Automation

additional installation space. With Optimal

products such models covering single phase

Braking the need for these additional resistors is

input, three phase input in low voltage and

reduced. (See above)

medium voltage, IP ratings from IP20 to IP56,

The CFW-11 is C-Tick compliant, comes in IP21,

and softstarters.

IP54 variants for flexible installation, has DC link

CASE STUDY

reactors to improve power factor, has a high

A Major Food Processing Facility Energy savings of $6300

to reduce conveyor speed in lightly loaded

A major food processing facility had a problem with two screw

conditions to save energy.

75 T pa

conveyors in their grain handling plant. The conveyors, driven

The CFW-11 can provide 200% starting torque for 3 seconds

by 2 x 22kW motors were started with star-delta starters. The

followed by 150% overload for one minute – enough in this

star-delta starters were installed to replace previously used DOL

instance to start the loaded conveyors, saving 2 hours of lost

starters, in an effort to reduce the high starting currents. The

production each time the loaded conveyor was stopped.

customer mentioned that during certain conditions when a

With the ability to control the speed of the screw conveyors to

loaded conveyor was stopped due to bottlenecks within the

match the loading, the CFW-11 variable speed drives were able

plant, the star-delta starters did not always get the conveyors

to provide energy savings of approximately $6300 based on

started due to the low starting torque. Operators would have

the loading of the conveyors during various production cycles.

to manually unload the grain, which would take on average 2 hours, adding unnecessary down time and lost production.

The BSC solution was to offer two 22kW, heavy duty rated CFW-11 WEG variable speed drives which could provide the necessary starting torque and the added benefit of being able

10

REDUCTION

Energy consumption was reduced by 52.,560kWh per annum and CO2 emissions were reduced by 75 tonnes.

Engineering Services

Sustainability Solutions for Australian Industry

BSC’S Engineering Services

H

elp your business enhance its

BSC’s major priority in supporting our

Reducing lubricant usage and waste are also

sustainability and improve profitability

customers in this area is electricity

important areas that contribute to an overall

and competitiveness.

consumption reduction. Electricity is the largest

level of sustainability and BSC’s expertise and

Corporate sustainability encompasses

resource consumed in the industrial process

niche products again support these goals.

strategies and practices that aim to meet the

and, with significant price/kwh increases in

The products and services featured have been

needs of stakeholders today whilst seeking

recent years and forecast in coming years, the

carefully selected and designed to provide

to protect, support and enhance the human

critical priority for industry is the management

BSC’s customers with the benefit of the latest

and natural resources that will be needed in

of electricity usage.

technologies that can support you build a

the future.

Our proven strategies are guaranteed to deliver

sustainable and competitive business by

From a macro perspective, the challenge for

immediate reductions in energy consumption,

reducing consumption & increasing reliability.

business is to lower greenhouse gas emissions

increasing reliability and reducing the total cost

whilst remaining globally competitive.

of ownership for our customers.

At plant level the opportunities to achieve

Water consumption is generally a much

lower operating costs through reduced energy

smaller input to industry costs than electricity

and resource consumption, reduced materials

or gas; however business recognizes a social

spend and increased reliability....and in doing

obligation to the broader community to lower

so improve profitability and competitiveness...

water usage. BSC’s water management systems

by adopting environmentally sustainable

and new technologies contribute notably to

practices, are significant.

achieving these goals.

As one of Australia’s largest suppliers of bearings, sealing and power transmission products, BSC recognises the positive impact that our specialised products and services can, and do, have in helping our customers become more sustainable across economic and environmental objectives.

BSC has been actively working with our customers to achieve these outcomes for several years and we have achieved a level of experience and market leadership demonstrated with significant success across all market segments.

“

If we are going to carry on growing, and we will, because no country is going to forfeit its right to economic growth, we have to find a way of doing it sustainably.

Tony Blair

www.bsc.com.au

11

Engineering Services

ENERGY SAVING

ENERGY SAVING

SOLUTIONS

SOLUTIONS

Engineering Services To partner our customers to achieve

BSC Engineering Services include:

optimum plant reliability through

• Energy Reduction Program –

the application of knowledge and technologies which deliver the highest level of service and results.

BSC Engineering Services provide a range of services designed to assist you to achieve optimum plant reliability. This can be through a complete reliability program using a variety

• Predictive Maintenance PdM using Condition Monitoring • Stop Leak – Air Leak Detection • Oil Analysis • Infra Red Thermography

of technologies and services. By utilizing

• In-situ Balancing

our complete program, BSC Engineering

• Laser Alignment

Services will work in conjunction with clients

• Failure Investigation

engineering and maintenance teams to

• Installation & Training

achieve agreed results that deliver improved

• Product Redesign

plant reliability and productivity whilst reducing maintenance and capital costs.

12

Energy Audit Service (EAS)

Engineering Services

Sustainability Solutions for Australian Industry

ENERGY SAVING

ENERGY SAVING

SOLUTIONS

SOLUTIONS

Energy Reduction Program – Energy Audit Service understanding how much energy you

reduction of energy consumption via power

up to 40% by analysing inefficient and

currently use and how you can reduce that

transmission and covers AC motor survey,

poorly designed drives and adopting

consumption. BSC is very active in the

analysis and upgrade recommendations to

good drive design practices.

reduction of our customers’ carbon footprint

premium high efficiency super long life motors,

The path to becoming an environmentally

via the BSC Energy Audit Service (EAS). The

gearbox analysis and upgrade, belt and chain

sustainable manufacturer begins with

program focuses upon the meaningful

drives analysis and upgrades.

CASE STUDY

Energy consumption can be reduced

Food Manufacturing Energy Audits for energy savings.

BSC Engineering Services conducted an Energy Audit at a manufacturer in

BSC Engineering Sevices conducted a REDUCTION

304 T pa

detailed Energy Audit and Analysis of AC motors at two sites of a large dairy

REDUCTION

1032 T pa

Smithtown. A total of 213 motors were

products manufacturer in Western Victoria

identified for improvement as a result of the audit. Utilising the

who are committed to manufacturing efficiency, quality and

BSC super long life High Efficiency motor range

sustainability. Utilising the super long life High Efficiency motor

• Energy consumption reduction $21,216pa.

• Annual CO2 reduction >304 tonnes.

• Creation of an up-to-date Asset (motors) Register detailing application, type and size.

range BSC provided an excellent outcome for both sites.

• Site 1 • Energy saving $44,748 pa • Annual CO2 reduction 642 tonnes

• >300% increase in motor design life.

• Design life materials and energy savings $1.3m

• Design life materials and energy savings of $887,581

• Project Payback – 10 months

• Project Payback – 16.6 months

• Site 2 • Energy saving $27,198 pa • Annual CO2 reduction 390 tonnes • Design life materials and energy saving $1.1m • Project Payback – 14 months

www.bsc.com.au

13

Engineering Services

ENERGY SAVING

ENERGY SAVING

SOLUTIONS

SOLUTIONS

Predictive Maintenance PdM Program For Asset Optimization.

analysts are called into action immediately

Predictive maintenance PdM aims to find

reviewing detailed machine data to assess

measures of machinery condition and use

condition and recommend the most cost

them to prevent breakdowns. Establishing

effective actions available. Remote program

trends allow accurate pinpointing of

benefits include reduced failure risk and allows

machinery problems and their severity.

for just-in-time maintenance of equipment.

Increasing up time on machines is the primary

Our expertise spans all areas of condition based

aim, while reduced likelihood of secondary

maintenance, including:

failures and less unnecessary maintenance are

• Vibration analysis

additional benefits.

Condition Monitoring is most frequently used as a Predictive or Condition-Based Maintenance technique. Condition Monitoring uses advanced technologies in

• Lubrication analysis • Infrared thermography • Laser alignment

order to determine equipment condition, and

• Failure analysis

potentially predict failure.

• In situ balancing

BSC’s Predictive Maintenance Program

• Installation

utilises Azima DLI technology. AzimaDLI is a world leader in condition monitoring services to industry delivering a wide range of technologies and services reducing maintenance costs whilst ensuring maximum equipment reliability.

The BSC – Azima Watchman Remote is a robust, automated monitoring and diagnostic service that links industries critical equipment with our best systems engineers and analysts via automated alarms and advanced internet technologies 24/7. When an alert occurs our

14

• Onsite data collection

Engineering Services

Industry Information

Sustainability Solutions for Australian Industry

Predictive Maintenance Published - U.S. Department of Energy - Energy Efficiency & Renewable Energy

Basically, predictive maintenance differs from

Disadvantages

preventive maintenance by basing maintenance needs

• Increases investment in diagnostic equipment

on the actual condition of the equipment, rather than on some predetermined schedule.

A predictive maintenance approach strives to detect the onset of equipment degradation and to address the problems as they are identified. This allows causal stressors to be eliminated or controlled, prior to any significant deterioration in the physical state of the component or equipment. This leads to both current and future functional capabilities.

• Increases investment in staff training • Savings potential is readily seen by management There are many advantages of using a predictive maintenance program. A well-orchestrated predictive maintenance program will all but eliminate catastrophic equipment failures. Staff will then be able to schedule maintenance activities to minimize or eliminate overtime costs. And, inventory can be minimized, as parts or equipment will not need to be ordered ahead of time

Recall that preventive maintenance is time-based. Activities

to support anticipated maintenance needs. Equipment will be

such as changing lubricant are based on time, like calendar time

operated at an optimal level, which will also save energy costs

or equipment run time. For example, most people change the

and increase plant reliability.

oil in their vehicles every 3,000 to 5,000 miles traveled. This is effectively basing the oil change needs on equipment run time.

No concern is given to the actual condition and performance capability of the oil. It is changed because it is time.

Past studies have estimated that a properly functioning predictive maintenance program can provide a savings of 8% to 12% over a program utilizing preventive maintenance strategies alone. Depending on a facility’s reliance on a reactive

This methodology would be analogous to a preventive

maintenance approach and material condition, savings

maintenance task. If, on the other hand, the operator of the

opportunities of 30% to 40% could easily be realized.

car discounted the vehicle run time and had the oil analyzed at some periodicity to determine its actual condition and lubrication properties, he or she may be able to extend the oil change until the vehicle had traveled 10,000 miles. This is the fundamental difference between predictive maintenance and

In fact, independent surveys indicate the following industrial average savings resulted from initiation of a functional predictive maintenance program: • Return on investment: 10 times

preventive maintenance, whereby predictive maintenance is

• Reduction in maintenance costs: 25% to 30%

used to define needed maintenance tasks based on quantified

• Elimination of breakdowns: 70% to 75%

material and equipment condition.

• Reduction in downtime: 35% to 45%

Advantages & Disadvantages

• Increase in production: 20% to 25%

Advantages

The down side of using a predictive maintenance approach are

• Provides increased component operational life & availability

its initial costs. The up-front costs of starting this type of program

• Allows for preemptive corrective actions • Results in decrease in equipment and/or process downtime • Lowers costs for parts and labor

can be expensive. Much of the equipment requires expenditures in excess of $50,000. And, training of in-plant personnel to effectively utilize predictive maintenance technologies and practices will require substantial additional funding. And,

• Provides better product quality

beginning a predictive maintenance program requires an

• Improves worker and environmental safety

understanding of the facility’s predictive maintenance needs and

• Raises worker morale

the approaches which need to be undertaken. It is also essential

• Increases energy savings

to have a firm commitment, by management and all facility staff

• Results in an estimated 8% to 12% cost savings over which might result from a predictive maintenance program

www.bsc.com.au

and organizations, to make it work.

15

Engineering Services

ENERGY SAVING

ENERGY SAVING

SOLUTIONS

SOLUTIONS

Operation Stop Leak Air leaks are one of the biggest

its location, severity and cost. From this, total

• Reduce fluid loss

contributors to needless costs in any

estimated savings are generated within a

• Identify Cost Savings

industrial plant/facility.

corresponding report. The report provides a detailed format for a targeted approach and

• Energy savings translate into cost savings

A leak is a costly drain on overall operating costs. State-of-the-art ultrasonic equipment is

allows monitoring of progress by cfm and

used to identify air leaks.

dollars saved.

The “Operation Stop Leak” Process is the first

Objectives of Operation Stop Leak

step in continuous improvement. Every

• Identify Air and Fluid Leaks

identifiable leak, including fittings, valves,

• Reduce energy usage

CASE STUDY

• Increase Safety & Reliability • Identifying air and fluid leaks enable corrective action to be implemented • Training in use of Loctite solutions reduces rework and improves equipment reliability

flanges and hoses are tagged with a number,

Printing Works

REDUCTION

945 T pa

BSC Engineering Services utilising Ultrasonic Leak

all the leaks rectified the company was able to

Detection has produced annual savings of $80,000

shut down one of their compressors as the third compressor

for a large Sydney based printing works.

was just servicing their air leaks.

Producing high volume magazine and brochure print requires

This was a cost saving of $80,000 in energy costs alone and

volumes of compressed air to be transported to machinery

a substantial reduction in green house emissions! The third

throughout the plant as do many packaging processing

compressor is used today as a back up and in time will be

plants. This particular printer uses three large Atlas Copco

decommissioned further reducing maintenance and

Compressors to service their plant and was concerned about

operating costs.

their inability to identify problem leaks.

Using the Ultrasonic Leak Detection service BSC Engineering Services were able to tag and locate the costly leaks providing a comprehensive report on the actions and products required to repair the compressed air system. Three months later with

16

• Reduce cleanup costs

Sustainability Solutions for Australian Industry

GEAR BOXES

Nord Helical-bevel geared motor

ENERGY SAVING

ENERGY SAVING

SOLUTIONS

SOLUTIONS

Nord Helical, Parallel shaft & Helical-bevel gear units Highly efficient power transmission.

A worm gear unit can have efficiencies

Operating at 16 hours per day with a cost of

Gearboxes are used throughout industry to

ranging from as low as 40% to as high as 93%

15cents/kWh, it costs $1603 per annum in

achieve a speed reduction from the motor

depending on the worm size, ratio and input

electrical energy. A 15% reduction compared to

shaft to the output shaft. Conversely, gearboxes

speed. A 2 stage helical-bevel box has an

the worm gear unit. This saving does not even

multiply torque as they reduce speed. There are

efficiency of up to 98% and a 3 stage helical-

include the use of a W22, super high efficient

various forms of gearboxes and consideration

bevel of up to 95%. A large amount of energy

motor compared to a standard efficient motor

should be given to the efficiency of the

saving can be achieved by using helical-bevel

– which at 2.2kW can provide approximately 6

gearbox during the selection process.

gear units instead of worm gear units.

to 7% additional savings.

NORD gear units are the right solution for your

Taking an example of a 3 inch worm box with

Multiplied by the number of gearboxes that

application if the highest levels of efficiency are

an output speed of 72 RPM and providing

can installed on one production line, not to

required. Due to optimised gear design relative

239 Nm. This equates to 1.8kW of mechanical

mention the whole plant, installing helical-

to rolling motion, especially in NORD helical

power however, due to the low efficiency of

bevel gearboxes can provide significant

and bevel gear units, mechanical losses caused

the worm box, it requires a 2.2kW motor to

savings, especially as the above comparison

by friction are reduced to a minimum – the

operate. This worm gear unit has an efficiency

was with a relatively high efficient worm gear

drive is practically without losses!

of 82%. Operating this unit 16 hours per day

unit. In certain instances it is even possible

with a cost of 15 cents/kWh, it costs $1880 per

to reduce the motor size as the helical-bevel

annum in electrical energy.

boxes have higher torque ratings.

An equivalent helical-bevel gear unit to provide

All NORD drives are built in the UNICASE™

the same mechanical power would only

housing design first developed by NORD in

consume 1.83kW of electrical power.

1981. In addition to the high levels of efficiency of the NORD gear drives helical and bevel gears there are other key advantages for the user.

Greater operational reliability, high output torques, high axial and radial loading capacity, quiet running, high efficiency as well as

www.bsc.com.au

17

GEAR BOXES

Nord Helical, Parallel shaft & Helical-bevel gear units (Continued)

Nord Unicase housing - cutaway

ENERGY SAVING

ENERGY SAVING

SOLUTIONS

SOLUTIONS

and therefore no sealing surfaces are subjected

longer service life of the product are the key

to torque loads. Additional advantages of

features of this series.

this system are the high rate of production

The main feature of the UNICASE™ housing

accuracy, lowest tolerances and smooth,

design is that all boreholes are integrated into

quiet running.

one housing block. All boreholes and sealing

Nord are a leading German drive manufacturer

surfaces are incorporated into a single-line. The

for the global market with a range of gearboxes

advantage: no screwed-on bearing surfaces

from 0.12kW to 1MW, 19Nm to 200,000Nm.

CASE STUDY

reduced maintenance requirements and a

Mixing Application

138 T pa

Total Increase in Gearbox Efficiency of 88%

The outcome for the customer:

Major BSC confectionery customer in Tasmania recently

• Reduction in energy consumption of 96, 910 kwh

worked with the local BSC branch for 5 replacement specialty

per annum

inline gearboxes on mixers. The existing gearboxes that had to

• Reduction in CO2 emissions of 138 tonnes per annum

be replaced had an efficiency of 51%.

• Nett reduction in energy costs of $9,691 per annum

After consultation with the customer and Nord, BSC offered helical-bevel boxes which were ex-stock and had an efficiency of 96%. Being a Nord standard gearbox configuration, the purchase cost and lead time was lower compared to a direct replacement from the original vendor.

18

REDUCTION

BELTS

Sustainability Solutions for Australian Industry

Belt Drives & Energy Efficiency

A

bout one-third of the electric motors

strides to improve efficiency and productivity

Timing Belts are toothed and operate by

in the industrial and commercial

of motors and driven equipment. However,

mating the tooth profile of the belt with that of

industry sectors use belt drives. Belt

little attention has been given to the power

a sprocket. Timing belts are also called positive

drives provide flexibility in the positioning

transmission component connecting the

or synchronous and offer efficiency levels of

of the motor to the driven equipment.

equipment. Ordinary wrapped belts waste

about 98% and maintain this efficiency over

Pulleys of varying diameters allow the speed

energy - an average typical operating

a wide load range. In contrast timing belts

of the driven equipment to be increased

efficiency for wrapped V-belts is 90% to 94%.

do not have the sharp reduction in efficiency

or decreased. A properly designed belt

There are two belt constructions that can

at high torque due to increase in slippage as

transmission system provides high efficiency,

improve efficiency levels.

v-belts do.

low noise, does not require any lubrication,

Raw Edge Cog Belts have cogs that run

Energy savings of up to 20% can be realised

and presents low maintenance requirements.

perpendicular to the belts length and are

immediately by simply upgrading the belt

However, certain types of belts are more

manufactured in raw edge construction.

transmission used on the drive. Timing belts

efficient than others, offering potential energy

The cogs improve the belts flexibility

are the most efficient choice, however cog

cost savings.

reducing bend resistance and the raw-edge

belts may be a better choice when vibration

The majority of belt drives use V-belts. V-belts

premium rubber sidewalls allow better grip

damping is needed or shock loads are present

use a trapezoidal cross section to create a

characteristics reducing belt slip.

causing abrupt torque changes in the drive.

wedging action on the pulleys to increase

On average the raw edge cog belts will

Cog belts also do not require any pulley

friction and the belts power transfer capability.

run 4.5% more efficient than ordinary

modifications as cog belts can be installed on

Joined or multiple belts are specified for

wrapped belts.

existing pulleys.

heavy loaded drives. V-belts can have a peak efficiency of 95% to 98% at the time of installation. Efficiency is also dependant on pulley sizes, driven torque, under or over belting, belt tension and V-belt design and construction. Efficiency can deteriorate by as much as 5% to 15% (to nominal efficiency of 93%) because of the belts tension. If tension is not applied correctly at installation or is not periodically checked over time slippage occurs thus dramatically reducing efficiency levels.

In all drive systems the efficiency of a drive system is at the mercy of its weakest link.

The maintenance industry has taken great

www.bsc.com.au

“

We must all work together in order to save the environment and the world that we live in from further change.

Dave Foreman

19

BELTS

ENERGY SAVING

ENERGY SAVING

SOLUTIONS

SOLUTIONS

Gold Label Raw Edge Cog Belts pulleys better and precision molded cogs for

immediate energy savings without changing

energy waste by 50% or more.

improved flexibility and cooler running. Saving

pulleys or modifying your drive! Conventional

Ordinary v-belts waste energy and money.

energy on air moving systems is as easy as

V-Belts deteriorate to a nominal efficiency of 93

Tests prove the Gold Ribbon Cog-Belt by

taking old v-belts off the drive and installing

percent. Carlisle Gold Label Cog-Belts maintain

Carlisle is more energy efficient than ordinary

a factory matched set of the Carlisle Gold

higher efficiency ratings, resulting in significant

v-belts. The secret to the energy saving

Ribbon Cog-Belts. Gold Ribbon can be installed

savings.

power of the Gold Ribbon Cog-Belt is in its

on your existing drives without any special

unique design. The Gold Ribbon Cog-Belt has

drive modifications. Install Carlisle Gold Label

raw-edge premium rubber sidewalls to grip

Cog-Belts on your existing V-Belt drive to realize

CASE STUDY

Gold Label Cog-Belts can reduce

Fine Sediment Crusher An Improved Crusher Drive Saving $1700 Annually

The drive was installed and run, with the New Carlisle

Standard wrapped V-Belts were lasting up to 6 weeks on a Fine

SPBX3000 running for nearly 9 months, more than 6 times

Sediment Crusher. The cost of the continual maintenance and

longer than the original set up. The plant noticed that the

shut down of the machine was a large factor in the annual

drive no longer required maintenance due to belt problems.

maintenance budget for the plant. The abrasive environment

The improved up-time and reduced maintenance meant time

was considered the main root cause for the failures.

could be invested in other problem areas. Altogether a saving

With the drive information supplied by the site, we were able

for the plant of more than $1700 annually.

to use the Carlisle Drive Engineer 3.1 program to analyze the

ANNUAL BELT LIFE COMPARISON

drive. The change from the original “B� section to the high power SPBX3000 Cogged Raw Edge belts ensured that the

300

drive had sufficient capacity for all situations. With the new

200

drive tensioning was also pointed out as the probable culprit of some of the failures.

262

100

42

0

DAYS Original Life

20

New Life

BELTS

Sustainability Solutions for Australian Industry

ENERGY SAVING

ENERGY SAVING

SOLUTIONS

SOLUTIONS

RPP Panther® of 98% efficiency. RPP Panther is the power

these components are likely to be worn out

effectively transfer power at

transmission system of choice on many

and wasting energy due to drive slippage and

98-99% efficiency.

new installations. Because of the positive

tension loss. It’s probably time to replace these

For maximum drive system efficiency, the

engagement power transfer of Panther,

worn out components. It is also an opportune

Carlisle RPP Panther high torque synchronous

operating speeds can be controlled much

time to upgrade your existing power

belt can put some real teeth into your plant

more closely than with ordinary v-belts. The

transmission system from outdated chain or

maintenance energy conservation program.

RPP Panther is ideally suited for modern

v-belt drives to the modern and efficient RPP

The RPP Panther synchronous drive system

systems where inverter devices and / or

Panther drive system. The payback in energy

operates on a “teeth in mesh” principle for

modern systems where inverter devices are

savings is often recovered in just a few short

positive engagement between belt and

used because of its inherent high operating

months.

sprocket. As a result, power is transferred

efficiency. Also, if your belt drive pulleys or

from the motor to the driven unit at a rate

chain sprockets are more than five years old,

CASE STUDY

Tests show that RPP Panther can

Stock Feed Plant Total Cost Savings $5,500 per individual auger Premature failure of the roller chain drive on the auger was causing ongoing downtime losses every 4 months. Time was also being lost in having to lubricate the chain drive. This was not a regular program and the inevitable failure of the drive caused loss of production and unplanned downtime to replace the chain. The augers were difficult to access and operated in a hot, dry and dusty environment.

BSC’s objective was to design a drive that would extend life from the existing 4 months to a minimum 12 months. BSC recommended the new Panther Ultra Cord and completed a drive design for this application, the Dayware software selection offered a drive that would meet all space requirements and provided an adequate service factor for the application.

In most harsh environments Panther Ultra Cord belts last many

www.bsc.com.au

times longer than conventional chain. The new drive was installed and has been a success. The customer has already ordered some more belts for the other 8 augers as the trial is running so well.

Extended Life = 20 months… AND STILL GOING!

EXTENDED LIFE = 20 MONTHS + 600

600 400 200

120

0

DAYS Original Life

New Life

21

BELTS

ENERGY SAVING

ENERGY SAVING

SOLUTIONS

SOLUTIONS

Power Wedge Raw Edge Cog Belts Wedge Cog-Belt is heat and oil resistant and

Raw Edge sidewalls provide greater contact

belts improve system performance.

static dissipating. It’s available in SPZX, SPAX,

with the pulley surface and produces a

Transmit more torque with less slippage.

SPBX, SPCX & SPPX cross sections lengths up

smoother running belt.

Higher horsepower ratings translate into

to 5000mm.

greater design flexibility, reducing space,

The Hi-Modulus cord carries high horsepower

weight and drive costs. Carlisle’s raw edge

loads with minimum stretch and improved belt

construction creates outstanding operating

stability, requiring fewer take-up adjustments.

efficiency. More torque with less slippage

Fabric Laminates are located in the “Power

reduces energy costs. The Power-

Zone” to maximize response to shock loads.

CASE STUDY

Efficient raw edge and synchronous

Fan Drive Refurbishment

120 T pa

$10,000 energy saving per annum

the top performing V belt available and the

A major industrial site had advised a need to refurbish the

Megadyne Silver Series High Performance Timing Belts were

existing fan drives as they were over 14 years old. The fans

also an option.

we visually inspected and condition of the pulleys all had

The proposal for the total refurbishment included both belt

shown signs of extreme wear. The site was also heavily into

types. The extra cost for changing the drives to the Megadyne

conservation of resources so they expressed an interest in the

Silver RPP profile timing belt was a $2,000 premium over the V

energy conservation options available

belt version.

Using the Carlisle Design program each drive was checked

The lower bearing loads by up to 30% that the timing belt

to ensure the latest belt types would be used to offer the

offered, plus the $10,000 energy saving over the V belt per

best drives for the purpose. As the pulleys would also be

annum resulted in a payback period measured in only months..

looking at getting replaced there was an opportunity to explore the timing belt option as a way to improve efficiency and also lower the bearing usage from the site. The Carlisle Power Wedge Cogged Raw Edge design was favoured as

22

REDUCTION

BELTS

Sustainability Solutions for Australian Industry

ENERGY SAVING

ENERGY SAVING

SOLUTIONS

SOLUTIONS

Super II Energy savings of up to 20% can

mill debarkers, pipe descalers, and any other

eliminates backside idler problems. Superior

be realised immediately by simply

application known for being tough on v-belts.

grade 100% neoprene rubber compound

upgrading the belt transmission used

The secret to the Super II v-belt’s durability is

resists cracking from heat and flex fatigue

its unique construction. Several innovative

better than ordinary wrapped v-belts that use

Many heavy-duty, industrial drive system

Super II design features allow you to avoid

cheaper, less effective rubber. Neoprene also

applications demand more than conventional

many problems common to ordinary wrapped

provides the best resistance available against

v-belts can stand. Punishing drives make

v-belts. Rugged multiple fabric plies on both

dirt, dust, ozone, oil, and grease. Unique fabric

ordinary wrapped v-belts crack under pressure,

the top and bottom of the v-belt help relieve

loaded raw edge sidewalls grip pulleys better

resulting in costly downtime. End the hassle

stress on the centre cord, assist in minimizing

than wrapped v-belts but still allow controlled

and expense of constant v-belt breakdowns

belt stretch, and help to control slippage under

slippage during extreme shock loads for

with Super II from Dayco. This rugged v-belt

heavy loads. The high modulus polyester

increased productivity. The raw edge Super II

is specifically designed to provide superior

cord located in the mid-section of the v-belt

also dissipates heat quicker for cooler running,

performance on the most brutal v-belt drives

resists extreme shock loads without stretching,

longer lasting v-belts.

including rock quarry shaker screens, lumber

increases v-belt flexibility for longer life, and

CASE STUDY

on the drive.

Aggregate Plant Carlisle Super II V-belts outlast wrapped belts up to

II having the characteristics of wrapped construction but the

6 times longer.

performance of raw edge would make them ideally suited for

A large Aggregate Plant using wrapped construction v-belts

the off & on load cycles generated by the shaker screen drive.

was constantly having to change out the V-belt drives on

After 8 weeks no belts had failed and the Super II was proving

their shaker screens. Belts would only last 2-4 weeks on

to be a great success. The original set of Super II was eventually

average depending on the volumes being processed. The

replaced after 18 weeks in operation. Performing over 4 times

constant changing of belts was a huge problem in belt costs,

longer than the wrapped construction belt.

maintenance time and down-time.

The maintenance supervisor was introduced to Carlisle Super II V-belts. It was explained that the unique construction of Super

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23

BELTS

ENERGY SAVING

ENERGY SAVING

SOLUTIONS

SOLUTIONS

Powermiser Software Use the Powermiser program to calculate the energy savings you can enjoy with efficient Carlisle Raw Edge V-belts and timing belts.

An area not often considered when looking at a cost of a belt is energy efficiency. The efficiency of a v-belt drive is a measure of the utilization of total energy input to the belt pulley system. A major source of energy loss in a v-belt is internal friction of the rubber, cover and cords when they are cyclically deformed while traversing a pulley. The magnitude of energy loss depends upon material properties and the amplitude of deformation.

CASE STUDY

Many original equipment manufacturers tend to standardise on traditional wrapped V-belts. These belts are generally designed

for long life, high load, power capability and smooth running. One of the design criteria of a wrapped belt is also its ability to slip somewhat on start-up, which tends to compensate for high starting torque or load, which can sometimes vary from 1-1/2 to 3 times the normal running torque of the motor.

While these belts will provide exceptional performance on a drive, they generally have an overall efficiency rating of between 88% - 94%, which equates to a performance and energy loss between 6 to 12 percent. This unfortunately is a potential savings that is overlooked when doing system design or system maintenance.

Features • Will allow you to calculate the energy savings you can enjoy.

• Input fields hours of operation per year, Motor Power rating. Motor efficiency level, Utility rate, belt efficiency % increase.

• User friendly and Windows® based • Calculates the annual dollar savings based on your utility costs.

• Include V-belts and timing belts

This energy loss can be difficult to measure, however Carlisle Power Transmission has

Paper Mill Savings of $156,000 per annum In today’s economic environment it is important that each industry operates efficiently and economically. BSC was asked to evaluate 132 belt driven machines in a Pulp and Paper mill to ascertain any problems and offer advice on improving belt performance and efficiencies With the drive information supplied by the site, we were able to use the Carlisle Drive Engineer 3.1 program to analyze each drive. We checked for conformance to ISO design standards, noticeable drive warnings such as excessive shaft loadings and under designed drives. We advised remedial action for the

24

developed a software program called POWERMISER that will enable end users to calculate the energy cost when changing to more efficient belt construction such as Raw Edge Cog or Timing Belts.

REDUCTION

under designed and over designed drives and tensioning information for all drives to ensure best maintenance practices were followed.

286 T pa

The 9 drives evaluated as under designed could be the cause of at least 9 plant stoppages a year. With the cost of downtime at the plant at approx $16,500 per hour, the possible savings from a belt drive re-design was estimated in excess of $121,000 a year. Combined with an energy saving of up to $30,000 per year by using the most efficient belt drive types and tensioning drives correctly, the customer can enjoy the benefit of a $156,000 saving per annum.

Sustainability Solutions for Australian Industry

WATER SAVING

WATER SAVING

SOLUTIONS

SOLUTIONS

WATER MANAGEMENT SYSTEMS

Habasit TS EXTRA Low Friction Flat Top Chain The environmental choice, save money

Habasit’s TS option for Flat Top chain, uses

than standard low friction models, which also

save the environment.

extra low friction resin technology, resulting in

contributes to smooth, effortless and quiet

•

the lowest coefficient of friction, with special

operation.

self-lubricating agents built into its molecular

Habasit TS, is dimensionally interchangeable

structure.

with most LF products on the market, so there

Ideal for critical bottling applications, this chain

is no need to change out sprockets and wear

Reduce water usage Reduced power consumption

•

Reduce noise

•

Smooth operation

is well suited to dry running applications. The

•

Long life

strips unnecessarily. However, Habasit can also

benefits include, reduced water consumption

provide a special low noise sprocket option

•

Improved reliability

associated with top chain lubrication. The

complete with a patented split sprocket / split

extra low friction Habasit “TS” uses less energy

bush and suitably compatible wear strips.

CASE STUDY

•

Major Bottling Plant TS Series Habasit / KVP chain has been recently

In straight water saving this saves the site over $15,000 per

installed as the exclusive specification within a

annum in water consumption costs alone. An additional

major bottling plant in Queensland.

benefit of moving from the ‘LF’ chains to the TS Series is the

In the past the plant had used standard low friction ‘LF’ acetal

240% - 270% extra life that will be achieved thanks to the

table top conveying chains throughout the site. The ‘LF’ series

harder-wearing nature of the special TS material.

chains did the job, however this busy plant was consuming

The TS Series table top conveying chain has proved to be a

over 11 Million litres per annum in potable water in order to

significant weapon in the battle to reduce ongoing operational

constantly lubricate the acetal conveying chains.

costs in the areas of resource consumption and maintenance

The significantly increasing cost of water plus the social

expenditure.

imperative to preserve what is the most precious and often taken for granted resource on our planet, were driving factors in the site’s decision-making process.

The self-lubricating properties of the TS Series chain have resulted in the plant ‘turning off the taps’ as the need to water lubricate no longer exists. www.bsc.com.au

25

WATER MANAGEMENT SYSTEMS

WATER SAVING

WATER SAVING

SOLUTIONS

SOLUTIONS

AESSEAL Water Management “The Problem” Mechanical Seal water wastage and seal unreliability.

one pump of 6.3 million litres per year (1.7 million gallons per year).

The most common methods of supporting mechanical seals with water are either flush/ quench to drain or into the process fluid.

Bearing in mind there is an initial cost attached to this water which multiplies upwards when we consider the cost of steam generation required to drive this flush water out of the process via the evaporator. This figure further escalates with the number of pumps associated in any given production line.

The two key impacting negatives here are the high water consumption and high cost of removing injected water by evaporation further along in the manufacturing process.

These methods typically waste huge amounts of water, and in some cases produce vast amounts of water effluent which subsequently needs to be treated, adding even more cost and consuming even more environmental resources.

CASE STUDY

Typical water consumption of a single mechanical seal in this arrangement is in the region of 12 litres per minute (3.17 gallons per minute), which gives a total consumption for

26

AES Water Management Seal Support Systems – “The Solution” Rather than running water straight through the seal to drain, the AES standard water management system removes heat and lubricates the mechanical seal faces by use of the ‘thermosiphon effect’.

Colder water is supplied to the mechanical seal, which is in turn heated

up by the seal faces. This ‘warmer’ water then rises back into the vessel, raising the bulk temperature of the vessel. The vessel then loses heat to the atmosphere which results in an ‘equilibrium temperature’ being reached. Should the vessel be required to lose more heat to the atmosphere, the increased surface area of the system ensures that this can occur.

In order to prevent contamination of the system, a positive pressure is applied to the clean water in the system. This is achieved by connecting the system to the plant mains water supply and adjusting the integral water pressure regulator to the required pressure. This also ensures that if a small trace of water is lost into the process across the seal faces, this will be immediately replaced by water from the mains supply.

Mechanical Sealing & Water Management Payback: the total cost of the redesign was $30,813.50, bringing the full payback period below 12 months and ensuring significant nett savings each following year of nearly $35,000pa.

BSC Engineering Services, working in conjunction with one of BSC’s national contract customers, analysed mechanical sealing and water management systems around 12 individual pump applications. The site had 10 pumps that were flushing to drain and 2 that were flushing to process.

Measuring the flow from the pumps that were flushing to drain revealed an annual usage of 24.2 million litres of water at a cost of $35,562 per annum.

BSC Engineering Services redesigned the mechanical seals to reliable double seal assemblies with AES SW02 water management systems fitted with flow and purge fuses.

The reduction in water usage was dramatic – reducing to only 450 litres per annum across all 10 pumps ...a saving of over 24 million litres per year.

In addition to the huge savings, the application of the flow and purge fuses had the benefit of removing the opportunity for bacterial growth within the system vessel. The flow fuse also provided a further benefit of protecting the final product from mass contamination in the situation of eventual momentary upset or failure of the mechanical seal.

BEARINGS

Sustainability Solutions for Australian Industry

In recent years, demand for hybrid vehicles has been rising rapidly due to their low fuel consumption and low emissions, realised through a more efficient integration of the engine and electric motor.

NSK has developed low-torque ball bearings for hybrid vehicles designed to improve fuel efficiency.

In order to further improve fuel efficiency, there is a growing need to reduce torque loss in the bearings used in the transmissions (drivetrains) of new generation hybrid cars.

ENVIRONMENTAL

ENVIRONMENTAL

SOLUTIONS

SOLUTIONS

NSK has met this need with its lowtorque bearings, which reduce frictional loss.

The new product will be featured in Toyota’s latest Prius model.

NSK has claimed to have found a way to cut torque by 50-65 per cent compared to existing bearings.

Molded-Oil™ Bearings Environmentally friendly lubricant.

Anti-friction bearings by their very nature are designed to be energy efficient. One particular area of modern bearing technology that does make a noticeable contribution to sustainability is the NSK Molded-Oil Bearing.

Molded-Oil Bearings are lubricated with NSK’s own oil-impregnated material, consisting of lubricating oil and polyolefin resin that has an affinity for oil. Oil slowly seeping from this material provides ample lubrication to the bearing for the life of the bearing.

CASE STUDY

The solid lubricant is resistant to both water

and dust and acts as a barrier to protect the bearing from penetration of contaminants.

Bearing life in water or dust contaminated environments is consequently increased significantly.

A significant benefit of the Molded-Oil Bearing is that once fitted there is no subsequent need to worry about relubricating. Environmentally friendly as oil seeping from the Molded-Oil inside the bearing provides sufficient lubrication, troublesome oil refilling or grease repacking is not required and, as well as consumption of lubricant being negated, contamination of the environment is negligible.

The number of balls has been reduced, and ball diameters, race dimensions and clearances have been optimised utilising analysis technology, which has allowed rolling friction losses to be minimised.

NSK’s new manufacturing processes overcame conventional hurdles to decrease the number of balls.

Losses have been reduced by agitating lubrication oils during operation via the introduction of specially shaped cages made of resin.

NSK has achieved compactness, lightness and low torque for automobiles via its four core technologies: tribology, materials, analysis and mechatronics.

Cane Train Locomotives Total maintenance & materials savings > $270,000 PA A Sugar Mill was experiencing ongoing life problems with the performance of crank bearings on its fleet of cane train locomotives resulting in frequent maintenance and re-greasing.

Normally the cranks are totally covered in grease which, apart from being environmentally unfriendly, results in contaminants sticking to the lubricant and eventually working their way into the bearing set-up and shortening bearing life. The bearings would need to be changed every year.

The cranks in each of the 16 locomotives would require 182 hours of re-greasing per season, using 26 barrels of grease each year.

www.bsc.com.au

Engineering asked BSC Cairns to assist by identifying a ‘better way’. The solution was to replace the bearings with NSK Molded Oil bearings which contain an integral solid lubricant with oil life designed to last approximately 8 years and are therefore maintenance-free.

The Molded Oil bearings have now completed two years and will remain in service for a third year with the likelihood of that extending out an additional year or two as the Mill is intending to run them until failure – no additional lubrication is required.

The maintenance and materials (grease) savings have been significant and will continue to be enjoyed in subsequent years.

27

VICTORIA

QUEENSLAND

WESTERN AUSTRALIA

SYDNEY STATE OFFICE

MELBOURNE STATE OFFICE

BRISBANE STATE OFFICE

PERTH STATE OFFICE

MOOREBANK Phone: (02) 9824 2100

CLAYTON Phone: (03) 9560 3222

NORTHGATE Phone: (07) 3866 8333

Welshpool Phone: (08) 9251 4444

BRANCHES

BRANCHES

BRANCHES

BRANCHES

ARNDELL PARK (Bearing Traders) Phone: (02) 9622 9322

BALLARAT Phone: (03) 5337 6001

ARCHERFIELD Phone: (07) 3277 4488

O’CONNOR Phone: (08) 9337 3000

DANDENONG Phone: (03) 9794 5624

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