Machinery & Equipment MRO November 2011 by Annex Business Media

MACHINERY AND EQUIPMENT

Great balls of fire! Controlling dust explosions Maintenance man must do it all Mill cuts maintenance cost per ton of output by 16.8%

Vol. 27, No. 5

NOVEMBER 2011

Compressor knocking? Here’s help Packaging plant raises parts availability to 95% NEW COLUMN! Maintenance 101

Publications Mail Agreement #40069240

INNOVATIONS

IN TEST & MEASUREMENT

WHAT’S NEW p01 Nov11 MRO Cover.indd 1

SEALS & GASKETS

POWER TRANSMISSION

DUST CONTROL 11-10-25 1:58 PM

P R O D U C T

SP TLIGHT

Machinery & Equipment MRO

Online Reader Inquiry No. 796

Economy chain offers consistent reliability

Motion Canada offers automation as well as fluid power products and solutions. The company also offers on-site troubleshooting and repair with its qualified service technician team. Its hydraulic expertise allows it to solve the kinds of situations that jeopardize plant productivity, such as contamination and heat, the two worst enemies of hydraulic systems, which are usually due to lack of preventive maintenance. Motion Canada can provide the solutions to prevent these

Inspection camera’s rotating screen permits easy, one-handed use

issues and increase uptime. Motion Canada

Automation products, troubleshooting service keep plant facilities operating

November 2011

Renold manufactures the SD standard-duty economy roller chain. This reliable, quality range offers an extensive product line of European (BS), ANSI and DIN standard chains, competitive prices and delivery, consistent quality and depth of inventory. Included in this product line are transmission chain, nickel plated chain, multi-strand chain, stainless steel chain, conveyor chain and agricultural chain. Renold Canada Online Reader Inquiry No. 794

Milwaukee Electric Tool has expanded the versatility of its M12 lithium-ion system with the introduction of the M-Spector 360 digital inspection camera. The camera features a rotating screen for fluid image control, allowing the user to adjust image orientation easily with one hand, while keeping the other hand free to control the cable. The optimized 2.7-in. LCD display delivers a crisp, clear picture. A 9-mm 640x480 digital probe and an enhanced cable provide improved durability and pipe manoeuvrability in even the tightest spaces, while four surround LED lights offer superior brightness without shadow or glare. A mirror, hook and magnet are included to help the user inspect, diagnose and solve countless problems in service, maintenance and repair applications. A bare tool model also is

Big Motors. Small Wait.

available, without a battery and charger. Milwaukee Electric Tool Online Reader Inquiry No. 799

Borehole pump can recover brackish water from deep underground deposits

KSB’s UPA and UPZ families of multi-stage borehole pumps are designed to fit into a cylindrical space such as pipe or borehole. They are available in diameters from 50 mm to 200 mm (2 in. to 8 in.) and can be supplied in a variety of corrosion-resistant materials, making them suitable for handling aggressive fluids such as alkaline or brackish water. For abrasive conditions, the pumps can be fitted with silicon-carbide pump bearings and special wear rings. Available with capacities of up to 2,200 cm/hour and heads as high as 1,400 metres, these efficient pumps are suitable for water supply, mining, and oil and gas operations. They have the potential of playing an important role in the Alberta oilsands industry, as their corrosionresistance enables them to recover water from deep underground wells. KSB Pumps Online Reader Inquiry No. 795

Quick-clamping shaft collar speeds up positioning adjustments

Designed with a low-profile integral clamping lever, the quick-clamping shaft collar from Ruland is suited for quick positioning adjustments in light-duty stationary or low-rpm rotating shaft applications with frequent setup changes or adjustments, or in situations where the use of tools is not practical. The design of the cam on the lever and the mating machined surface on the collar assure a tight fit with a maximum axial load of 133 N to 489 N (35 lb to 120 lb), depending on the collar bore size. Available sizes are 8 mm to 38 mm and 0.375 in. to 1.5 in. The collar is suited for use in a wide range of applications, including packaging, food processing, general manufacturing, medical and more. RotoPrecision Inc. Online Reader Inquiry No. 728

POU inventory management device offers small size, small price Baldor’s new Quick-Ship (QS) large frame AC motor program delivers the large motor you need faster than ever before. The QS program offers a broad list of design options to build a custom motor that fits your application requirements. Available in TEFC, 200 Hp – 700 Hp, and 449 through 5000 frame sizes. Best of all, your QS motors will ship within two weeks from the day you place your order! Plus, any large frame AC motor we have in stock that fits your needs will typically go out the door the same day we receive your order.

• Unmatched Quality • Superior Reliability • Energy Efficient • Made in the USA

Big motors, custom or stock...fast. Only from Baldor. baldor.com

479-646-4711

• QS Program Orders Ship in Two Weeks

The attractively priced SupplyPod point-of-use inventory management solution from SupplyPro provides all of the control, reporting and order management of larger POU solutions in a compact footprint that can be placed virtually anywhere, on a desktop, cabinet, tool chest, workbench or wall. The design, full-feature set and ease of use facilitates the management and control of smaller-sized tooling needs right at the work cell. Standard configurations are designed for smaller parts, such as drill bits, inserts, taps, small tooling, fuses, switches, keys and more. It supports such standard features as take/return, check-in/check-out and serialization, lid level control by part number, industrial design and durability, full access to information via the device and integration with ERP systems. SupplyPro Online Reader Inquiry No. 797

Online Reader Inquiry No. 115

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MRO

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

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BRamPton, on Canada CRossville, tn • denveR, Co • Fulton, il • houston, tX • sPaRks, nv • lakeland, Fl RolleR Chain • ConveyoR & engineeRed Class Chain • PReCision attaChment Chain Online Reader Inquiry No. 116

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C O N T E N T S

Machinery & Equipment MRO

November 2011

in this issue

p35

Case study: Maintenance man must do it all / 13

columns

At this Nova Scotia egg processing plant, the one-man maintenance department must have many skills to manage equipment that puts through one million dozen eggs each month.

Great balls of fire! / 26

Editor’s Notebook / 6

Dust clouds can be ignited by the effects of mechanical friction from overheated bearings or motors, sparks from grinding machinery, static electricity, electrical arcing, welding sparks or naked flames. Here’s Part 2 of our guide to understanding, preventing and controlling dust explosions in your facility.

Industry Newswatch / 8

Plant zaps motor damage / 16

This dusty cement plant is using bearing protection rings to prolong the life of its bearings, motors and motor-driven systems by draining away harmful electric currents.

departments Business Briefs / 9 Mr. O, The Problem Solver / 11 The Safety File / 26 Maintenance 101 / 28 Maintenance Management / 29 Literature Reviews / 38 Product News

p22

How to achieve world-class maintenance / 28

Introducing Maintenance 101: The first set of activities in this eight-stage program will help you begin to create an efficient, professional, team-driven maintenance environment.

Focus on Mechanical Power Transmission / 33

MRO Components / 35

p37 editor’s selections

p33

Aluminum rolling mill optimizes reliability / 20

‘We get a lot of water on the bearings. Buying a better grade of them has more than doubled their lifespan.’ Mike Eagles / 13

‘We’d send the pulled motor out to be rebuilt, Then 3-6 months later, we’d have to do the same thing all over again.’

Sapa Heat Transfer was able to decrease its maintenance cost per ton of output by 16.8% after it began using a CMMS and listening to the advice of a trusted supplier.

Randy Riebel / 16

Compressor knocking? Here’s help / 22

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Focus on Safety / 32

Follow along with Step 41 in a journey to world-class maintenance at the Plentya Paper Company as the maintenance team begins to see changes for the better.

Five months after implementing a new CMMS system, the rate for the availability of maintenance parts increased from 60% to 95% at the Norampac Drummondville plant.

Developments in the basic clamp meter reflect the digital trends in test and measurement devices.

Focus on Dust Control / 31

Focus on Test & Measurement / 34

Packaging plant raises machine availability to 97% / 18

Cover feature: Innovations in test and measurement / 24

Focus on Seals & Gaskets / 30

Moving from reactive to proactive maintenance / 29

p31

It’s all about listening. Ultrasonic devices help, but all you really need is a screwdriver to find the source of problems in reciprocating compressors.

Product Spotlight / 2

‘We have just started a new project that I hope will launch our journey to world-class maintenance.’

p34 Cover: Photo courtesy of Fluke Electronics Canada

Wang Yeuming / 20

‘Having a world-class storeroom takes several months of steady dedication and resources.’ Peter Phillips / 28

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Online Reader Inquiry No. 117

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E D I T O R’ S

N O T E B O O K

Machinery & Equipment MRO

November 2011

Helping you achieve world-class standards

s Peter Phillips points out in his new Maintenance 101 column, which launches with this issue, hardly anyone goes around saying ‘we need world-class maintenance.’ What does this term mean anyway? The way we see it, it’s simply a series of steps that involve continually improving your maintenance activities and support systems. Almost everyone can point to aspects of their maintenance department that could use improving, whether it’s better organization, updated procedures or more accurate tracking of equipment histories. Improving any or all of these areas would result in better service to the production department and more reliable equipment. Over the next year or so, Phillips, who

is a widely experienced CMMS guru and training expert based in Windsor, NS (aka ‘the birthplace of hockey’), will present an eight-stage program to help you begin to create an efficient, professional, team-driven maintenance environment – one that will help you achieve worldclass maintenance. We’ve already been talking about how to achieve world-class maintenance regularly in this magazine since February 2005, when we launched another column, Maintenance Management, by Cliff Williams. Williams has many years of hands-on experience running maintenance departments, and currently is the corporate maintenance manager of Erco Worldwide in Toronto.

The Maintenance Management column has taken readers step-by-step on a detailed journey of maintenance improvement, through the story of a fictitious pulp and paper plant. This issue brings you the 41st instalment of this series, which will reach its conclusion after four more instalments. By following along and implementing the advice offered in each episode, readers have been able to take their own journey towards world-class maintenance. Like all of our content since the year 2000, these columns are archived on our website at mromagazine.com (unfortunately, our issues from 1985-1999 predate our transition to online publishing). To learn more about world-class maintenance, you can start by looking up the February 2005 issue to read Cliff Williams’ first column. You’ll also be able to keep up with the Maintenance 101 column from Peter Phillips the same way, as we’ll continue to post the complete contents of every issue online after the print

edition is mailed out across the country. In other news, our parent company, Business Information Group, a subsidiary of Vancouver-based Glacier Media, earlier this year acquired several industrial publications from Rogers Media. There has been a smooth transition as we’ve embraced the synergies available by sharing information and resources with these new magazines and websites, which include the Frasers.com directories, Canadian Plant newspaper and the web portal canadianmanufacturing.com. A total of 15 properties joined our existing stable of more than 30 publications, directories and websites, solidifying Business Information Group as the largest publisher of business and trade magazines in the country. Finally, our office has moved. We’re now located at 80 Valleybrook Dr., Toronto, ON M3B 2S9. Our phone, fax and e-mail addresses haven’t changed. Bill Roebuck, Editor & Associate Publisher

MACHINERY AND EQUIPMENT

MAINTENANCE, REPAIR AND OPERATIONS

NOVEMBER 2011 Volume 27, No. 5 Established 1985 www.mromagazine.com www.twitter.com/mromagazine EDITORIAL Bill Roebuck, Editor & Associate Publisher 416-510-6749 broebuck@mromagazine.com Ellie Robinson, Art Director Contributing Editors Richard G. Ensman Jr., Simon Fridlyand, Carroll McCormick, Peter Phillips, Angela Webb, Cliff Williams BUSINESS

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

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

Nick Naunheimer, Publisher 416-510-6868 nnaunheimer@mromagazine.com Eric Achilles Cousineau, Adv. Sales Manager 416-510-6803 eachilles@mromagazine.com Kimberly Collins, Advertising Production 416-510-6779 Melinda Marasigan, Subscription Enquiries 416-442-5600 x3548 Machinery & Equipment MRO is published six times a year to help improve the effectiveness, productivity and practical knowledge of maintenance professionals in Canada’s manufacturing, utilities and resource industries. Editorial & sales office: 80 Valleybrook Drive, Toronto, ON Canada M3B 2S9; tel: 416-442-5600, 1-800-268-7742; fax: 416-510-5134. Subscription rates. Canada: 1 year $57.95, 2 years $92.95. United States: 1 year $85.95. Elsewhere: 1 year $85.95. Single copies $10 (Canada), $16.50 (U.S.), $21.50 (other). Add applicable taxes to all rates. On occasion, our subscription list is made available to organizations whose products or services may be of interest to our readers. If you would prefer not to receive such information please contact us via one of the following methods – phone: 1-800-668-2374, e-mail: privacyofficer@businessinformationgroup.ca, fax: 416-442-2191, mail to Privacy Officer-Business Information Group, 80 Valleybrook Drive, Toronto, ON Canada M3B 2S9. ©2011. Contents of this publication are copyright and may not be reproduced in whole or in part in any form without written consent of the publisher. The publisher cannot assume responsibility for the validity of claims in items reported or advertised. Machinery & Equipment MRO is published by BIG Magazines LP, a div. of Glacier BIG Holdings Company Ltd. Bruce Creighton, President, BIG; Alex Papanou, Vice-President, BIG. Publications Mail Agreement No. 40069240. Return postage guaranteed. ISSN 0831-8603 (print). ISSN 1923-3698 (digital). Return undeliverable Canadian addresses and change of address notices to: MRO Circulation Dept., 80 Valleybrook Drive, Toronto, ON Canada M3B 2S9.

Making bearings since 1921.

MRO, USPS 012-846 is published six times per year by Business Information Group. US office of publication: 2424 Niagara Falls Blvd., Niagara Falls, NY 14304-0357. Periodicals Postage Paid at Niagara Falls, NY. US postmater: Send address changes to Machinery and Equipment MRO, PO Box 1118, Niagara Falls NY 14304.

Tel: 1.800.263.5163••••••Fax: 1.877.326.5696••••••Email: info@koyo.ca••••••www.koyo.ca

We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) for our publishing activities.

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KIN-EN-PUB

28/01/11 4:14 PM 11-10-25 2:00 PM

Kinecor and Peacock are now proud to be Wajax Industrial Components We are a nationwide distributor of industrial components providing technical solutions and services to all major industries across Canada. Over the years our company has forged itself through the contributions of numerous businesses, resulting in our present-day expertise. Kinecor, one of Wajax Corporation’s three divisions, will now share the Wajax name. The Wajax company has existed for over 150 years and is largely recognized within the industrial sector of the Canadian economy. Kinecor and Peacock will begin operating under the Wajax Industrial Components name on December 31st, 2011. Only the name of our facilities – head ofﬁce, distribution centres and branches – will change; their locations will remain the same.

1.866.546.3267

www.wajaxindustrial.com Online Reader Inquiry No. 119

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I N D U S T R Y

N E W S W A T C H

Machinery & Equipment MRO

November 2011

US BEARINGS MARKET IN RECOVERY PHASE; TO EXPAND 3% ANNUALLY THROUGH 2015 Dublin, Ireland – According to a new report, the bearings market in the US has faced a slowdown for almost half a decade and has encountered a loss of a massive $7.6 billion in revenues. However, the market now is projected to expand 3% annually through 2015. So says the US Bearings Market from Research and Markets. Here are some highlights from the research: Gains will be supported in part by sales of high-value, large diameter bearings used in wind energy and heavy equipment markets. Ball and roller bearings will outpace plain bearings, with roller bearings posting the strongest market gains. Major end-user industries such as automotive, consumer, agricultural, construction equipment, and steel and paper would continue to shape the fortunes of the bearings sector. Industrial machinery continues to dominate bearings demand on the strength of recovery in global capital expenditure, and growing output of industrial products that use bearings. Demand for mounted bear-

p08-12 MRO Nov11 News.indd 8

ings and bearing parts will also outperform overall bearing demand. Sales of bearing parts will be driven by increases in the number of bearing-containing products (aircraft, automobiles, industrial equipment, etc.) in use and by demand for the improved performance associated with more advanced parts. The biggest players in the industry are NTN Bearing Corp. of America, SKF Group, Koyo Bearings USA, The Timken Company, ASB Bearings, Schaeffler Technologies and Minebea. According to the report, these companies differentiate their products through certain mechanisms, such as intelligent products with sensors, customized products, and value-added systems with high service. Bearing companies have reduced their capital intensity by decreasing vertical integration, increasing outsourcing, and improving just-in-time manufacturing. Demand for bearings in wind turbines has been witnessing significant growth

Mitch Bouchard, General Bearing Service, Ottawa, shows off his newly acquired gavel.

Photo: ©istockphoto/Thinkstock

Ottawa, ON – Canadian workers were less likely to be laid off during the last economic recession than their counterparts during the two recessions in the early 1980s and 1990s, according to a new study by Statistics Canada. They were also more likely to find a job in the short term. The study covered the period from 1981 to 2010. On a monthly basis, 2.0% of employees were laid off temporarily or permanently between October 2008 and December 2010. This compares with 2.9% during the early 1980s and 2.7% in the early 1990s. Of all workers laid off between October 2008 and December 2010, 50% found a paid job between one and four months after they were laid off. This compares with roughly 42% during the two previous recessions. The chances of being temporarily or permanently laid off were relatively high among young people aged 15 to 24, those with no university degree, workers with fewer than two years of seniority and those employed in the goods sector. The workers most likely to have found a job in the short term had a university degree, more than five years of seniority, and initially expected to be recalled. The last recession was also of shorter duration in terms of employment. Total employment on a seasonally-adjusted basis took 27 months to return to its predownturn level. This compares with 53 months during the early 1990s and 40 months during the early 1980s. On average, employees who were laid off during the most recent downturn and who found a job in the short term saw their average weekly wages drop from $734 to $703. Among these employees, one-quarter saw their weekly wages decline by 23% or more, while another one-quarter saw increases in weekly pay of at least 18%. The study, Workers Laid-off During the Last Three Recessions: Who Were They, and How Did They Fare?, profiles workers laid off during the downturns that took place during the early 1980s, the early 1990s and from 2008 to 2010. It can be found at statcan.gc.ca.

Photo: Eric Achilles Cousineau

Latest recession had fewer layoffs than others

Study says bearing sales will increase in both OEM and MRO markets.

over recent years and the trend is projected to continue further in the years to follow. Increasing concerns over global warming have compelled many governments worldwide to seek alternative clean sources for generating energy, and towards this end, wind energy is fast gathering popularity. MRO bearing demand will be bolstered by continued increases in government spending and by a rebound in residential construction expenditures. The cost for a pdf of the report is 347 Euros. For more information, visit researchandmarkets.com.

OTTAWA’S MITCH BOUCHARD TAKES HELM AT PTDA’S INDUSTRY SUMMIT Washington, DC – The Power Transmission Distributors Association (PTDA) elected a Canadian as its 2012 president at its Industry Summit in Washington, DC, on Oct. 14, 2011. Mitch Bouchard, secretary-treasurer, General Bearing Service Inc., Ottawa, ON, was elected PTDA’s president for 2012, effective immediately. He succeeds David Mayer, vice-president, marketing, Kaman Industrial Technologies Corp., Windsor, CT. Bouchard has been active in PTDA since 2005, when he joined the Technical Education Committee. He served on the Industry Summit Planning Committee and the Employee Development Committee before joining the PTDA Board of Directors in 2009. “I’m excited to assume the role of president of the leading trade association in the power transmission/motion control industry,” said Bouchard. “The debut of a new strategic plan makes this an especially exciting time for PTDA.”

George Rizza, president, Rossi Gearmotor Division, Habasit America, Suwanee, GA, assumes the duties of the PTDA Manufacturer Council chair in 2012, succeeding Pamela Kan, president, Bishop-Wisecarver Corp., Pittsburg, CA. Rizza joined the Marketing Committee in 2006 and was elected to the Manufacturer Council in 2007. “I’m deeply honoured to be part of the PTDA leadership, especially as the association rolls out its new ‘focused and forward’ strategic plan,” said Rizza. “I am happy to act as a voice for manufacturers of all sizes in the coming year.” For more information, visit ptda.org.

WBA RELEASES COUNTERFEIT BEARING AWARENESS VIDEO Washington, DC – The World Bearing Association (WBA) has released a video to further educate the bearing supply chain and consumers about the problems and safety concerns associated with counterfeit bearing products. According to the WBA, using counterfeit bearings can put a business, as well as human lives, at risk. Buying counterfeits means you’re not getting what you paid for. Unfortunately, it is practically impossible for you to tell the difference between genuine and fake. So, what can you do about it? WBA advises that you protect yourself, your business and the public from the dangers of counterfeits. The best way to do this is by turning to trusted sources for all your bearing purchases, it says. The new WBA video is one part of a comprehensive awareness campaign that also includes the website stopfakebearings.com, along with a brochure in five different languages. The brochure can be downloaded from the website. The Stop Fake Bearing information campaign was developed by the World Bearing Association. At stopfakebearings.com, interested consumers can learn more about counterfeiting and what branded-bearing manufacturers are doing to stop it. WBA is a non-profit and unincorpo-

The World Bearing Association website features various resources to fight counterfeit bearings.

rated industrial association. It was founded in 2006 by three regional bearing associations: the American Bearing Manufacturers’ Association (ABMA), the Federation of European Bearing Manufacturers’ Association (FEBMA), and the Japan Bearing Industrial Association (JBIA). WBA promotes the common interests of the world bearing industry, such as open economic engagement, sustainable development and the protection of the legal rights of companies. WBA has created an Anti-Counterfeiting Committee. This committee within the WBA is dedicated to addressing the counterfeiting of premium brand bearings and to assisting competent authorities in eradicating it. The WBA, and each bearing company, take action and arrange informational campaigns, such as this, to raise awareness about counterfeiting.

SCANNER HELPS REVERSEENGINEER KEY IMPELLOR AT HYDROELECTRIC PLANT Coppell, TX – Engineers from NVision, Inc., using the company’s HandHeld Scanner, were able to quickly reverseengineer a large impellor for a major hydroelectric facility, sparing the facility what would have been an extended shutdown had they needed to produce a replacement impellor from scratch. In less than one week, NVision scanned the original impellor and provided a computer model of it to the facility, which then used the model to manufacture a duplicate impellor for installation. Only a relatively short shutdown was necessary to accommodate the scanning and reproduction of the impellor. The turbines that move the water in hydroelectric plants employ massive impellors. In this case, one of the facility’s key impellors had suffered damage that forced the facility to replace it. However, the facility did not possess a computer model of the impellor, which was necessary in order to manufacture a replacement. Without a replacement

A A

Scanner took less than a week to create a computer model of plant’s impellor.

available, the plant was facing an extended shutdown with potentially high losses in time and money. The facility’s management contacted NVision to produce a computer model of the impellor. Two days after the initial contact, with a refurbished impellor temporarily in use as a replacement, an NVision engineer was on site to scan the impellor using the HandHeld laser scanner. The HandHeld scanner is attached to a mechanical arm that moves about the object being scanned, freeing the user to capture data rapidly and with a high degree of resolution. For more information, visit the website at nvision3d.com. MRO

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life

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I N D U S T R Y

N E W S W A T C H

November 2011

Machinery & Equipment MRO Photo: Bill Roebuck

Business Briefs

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

Photo: Bill Roebuck

• The Canadian subsidiary of German manufacturer Getriebebau NORD, NORD Drivesystems (Canada), Brampton, ON, celebrated its 25th anniversary with an open house on Sept. 21, 2011. The plant assembles high-efficiency mechanical power transmission products for customers across Canada. Nord Gear moved into its current location in Brampton in 1997 and in 2008,

Guest Scott Bebenek, president of IDI Independent Distributors Inc., chats with NORD Drivesystems (Canada) president Denis Dryburgh at an open house held to mark NORD’S 25th anniversary in Canada.

built an extension that almost doubled its shop floor space. The plant is one of more than 60 international assembly plants in 35 countries that take the company’s Germanmade components and put them together according to the specific needs of local customers. Nord Gear’s products are distributed by most major distributors across Canada. • Wajax Corporation, Mississauga, ON, a $1.1-billion distributor and service provider for equipment, industrial components and power systems, has unveiled new brands for its three key divisions. President and CEO Neil Manning recently unveiled logos for the newly named Wajax Power Systems, Wajax Industrial Components, and Wajax Equipment. “By bringing all three divisions under one common brand name, customers, suppliers and vendors will be able to appreciate the corporation’s size, strength, and integrated approach to business.” Wajax serves the following sectors across Canada: industrial/commercial, mining, oil sands, construction, oil and gas, transportation, forestry, government and utilities, and metal processing. The rebranding initiative will be completed before the end of 2011. The newly rebranded divisions include: Wajax Industrial Components – formerly known as Kinecor and its Peacock division, this division’s 58 branches distribute, service and repair industrial components, including bearings, power

Wajax executives announce the rebranding of three divisions, including the renaming of industrial distributor Kinecor as Wajax Industrial Components.

transmission parts, hydraulics, process equipment and automation technologies; Wajax Power Systems – this division combines Waterous Power Systems, DDACE Power Systems, and the recently acquired Harper Power Products. Its 28 branches distribute engines, transmissions and related products; Wajax Equipment – Wajax Industries receives this updated brand name throughout its 31 branches, which reflects the division’s role as the country’s largest multi-line distributor of heavy equipment for construction, mining and utilities industries. • The Timken Company, Canton, OH, has completed its US$92 million acquisition of Drives LLC, Fulton, IL, a manufacturer of highly engineered drive chains, roller chains and conveyor augers for the mobile and industrial machinery sectors.

“We are pleased to welcome Drives to Timken. It is another exciting step in our diversification into power transmission and mechanical motion, and broadens our overall technology offering to customers,” said Christopher Coughlin, president of Timken’s Process Industries segment. Drives has 430 employees in North America. Its products are sold for a wide range of mobile and industrial machinery applications, including agriculture, oil and gas, aggregate and mining, primary metals, forest products and other heavy industries. Also covered are the food and beverage and packaged goods sectors, which require highend, specialty products such as stainless steel and corrosion-resistant roller chains. “We are delighted to join forces with Timken, and look forward to pursuing new opportunities with them,” said James F. Lamb, current president of Drives, who joins Timken and will lead the new Timken Drives LLC business. • Camfil Farr Air Pollution Control (APC) has produced a video that describes how the company’s dust collection products and capabilities can help factocontinued on page 10

Video shows dust-testing facility.

ADVANCED PERFORMANCE. ADVANCED RELIABILITY. ADVANCED INNOVATION.

ate

ROLLING BEARING AND LINEAR MOTION PRODUCTS NSK supports its customers with a full range of rolling bearing and linear motion products engineered to perform better – and last longer. Our unrivalled technical knowledge allows us to understand their operational challenges and provide industry-speciﬁc solutions that improve bearing life and increase operating performance. For maximum productivity through advanced innovation, reliability and performance, Think NSK.

1.877.994.6675 BALL BEARINGS

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ries be safer, more productive and more energy-efficient. The video can be viewed at youtube.com/CamfilFarrAPC. The 9-1/2 minute video includes an overview of Camfil Farr APC capabilities – including engineering services, application and technical support, and in-house dust testing at the company’s full-service dust test laboratory. It also describes Gold Series dust collectors and HemiPleat filters. Applications and markets served world-

wide are detailed in the video as well. Camfil Farr APC is a global manufacturer of dust and fume collection equipment and is part of Camfil Farr, the largest air filter manufacturer in the world. For more information, visit farrapc.com. • Tsubaki of Canada Ltd., Mississauga, ON, hosted an open house on Sept. 22, 2011, to showcase its distribution and production facility. At the event were 89 attendees from 24 different companies who had travelled from as far Photos: Eric Achilles Cousineau

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November 2011

Right: Tsubaki of Canada marketing manager John Davis talks about the company’s products. Below: Tsubaki showcased its sprocket production capabilities at its recent open house.

away as Dartmouth, NS, and Prince George, BC. Tsubaki of Canada, a division of Japan’s Tsubakimoto Chain Co., has been operating in Canada for the past 39 years. The company is mostly known for its success in precision roller chain, however sprockets are the core of its production at the Mississauga facility.

During the open house, Tsubaki showcased its design engineering capabilities and knowledge of machining special materials, hardness levels, surface finishes and tolerance control. • Scientific Dust Collectors (SDC), Alsip, IL, has produced several new indepth technical papers describing the improved cleaning benefits available for reverse pulsejet baghouses used in dust collection applications. The technical paper abstracts are available at scientificdustcollectors.com. • Acklands-Grainger Inc., Toronto, a distributor of industrial, safety and fastener supplies, has acquired the assets of Baie-Comeau, QC, industrial distributor Fercomat Inc., effective September 19, 2011. Acklands-Grainger expects an incremental sales contribution of approximately $3 million from this acquisition over the next 12 months. “Fercomat has a strong track record of service and by working together, we will leverage our combined expertise to offer local customers – such as mining, hydroelectricity and aluminum industries – access to the broad array of products and services they need to help keep their facilities running and their employees safe,” said Sean O’Brien, president, Acklands-Grainger. “Fercomat has worked hard since 1957 to provide businesses and institutions in Quebec with quality products and strong technical expertise,” said Pierre Dassylva, president, Fercomat. “We ... know our customers will benefit from AcklandsGrainger’s broad product offering ... supply chain and commitment to service.” Acklands-Grainger has served Quebec for more than 74 years through 14

branch locations, an award-winning French website and a French catalogue with more than 120,000 products. The acquisition of Fercomat is the company’s third in Quebec in the past three years. For more information, visit acklandsgrainger.com. • Emerson Bearing, Boston, MA, providers of bearings and related products to OEM (original equipment manufacturer) and MRO (maintenance, repair and operations) markets internationally, Emerson’s has created a dedicatRick Piracini. ed Wind Power Generation division to accommodate the unique bearing requirements of the wind turbine market. Wind turbines often stand 250 ft in the air and are mechanical and technical marvels that rely on bearings, which are the key components of the gearbox, generator and blade. Emerson Bearing provides the necessary roller bearings, deep-groove ball bearings and four-point contact bearings for gearboxes. The generator in the nacelle of a wind turbine is subjected to significantly greater vibration loads than land-based equipment, so bearing size, design and lubrication all play a critical role. The bearing arrangement of a generator generally contains a combination of deep-groove ball bearings or cylindrical roller bearings. Due to the risk of serious damage, such as melt craters and false brinelling, Emerson Bearing advises using current-insulated bearings in many applications.

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November 2011

It is critical that the turbines be aligned optimally to the wind. This is controlled by blade bearings (pitch bearings), yaw bearing and blade adjustment, which requires sealed spherical bushings that have corrosion protection. Rick Piracini, a marketing specialist and industry expert at Emerson Bearing, oversees the company’s Wind Power Generation division. For more information, visit emersonbearing.com. • For the 12th successive year, the SKF Group, Gothenburg, Sweden, has been selected to be a member in both the Dow Jones Sustainability World Index (DJSI) and the pan-European sustainability benchmark for the Industrial Engineering sector. The DJSI represents leading global companies from 57 sectors in the area of sustainability. “Sustainability is a long-term commitment for SKF and I am very proud that we have been recognized for our efforts, particularly in the areas of promoting sustainable products,” says Tom Johnstone, president and chief executive officer. “SKF is committed to sustainability not only as a responsibility, but also as a way of developing our business. We see this as one of our competitive advantages in working with our business partners and in attracting, retaining and developing our employees.” SKF defines sustainability as SKF Care, which encompasses Business Care, Environmental Care, Employee Care and Community Care. SKF has a strategy called Beyond Zero, which focuses on both reducing the environmental impact of its own operations and on helping its customers reduce the envi-

Machinery & Equipment MRO

ronmental impact in their operations and in the use of their products. The SKF Group also has opened its second bearing factory in Dalian, northeast China. The factory produces medium-size bearings that complement the range of large bearings produced in an existing factory, which opened in 2006. The industrial bearings from the factories will mainly serve customers within the electric motor, industrial electrical, industrial transmissions, metalworking, mining, mineral processing and cement, off-highway, pulp and paper and renewable energy industries. “By expanding the production of medium-size SKF industrial bearings in China, we will further strengthen our position in the industrial bearing market,” says Erik Nelander, president, SKF China. “This factory will enable us to significantly reduce lead times and create closer interaction with our key customers.” SKF China is headquartered in Shanghai and employs close to 5,000. • Bishop-Wisecarver Corp., Pittsburg, CA, which manufactures DualVee guide wheels and guided motion technology, has hired Ali Jabbari as its vice-president of engineering. Jabbari will have the primary responsibility of overseeing the engineering department for BishopWisecarver and provide a focus on new product Bishopdesigns. Wisecarver’s “ I joi ne d Bi shop Ali Jabbari. Wisecarver because of

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its strong history in linear motion, its record of innovation, and its commitment to not only keep up with market trends, but its forward-thinking philosophy that encourages out-of-the-box ideas,” said Jabbari. “I am very impressed by the depth and breadth of engineering knowledge that Ali brings to our team,” said Pamela Kan, president of Bishop-Wisecarver. “He has a great practical sense to engineering that is very reminiscent of how my father looks at engineering, yet, at the same time, he is extremely innovative. It’s a very exciting time for Bishop-Wisecarver right now, and I look forward to the next chapter of product development.” • PTM Industries, North York, ON, is now the Canadian sales representative for Rossi Gearmotors, Suwannee, GA. Rossi offers a complete line of gearmotors, gear reducers and motion control products to distributors and original equipment manufacturers across North America. Established in 1984, PTM is a supplier and sales agency of industrial power transmission components. It serves an extensive distributor and OEM customer base from two regional distribution centres, in Toronto and Calgary, and has sales offices in Toronto, Edmonton, Calgary and Montreal. Rossi Gearmotors manufactures gear reducers, gearmotors, electric motors and brake motors. For more information, visit ptmindustries.com. MRO More detailed versions of these stories, along with many additional news items, can be found online at mromagazine.com.

Mr.0 The Practical Problem Solver

Dirty drives? Problem: My plant’s dirty environment is causing problems with our belt drive systems. What can I do? Solution: Drives that require multiple V-belts provide an opportunity for using either matched single belts or joined construction belts. In applications where debris can enter the belt drive environment, however, single belts may be a better choice. Debris will have a greater chance of escaping before inflicting damage and reducing drive life. Dirty environments often mean the use of water-based cleaning and washdown solvents, which can cause rust problems with standard belt sprocket and bushing materials. With polyurethane belt drives using stainless steel sprockets and bushings, you won’t need to cover and protect the drive components prior to washdown. Mr. O’s tip of the hard hat for these tips goes to Gates Corp. engineers. Do you have a solution for a maintenance problem? Send it in and if it’s published, we’ll send you a Mr. O Problem Solver T-shirt. Include your address, telephone number, print complete details and, if possible, add a sketch to help explain your tip. Send your tips to Mr. O, Machinery & Equipment MRO, 80 Valleybrook Drive, Toronto, ON M3B 2S9.

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DECENTRALIZED DRIVE SYSTEMS DECENTRALIZED DRIVE SYSTEMS

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In many industries and applications, implementing economical automation concepts means utilizing decentralized systems throughout. Long rows of control cabinets with complex wiring, expansive space requirements and long distances between control cabinet and motors are too rigid and not very economical. Only the combination of flexible, versatile, economic and target-oriented modules will provide an efficient solution. This is the reason why system operators opting for decentralized drive systems from SEW-Eurodrive are always ahead of the game.

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PSC Planetary servo gear units The low backlash PSC planetary servo gear units are designed for torque classes from 30 to 305 Nm. They are designed to offer the greatest possible flexibility and ROI, as not every application demands machines designed for maximum performance. These planetary servo gear units are the basis for versatile, dynamic, and above all cost optimized drive solutions.

MOVITRAC® LTX Simple, fast and diverse: as part of the Smart Servo Package, SEW-Eurodrive offers the new Movitrac® LTX servo inverter for universal use. It stands out with advantages such as ease of operation, short startup times as well as optimized costs. Available in two sizes and covers a power range from 750W to 5.5 kW. The Movitrac® LTX is particularly suitable for use in applications such as secondary packaging, handling, and logistics.

DECENTRALIZED CONTROL: MODULAR, FLEXIBLE & ECONOMICAL

The demands on material handling systems today have never been more wide ranging or more challenging. That’s why SEW-Eurodrive offers drive solutions for every kind of industry application. From the simple to the sophisticated, our pyramid of solutions allow you to control costs and limit complexity by giving you the ability to tailor our products to the exact intelligence and performance specs you require. Reducing energy consumption is also an important imperative today for the modern production line. Just ask Coca-Cola, who achieved a sensational 75% reduction in energy consumption by incorporating 40 of SEW-Eurodrives’s revolutionary decentralized MOVIGEAR® units in a recent overhaul of a European Driving the world bottling plant transport line.

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November 2011

Machinery & Equipment MRO

AT THIS NOVA SCOTIA EGG PROCESSING PLANT, THE ONE-MAN MAINTENANCE DEPARTMENT MUST HAVE MANY SKILLS TO MANAGE EQUIPMENT THAT PUTS THROUGH ONE MILLION DOZEN EGGS EACH MONTH. BY CARROLL MCCORMICK

The loader is complex, but generally reliable. Eagles occasionally shuts it down briefly to replace a faulty suction cup – a task which takes all of maybe 25 seconds. Still, this summer, some bearing play was making the loader act up. Eagles temporarily fixed the problem by dialing down the processing speed to 100,000 eggs an hour until new bearings arrived and he could schedule the downtime for the repair. Strong detergents in the egg washer have severely corroded the steel in its recirculation pumps, but Eagles, in his nicely kitted-out repair shop, has been drilling oversized holes, tapping them and installing beefier bolts before recontinued on page 14

Photographs for MRO Magazine by Carroll McCormick

t seven o’clock in the morning, operators at Maritime Pride Eggs in Amherst, NS, turned on the plant’s egg-grading line. Three minutes later, the mechanical loader that picks up 60 eggs at a time and sets them into the sorter started dropping eggs. The operators quickly shut down the equipment. Mike Eagles, the plant’s maintenance supervisor and one-man maintenance team, began searching for the cause. It took a little time, but he tracked the problem to a worn keyway, misaligning holes and a resulting drop in the air pressure used to create a vacuum in the soft suction cups that pick up the eggs.

It seems a little unusual that a 35,000 sq ft (3,252 sq m) plant that grades between 550,000 and 600,000 eggs a day would require only a single maintenance person, but the grading station and equipment are barely five years old. Breakdowns are fairly infrequent and Eagles can deal with most problems inhouse. “I can take care of any mechanical equipment and I do MIG, TIG and stick welding,” Eagles explains. He came over to Maritime Pride Eggs in 2006 after a 10-year stint in the maintenance department at Venture Lighting in Amherst. The more straightforward equipment used in the grading process includes a tray washer, a lift for getting eggs onto the front-end of the line, a loader, an egg washer, some conveyors and a box maker. An operator greases the tray washer bearings every couple of days and can replace any broken rods that hold the trays in place. Eagles does monthly preventive maintenance on the box maker, conveyors and tray wash. “We also blow down the equipment, oil moving parts, grease [the equipment], and check bearing plates.”

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Top right: Maintenance supervisor Michael Eagles (left) and plant manager Dwayne Ogilvie. Ogilvie is learning more about maintenance so Eagles, who is a maintenance team of one, can take more uninterrupted days off. Top left: Maritime Pride Eggs processes a million dozen eggs a month running at 60% capacity. Above left: Proper air feed is critical to the operation of the loader, which lifts 60 eggs every two seconds. Above right: The Moba sorter weighs and sends medium, large, extra large and jumbo eggs to separate packing lines.

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continued from page 13 painting the pumps. Eagles tells a story, which comes with a little lesson, about the egg washer: “The guy that was here before bought cheap bearings. He thought they would do, as the back and forth motion on the bearings is not that much. When I changed the bearings I asked the supplier if he had a better grade of bearings. I told him to give me his dearest bearings. They cost five dollars more. We were only getting three months out of the other bearings because we get a lot of water on them. We have gotten six months and counting out of these new bearings.” The heart of the production line is an Omni 330 sorter manufactured by Holland-based Moba. This enormously complex device is several machines in one: egg inspector, crack detector, ultraviolet disinfector, weighing system and finally, sorter by size for packing into cartons. Because it is as much a computer as it

Photograph for MRO Magazine by Carroll McCormick

Machinery & Equipment MRO

is a mechanical system, the sorter is serviced mostly by Moba’s on-line technicians. “Moba can log on and take over the computer. The technicians can tell us what to look for. I take the portable phone and start looking around,” Eagles explains. In 2007 Eagles flew to Holland for an entry-level service course on the sorter. Moba technicians who have visited the plant give Eagles high marks for his maintenance work on the mechanical side of the sorter. Still, notes Dwayne Ogilvie, plant manager, “We need more skill on the technical side of the grader. It is complicated.” Eagles agrees, “I want to learn more about the sorter. I might be able to go back next spring for an advanced course.” In the meantime, he continues to learn about the sorter as problems arise. “On the electronic side, if I have any problem, the [Moba] technicians help me. Sometimes they don’t have to take over the computer. They just have to walk me through the Strong detergents have corroded the bolt holes in this egg washer recirculation pump housing.

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problem one step at a time. Until I get more training on the sorter and get deeper into it, that’s all I can do for now.” Eagles rounds out his maintenance duties with other plant tasks; e.g., unloading trucks and moving them around the yard, working on the production line and driving the pallet jack. It is not so much a matter of not having enough maintenance tasks to do, but more a matter of the plant, which has 32 employees, including seven company truck drivers, tapping Eagles to cover for any absent employee. Eagles and Ogilvie, realizing that more maintenance is in their future as their equipment ages, have been plotting a strategy. For example, Ogilvie says, “When I first came here, in January 2008, we had no parts. I pushed to get a stock of spares and we have brought in a lot of parts over the past two years. As the sorter ages, we know parts will start to break. Our previous maintenance manager consulted with Moba on what parts we should store. We now have between $50,000 and $60,000 worth of spares — mostly electronic spares like circuit boards.” The grading station operates Monday to Friday , 7 a.m. to 3:30 p.m., with no annual shutdown. This means challenges in scheduling longer maintenance tasks, such as a bearing swap in the loader that required stopping production for a day. Ogilvie has a plan that will let Eagles schedule longer jobs without interrupting production: “Every now and again, we have to shut down for a day to line up a project, so in October we are going to try an experiment: we are going to go to four 10-hour days for production.” That will provide a day for maintenance. Maritime Pride Eggs currently serves an area reaching roughly from St. Stephen north to Fredericton, east to Newcastle and south to Amherst, as well as the Truro and Halifax markets. It picks up eggs from 10 farms for grading and delivers them to major chains – to the tune of one million dozen eggs a month. Still, the grading station is operating at just 60% capacity. This will rise with time, and when it does, Eagles will undoubtedly find himself busier than ever. MRO

CMY

Carroll McCormick, senior contributing editor, is based in Montreal. He is the recipient of several awards for his articles in Machinery & Equipment MRO.

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Figure 1: Monarch Cement Company’s plant produces 1.3 million tons of cement per year. Figure 2: The ball mill is where the first two grounding rings were installed at the Monarch plant. The bearings of the mill’s 5,000hp motor failed regularly until damaging voltages were diverted by a bearing protection ring (inset) at each end of the motor. Figure 3: An AEGIS iPRO Bearing Protection Ring is installed in an internal bearing retainer at the IEMCO shop as part of a motor overhaul for Monarch’s machinery.

ing protection ring on its ball mill, Monarch installed a ring on this baghouse fan motor (painted blue) that had also required frequent bearing replacements. Fig. 1 Photos: Cougar Tool Inc.

THE RING’S THE THING

Figure 4: Following the success of the bear-

Fig. 2

This dusty cement plant is using bearing protection rings to prolong the life of its bearings, motors and motor-driven systems by draining away harmful electric currents.

seemed as though nothing could stop the squealing. Not that the Monarch Cement Company’s huge ball mill wasn’t already loud. Powered by a 5,000-hp motor, it pulverizes 100 tons of clinker (a burned mixture of limestone and shale) per hour. But the squealing was not what Randy Riebel wanted to hear. As electrical supervisor at Monarch’s plant in Humboldt, KS, he knew the noise meant the motor’s bearings were going – again. In fact, the sound of chronic bearing damage was all too familiar at the plant, which has the capacity to produce 1.3 million tons of cement a year. Since 2001, when the ball mill was new, its motor bearings had been replaced three times. “We kept greasing those bearings, but they kept on squealing,” Riebel recalled about the summer of 2009. “We knew that if we waited too long, the bearing race walls would become fluted like they had in the past, and we weren’t looking forward to another replacement because of all the expense and downtime. “It takes at least 10 days to pull that motor – it’s a major production. Sometimes we have to hire help, rent a hoist to put it on a truck, and take it away to be rebuilt. So this time, I decided to try something else.” The ‘something else’ was the Aegis iPRO Bearing Protection Ring, manufactured by Maine-based Electro Static Technology (EST). By safely channelling harmful electrical currents away from bearings to ground, the bearing protection ring extends the life of medium-voltage motors and generators, thus improving the reliability of entire systems in

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which they are used. It is available in a range of sizes to accommodate generator/ motor shafts up to 30 in. in diameter. Maintenance-free, the ring is ideal for medium-voltage motors that drive pumps, compressors, mixers, shredders, conveyors, and other machinery used in mining, food processing, wastewater treatment, petrochemical refining, and many other high-current applications. The ring also can protect the bearings of generators in both utility and on-site power generation systems. Riebel had been discussing electrical bearing damage with Scott Wilkins, manager of motor shop operations for Independent Electric Machinery Company (IEMCO), a local motor and equipment repair shop. Wilkins recommended the iPRO, and Riebel had IEMCO install two of them on the ball mill motor. While for most large motors EST recommends installing a ring in the drive end and insulation on the non-drive end, for some large motors – especially those that do not have insulation designed into them or where insulation cannot be easily installed – EST recommends installing rings at both the drive end and the non-drive end of the motor. Riebel and Wilkins chose an iPRO split-ring model, which is designed to facilitate field retrofits. The mating halves of each ring were installed around the motor shaft without the need to decouple the motor from the mill.

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Mitigating electrical bearing damage If not diverted, shaft voltages can discharge through bearings, pitting the balls and race walls. Without long-term

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bearing protection, concentrated pitting at regular intervals along a race wall can cause washboard-like ridges called fluting, a source of noise and vibration. The eventual result is motor failure. Ironically, some products designed to protect bearings, such as conventional spring-loaded grounding brushes, require extensive maintenance themselves. Others, such as insulation and ceramic bearings, can shift damage to connected equipment. To boost the electron-transfer rate, the iPRO’s entire inner circumference is lined with multiple rows of conductive microfibres. Locked securely in the ring’s patented Aegis FiberLock channel, these microfibres completely surround the motor shaft, providing millions of discharge points for harmful shaft currents and creating the path of least resistance that effectively diverts these currents away from the bearings to ground. The microfibres themselves are specially engineered for exceptional flexibility to prevent breakage and ensure that the ring will last for the life of the motor.

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one of its VFD-controlled fan motors is overhauled. Another such installation was on the 2,250-hp motor for an ID (induced-draft) fan that pulls kiln-heated air through a roller mill, to dry the limestone and shale during the raw grinding process. Other motors that now have the rings include four at the plant’s kilns, where air is forced in and out: two 2,000-hp ID fan motors and two 1,000-hp baghouse (dust-collecting) fan motors. Also, because a cement plant is a very dusty place and many motors are outdoors, Monarch has begun to specify that some of its new motors must come equipped with the Aegis Severe-Duty SGR Bearing Isolator Shaft Grounding Ring, another ETS product. As in the iPRO, the secured conductive microfibres of the Severe-Duty SGR completely surround the motor shaft for efficient grounding, but this model has a built-in IP56 non-contact isolation seal to pro-

vide extra protection from dust, water and other contaminants. Monarch’s maintenance manager, Mark Pily, authorized the purchase of the plant’s first motor with a factory-installed Severe-Duty SGR, after consulting IEMCO’s Wilkins. As of this writing, a 200-hp air-compressor motor is the only such motor in operation at the plant. “We want to keep the bearings clean because we push that motor really hard,” Riebel explains. “We usually lose that motor because of winding failure. I think most of that is caused by the bearings starting to fail, which causes the motor to overload.” An ounce of prevention Using a voltage probe and oscilloscope, Riebel periodically takes shaft voltage readings on all the plant’s motors with grounding rings. He is pleased with the results because the readings are low, indicating that the rings have reduced po-

tentially damaging shaft voltages. Riebel also gives a high grade to the service the plant has received from IEMCO: “In my opinion they are by far the best shop we’ve worked with, and we’ve worked with most every shop in the area. Scott [Wilkins] is really involved. He’s really a get-it-right-the-first-time kind of person.” Time will tell exactly how much money the rings will save Monarch overall, but Riebel is convinced the Aegis iPRO provides effective, long-term bearing protection that reduces the costs of downtime and motor maintenance. “So far, so good,” he says. “On the 5,000-hp, since the last set of bearings only lasted a year, chances are we would have noticed problems by now, but we haven’t had any – no squealing.” MRO For more information, visit the website at www.est-aegis.com. Online Reader Inquiry No. 832

A nagging, widespread problem When Monarch was founded in 1908, chunks of blasted limestone (also known as shot rock) up to 4 ft across were loaded by hand into mule-drawn carts. Now this limestone is moved by huge front-end loaders, 50-ton dump trucks and conveyors, to be processed by a series of computer-controlled crushers, kilns and mills until it is as fine as face powder. Most of the processing machinery is powered by electric motors, and the problem of chronic bearing damage is by no means limited to the plant’s ball mills. Many of the motors are controlled by variable frequency drives (VFDs), which induce additional high-frequency currents on motor shafts. A fan or pump motor tends to use less power if the input is modulated by a VFD, but the benefits of improved efficiency are lost if the motor keeps breaking down. Such breakdowns were recurring headaches for Riebel, but because the two Aegis iPRO rings installed in 2009 appear to be protecting the bearings of the ball-mill motor, he has since had IEMCO install the rings on nine more motors that had to be removed from service for repair. A case in point is a VFD-controlled cooler-vent fan where a 300-hp motor had to be replaced frequently for almost eight years. Every time, the kiln had to be shut down for at least a day. The old motor had to be removed, and the rebuilt spare motor had to be aligned and coupled. “We’d send the pulled motor out to be rebuilt, but then three to six months later, we’d have to do the same thing all over again,” says Riebel. “For the cooler vent fan motor, we tried insulation on both bearings. With the insulation, the motor lasted two years between breakdowns. The shunted electricity might have hurt the bearings in the fan itself. Insulation just pushes the problem on down the line. The electricity has got to go somewhere if it’s not grounded. The iPRO has given this fan a fresh start. “We didn’t really realize what the problem was,” Riebel reflects. “There wasn’t much information available about electrical bearing damage. We just knew that bearings would fail and the motor would overheat, but we were not looking to see why. Again and again, we just sent the motor out, got it rebuilt, and put it back in service. We didn’t know the root cause.” Green technology It is now Monarch policy to have IEMCO add the iPRO ring in the shop whenever

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Plant Cuts Extensive Parts Inventory Five months after implementing a new CMMS system, the rate for the availability of maintenance items increased from 60% to 95% at Norampac Drummondville’s packaging plant. BY ROBERT LAMARRE

pare parts inventory management has always been a necessary evil for Norampac Drummondville, a Cascades-owned Quebec plant that specializes in the design and production of corrugated packaging. The plant has a production capacity of 1 billion sq. ft. per year. It manufactures corrugated boxes for medium- and large-volume customers, in addition to providing storage services, special coatings for different types of packaging materials, and high-resolution printing. The plant manually managed its minmax for nearly 15,000 stock items. There were many shortages in spite of several million dollars invested in inventory. Norampac had no tools to help properly manage its inventory. Then, in October 2010, Norampac Drummondville began using the inventory management parameters optimization software offered in Web mode by the company IMAFS Inc., St-Lambert, QC, an inventory management solution provider. It is the outcome of a partnership between COGEP Inc., Quebec City, QC, and IMAFS to allow COGEP’s customers to improve the management of their inventory. Norampac Drummondville agreed to participate as a pilot site for this partnership. Maintaining production equipment in operational condition is a major factor for the efficiency and competitiveness of the plant. In this context, the local organization chose to implement the Guide TI computerized maintenance management system/enterprise asset management (CMMS/EAM) software from COGEP. The software is widely used in the province of Quebec and

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in other locations around the world. IMAFS SaaS solution is fully integrated with Guide TI. IMAFS SaaS performs the optimization of inventory management parameters by calculating the optimal minmax to meet customer service objectives with the least possible inventory. IMAFS SaaS offers Norampac executives inventory management dashboards as well as the functionality to handle exceptions. According to Jean-Francois Cartier, director of operations at Norampac Drummondville, “Guide TI provides more versatility and more flexibility than all major CMMS. We are very satisfied with the results.” Between October 2010 and February 2011, the rate for the availability of maintenance items increased from 60% to 95%. This improvement has had a major impact on keeping the production equipment operational, in addition to having an impact on maintenance activities. There is less time wasted and there are fewer maintenance tasks that must be postponed or performed in two steps due to part shortages. These exceptional results have been achieved with an increase in inventory of about 5% within the implementation phase. Moreover, the simulation results that were completed in IMAFS SaaS-Guide TI indicated that Norampac could reduce its inventory by more than 30% over the next few months while maintaining good levels of service and the availability of parts. Project schedule The first phase of this project consisted of ensuring that good data was being used for the inventory optimization. Teams

from Norampac, COGEP and IMAFS worked collectively to validate the data and make any necessary adjustments. IMAFS and COGEP are experienced for this type of exercise and have simplified the work for the people from Norampac. In the next phase, the functionalities of IMAFS SaaS allowed for completing a classification of Norampac’s items that reflects criticality, frequency of consumption, consumption value, life cycle status (birth, maturity, obsolescence) and item status. Karl Ouellette, supervisor of maintenance for Norampac, said he had never seen such powerful and flexible software for efficiently categorizing the maintenance items. An internal effort was completed to validate classes of parts. This effort brought great value since item classification is the foundation for a common language between the supply and maintenance departments. IMAFS SaaS measured the parts availability level per item class at the start the project. Executives from Norampac Drummondville then established service targets by classes and product families. Thanks to Guide TI and IMAFS SaaS, the executives valued having not only a method to manage customer service, but having the min-max that will allow achieving the target levels. Simulation tools offered in IMAFS gave the ability to estimate the impact on inventory and service before launching the program. IMAFS SaaS scientifically and dynamically calculated min-max that was used to supply the replenishment that is completed in Guide TI. The min-max are updated monthly, taking into account seasonality, demand growth and decline, lead time and objective variations for service levels. In the beginning, Norampac’s team invested one to two additional days per week to better control its inventory. The results justified the effort since, over time, the work related to replenishment will become again more automated, but with good dynamic results. Jean-Francois Cartier, director of operations at Norampac, revealed that he greatly appreciated being able to observe, according to his needs, all inventory man-

Top: Norampac Drummondville has a production capacity of 1 billion sq. ft. per year of corrugated packaging. Above: Data mining allows users to visualize, understand and correct problems.

agement results, such as the evolution of service levels, inventory levels, surplus and others metrics that finally give the impression of better controlling inventory. “We did not have any performance indicators for the management of inventory before Guide TI offered us this possibility with IMAFS SaaS. I am very pleased with these new functionalities,” said Cartier. There is a definite potential to further reduce inventory by more than 30% without affecting the service. A concrete action plan was developed with the internal team to achieve these results. The project’s success to date and what is expected for the future are very much the result of the efficient work from the resources of Norampac, COGEP and IMAFS. According to IMAFS, the involvement and dedication of resources for the implementation were remarkable and all successes belong to the team. MRO Robert Lamarre is an inventory management solutions specialist with IMAFS Inc. For information from IMAFS, visit www.imafs.com. For information from COGEP Inc., visit www.cogep.com. Online Reader Inquiry No. 833

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Sapa Heat Transfer was able to decrease its maintenance cost per ton of output by 16.8% after it began using computerized maintenance management software.

ith an average production output increase of about 30% per year, Sapa Heat Transfer AB’s Shanghai facility needed to plan and develop a strategy to accommodate its growing business performance for the long term. Being the only company in the world with rolling mills that deliver aluminum strips for brazed heat exchangers, it was impera-

tive for it to maintain its leading position in the market. Sapa Heat Transfer, which has offices in Mississauga, ON, Montreal and Vancouver, is based in Finspång, Sweden, and is a part of Sapa Holding AB, which is owned by the Norwegian company Orkla ASA. It is estimated that 60% of all cars in Europe have radiators originating from

Fig. 1

Sapa aluminium strip, and of course many cars in North America and the Asia Pacific region are also equipped with Sapa material. In addition, in recent years Sapa has been increasingly active in HVAC&R (heating, ventilation, air conditioning and refrigeration) and power industry applications for heat transfer material. In terms of a basic approach, adding more capacity was perhaps the easiest part to agree upon and was executed, doubling the previous production capacity. But a more complex part, and one that had additional benefits, was to optimize the reliability and availability of the entire production facilities; both existing and those to be added. This optimization would contribute to the ability to deliver increased output, but it would also deliver considerable maintenance cost savings to the bottom line. However, it would involve an approach to maintenance efficiency that would also require its own new strategy, development, introduction and execution.

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Modern data tracking The first move away from the previous system was to select and install a computerized maintenance management system (CMMS). This would replace the paper and spreadsheet systems, where data logging and retrieval was relatively slow, and data updating, preparing statistics and sharing this information was becoming more time consuming and inefficient. Being well aware that the success of any CMMS depended on it being selected and tailored to ‘fit’ the manufacturing and maintenance reality of Sapa’s factory, Wang Yeuming, Sapa’s maintenance manager, asked SKF for assistance. Wang believed the ‘fitting’ of a CMMS to Sapa’s situation could only be done by experienced professionals in the maintenance and reliability business. SKF was well known to Sapa’s maintenance staff from previous co-operation on engineering and maintenance issues, and SKF’s application of its high-end Integrated Maintenance Services (IMS) was known to be successful in many industries, in different countries around the world, including China. During initial discussions on the future direction of maintenance at Sapa, Wang received recommendations from SKF about which CMMS system suited them best. “Although not expected at such an early stage of discussions, their suggestion was backed up with solid reasoning that convinced us that they knew our manufacturing needs and the CMMS solutions on the marketplace. So I felt

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Fig. 2 Figure 1: Aluminum slabs are ready to be reduced to fine-dimensioned strips. Figure 2: Both production and inspection are highly automated. Figure 3: The strip rolling machine is at the end of the finishing line.

ability and drive down costs. Compared to figures from 2007, the average machine availability increased in 2010 from 95.4% to 97%, and maintenance cost per ton of output was decreased by 16.8%.” SKF staff maintains a constant presence at the factory, assisting with extending the CMMS application and

training for the 53 Sapa maintenance staff. “The SKF knowledge is so strong that having them on-site daily is a really efficient way to ramp up the learning curve of all our people,” said Wang. “While their on-site staff can answer most of our questions, if there are any areas in the slightest doubt, they can easily access the worldwide SKF knowledge of their asset efficiency colleagues, who are experienced, having worked with numerous major corporations around the world. And they have a unique database of maintenance knowledge on so many pieces of machinery that we also use, that speeds up the answers to even the most difficult questions that we have so far come across. “We have official meetings weekly and monthly and that helped to get the CMMS installation done so quickly, and also to act on all key issues as we started to use it.” continued on page 23

Fig. 3

Let us help you save time and money! comfortable going with their suggestion and, I must say, it turned out to be perfect,” said Wang. “Since acquiring the CMMS, SKF have helped us to identify, tag and upload all necessary assets into the system and have trained our people in the process. Although this is a very difficult job to complete while you are still managing the daily maintenance needs, my team and SKF did exceptionally well to complete the implementation within four months. “Of course, training and support continued with our people to ensure that they switched to using the CMMS on a continuous basis. It is well known that sometimes, with the pressure of normal operation, increasing demand and daily maintenance reviews and actions, it can seem easier to use old, well-known methodologies than newer, less-familiar ones. It was important that we stayed on track to use the new system, and I am happy to say that we met that goal too.” New approach to maintenance In parallel with the CMMS activity, Sapa and SKF revised the maintenance strategy, standardizing maintenance actions where necessary, determining which were Sapa’s really critical assets and focusing more on the specific needs to increase reliability. “We are really happy with this new situation,” said Wang. “Not only do we have more detailed information on our critical assets and their typical service lives, we know what to monitor in search of potential failures and can detect developing problems very early. That gives us time to understand them and to take actions to prevent more of them from becoming actual failures. And we also know more about the man-hours we spend to diagnose and fix any issues. “This information is now instantly available to any of our maintenance staff and is already helping us to drive up reli-

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eciprocating compressors make noise, even in the best conditions. The trick is to train your ears to pick up new, potentially damaging sounds before they silence your compressor. The ability to pick up changes in the noise is a skill that will make you a better troubleshooter. You can develop this skill by spending time, each day, paying attention to the sounds of your compressors and learning what each compressor sounds like when it is running well. You can buy a stethoscope or ultrasonic device to help you trace the source of the noises from a compressor. However, these tools take time to learn, and they pick up more sounds than you need. An ‘old school’ technique is easier, and all you need is a long screwdriver (Fig. 1). You place the handle to your ear and the metal tip to any area on the compressor to listen to the sounds in that particular area. If you try this on each valve cover, you can quickly distinguish normal and abnormal valve operation. Valve knocks: A loose valve (Fig. 2) will give a deep, hollow knock that is similar to the sound of a bongo drum. Here are some situations that can cause a valve to become loose: • Issues that create a gap between the seat gasket and the valve: Debris or nicks on the sealing surface can break the gasket or the gasket could slip out of position during installation. • Valve installation mistakes: Not making sure the valve seat was in good contact with the seat surface, or using the wrong torque and having the valve bolts vibrate loose from the pulsations of a running compressor. Maintenance tip: Always check valve bolts/setscrews a few hours after startup, a day after startup and then once a month. And, if you find a loose valve, don’t just tighten the bolting and think you have solved the problem. Remove and inspect the valve and its internal parts, because it is common for parts to break when a valve rattles loose in the valve port. Broken valve parts: A ticking or clicking sound will be heard when broken valve parts rattle around in the valve or in the valve port (Fig. 3). Valve parts can break without warning for a variety of reasons. This includes the following: • mistakes during valve repairs • installation errors

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Fig. 1: The old-school technique of using a long screwdriver to listen to compressor noises. Fig. 2: The illustration shows damage from a loose valve, which also ruined the gasket seating surface inside the cylinder. Fig. 3: A ticking or clicking sound will be heard when broken valve parts rattle around in the valve or in the valve port. Fig. 4: A loose piston will produce a loud, metallic noise once the nut becomes loose. The illustration shows the effect of ignoring a knock in the cylinder. Fig. 5: Once a knock has been confirmed to be resonating from the frame, a lift check inspection will help you zero in on a starting point for bearing disassembly.

World-class maintenance management “Having gotten off to a great start with our new maintenance approach, we are now going further with SKF,” said Wang. “We have just started the new IMS project that I hope will launch our journey to world-class maintenance management. We will fully optimize the value that CMMS offers and will further apply advanced predictive maintenance procedures, including off-line and online monitoring, plant wide. “Our on-site mechanical services will cover identifying and eliminating repeat failures, professional and speedy mounting and dismounting of bearings, and establishing extensive lubrication systems and lubrication monitoring for key equipment. “It will be a tough journey, but the rate of success with our performance and attitude to change – from the old time-based preventive maintenance routines, to advanced pre-

dictive maintenance routines – gives me great reason to be optimistic,” said Wang. “Already with IMS, we have looked at our critical equipment and have set Key Performance Indicator (KPI) targets for availability and prevented downtime for the next three years. This is in contrast to executing a great maintenance strategy and waiting to see what results we get. “Even though that delivered more than we expected, with the new focus on SKF IMS as our way ahead, I am very optimistic that we will be more in control of what we expect and what we get. That is the start to world-class performance and we intend to follow that with performance data comparable with best-in-class companies, where SKF’s experience, knowledge and assistance will be invaluable.” MRO For more information, visit www.skf.ca. Online Reader Inquiry No. 834

• normal wear and tear from old age • a slug of liquid (water from condensation or oil from over-lubrication) • large solid contaminates getting past the inlet air filter • pieces that break away from other internal components (piston rings, coolers, etc.). You can confirm which valve has broken internals by using the screwdriver to listen at each valve cover, or use a thermometer to do a quick comparison of valve temperatures to search for the hottest valve. The piston: A loose piston will produce a loud, metallic noise once the nut becomes loose. Ignoring a knock in the cylinder can have a devastating effect (Fig. 4). The most common causes occur during installation. • Torque: Using inadequate torque or backing up the nut after reaching the torque spec to install a cotter key. • Contamination: If the components are assembled without attention to cleanliness, a single burr or solid contaminate can create a false sense of security. The nut can be installed with the proper torque, and trap a burr or debris particle between the piston and the nut. This particle will release as the piston contracts and expands through normal operation, creating a noisy and destructive gap between the piston and the nut. Maintenance tip: A noise caused by a problem in the cylinder can be heard in the cylinder and in the frame. This is because the knock can travel through the piston rod. Bearings: A knock in the frame can produce a wide range of sounds, depending on which bearing is causing the problem (Fig. 5). A knock can be caused by bearing clearances opening up, but this is usually the last place to look for the source of a knock. As a general rule, the crosshead pin bushing will typically fail before the crankpin bearing or the main bearings. In fact, it is common for the precision bearings to last for decades. Once a knock has been confirmed to be resonating from the frame, a lift check inspection will help you zero in on a starting point for bearing disassembly and more in-depth evaluations. Maintenance tip: Bearing knocks typically do not travel up the piston rod and into the cylinder. MRO Dan Wise is the webmaster for the CompressorWise website located at http://www.compressorwise.com.

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’s of

The iFlex flexible current probe gives the Fluke 376 clamp meter the ability to measure around awkward-sized conductors and improves wire access.

Developments in the basic clamp meter reflect the digital trends in test and measurement devices. BY COLIN PLASTOW

ike the multimeter, the clamp meter has passed through the analogue period and into the digital world of today. Created primarily as a single-purpose test tool for electricians, today’s models have incorporated more measurement functions, more accuracy, and in some instruments, some very special measurement features. Today’s clamp meters have many of the basic functions of a digital multimeter (DMM), but with the added feature of a current transformer built into the product. A clamp meter is an electrical tester that combines a voltmeter with a clamp type current meter. Choosing a clamp meter not only requires looking at specifications, but also looking at features, functions, and the overall value represented by a meter’s design and the care taken in its production. Resolution, digits and counts: Resolution refers to how fine a measurement a meter can make. By knowing the resolution of a meter, you can determine if it’s possible to see a small change in the measured signal.

Clamp Meters

Accuracy: Accuracy is the largest allowable error that will occur under specific operating conditions. In other words, it is an indication of how close the meter’s displayed measurement is to the actual value of the signal being measured. The accuracy for a clamp meter is usually expressed as a percent of reading. An accuracy of 1% of reading means that for a displayed reading of 100 amps, the actual value of the current could be anywhere between 99.0 and 101.0 amps. Measuring ac current: One of the most basic measurements of a clamp meter is ac current. Typical ac current measurements are taken on various branch circuits of an electrical distribution system. Determining how much current is flowing in various branch circuits is a fairly common task for the electrician. By taking current measurements along the run of a branch circuit, you can easily tell how much each load along the branch circuit is drawing from the distribution system. True RMS: With the growth of electronic loads, the currents drawn from today’s electrical distribution system are no longer pure 60- or 50-cycle sine

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waves. These currents have become fairly distorted; due to the harmonic content these non-linear loads generate. However, electrical power system components such as fuses, bus bars, conductors and thermal elements of circuit breakers are rated in RMS current because their main limitation has to do with heat dissipation. If we want to check an electrical circuit for overloading, we need to measure the RMS current and compare the measured value to the rated value for the component in question. Therefore, today’s test equipment must be able to accurately measure the True-RMS value of a signal regardless of how distorted the signal may be. Measuring voltage: Another common function for a clamp meter is measuring voltage. Today’s clamp meters are capable of measuring both ac and dc voltage. An electrician’s job is to be able to take measurements throughout the system to isolate and fix electrical problems. Another common voltage measurement would be testing battery voltage. In this case, you would be measuring dc voltage. Testing for proper supply voltage is usually the first thing measured when troubleshooting a circuit. If there is no voltage present, or if it is too high or too low, the voltage problem should be corrected before investigating further. Resistance: Resistance is measured in ohms (V). Resistance values can vary greatly, from a few miliohms (mV) for contact resistance to billions of ohms for insulators. Most clamp meters measure down to 0.1 V. When the measured resistance is higher than the upper limit of the meter, or the circuit is open, ‘OL’ appears in the meter’s display. A very common electrical resistance measurement is reading the resistance of a contactor coil. Meaningful resistance measurements need to be made with the circuit power off. Better-designed clamp meters provide protection in the ohms mode in case of accidental contact with voltages, but many will be damaged or worse, cause injury. The level of protection varies greatly among different clamp meter models. Continuity: Continuity is a quick go/ no-go resistance test that distinguishes between an open and a closed circuit. A clamp meter with a continuity beeper allows you to complete many continuity tests easily and quickly. The meter beeps when it detects a closed circuit, so you don’t have to look at the meter as you test. The level of resistance required to trigger the beeper varies from meter to meter. Typical resistance values to turn on the beeper is a reading of less than somewhere between 20 and 40 ohms. Special functions: A fairly common measurement function is reading the frequency of an ac current waveform. With the clamp meter’s jaws wrapped around a conductor carrying ac current, switch on the Frequency function and the meter’s display will indicate the frequency of the signal flowing in the conductor. This is a very helpful measurement when tracking down harmonic problems in an electrical distribution system or, with some instruments, measuring the output frequency of VFD’s or generators and UPS’s. Another feature that can be found in some clamp meter models is MIN MAX storage. When this feature is activated, each reading the clamp meter takes is compared against any previously stored readings and the highest and lowest values are stored for later review. Clamp meter safety: Making measurements safely starts with choosing

Machinery & Equipment MRO

the proper meter for the environment in which the meter will be used. CSA C22.2 No. 6010 defines the electrical environment according to categories and then voltages within those categories. Most industrial users will need an instrument with a minimum 600V Cat III rating. Many instruments on the market have lower levels of protection, depending how they are being used. Only use instruments where the stated protection level is applicable to all functions, ranges and inputs. It’s also essential that the instrument has been independently verified as meeting the standard and has CSA or equivalent approval to show it. Once the proper meter has been chosen, you should use it by following good measurement procedures as shown in CSA Z462 or NFPA70E. With technological advances in electrical equipment and circuits come

more challenges for electricians and technicians. These advances not only require more capability in today’s test equipment, but more skills on the part of the people who use them. An electrician who has a good grounding in the fundamentals of test equipment use will be better prepared for today’s testing and troubleshooting challenges. The clamp meter is one such important and common tool found in the toolboxes of electricians and technicians alike. MRO Colin Plastow has been with Fluke Electronics Canada since 1987 in various support and product management positions. Today, as industrial product manager for Fluke, he brings his expertise in electronic test and measurement to customers in high-tech and industrial markets. He may be contacted at colin.plastow@fluke.com.

Today’s clamp meters have many of the basic functions of a digital multimeter (DMM).

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Explosion venting The basic principle of venting provides for the rapid opening of a vent, of sufficient area, to allow unburned dust and explosion products to escape, thus limiting the resulting pressure rise to an acceptable level. The acceptable pressure rise is determined by the requirement that the vessel should not rupture and, in some cases, that it should not deform. The maximum explosion pressure in a vented vessel is called Reduced Explosion Pressure, or Pred. This is usually designed to be approximately twothirds of the pressure required to rupture the vessel. In a given vessel, the Reduced Explosion Pressure will depend upon the size, number and location of the vents, the opening pressure and inertia of the vent cover, the presence of ducts from the vent, the presence of obstructions inside the vessel and the state of the dust cloud. The explosive characteristics of the dust will also have a bearing on the vent area.

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ment are low initial capital and maintenance costs. Rapid-Action Valve: An explosion isolation valve such as a rapid-action valve provides a mechanical barrier against the flame front of an explosion. The intent is to isolate the explosion and protect the area beyond the valve. The valve must be activated upon detection of the explosion. An explosion suppression system or explosion venting is required on the ignition side of the valve because, when the isolation valve closes, the ducting or vessels are subject to over-pressurization. The main advantage of this isolation method is the certainty of preventing flame propagation to other equipment or processes.

BY SIMON FRIDLYAND

DUST CLOUDS CAN BE IGNITED BY THE EFFECTS OF MECHANICAL FRICTION FROM OVERHEATED BEARINGS OR MOTORS, SPARKS FROM GRINDING MACHINERY, STATIC ELECTRICITY, ELECTRICAL ARCING, WELDING SPARKS OR NAKED FLAMES. HERE’S PART 2 OF OUR GUIDE TO UNDERSTANDING, PREVENTING AND CONTROLLING DUST EXPLOSIONS.

Process isolation An effective method of explosion protection is to isolate the particular process, such as the unloading of powdered ingredients, into a separate room that must be constructed with sufficient strength to withstand the effects of an explosion, or a room that has its own explosion relief vents positioned in the wall. Doors and other closures in an isolated room must be capable of withstanding the effects of an explosion. Equipment isolation Individual plant equipment, such as silos, filter receivers, etc., should be protected against the effect of an explosion and should be isolated from each other in order to control the transfer of burning and smouldering material; and to avoid an explosion in the first vessel causing re-compression, increased turbulence

and a subsequent increase in the rate of pressure rise in the second vessel. There are three types of equipment isolation equipment. Chemical Explosion Blocking Systems: These systems are typically used with explosion suppression systems. The duration of the discharge, quantity of the suppressant discharged, location of the discharge point, flame propagation velocity and operating flow rates must all be considered in the design of a blocking system. Processes with high flow rates and/or large primary vessels may not be suitable for chemical explosion blocking systems. Flame Front Diverters: The flame front diverter incorporates the need to vent deflagration pressures with the need to direct the flame front so that it does not ignite material in the process downstream. Advantages of this equip-

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Pressure vessels Where the equipment is relatively small, or hygiene constraints limit the application of other systems, it may be preferable to design the vessel to withstand the pressure, rather than use other protection systems. Vessel design can be based on either pressure-resistant vessels or pressureshock resistant vessels. In both design cases, the pressure rating of the vessel must be able to withstand the maximum pressure rise for the dust concerned. Pressure-resistant vessels are designed to contain an explosion without rupture or deformation. Pressure-shock resistant vessels are designed to withstand the maximum explosion pressure without rupture but would be liable to permanent deformation. This approach reduces the capital cost but accepts that following an explosion, the vessel might need substantial repair or replacement. Explosion suppression Explosion suppression is an active protection method which relies on sensing the start of an explosion and delivering an extinguishing agent as quickly as possible to quench the explosion and reduce the maximum explosion pressure to a substantially lower level. The lower pressure – the Pred – must be lower than the vessel design strength for an explosion to be successfully suppressed. The advantages of explosion suppression systems include the ability to: • Stop the explosion before the developing pressure can damage the process equipment. • Control any ensuing fire and reduce flame front propagation to other process equipment. • Not vent flame or other material, which is useful when toxic, radioactive or corrosive materials are being handled, equipment is located indoors, or venting exposes personnel to a discharge of pressure and combustion products. The disadvantages of explosion suppression systems include the following: • The design and installation of systems are expensive. Also refilling and resetting the system after a discharge is expensive. • Maintenance requirements are more severe than for conventional venting systems. Clearly, there’s no simple solution to the important task of reducing the chance of a dangerous dust explosion, or dealing with one after it occurs, but the appropriate solution must be matched to the conditions in every industrial facility. MRO MaxMotion

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ow can you create a ball of flame? Where combustible material is conveyed, filtered, milled or sprayed in a fine powdered form, and the dust is confined to an unprotected process volume with it being dispersed, and when an ignition source is present, a deflagration can take place resulting in an immediate overpressure and flame ball. Should this scenario take place, it will result in deadly consequences, as reported in the previous issue of this magazine (Dust, Dangerous Dust, Safety File, Sept. 2011, pg. 29). But there are methods to prevent such tragedies and some recommendations follow. An explosion risk assessment will typically recommend that a series of protective measures be implemented, ranging from improvements in housekeeping to an investment in protection equipment. Applying protection technology requires that the constraints of the process equipment, building facilities, environment and budgets are taken into account in achieving the level of personnel safety required by codes and standards. A Pre-Start Health and Safety Review (PSR) must be done in Ontario, as it is mandated by Section 7 of Reg. 851 under the province’s Occupational Health and Safety Act. Here are the options available to minimize the impact of a dust explosion: • Explosion venting • Process isolation • Use of pressure vessels • Explosion suppression.

1/3HP to 20HP Stainless Steel Simon Fridlyand, P.Eng., of SAFE EngiMotors

neering Inc., specializes in industrial health and safety concerns and PSR compliance. For more information, visit www. safeengineering.ca.

* Availability * Expertise * Warranty * Online Reader Inquiry No. 134 Online Reader Inquiry No. 838 Complete product benefits at www.motors.mep.ca 10/7/10 2:27:26 PM

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M A I N T E N A N C E

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Machinery & Equipment MRO

November 2011

THE FIRST SET OF ACTIVITIES IN THIS EIGHTSTAGE PROGRAM WILL HELP YOU BEGIN TO CREATE AN EFFICIENT, PROFESSIONAL, TEAM-DRIVEN MAINTENANCE ENVIRONMENT.

BY PETER PHILLIPS

n this issue, I am beginning a series of eight articles that will explore what many companies would like to achieve – a world-class maintenance department. Over the next eight issues, I’ll offer maintenance managers guidelines on how to move their departments toward an efficient, professional, team-driven environment. Whether or not you take the time to implement all of the points, I’m sure there will be ideas you can use to improve your maintenance activities. So here is the first stage you’ll need to follow to get a step closer to a world-class maintenance (WCM) department. But first, what exactly is WCM? It is simply a series of steps that involves improving your maintenance activities and support systems. Most of us at one time or another have looked at our maintenance department and recognized that the storeroom could use some work to be better organized, the preventive maintenance procedures needed updating, that you need a CMMS to better track equipment history, and so on. All of these improvements result in better service to the production department and more reliable equipment. Do we hear managers say, ‘We need WCM’? Not really, but everyone understands that improvements cannot be made without a good deal of effort and dedication. So call it what you wish, but world-class maintenance is a desirable outcome for maintenance departments that want to pursue a more efficient, costeffective way of doing business.

Stage 1: Prepare for professional maintenance There are eight activities in this first stage. They prepare you for all the other seven stages. The activities are: 1. Defining equipment and its priority 2. Developing a maintenance

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©Photodisc/Thinkstock

How to Achieve World-Class Maintenance work order flow 3. Implementing a CMMS system 4. Managing spare parts inventory 5. Developing professional maintenance shops 6. Lubrication storage 7. Managing reactive maintenance 8. Benchmarking and measuring progress. Let’s look at each activity in detail. 1. Defining equipment and its priority: When defining the equipment list, you need to ensure that every piece has been identified in the manufacturing process, along with all support equipment. In order to create a workflow or write a preventive maintenance schedule, you need a complete equipment list. Next you need to prioritize the equipment. Determine the degree of influence it has on the manufacturing process or the facility operation. The higher the degree of influence or risk, the higher the priority. The equipment priority will have a role to play when tradespeople need to determine what machine to work on first. 2. Developing a maintenance work order flow: To successfully manage a work order system, every person involved with the work order needs to understand how to execute his or her part. A flow chart will identify every step in the work order process, as well as identify weak spots such as training or corrective actions that are needed to guarantee the success of the work order system. 3. Implementing a CMMS system: Although it takes significant resources to implement, the CMMS will help you develop the history of the equipment through work orders, inventory usage and preventive maintenance schedules. The software will aid in the planning and scheduling of tradespeople to effectively use their labour hours. Also, equipment spare parts are entered into the program and linked to the equipment so

they can be tracked effectively. 4. Managing spare parts inventory: Equipment spares and materials play a vital role in supporting work execution and ensuring plant availability. The primary function is to respond to the requirement of needing to stock an item or providing a route for quick purchasing through supplier agreements. With the addition of reorder points, a CMMS can create purchase requisitions to reorder stock. Having a world-class storeroom is a very large task and takes several months of steady dedication and resources to complete. If you have a typical maintenance stockroom, you need to start by sorting and purging. You can begin by using the 5S routine (sorting, straightening, shining, standardizing and self-discipline). • Start organizing what you have left • Give every part a home. • Document your parts and get them entered into the CMMS. • Determine the quantity to keep for each spare part. • Develop a visual management system so parts can be found quickly. One minute or less is the benchmark for finding parts in a world-class storeroom. 5. Developing professional maintenance shops: Many of the workshops I encounter are less than ideal. Many are much too small to work in, crowded by oversize toolboxes, lathes, welding machines and so on – you’ve likely seen the picture. On top of that, they are usually dirty and unorganized. If you can’t expand your workshop footprint, at the very least you can make it look professional. • Start by doing a complete 5S, including the trade’s personal toolboxes. • Using shadow boards and cabinets, arrange specialized tools used for repairs and preventive maintenance tasks (PMs). • Place special fluids and chemicals in fireproof storage cabinets. • Develop clean work areas. You need to ensure that dirt and debris does not enter gearboxes, etc., when you are doing rebuilds. • If your welding shop is part of your maintenance area, then build some walls around it and vent it properly. Welding and grinding are two big contaminators of the parts you may be storing in your shop and can cause rebuilds to become full of crap. • Do you really need to store the personal tool boxes of your tradespeople in the shop? It seems these boxes are getting bigger every year. They take up a lot of room. I understand the person working that day needs his or her toolbox open and available, but do you need the offshift toolboxes there too? I look at it this way: Maintenance people generally are paid well. It takes a minimum of four years to become certified, so why don’t you look like the professional you have become? 6. Lubrication storage: Your lubes keep the plant running. The biggest documented causes of premature failure is

the lack of lubrication, or contaminated greases and oils. To store your lubricants you need to: • Create an area to store lubricants. It must be clean, dry, ventilated and have environmental controls. • Everything needs to be organized and labelled. • Housekeeping practices need to be put in place. • All the lubricants you stock need to be reviewed to see if they are adequate for their purpose. Best pricing is not the best way to purchase; lubes must meet OEM specifications. • The shelf life of oils needs to be considered. Buying in bulk is not always the best practice. • Inspect grease and oil dispensing tools, as they need to be kept clean and in good condition. They should be tested and possibly calibrated to ensure they deliver the correct amount of lubricant. • Lubrication schedules need to be developed and adhered to. Create lubrication PMs and frequencies and enter them into your CMMS. 7. Managing reactive maintenance: Many maintenance departments have a hard time completing their preventive maintenance work orders because they are too busy putting out fires. Breakdown repairs come first, of course, but we need to manage them. How? • Every breakdown needs to be analyzed to uncover its root cause. • Worn and broken parts need to be collected and analyzed. • Information about breakdowns needs to be captured. You need to: • Set up a system to investigate breakdowns and record the details. • Set up a system to gather and tag damaged parts for analysis. • Set up a system to review all equipment for similar reoccurrences. • Train personnel on Root Cause Analysis (RCA) methods. 8. Benchmarking and measuring progress: The goals for a world-class maintenance department are to improve maintenance activities and to provide better service in order to create more reliable equipment and more uptime. Before you start the WCM quest, measure where you are now, so you will be able to see your improvements later. Measure the following: • How long does it take to find a part in the stockroom? • What is your current breakdown to PM ratio? • Measure your downtime per machine. • What is your Mean Time Between Failures (MTBF)? • What is your Mean Time To Repair (MTTR)? • Measure your craft utilization. It’s a good idea to take before and after pictures of your improvements in all areas. Many of you are probably saying, “Look at all the work we would have to do just for Stage 1.” Indeed, it is a lot of work, but it’s worth every minute. It will also cost considerable money to complete. However, this money will be returned quickly through increased uptime. We have seven more stages to complete. In the next article, we’ll move into Stage 2 and look at equipment evaluation and deterioration. MRO Peter Phillips of Trailwalk Holdings, a Canadian CMMS consulting and training company, can be reached at 902-7983601 or by e-mail at peter@trailwalk.ca. Online Reader Enquiry No. 839

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Machinery & Equipment MRO

Moving from Reactive to Proactive

Follow along with Step 41 in a journey to world-class maintenance at the Plentya Paper Company as the maintenance team begins to see changes for the better. This article is part of an ongoing series. The introduction appeared in Machinery & Equipment MRO’s February 2005 issue and the series has run in every issue since. Previous instalments are archived online at www.mromagazine.com. This month, we pick up where we left off in the September 2011 edition, as maintenance manager Bob Edwards begins to see new efficiencies from ideas brought forward by his maintenance team and also has a chance to celebrate a new milestone.

e were into the second week after we had taken one millwright off-shift and there didn’t seem to be any problems. This meant I had to ensure that we made the best use of the extra guys on the dayshift, which brought me to a problem. Pete, a millwright, had commissioned the hydraulics for the mill and was acknowledged as being the ‘expert’. One of the prompts for bringing the guys off-shift was his commitment to develop troubleshooting hints and training for all of the group. He also had been heavily involved with John, the vibration consultant, from the beginning, and he was just about to go on a training course with Ivan, another millwright, with a view to taking over John’s role of interpreting the online vibration readings and taking hand-held measurements. There was no way he was going to have the time to do both, and we had four extra guys who were looking to take on more responsibility. I talked with Pete and asked what he thought. “I think this is simple, Bob. Even though I really enjoy learning with John, Ivan also works with him and – as we’re just starting to take over his role – it’s easier for someone else to get involved now. On the other hand, I had great training and experience when I was commissioning the mill hydraulics with the manufacturer’s reps – and that can’t be gained by anyone – so I guess I’ll take on the responsibility for developing new hydraulic training and troubleshooting guides.” “ Thanks, Pete. That makes it

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easier. Now I just have to figure out which of the guys I should send on the vibration training with Ivan.” I went down to the workshop where most of the day millwrights were gathered. I explained what Pete and I had talked about and asked if anyone had a particular interest in taking over the vibration role. I was quite surprised when Terry, who rarely said anything unless specifically asked, volunteered. “I’ve been taking some online courses on vibration – I find it really interesting – so if possible I’d like to take this course.” The other millwrights seemed okay with this and in fact, some of them seemed relieved that Terry had volunteered, so I asked a second time. “Anyone else interested?” and when nobody replied, I asked, “Why is nobody else interested in this?” It was Steve, Terry’s ex-partner on shift, who spoke up. “We know that vibration is important, Bob, but some of us still want to take pride in our trade skills. Remember when we talked about taking people off-shift, I mentioned that we could do the major gearbox rebuilds in-house, instead of sending them out? With just a little bit of investment in some tools, I’m sure we could save the company quite a bit of money. Those are complex rebuilds and we’d get great job satisfaction out of it, as well as help the cause.” Again, I thought about how people were different and needed different types of motivation and that made my reply an easy one. “That’s a good idea. Steve, will you make up a list of what you need? I’ll do the rest.” That seemed to take care of my first issue of the day and as I made my way over to see Carol in the reliability engineer’s office, I thought about how things had changed for me. Without realizing it, my workload had become less pressured; I seemed to have more time to think about the future and how we wanted things to be. It suddenly dawned on me that we had made the change – or at

least had started to – from being reactive into being proactive. When I reached Carol’s office, I asked if she had the most recent gearbox rebuild reports. When she laid them out on the desk, we saw that the cost averaged $25,000 each. “Steve was right; this will save us around $100,000 a year, as we usually send out four of the 12 that we have in service. Another benefit is that we will still have the gearboxes in-house, since when we send them out, it usually takes a week each way.” “Have you seen this, Bob?” Carol showed me a sheet that listed several questions: • What component failed? • What signs were there before the failure? • What specific repair was required? • What was the failure mode? • Were there checks/PMs in place to identify this failure mode? • What root cause was found from asking the 5 Whys? “No I haven’t. Where did you get it?” “Ben asked me to set something up. He said he’d mentioned it to you.” “He did mention that he’d been thinking about breakdown analysis, but I didn’t think he’d actually formulated something. This looks as if it might work.” “It’s actually very good, as he also suggested that the analysis be carried out by the operators and the tradespeople. That way, we’d get better information in answer to, “What signs were there before the failure.” We can then set up some way of monitoring the signs. He also made sure that there was a tie-in to the failure codes we have in the CMMS, so we could pull out some meaningful reports.” “Well, let’s get this set up and we’ll have Ben do some training for the guys. Can you help him with that, Carol? You know – how to tie it in to the CMMS and such.” As I sat in my office, I thought about how Corporate would be happy with what we’ve achieved and I was certainly proud of what the guys had done. I started to wonder about how the guys felt

November 2011

BY CLIFF WILLIAMS

M A N A G E M E N T

about it all – how they felt about the changes, how they felt about what I had been doing, and how they felt about the way I’d been doing it. I realize that I hadn’t really had a structured way of giving feedback. We had held meetings, but that meant that they had to bring up the subject in that setting, and that didn’t happen, so I then thought of how I could get their comments. I decided that I would give them a questionnaire that they could fill out, and then I would set aside 15 minutes with each of them to go over their answers. After a while, I settled on the questions. • What are the biggest challenges you face because of the changes in how we work? • How can I help you with the challenges? • What am I doing that I should do more of? • What am I doing that I should do less of? • What three things are we going to work on? (This was to be developed at the meeting.) I decided to call it the ‘15 Minutes of Fame’, as I wanted them to understand that this was the time for them to be in the spotlight, the 15 minutes was theirs, and that they should feel free to bring up anything they liked. I scheduled a big meeting for the following Tuesday so that I could roll out the concept and explain what I was trying to achieve, which was making sure we carried on in the direction we were already going. There were some curious looks when I posted the notice of the meeting and they saw the agenda was about ‘15 Minutes of Fame’, but I didn’t give anyone any hints as to what was involved. The weekend came and went with no upsets at the mill, so I was more than curious myself when I arrived at work on Monday morning and found a message in my voice mail from Joe, the plant manager. “Bob, please make sure you’re in the meeting room 15 minutes early. There’s something important I need to talk about with everyone.” When I did get to the meeting room, there was a quite a buzz as everyone tried to figure out what was going on – all except Fred, the production manager, who just sat there with a hint of a smirk on his face. This helped me relax a little, as there was no way that Fred would be so calm if there was a major problem. I wondered what he knew that we didn’t. When Joe arrived, he was carrying a large box, which he set on the table. “I asked you all to come a little early so I could talk about our progress on Project 600.” He stopped talking and quickly opened the box, pulling out a large cake. “And what I wanted to say was, we did it! Last week we averaged 600 tonnes per day! Congratulations!” Everyone started cheering and shaking hands as Joe cut the cake. “I’ve already let Corporate know and they’ll be sending some communication through later today,” Joe added. “There are cakes for each department and one for each of the shifts. You should all be proud of what you’ve achieved, but you also need to remember that this must be the first of many accomplishments. We’ll work on that together, but for now, enjoy your achievement.” MRO Cliff Williams is the corporate maintenance manager at Erco Worldwide in Toronto, ON, and a consultant with TMS – Total Maintenance Solutions Inc., Markham, ON. He can be reached by e-mail at williamscliff@rogers.com. Online Reader Inquiry No. 840

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Machinery & Equipment MRO

November 2011

What’s new in seals & gaskets t

Bearing isolator is for flooded, oil mist applications

Online Reader Inquiry No. 826

Custom transmission gasket seal can be moulded into a continuous web

Minnesota Rubber and Plastics has introduced custom transmission Quad Ring gasket seals designed in a continuous web. By moulding the seals into a connected network and forming a gasket, the fourlobe design feature is multiplied over the entire transmission surface that requires sealing. Two sealing surfaces within each seal multiply the point of contact for greater seal protection, and, with two sealing surfaces, each seal requires

The EnDuro bearing isolator for flooded and oil mist applications has been developed Garlock Sealing Technologies. Combining traditional labyrinth and advanced sealing technologies, it prevents the loss of environmentally harmful lubricants and provides IP56 protection against the ingress of contaminants. Designed to easily replace contact lip seals and traditional bearing isolators, the unit accommodates axial motion up to 0.38 mm (0.015 in.), and is available in shaft sizes from 22.2 mm to 152.4 mm (0.875 in. to 6.00 in.) in flanged, flangeless and custom configurations. Pressure rating is 7 psi and temperature range is minus 30°C to plus

204°C (minus 22°F to plus 400°F). Garlock Sealing Technologies

Rotary union withstands harsh processing conditions

The Barco E-75 RS Plus rotary union is designed for liquid-related applications in steel mill, rubber, printing, plastics and paper mill processing operations. It incorporates a sealing technology that provides continuous production time. The Nitrotec all-gaseous surface treatment increases wear and corrosion resistance, eliminating rust build-up. Additional features include dry run capability, silicon carbide to carbon graphite mechanical seals, and mono-flow and duo-flow configurations. Sizes are available from 3.8 in. to 2 in. in length. Barco Online Reader Inquiry No. 828

less squeeze to maintain a tight, leak-free fit. The nitrile butadiene rubber construction material has good compression set and is resistant to oil, fuel and chemicals. It withstands a range of temperatures from minus 40°C to plus 108°C, making it suitable for vehicular sealing appli-

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cations. For similar sealing applications, any number of these seals in custom diameters and thicknesses can be moulded into a continuous web gasket. Minnesota Rubber and Plastics Online Reader Inquiry No. 825

Interchange system makes shaft seal ordering a breeze

Dichtomatik has expanded its TCM radial shaft seal product line with the addition of 1,400 new shaft seal SKUs. The company has also upgraded its parts interchange system, allowing customers to match shaft seals from other vendors to its inventory, making the ordering process easy and efficient. The interchange system is available to all customers. The changes to the product line and interchange system took just over a year to complete. Dichtomatik Americas Online Reader Inquiry No. 827

Training program instructs in essentials of leak prevention

Containing liquids and gases is essential to both safe and efficient process operation. New Standard Institute has introduced a computer-based training program to help technicians avoid leaky systems. This training shows how to achieve a good flanged connection, as well as the essentials of studs, bolts and nuts. The course includes gasket terminology and selection criteria, minimum operating bolt load, stress vs. strain relationship, bolt and stud size and thread standards, flange leakage and maintenance, and more. The course is available as CD, download or web-based at www.newstandardinstitute.com. New Standard Institute

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Bearing isolator features shaft grounding

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Garlock’s SGi bearing isolator incorporates maintenancefree, shaft voltage mitigation technology, which prevents contamination, lubrication loss and electrical damage in variable-speed drives and other industrial applications. It combines the technology of its Guardian bronze non-sparking, non-contact labyrinth seal and Aegis shaft grounding ring, and its performance meets NEMA MG 1-2003, as required by IEEE 841-2001. Axial motion from 0 to 0.25 mm (0 to 0.010 in.) can be accommodated, and shaft diameters range from 22.2 mm to over 152.4 mm (0.875 in. to over 6.00 in.). Temperature range is minus 30°C to plus 149°C (minus 22°F to plus 300°F). Garlock Sealing Technologies Online Reader Inquiry No. 830

MRO

11-10-25 2:33 PM

P R O D U C T November 2011

What’s new in dust control and extraction Video series offers basic training in baghouse dust collection

Sly has produced a three-part dust collection video lecture series, Baghouse 101, offering an introduction to fabric filter dust collection systems. Lecture 1 examines overall dust collection system design. Lecture 2 covers specifics about design and construction features of fabric filter dust collectors. Lecture 3 contains a discussion of dust collector sizing and selection fundamentals for various application conditions, and concludes with an overview of combustible dust considerations. Sly has sponsored this video training series with Powder and Bulk Dot Com. The video training series may be purchased as individual lectures, which include a seven-day validity, or all three lectures may be purchased together with a 21-day validity. The series includes downloadable class notes and a self-administered quiz with answer sheet for each lecture. Video classes may be reviewed an unlimited number of times within the validity period. Further details are available at www.powderandbulk.com/online_training. Sly Inc. Online Reader Inquiry No. 777

Vacuum sucks up large quantities of dry materials quickly and quietly

Exair’s Premium Heavy Duty Dry Vac system is a rugged, industrial-duty vacuum cleaner that has been engineered to speedily vacuum high volumes of dry materials. Equipped with a 30-gal, 55-gal or 110-gal drum, it is compressed-air powered and attaches to the included drum. The wear-re-

sistant design is particularly suitable for the clean-up of abrasive materials such as steel shot, garnet, metal chips and sand. Surrounding air is kept clean by the 0.1-micron filter bag that traps particles when vacuuming dusty materials. This quiet, 82-dBA system comes with a 3-m (10-ft) static-resistant hose, 6-m (20-ft) compressed air hose, shutoff valve, pressure gauge, heavy-duty tools, toolholder (most systems) and drum dolly. Exair Online Reader Inquiry No. 775

Explosion vent allows for safe operation of dust collection systems

Combustible dust is a hazard in the workplace. Employing an SDC explosion vent on dust collection systems allows for safety and security during continuous operation. The company provides explosion vent

N E W S

Machinery & Equipment MRO

High-pressure sodium light safely illuminates dusty areas

Larson Electronics’ EPL-ACH-HPS150W explosion-proof, high-pressure sodium light penetrates airborne dusts, including coal and grain dusts. UL 844 Class II Division 1 and Class 1 Division 2 certified, this 150-W high-pressure sodium light can be used with flammable vapours in Groups C and D and explosive dusts in Groups E, F and G. Its deep reflector concentrates the light in such dark areas as silos and other storage areas. A trunnion mount and factory-sealed cord allow for permanent mounting. Larson Electronics Online Reader Inquiry No. 322

and after cleaning. Dust from cleaned bag filters cannot be re-entrained onto adjacent bags, resulting in lower pressure drop and reduced energy costs. An integrated helix in the hopper reduces dust-holding on filter bags, while the single inlet, outlet and hopper reduces ducting and hopper costs. The system comes with the company’s Dura-Life filter bags, which are manufactured using water to blend the fibres for better cleaning and longer life. Donaldson

screen, eliminating the need to analyze results on a PC. Suitable for industrial hygiene, indoor air quality and workplace exposure investigations, this hand-held, ergonomically designed device monitors airborne microscopic particles, such as

Online Reader Inquiry No. 778

Long-life conductive dust collector filter provides static dissipation

sizing and recommendations for specific applications according to the latest regulations provided by the National Fire Protection Agency (NFPA) and the NFPA standards. In addition to explosion vents, the company also works with other manufacturers to provide solutions for specific applications, such as sprinkler systems and explosion prevention systems. Scientific Dust Collectors

The HemiPleat dust collector filter from Camfil Farr Air Pollution Control uses carbon-impregnated media for use where conveyed dusts generate static charges that require dissipation. Its conductive properties combine with an open-pleat design for improved airflow through the cartridge and improved cleaning characteris-

dust, dirt, soot, mould spores, smoke or liquid droplets, using near-forward lightscattering technology. Its internal logger can store up to 15,700 data points over 32 separate runs, and data is easily downloaded to a PC or printer using an RS-232 interface cable. The monitor is available with detachable probe and all required accessories in a convenient carrying case. Casella USA

Online Reader Inquiry No. 782

Online Reader Inquiry No. 781

Extraction system safely disposes of welding electrode dust

Upblast roof ventilator has lowsilhouette weatherproof closure

Huntingdon Fusion Techniques has released a vacuum dust extraction system for its TEG-3 tungsten electrode grinding machine. This more comprehensive tungsten grinder has all the features of the non-extraction version, but with the added extraction system. Using this system, potentially dangerous radio-toxic dust generated during grinding of some types of welding electrode can be collected and disposed of safely. The transport packaging, which has been redesigned to accommodate the extraction system, meets international transportation requirements. Huntingdon Fusion Techniques Online Reader Inquiry No. 779

Reverse-air baghouse dust collector is designed for long life and efficiency

tics, resulting in high filtration efficiency, energy-efficient performance and long life. Applications include fumed silica dust, plastic, PVC or composite dusts and carbon black/toner dusts. The conductive media is available in all HemiPleat cartridge styles, and fits virtually all new and existing cartridge dust collectors. Camfil Farr APC Online Reader Inquiry No. 780

Particulate monitor combines hand-held portability with wide sensitivity range

The Donaldson Torit LP baghouse dust collector uses a reverse air design for efficient filtration. Its cleaning arm, manufactured with a flow-stop plate, keeps air from flowing through the bag filters before

Casella’s Microdust Pro airborne particulate monitor assesses concentrations of suspended matter in a wide sensitivity range. It is capable of presenting variations in dust concentration on a real-time scrolling graph directly on the LCD

Continental Fan has introduced a line of UBVL upblast roof ventilators, offering a low-silhouette design and capacities to 44,000 cfm. These rugged, aerodynamically efficient ventilators are constructed with a heavyduty welded steel base, galvanized butterfly exhaust damper section and a sparkresistant cast aluminum airfoil axial impeller, and have a v-belt drive for quiet, low-speed operation. Available in 24-in. to 60-in. diameters, they are suitable for exhausting hot or contaminated air streams, including smoke fumes, and are also suitable for general ventilation applications. Continental Fan Canada Online Reader Inquiry No. 776

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

Online Reader Inquiry No. 137

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What’s new in safety Personal protection welding apparel line puts emphasis on safety

Designed to protect, clean and care for hard-working hands, the RCP ProRx industrial skin care system from Rubbermaid Commercial Products allows for up to 3,333 hand washes per refill and delivers low cost-in-use and product waste. To help reduce waste, the durable, low-maintenance dispensers feature easily adjustable portion control levers. Portable bottles and tubes also are available. The system offers fully biodegradable soaps and solventfree formulas with all-natural grit scrubbers, and can be used in manufacturing facilities, automotive shops and maintenance or housekeeping areas. Rubbermaid Commercial Products

as heavy-duty leather panels for high-spatter-exposure and high-wear areas. The doo rags, beanies and caps can be worn under the welding helmet for top-of-the head protection. Four pairs of indoor safety glasses and four for outdoor applications round out the apparel line. Lincoln Electric

Online Reader Inquiry No. 787

Online Reader Inquiry No. 788

Lightweight work boot offers all-day comfort and support

crease energy, supporting those who work long hours on their feet. These boots help eliminate the need for expensive anti-fatigue mats, which can pose dangerous tripping hazards. The anti-fatigue technology includes moulded, inverted cones that support,

The Red Line personal protection clothing line from Lincoln delivers protection in welding applications. The apparel line includes gloves, jackets, caps and safety glasses. Five types of welding gloves are available: premium leather MIG/ stick, traditional MIG/stick, leather TIG, and heat-resistant and fullleather Steel Worker gloves. Four jacket options, available in cloth, heavy-duty leather or cloth/leather, offer flame-retardant cloth panels, as well

Skin care system protects hard-working hands from industrial grime

The Timberland PRO Helix collection of rugged 6-in. boots combines lightweight materials with the company’s anti-fatigue technology to absorb shock and help in-

Create Your Own Leads in

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collapse and return in key pressure zones, providing higher energy return and comfort. Features include flexible, soft durable leathers, mesh lining with Agion microbial treatment for odour control, and Titan alloy or composite safety toe. Timberland Online Reader Inquiry No. 785

Device prevents excessive water damage from fire sprinklers

Fire damage is expensive, but so also is water damage caused by an activated sprinkler head. Once activated, a sprinkler system can take time to shut down, even though the fire may be out, during which time the water damage continues unabated. The Shutgun from Canadian Safety Equipment is a simple tool that shuts off an individual sprinkler head while leaving all others active. The single-hand design makes the gun fast, easy and safe to use, even from a ladder. Should the fire rekindle, the device includes a fusible link that releases when heated, and the gun drops out, reactivating the sprinkler. Canadian Safety Equipment Online Reader Inquiry No. 786

Three-piece rain suit withstands tough environmental conditions

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Safety Zone/Ralston CanSafe has introduced a durable, heavy-weight, three-piece rain suit, made of 35-mil PVC coated on polyester for extra strength. Available in sizes small through 5X, it comes with a detachable hood, adjustable bib pants, cape ventilated back, underarm vents, snap front and fly, two-flap pockets and a corduroy collar. The material is waterrepellent and abrasionresistant and has good chemical hold out. Safety Zone/Ralston CanSafe Online Reader Inquiry No. 789

Retainer attaches goggles to hard hat for worry-free combination use

The Uvex Stealth Goggle Retainer for hard hats has been introduced by Honeywell Safety Products. Designed to attach to most hard hats, the goggle retainer helps ensure workers’ eyes are protected by creating a gap-free seal around the eyes. When not in use, the goggles are held securely to the hard hat. Well-suited for use in the oil, gas and chemical manufacturing industries, as well as construction, the goggle retainer features easily adjustable neoprene straps Honeywell Safety Products Online Reader Inquiry No. 790

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What’s new in power transmission t

Permanent magnet motor line is expanded to 1,200 hp

Online Reader Inquiry No. 802

Re-engineered motion control centres suit wide range of industries

Siemens has introduced the family of Tiastar motor control centres (MCCs) manufactured at its plant in West Chicago, IL. Tailored to the needs of such vertical markets as water and wastewater, oil and gas, and general process industries, the line includes an arc-resistant MCC compliant to ANSI/ IEEE C37.20.7. The family comprises the Tiastar base model, Tiastar HD model with a small footprint, Tiastar H20 for water and wastewater industries, and Tiastar Smart, which is designed for high-end process industries and leveraging Profibus technology. Siemens Industry Online Reader Inquiry No. 803

Stand-alone planetary gearbox features floating sun gear

Groschopp offers stand-alone planetary reducers. The reducer consists of a ring gear around three planetary gears and a floating sun gear. The sun gear has a toothed central spline loosely fitted on to the shaft spline and operates at a lower decibel level. Floating the sun gear keeps the gears centred and reduces gear tooth damage. The planetary reducer has a standard mounting configuration, allowing it to mount to virtually any motor with a NEMA 23 or 34 input flange. It is available in a standard or a rugged design. The standard design contains powdered metal gears, whereas the rugged design incorporates steel gears. Groschopp Online Reader Inquiry No. 804

Variable frequency drive series is built for dependable performance

Designed to precisely manage the electrical current for ultra-high-speed motors and spindles, the Eazy series var-

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iable frequency drive system from Amtech Drives uses a proprietary PWM sinusoidal waveform for long bearing and spindle life, as well as production uptime. The system is easy to install, operate and maintain, and provides control and protection to AC induction motors in the 40-hp to 1,875-hp range. Applications include rayon spinning equipment, agitators, centrifuges, pulp and paper equipment, and air compressors. Amtech Drives Online Reader Inquiry No. 805

Adjusting hub changes phase relationship of PT system components

Zero-Max Phas-Lok adjusting hubs provide a fast and easy method for changing the phase relationship of components in a power transmission system. Compensating for required timing changes in a system, they provide an accurate, mechanical adjustment within a 24-degree range and eliminate the need to disconnect or remove drive components in order to reposition or re-synchronize them. The phase adjustment can be made quickly on the machine using ordinary hand tools. The hubs are available in three sizes with bores ranging from 1/2 in. to 2-1/2 in., and in metric bore sizes and with a variety of split taper bushings. Zero-Max

Baldor has expanded the RPM AC permanent magnet product offering up to 1,200 hp. This motor product line performs like a high-horsepower servo motor with low rotor inertia and high power density, and is available in NEMA frame sizes 180, 210, 250, 280 and 440 with permanent magnet rotor construction. Available as totally enclosed, blower-cooled TEBC ratings up to 150 hp with resolve feedback, these motors are offered in both NEMA and IEC (112, 132, 160, 180 and 280) frame sizes. They are all designed to provide continuous constant torque performance from zero speed up to base speed for use with closed loop PM AC drives. Baldor Electric

Robust servo motor operates in a variety of extreme environments

Wittenstein provides servo motors for a wide range of environments. Its extreme-temperature motors, while small, are designed to operate in the most demanding environments, from space to the ocean floor, at temperatures ranging from minus 70°C to plus 210°C. Radiation-hardened motors are custom-designed, and are suited for applications in military and aerospace due to their highly accurate positioning, dynamic acceleration and high constant stability. Ultra-high-vacuum motors require the use of special materials and extreme cleanliness due to their environmental restrictions, and come in a range of vacuum levels for a variety of applications. Wittenstein Online Reader Inquiry No. 808

ther Ultracord (8 and 14M) and RPP Plus (8, 14 and 20M). Panther Plus sprockets and taper-lock bushings also are available. Synchro-Cog HT belts are designed for high-torque applications and deliver trouble-free power transmission with a smooth and quiet drive system. They are available in 3-mm, 5-mm, 8-mm and 14-mm pitches. Carlisle Transportation Products Online Reader Inquiry No. 800

High-power intelligent soft start boosts performance

The RSQK high-power, intelligent soft starts from Carlo Gavazzi decrease the wear and tear on mechanical transmission components and reduce high starting currents and mechanical stress on gears, shafts and pulleys. They are designed for applications

up to 900 A/750 hp, including controlling large pumps, fans and mixers in the 200hp to 500-hp range. As this device can be connected inside the motor delta, a smaller soft start can be used. Features include automatic energy-optimization, automatic application setup, six-button keypad with LCD display for continuous display of relevant parameters, and up to 12 starts per hour. Carlo Gavazzi (Canada) Online Reader Inquiry No. 807

MRO

Online Reader Inquiry No. 806

Video showcases metric timing belt drives and more

A video from Econobelt features metric timing belt drives, plus belt and chain tensioners. It includes the company’s complete product offering of timing pulleys, timing belts, bushings, belt clamping kits, roller chain sprockets, roller chains, belt and chain tensioners, sonic

tension testers and planetary gearheads. The product line is featured at the QTC eStore, where online ordering is available, quotes may be requested, CAD models downloaded, stock checked, and catalogue specifications and technical pages viewed. The video channel can be viewed at www.youtube.com/qtcgears. Econobelt Division, Designatronics

When ultimate chain performance really matters, trust Canadian made Tsubaki sprockets. www.tsubaki.ca

Online Reader Inquiry No. 801

Synchronous drive system saves time, money and energy

Carlisle Transportation Products has introduced Panther Plus and Synchro-Cog HT synchronous drive systems, which offer quiet, energy-saving and maintenancefree operation. Panther Plus replaces Pan-

Online Reader Inquiry No. 138

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What’s new in test and measurement Oval gear meter can handle highly viscous/corrosive environments

sures DC and AC voltage to 600 V, AC current to 400 A and resistance to 400 V. Features include frequency tests to 400 Hz, and data/range hold and auto range buttons to keep the screen from updating when gathering values. Applications include HVAC, automotive, electrical/power and environmental monitoring uses. The meter comes with red and black test leads, two AAA batteries and carrying case with a belt loop. Dwyer Instruments

Badger Meter has introduced a line of inline and flanged oval gear meters and industrial registers for a variety of applications, including petroleum-based fluids,

Temperature chart recorder includes mounting flexibility

Online Reader Inquiry No. 761

Pipeline measurement system facilitates inspection procedures

Low-cost digital clamp meter offers multifunctional utility

Dwyer Instruments has introduced the compact, low-cost CM-1 digital clamp meter, suitable for general electrical testing and troubleshooting. The instrument mea-

Handheld oscilloscope is versatile

AEMC Instruments’ self-contained, hand-held, two- and four-isolated-channel oscilloscope comprises five tools in one: oscilloscope, FFT analyzer, fourchannel TRMS multimeter, harmonic analyzer and recorder. The model OX7100 (100MHz) and OX7200 (200-MHz) series are rugged, ergonomic instruments designed for both laboratory and field testing and troubleshooting. The 320-by-240 full-colour LCD touch screen provides detailed graphical and alphanumerical representations of all measurements, and the menus can be manipulated using the convenient stylus. A range of remote management capabilities is included. TechniCAL Systems 2002 Online Reader Inquiry No. 766

spections in accordance with PACP, MACP and similar guidelines, and plan relining jobs. A collapsible 24-ft pole and articulating measurement head enable the device to reach every structure requiring measurement, yet stow conveniently in the bed of a pick-up truck. Powered by an industrial-grade laser, it presents readings on a digital display, stores the 10 most recent measurements, can offload readings to a PC, and operates on rechargeable battery power. Envirosight Online Reader Inquiry No. 764

Linear accelerometer is for use while drilling in downhole well applications

Online Reader Inquiry No. 765

Online Reader Inquiry No. 768

water solutions and other highly viscous fluids. These industrial flow meters are available in aluminum with liquid crystal polymer gears and stainless steel with stainless steel gears. Designed to withstand extreme conditions and provide high accuracy even in low-flow environments, the model IOG includes 1/2-in., 3/4-in. and 1-in. sizes with inline NPT and BSP or flanged in 150, 300 and DIN 16. The simple design requires little maintenance. The meter can be installed in tight spaces either vertically or horizontally and does not require a straight run of pipe or conditioning. It operates up to 800 psi. Badger Meter

Operated from street level, the DiaMetrik pipeline measurement system measures depth and width of manholes, plus diameter of incoming lines, to an accuracy of 0.1 in. This dimensional data makes it easy to configure crawlers, complete in-

The microcontroller design of Omega’s series of temperature chart recorders enables it to accurately measure and record temperatures in air, gas, liquids, powders, solids and semi-solids using the stainless steel remote reading 102-mm (4-in.) probe with 4.6-m (15-ft) cable. The CT89 series features a large LED digital temperature display, three temperature ranges and four chart speeds, a battery back-up that assures normal operation during power interruptions, a durable polycarbonate case, cover and handle, as well as the ability to be freestanding or wall mounted. Applications include food storage, HVAC, general laboratory and computer room monitoring. Omega Engineering

Columbia Research Laboratories’ models SA-220RHT and SA-225RHT biaxial force balance accelerometers have been designed as Measurement While Drilling (MWD) sensors for use in downhole well service applications. Both sensors are completely selfcontained and provide a high-level, lowimpedance output, eliminating the need for high-temperature signal conditioning. The model SA-220RHT operates from + 15 VDC and is capable of operating at temperatures of up to 200°C. Model SA225RHT requires + 5 VDC and operates to 190°C. Units weigh 94.7 gm (3.34 oz.) and are packaged in nickel-plated aluminum cases. Customized versions are available. Columbia Research Laboratories

turing a clear window for easy access to the instrument’s controls and keyboard. Fluke Electronics Canada Online Reader Inquiry No. 762

Airflow measuring probe features aerodynamic sensors

The series JFM-P FloSen airf low measuring probes from Sensocon provide accurate, repeatable measurement of air movement in HVAC ducts. Featuring elliptically shaped sensors with good aerodynamic characteristics, the probes overcome loss of accuracy caused by fluid separation at the sensor body. They use an in-line groove for total pressure sensing and dual ports for static pressure sensing, which produces a higher differential pressure for very low velocity measurements. The probes have been designed for easy installation and maintenance, and can be completely installed from outside the duct. Sensocon Online Reader Inquiry No. 763

Lightweight inspection camera travels easily to remote locations

Weighing just five pounds and less than 12 in. across, the Sidewinder push camera from Peerless Creations travels with ease up ladders and across catwalks to inspect process piping, heat exchanger tubes, exhaust stacks and other confined spaces. Its camera extends 100 ft into openings as narrow as 7/8 in. in diameter. Footage is displayed on a detachable wireless LCD monitor capable of recording 32 GB of video and

Online Reader Inquiry No. 769

Documenting process calibrator withstands rugged environments

Online Reader Inquiry No. 139

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The 750 series documenting process calibrators has been introduced by Fluke. Operating this series is similar enough to the 743/744 series that existing users will require no training on the new model. It calibrates temperature, pressure, voltage, current, resistance and frequency and has three operating modes – measure, source or simultaneous measure/source – enabling technicians to troubleshoot, calibrate or maintain instrumentation with just one tool. Improvements over the original model include a graphical display that can be seen in any light condition, while the multi-lingual interface displays instructions in English, French, German, Spanish or Italian. Also new is the rechargeable lithium-ion battery pack. The calibrator comes in the C799 soft case, fea-

still images, and can be transferred to a computer or smart phone. The camera is made of stainless steel and has a scratchresistant sapphire window, while the push rod is composed of electrical conductors within a glass-fibre core, all sheathed in a rugged PVC jacket. It measures 3/16 in. in diameter, and coils neatly into a 11.5-in. reel. Peerless Creations Online Reader Inquiry No. 767

MRO

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

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What’s new…

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

Plug and play hose system reduces assembly time

The quick-to-connect hose and fitting system for low-pressure hydraulic and pneumatic systems from Parker Hannifin’s Parflex Division is a plug-and-play system that consists of Parflex 515H hose and Parker RA (Rapid Assembly) quickconnecting hose fittings and adapters.

The lightweight, fibre-reinforced, flexible, low-pressure thermoplastic hose has good kink resistance, making it suitable for routing through tight spaces. Sizes range from 3/16-in. I.D. up to 1/2-in. I.D in a single or multi-line assembly. The brass RA quick-connect fittings are compact, anti-corrosive and economical, while the connector design is simple and durable and allows tool-less installation. Parker Hannifin

protection as standard. They are insensitive to dust, humidity, fumes and other generally poor working conditions and can operate in a temperature range of minus 20°C to plus 70°C. J D Neuhaus

Machinery & Equipment MRO

Two-way ball valve can handle over-pressure

The Series MSV compact two-way ball valve has been released by W.E. Anderson Division of Dwyer Instruments. The series comes in a two-body stainless steel or brass design with the choice of either fractional tube fitting or female NPT connections, and provides quick quarterturn directional control of fluids. Features include a blowout-proof ball and stem, micro-finished ball and PTFE seats. The valves can handle pressure up to 1,500 psi over a temperature range of minus 40°F to plus 350°F. Dwyer Instruments Online Reader Inquiry No. 333

Online Reader Inquiry No. 711

Heat-sink analysis system is wafer-thin

The Tactilus heat-sink analysis system from Sensor Products enables research and design engineers to quickly and precisely test and correct the surface contact and pressure distribution between the heat sink and its source. The heat sink interface can be tested, manipulated and repositioned in real time, speeding the trial and error process and eliminating the need for additional assembly. Flexible

and only 0.38 mm (0.015 in.) thick, it can be placed between the CPU and heat sink. The sensor pad has 625 resistive sensing points arrayed on a 25-by-25 grid. Total sensing area is 2 in. by 2 in., scan speed is up to 1,000 Hz, and operating pressure range is 0 kg/cm2 to 7 kg/ cm2 (0 psi to 100 psi). Applications include tire tread footprints, door seals, heat seals, fuel cells, printed circuit boards, flat panel displays and wafer polishing, among many others. Sensor Products Online Reader Inquiry No. 325

Fluid connectors can be designed and delivered with short lead times

Parker’s Tube Fittings Division can manufacture custom fittings and adapters, as well as manifolds and many other fluid conveyance products, to a customer’s specifications for prototypes, emergency repair or pre-production applications, while keeping lead times to a minimum.

Products are machined in steel, stainless steel, brass, aluminum or numerous other types of market-specific materials such as nickel copper/copper nickel, VIM/VAR, duplex and Hastelloy. All parts comply with applicable conformance standards. The division has the necessary manufacturing capabilities to work with customers throughout their full product life cycle, from prototype and pre-production through full production to aftermarket support, and is able to transition quickly and seamlessly from low- to high-volume production of a specialty product. Parker Hannifin Online Reader Inquiry No. 338

continued on page 36

Online Reader Inquiry No. 317

Clutch line suits inclined conveyors

The Morse CB-HS high-speed conveyor backstop clutch product line from Emerson Industrial Automation packs more torque into a compact envelope, compared to the previous version, and allows users to reach higher speeds. The design incorporates a full complement of anti-rollover cams and dual ball-bearing support, which helps to improve energy efficiency. Two enhanced features are 28% larger spacers, for a 64% stronger clutch, and an advanced taconite sealing system. Applications include inclined aggregate-conveying and coal-handling. Emerson Industrial Automation

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

Based on you. Built by Fluke. qtr page Ads (4).indd 4

www.flukecanada.ca/810 Online Reader Inquiry No. 140

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Online Reader Inquiry No. 687

Materials handling equipment is insensitive to poor working conditions

J D Neuhaus offers handling equipment for chemical and other industries subject to hazardous environments. This equipment, which includes cranes, hoists and winches, is operated by compressed air (or optionally hydraulics), rather than using electric power, for safety and reliable, low-maintenance operation. Equipment safety ratings for use in potentially explosive conditions are Ex II 2 GD IIA T4(X) / II 3 G D I I B T4 ( X ) . I n creased spark protection can be supplied to achieve an Ex II 2 GD IIB T4(X) rating. All units feature sensitive, infinitely variable speed control for precise load positioning, with overload

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Online Reader Inquiry No. 141

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Connector reduces installation time

Feed-through connector keeps panels sealed

Quick and easy to install, Murrelektronik Profibus connectors feature two standard, b-coded M12 connections for Profibus cables. Installation takes just a few seconds, as the bus connectors are connected to the

Binder-USA has added a threaded feedthrough connector to its M12, 713 series connectors. The design of this connector allows for a secure, sealed connection through a panel, allowing M12 connectors to be connected on either end. The M12 feed-through adapter is constructed with a rugged metal design including an M12x1

bus device’s nine-pole Sub-D fieldbus interface and the fieldbus cables are connected via pre-wired M12 connectors. Designed for data rates of up to 12 Mbit/s, the connectors are available with three different housings and cable exits of 35 degrees, 90 degrees and 180 degrees. The full metal housing, made of zinc die-cast, ensures secure shielding. Murrelektronik

thread-locking termination. The connector is available in four, five and eight gold-plated contacts with A-coding, and the diameter of the mounting hole is 20 mm. When properly mated, the feed-through adapter maintains an environmental protection rating of IP67 at both the panel and mating area on each side of the adapter. Binder-USA

VFD compressor delivers varying amounts of air flow

Sullivan-Palatek’s variable-frequency-drive air compressor provides the air required at a power level corresponding to the air demand, reducing power requirements. If the air use in the plant reduces, the compressor slows down to supply the air demand while still maintaining the desired system pressure. It operates at a speed sufficient to supply the air being used, no matter the demand. When no air is being used, it goes into sleep mode. In addition, these compressors can be programmed to automatically change pressure for shifts where more or less pressure is needed. They come in a range of 15 hp to 400 hp. Sullivan-Palatek Online Reader Inquiry No. 386

branded chains include versions with low-friction running rollers, side bow conveyor chains and maintenance-free conveyor chains. The Elite range in-

Online Reader Inquiry No. 733

Accumulation chain keeps products moving

Iwis accumulation chains are for feed and assembly applications. The Iwis-

Online Reader Inquiry No. 330

cludes accumulation roller chains, chains with parts and finger protection, and double-pitch roller chains. Accumulation chains are used to provide gentle transportation of finished products and such workpiece carriers as pallets, containers or crates. These versatile units are used as links between stations of a production or assembly line, in warehouses, and in a range of material flow systems. Iwis Drive Systems Online Reader Inquiry No. 738

Scan Me!

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

Online Reader Inquiry No. 142

ENGINEERS REQUIRE PERFORMANCE. PURCHASING WANTS LOWER COSTS.

THE BOSS DEMANDS RESULTS.

Digital indicator installs easily into fixtures

Designed for use as a bench-top unit or for inline measurement, the compact EG-225 digital indicator from Ono Sokki is a multi-purpose, inch/ metric switchable gauge used for a variety of applications. It conforms to AGD Group 2 mechanical specifications, making it interchangeable with existing mechanical gauges, and performs highly accurate measurements to 0.00005 in. throughout its 1-in. measuring range. The indicator has a built-in rechargeable battery for portable applications, or it may be used with the supplied AC adapter. It has a fast data output speed of approximately 40 data/sec. Ono Sokki Online Reader Inquiry No. 313

Maintenance coating line provides durable coverage

Pratt & Lambert Paints offers a line of coatings for light- to medium-duty industrial applications. The line includes six product categories: primers, dry falls, enamels, epoxies, urethanes and floor coatings, suitable for both maintenance and new construction. Performance features include good corrosion and chemical resistance, impact and abrasion resistance, superior adhesion and ease of application, as well as aesthetics. The coatings can be used for walls, lockers, floors, pipes, machinery and bathroom stalls in most facilities, including factories, hospitals, offices, schools and restaurants. Pratt & Lambert Online Reader Inquiry No. 717

Solenoid valve is built for long-life service

Satisfying competing demands is easy with Diamond roller chain. With industry leading wear life engineers get their performance. With the Lowest Total Cost of Ownership, purchasing gets their cost reductions. Best of all – the boss gets results. When your business demands results, demand Diamond.

Scan the QR code for additional information about the Diamond Chain Company

www.diamondchain.com

Online Reader Inquiry No. 143

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Parker has introduced the high-flow, directmount Namur solenoid valve. This compact product line offers cost-effective solutions for a wide variety of general-purpose valve actuator applications. Features include a Namur mounting pattern, flow rates from 1.2 Cv to 3.0 Cv, spring return and screened exhaust nut. Designed for direct mounting in any position on a Namur interface, the valve is built with an anodized aluminum

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Machinery & Equipment MRO

body and stainless steel spool, and has internal parts made of brass. Pressure range is 30 psi to 150 psi. These rugged valves are offered with Class F DIN and Class H hazardous location coils and operate at fluid temperatures ranging from 32°F to 122°F. Parker Hannifin Online Reader Inquiry No. 342

Steel lockout hasp accommodates small lockout holes

Master Lock has expanded its lockout hasp line to fit smaller lockout holes such as small electrical throw switches, miniature circuit breakers and newer fluid valves. The compact and lightweight S430 hasp is made with a 4-mm-diam-

anical, electrical and environmental challenges in hydraulic pressure measurement applications. The sensor uses the company’s KrystalBond technology, in which the pressure port is constructed from a single piece of stainless steel, while the pressure-sensing element is machined from a bar of high-strength stainless steel. An all-stainless-steel housing welded to the sensing element protects against environmental conditions, such as outdoor installation or high-pressure washdown. American Sensor Technologies

Personal air sampling pump has ATEX approval

Casella USA has announced that its Tuff personal air sampling pump has gained ATEX and IECEx Intrinsically Safe approval for use in flammable atmospheres. The pump can be used to measure employee exposure to dangerous airborne particulates, such as lead, mould or asbestos, wherever there is a potential risk of explosive dust or gas. In addition, this rugged pump has received certification to M1 classification for mining applications, allowing it to be used safely underground without the need for a hot work permit. A double-acting diaphragm pump mechanism with precise digital control assures good real-time flow control and stability across a wide range of sampling media. Flow range is 5 ml/min to 4.5 l/min. Casella USA Online Reader Inquiry No. 309

Online Reader Inquiry No. 339

Servo drive series withstands extreme conditions

The AZX series of embedded, extendedenvironment servo drives from Electromate is designed to handle outdoor, mobile and otherwise rugged environment applications. Features of these plug-in modules include heat sink temperature shutdown

set at 115°C (239°F), ambient temperatures from minus 40°C to plus 85°C, full temperature range cycling under two minutes, and a weight of just 95 g (3.35 oz). They are suitable for a wide range of extreme or harsh-environment motion control applications, such as altitude research platforms, airborne vehicles, ground-

based fixed platforms, transportable devices, marine vessels, and more. Electromate Industrial Sales Online Reader Inquiry No. 323

MRO

Obtain free additional information about any of these items by using our Online Reader Reply Card at www.mromagazine.com/rsc.

eter (1/8-in.-diameter) steel shackle and is constructed of 316 stainless steel to prevent corrosion. It accepts up to eight padlocks, including two manager padlocks, and works with all Master Lock and American Lock safety padlocks, hasps and the S100 Lockout Leash. Master Lock Online Reader Inquiry No. 370

Magnetic sensors can be used in harsh environments

Designed for detecting moving ferromagnetic objects such as toothed wheels, gears or racks, Baumer’s magnetic Hall sensors feature a maximum switching frequency of 20 kHz. These high-resolution sensors feature IP68-rated housings for harsh environments exposed to vibration, shock and contaminants such as dust and oil. As they contain no moving parts and experience little wear, they can effectively re-

place incremental encoders for detecting rotational speed or direction. Able to withstand temperatures from minus 40°C to plus 120°C, they are suitable for use in a wide range of applications, including food and beverage processing, metalworking, oil processing, automotive and aerospace. Baumer

Created Equal.

Just because different companies’ washdown gearmotors may appear similar from the outside doesn’t mean they’re built the same on the inside. The Bison 230V inverter duty, IP69K rated SANIMotor™ is unique from other gearmotors, since it completely encapsulates all electrical components in thermally conductive epoxy resin, is sealed with EPDM rubber o-rings and secured with hex bolts to guarantee against leaking. SANIMotor™ products are part of Bison’s In-Stock, Instant-Ship (ISIS) program which supports distribution partners in the U.S. and Canada by offering same-day shipment for orders received before noon (CDT).

CERTIFIED Q U

Check the label to ensure it’s always a “Bison”! Get the most up-to-date news and industry updates on twitter at: http://twitter.com/bisongear

To learn more: 1-800-AT-BISON • info@bisongear.com • www.bisongear.com

9001:2008

MANAG EM ITY

The AST4000 series pressure sensor with special configurations for the hydraulic industry has been released by American Sensor Technologies. Through the use of a three-digit option code, the series can be modified to withstand a variety of mech-

All Gearmotors are

SYSTEM

Pressure sensor features special hydraulic configurations

T EN

Online Reader Inquiry No. 321

Gear & Engineering Corp.

Online Reader Inquiry No. 144

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L I T E R A T U R E

MACHINERY AND EQUIPMENT

G U I D E

NORD EXPANDS RANGE OF ‘SCP’ SCREW CONVEYOR DRIVE Nord Drivesystems has added an additional size to their very popular ‘SCP’ line of CEMA compatible screw conveyor drives. Now with seven sizes with output torque capacity to 32,475 lb.in. Many options and styles including right angle are available. Contact Nord at info@nord-ca.com for complete information.

Free MRO Product

Literature Guide NEW PULLEY CATALOG “B216” BRECOflex’s new B216 pulley catalog offers made-to-order and stock pulleys. The new domestic “CNC” pulley maufacture allows for precise machining standards, leading to superior product quality and quick product availability. BRECOflex now provides finished custom precision pulleys and stock pulleys with pilot bores, for immediate delivery. Custom pulleys include backlash, reduced backlash “SE” or zero backlash “0” tooth gap design. Call for our free engineering support! BRECOflex CO., L.L.C. 888-463-1400 or 732-460-9500, Email: info@brecoflex.com BRECOFLEX Online Reader Inquiry No. 273 ENERGY SAVINGS BROCHURE The 18-page brochure outlines the advantages of premium efficiency Baldor·Reliance Super-E® motors, which meet or exceed NEMA Premium® efficiency standards. Baldor’s BE$T (Baldor Energy Savings Tool) software, included with the brochure, can compare the operating cost of industrial electric motors with Baldor·Reliance motors. For a free copy, contact a Baldor District Sales Office, or visit baldor. com/support/literature_request.asp, complete the form and click ‘Energy Efficiency.’ BALDOR Online Reader Inquiry No. 276

NORD GEAR Online Reader Inquiry No. 271

Advertising Feature

CLEARANCE, MOUNTING AND LUBRICATION GUIDE NSK is dedicated to delivering value added information to keep your facility both efficient and productive. To help maximize uptime and lower maintenance costs, keep a copy of our reference guide for bearing ‘must-knows’ on: • Types and Tolerance Classes • Fits • Radial Clearance • Selecting the correct lubrication • Lubrication consistency • Mounting For more information, visit us at www.ca.nsk.com or contact us at info@ca.nsk.com or 1.877.994.6675 NSK Online Reader Inquiry No.272

2011 SMALLEY® CATALOGUE NOW AVAILABLE

HY-SPEC LAUNCHES NEW HYDRAULIC CATALOGUE!

Smalley’s new 132-page catalogue contains detailed specifications and technical information for the full range of retaining rings, wave springs and constant section rings available from Smalley. Over 10,000 Inch and Metric stock sizes are manufactured. Special designs including working prototypes from .200" to 120" (5 mm to 3,000 mm) can be produced in as little as two weeks as a result of Smalley's No-Tooling-Cost® process. Smalley products are stocked in Canada by RotoPrecision in strategic locations across the country.

Hy-Spec, Kinecor’s private label brand of hydraulic components, has recently launched a new mobile directional control valve catalogue which can be viewed at www.hy-spec.com. Hy-Spec specializes in the import and export of a wide range of high quality hydraulic components including utility cylinders, directional control valves, gas engines, gauges and much more. For further information, contact: Bruno Knesevitch Product Manager Tel: (514) 636-7477 x2312 E-mail: bknesevitch@kinecor.com

ROTOPRECISION Online Reader Inquiry No. 274

KINECOR LP Online Reader Inquiry No. 275

BELT DRIVE PREVENTATIVE MAINTENANCE & SAFETY PROGRAM

KNOWLEDGE-ENGINEERED LUBRICATION SOLUTIONS FROM SKF

Gates is dedicated to providing reliable information to keep your facility running safely at optimum capacity. When compared to the maintenance and replacement costs of roller chain or gear drives, belts can be the most cost-effective and reliable power transmission solution. An effective preventive maintenance program consisting of a safe working environment, proper belt drive installation, inspection and performance evaluations will continue to keep costs down. Let Gates help increase your facility’s uptime and avoid costly belt drive failures. Visit www.gates.com

Some 36% of premature bearing failures are caused by incorrect specification or inadequate application of lubricant. Preventing such failures means delivering the right lubricant, in the right amount, at the right time, to the right lubrication point. With over 100 years of rotating machinery expertise, SKF delivers a complete line of lubrication solutions to do exactly that. SKF Online Reader Inquiry No. 278

GATES Online Reader Inquiry No. 277 DRIVES IS PLEASED TO ANNOUNCE OUR “AS600” SERIES CHAIN Imagine a stainless steel product that could offer you Higher Gross Profit Margins with no premium over standard 300SS Series Chain. Drives imagined it — and we are making it work for you. With 600SS series round parts and 300SS series side plates, the Drives “AS” series chain gives your customers a 50% higher working load over 304SS series chain while increasing wear life and providing excellent corrosion resistance. To view our complete line of products, visit www.drivesinc.com.

WEG’S NEW W22 LINE OF MOTORS WEG’s new higher efficiency motor design incorporates a new airflow and end bell design for cooler running. W22 motors have 12:1 CT ratings for VFD use and flexible mounting for F1, F2, F3, vert. and horiz. options. The new flat foot design and FC200 High Grade Cast Iron provide less noise and vibration. W22 motors are CSA Inverter Duty rated for Div. 2 Class 1, Groups B, C & D.

KOYO CANADA ADDS NEW LINE OF NEEDLE ROLLER BEARINGS Koyo Canada now offers the full range of Torrington® needle roller bearings and cam followers from stock, in metric and inch sizes. Bearings can be ordered pre-lubricated to reduce assembly time and in bulk packaging which cuts down on material waste. Contact your local authorized Koyo distributor or Koyo Canada for more information at 1-800-263-5163, www.koyo.ca.

VJ PAMENSKY Online Reader Inquiry No. 280

KOYO Online Reader Inquiry No. 281

NTN ULTRA CLASS BEARING UNITS

LOCTITE® 243™ AND LOCTITE® 263™ – THE MOST ROBUST PERFORMING MEDIUM AND HIGH STRENGTH THREADLOCKERS

DRIVES, LLC Online Reader Inquiry No. 279 SPHERICAL ROLLER BEARINGS THAT SAVE YOU MONEY AND TIME The FAG X-life series E1 spherical roller bearings provides optimum operating life far beyond conventional values. With our optimized roller geometry and raceway finish, operating life is increased up to 70%, reducing downtime and maintenance costs. That is why you will find our bearings in all kinds of applications where heavy loads have to be accommodated or where shaft deflections or misalignments of bearing seats must be compensated for. They operate in the harshest environmental conditions, for example in gearboxes, paper machines, construction machinery and vibrating machinery. INA/FAG Online Reader Inquiry No. 282

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NTN Bearing Corporation, a leader in the supply of bearing units, also offers the Ultra Class Mounted Unit series. NTN’s research, along with extensive experience in original equipment and the aftermarket, has led to the development of a unit with unique features that take mounted units to an elevated level of design and performance. For more information on Ultra Class Bearing Units, or on our wide range of bearing products, visit us at www.ntn.ca NTN BEARING CORPORATION Online Reader Inquiry No. 283

Recent advancements in the chemistry of anaerobic threadlockers have resulted in the new Loctite® 243™ Medium Strength Blue Threadlocker and the new Loctite® 263™ High Strength Red Threadlocker. For more information, request LTC-1326 Threadlocker Sell sheet or call 1.800.263.5043 For a free sample, visit www.useloctite.com LOCTITE Online Reader Inquiry No. 284

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We see less downtime in your future. At NTN, we are dedicated to help you get the most out of your rotating machinery. Our people contribute to this vision every day. Invite us to roll up our sleeves with you.

Online Reader Inquiry No. 145

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EMO Cutting Edge

5/23/08

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UNMATCHED ENGINEERING EXCELLENCE FROM THE SCHAEFFLER GROUP Condition-based maintenance with FAG Detector III Condition-based maintenance encompasses 1) identifying damage at an early stage, 2) defining planned repairs, 3) making optimum use of bearing life, and 4) achieving considerable reductions in costs. FAG Detector III fulfils these tasks to an optimum degree and is also highly suitable for users with only minimal knowledge of vibration technology.

FAG Detector III is an offline vibration monitoring system, data collector and operational balancing device all in one. By means of various sensors, it can record

the vibrations, temperatures and speeds of machinery. Step by step, the device’s software guides the user through the measurement and balancing procedure. The userfriendly software then allows easy and effective data analysis. Furthermore, comments can be defined in the software, transferred to the FAG Detector III and selected as required after measurement. Any incipient damage can therefore be detected at a very early stage. As a result, maintenance can be planned and machine availability can be increased.

The Cutting Edge in Machine Tool Design Super precision bearing technology from the Schaeffler Group is focused on delivering innovative bearing solutions with improved operating efficiencies. As a result, Schaeffler products set standards unchallenged by other bearing manufacturers in the world today when it comes to performance reliability, running accuracy, high speeds, longer operating life and a sensitivity to cost. The extensive range of Barden, FAG, and INA super precision bearing products offered by Schaeffler can satisfy virtually any machine tool application requirement - from spindles to ball screws to turn tables - with an optimal solution from a single source. SCHAEFFLER GROUP SCHAEFFLER GROUP INDUSTRIAL INDUSTRIAL

FAG Detector III is the ideal entry level device for the detection of • imbalance and misalignment • rolling bearing damage • gearbox damage (tooth sets) Typical areas of application include the monitoring of • pumps • electric motors • fans • machine tools • compressors • gearboxes • spindles

For additional information about FAG Detector III, contact your local Schaeffler representative or visit www.fis-services.com. Online Reader Inquiry No. 146

Online Reader Inquiry No. 147

www.schaeffler.us

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