Machinery & Equipment MRO December 2012 by Annex Business Media

MACHINERY AND EQUIPMENT

Curing a stick-slip problem on chain-driven conveyors Improving efficiency in belt drive systems Weighing in on warranties

Vol. 28, No. 6

DECEMBER 2012

SPECIAL SECTION

INDUSTRIAL LUBRICATION Fighting improper lubrication practices Breakthough test machine examines bearing friction Choosing the right hydraulic fluid

The

DAILY

GRIND Improving grinding safety

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LUBRICATION

TOOLS

ELECTRICAL

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P R O D U C T

SP TLIGHT

Low-cost shaft alignment system includes Bluetooth technology

machines. Available in 1-gal, 5-gal, 30gal, and 55-gal containers, the product is a water-based, high-powered cleaner that is biodegradable, non-corrosive, non-toxic and non-flammable. It contains no acids, abrasives or petroleum solvents and will not harm the skin. Kafko International Ltd.

Online Reader Inquiry No. 606

Online Reader Inquiry No. 599

Cleaner/degreaser does the job of multiple products

IR camera fills the gap between thermometers and thermal imagers

Eco-friendly Oil Eater Original cleaner/degreaser quickly disperses grease, oil and grime from machinery, equipment, tools, concrete floors and much more. It is formulated to eliminate the need for multiple cleaning products and it can also be used in parts cleaning and pressure washing

trol. Pre-mounted units make the system easy to install on the machine and the programs guide the user step-by-step through the process. Results can be transferred to the EasyLink database program for PCs. For additional details, visit www.benchmarkpdm.com. Benchmark Maintenance Services Inc.

The Easy-Laser E420 entry-level laser shaft alignment system from Benchmark PdM is a compact, low-cost measuring unit with integrated Bluetooth wireless technology and a rechargeable battery. Features include a 5.7-in. colour display and an IP65-rated design that withstands harsh environments. Programs for alignment of both horizontal and vertical machines also are included, as are functions for soft-foot control, thermal growth compensation and tolerance con-

December 2012

The Fluke VT02 Visual IR Thermometer is a troubleshooting camera with an infrared heat map that combines the visual insight of a thermal imager, the visual images of a digital camera and the point-and-shoot convenience of an infrared thermometer to instantly detect problems. Conducting inspections for electrical, industrial, HVAC/R and automotive applications is considerably

A Better IEEE 841 Super-E® windings meet or exceed NEMA Premium® efficiency standards

High strength cast iron frame, endplates, conduit box and fan cover are designed to reduce vibration and assure accurate mounting dimensions

Oversize bearings on each end for long life

Insulation system meets requirements of NEMA MG 1, Part 31.4.4.2 for VFD use and considered inverter-ready

Inpro/Seal™ VBXX Bearing Isolators at both ends assure protection from contamination

Online Reader Inquiry No. 600

Cell phone booster allows workers to stay connected in the factory

Wireless Solutions of Richmond Hill, ON, has a line of robust, affordable and powerful cell phone booster systems that can raise the reception bars on cell phones from one bar to full reception. The system, which covers the major carriers and is designed for warehouses, factories, logistic/distribution centres, etc., comes with five antennas: one for outside (to grab the existing cell signal) and four for inside. Additional components include a splitter, cables and 68-dB power amplifier. Cell coverage of this industrial kit is 60,000 sq ft. The company supplies drawings and engineering support to assist in installation, which takes two to three days. For additional details, visit the website at www.wireless-solutions.ca. Wireless Solutions

All internal rotor, stator and shaft surfaces are epoxy coated to prevent corrosion

faster with the VT02 than an infrared thermometer, which requires multiple readings and manually recorded results. The device displays and saves images as full visual or full infrared, or in three blended modes (25%, 50% and 75%). Images are saved to a micro-SD card, eliminating the need to write down single or multiple measurements, and they can be imported into the included SmartView analysis and reporting software. For additional details, visit the website at www.flukecanada.ca. Fluke Electronics Canada

Online Reader Inquiry No. 601

Pump series is designed for sterile processes in industry Exclusive PLS® (Positive Lubrication System) assures proper bearing lubrication in all mounting positions

Two-part epoxy primer inside and out, plus epoxy finish coat to prevent corrosion

All joints gasketed and sealed for added protection against contaminant entry

The Vita line of five pump series for sterile processes from KSB caters to the strict hygienic requirements of the beverage and food processing industry. The family consists of four centrifugal pumps (Vitachrom, Vitacast, Vitastage and Vitaprime) and a rotary lobe pump (Vitalobe). These versa-

Foot flatness within 0.005 inches for precision alignment to driven equipment

Inside and Out Baldor•Reliance® 841XL severe duty motors are engineered and built to meet or exceed the most rigid severe duty service standards. You’ll find Baldor•Reliance severe duty motors hard at work around the world in some of the most brutal conditions you can imagine, like petrochemical, pulp & paper and mining operations. So, no matter how you look at it, you can always count on Baldor•Reliance severe duty motors to perform under the most extreme conditions...inside and out.

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tile and maintenance-friendly pumps can be employed for almost any task related to the transport of liquid or viscous food. Easy to clean, they meet every requirement in respect of absolutely sterile processes. Their excellent cleaning and steaming-inplace capabilities are also promoted by electropolished wetted components made of high-grade stainless steel. All pumps in the series have received certification relevant to the industry, while their elastomer components conform to FDA standards. For additional details, visit www.ksb.ca. KSB Pumps Inc. Online Reader Inquiry No. 603

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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Machinery & Equipment MRO

Cut-to-length Chain anD CustoMer serviCe now availaBle in CanaDa

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tiMken has an exPansive offering of ProDuCts inCluDing:

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Online Reader Inquiry No. 116

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C O N T E N T S

Machinery & Equipment MRO

December 2012

in this issue Weighing in on warranties / 11

What you get and what you don’t with guarantees on machinery and equipment. Cover story: Improving grinding safety / 13

This quiz will let you know when an employee can safety operate a pedestal or bench grinder. Curing conveyor stick-slip / 14

On extra-long chain-driven conveyors, this annoying problem can be resolved with bearing roller chain.

p11

Centralized lube systems enhanced / 21

departments

Improved pump unit for wind turbines boosts efficiency.

Editor’s Notebook / 6

Breakthough test machine examines bearing friction / 22

The Tribogyr, also known as the Beast of Lyon, provides new insights into the behaviour of friction in rolling elements.

Industry Newswatch / 8 Business Briefs / 10 Mr. O, The Problem Solver / 10 The Safety File / 16 Maintenance 101 / 17 MRO on the Road / 30

columns

Product News

Mr. O, the Practical Problem Solver / 10

Focus on Lubrication / 24

Product Spotlight / 2

Setting up regular routines to solve lubrication troubles.

Focus on Belt Drives / 26

The Safety File: They didn’t have to die / 16

Electronic Components / 27

How to reduce danger and avoid liability when handling flammable and combustible liquids.

Focus on Electrical/ Focus on Grinding and Cutting / 28

Maintenance 101: Establishing a maintenance system / 17

Stage 7 in an eight-part program towards achieving world-class maintenance.

Improving efficiency in belt-drive systems / 15

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When it comes to air handling in HVAC equipment, synchronous belts can offer energy savings.

editor’s selections

MRO on the Road / 30

PTDA’s Industry Summit in Dallas sees a jump in attendance.

Special Section: Industrial Lubrication

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Fighting improper lubrication practices / 18

Choosing the right hydraulic fluid / 20

Examine what it is that your current fluid is not delivering.

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‘Some people think warranties are about performance, but they are not.’ John Melanson / 11 ‘The BP employees and the workers at the Quebec plants did not have to die.’ Simon Fridlyand / 16

An ineffective game plan will increase your operating costs.

‘If no one has defined the level on the metric where performance becomes bad enough to require corrective action, then there is no point in recording it.’ Peter Phillips / 17

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‘Done correctly, lubrication can eliminate equipment failures and increase uptime. Done poorly, it can result in losses as high as 30% of a plant’s maintenance budget.’ Bill Quesnel / 18

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E D I T O R’ S

N O T E B O O K

Machinery & Equipment MRO

December 2012

Wrapping up another year

here’s an eclectic mix of articles in this issue as we wrap up another year – our 27th in fact. Finally, government and industry seem to be waking up to the severity of the skills shortage problem, as you’ll see from the stories on our Industry Newswatch pages. There, you’ll also learn about the future of lubricant markets around the world. You’ll probably note that this issue has a heavy emphasis on lubrication, from our special Industrial Lubrication section that begins on page 18, to our Product News pages and Mr. O’s problem solver tip. This edition also examines the issues around equipment warranties, a topic that a lot of readers have told us they wanted to

understand better. Senior contributing editor Carroll McCormick unearthed insider information on the topic from a manufacturer, a manufacturer’s rep and a major distributor for this feature story. Our cover article, The Daily Grind, was inspired by the fact that we often have witnessed workers using grinders without wearing proper protection. It may be macho to think you’re immune to getting shrapnel in your eye so you don’t need to wear safety glasses, but the dangers of grinding go much further than that, even to the point of being deadly. The quiz in the article will help tell when you’re ready to operate grinders safely. This issue also touches on solving

problems with chain and belt drive systems, and looks at what’s new in belt drives too. And both Simon Fridlyand and Peter Phillips continue their respective Safety File and Maintenance 101 columns, two important and popular topics for our audience. Looking back on the year, we were very pleased to bring you articles from two newto-us writers, Steve Gahbauer and Robert Robertson. Both have many years of experience in industrial journalism. Steve’s an engineer who turned his hand to writing and we’re certainly happy he did, as he’s an expert at boiling down technical mumbo-jumbo into clearly understandable and readable prose. He’s also a past winner of the Sergio Guy Memorial Award from the Plant Engineering and Maintenance Association of Canada (PEMAC). Rob’s talents come from decades of editing and writing about industrial maintenance and reliability issues and through his volunteer work with PEMAC.

By the way, this year’s recipient of the Sergio Guy Memorial Award is Cliff Williams, whose popular Maintenance Management series ran for six years in this magazine. The past year has seen our presence at more events than ever, from the conferences of the Power Transmission Distributors Association (PTDA) and the Bearing Specialists Association (BSA), to meetings of the Electrical Apparatus Service Association (EASA), the Society of Maintenance and Reliability Professionals (SMRP) and the Society of Tribologists and Lubrication Engineers (STLE). We now take more photos than ever before at these events, because we have lots of room to publish them in the Photo Gallery on our website. Staffer Eric Achilles Cousineau has taken to photography like a duck to water and has produced an amazing array of wonderful photographs for us this year. Bill Roebuck, Editor & Associate Publisher

MACHINERY AND EQUIPMENT

MAINTENANCE, REPAIR AND OPERATIONS

DECEMBER 2012 Volume 28, No. 6 Established 1985 www.mromagazine.com www.twitter.com/mromagazine www.twitter.com/mroontheroad EDITORIAL Bill Roebuck, Editor & Associate Publisher 416-510-6749 broebuck@mromagazine.com Ellie Robinson, Art Director Contributing Editors Simon Fridlyand, Steve Gahbauer, Carroll McCormick, Peter Phillips, Robert Robertson, Angela Webb BUSINESS Nick Naunheimer, Publisher 416-510-6868 nnaunheimer@mromagazine.com Eric Achilles Cousineau, Adv. Sales Manager 416-510-6803 eachilles@mromagazine.com Kimberly Collins, Advertising Production 416-510-6779 Melinda Marasigan, Subscription Enquiries 416-442-5600 x3548 Machinery & Equipment MRO is published six times a year to help improve the effectiveness, productivity and practical knowledge of maintenance professionals in Canada’s manufacturing, utilities and resource industries. AWARD-WINNING MAGAZINE

Editorial & sales office: 80 Valleybrook Drive, Toronto, ON Canada M3B 2S9; tel: 416-442-5600, 1-800-268-7742; fax: 416-510-5140. Subscription rates. Canada: 1 year $58.95, 2 years $94.95. United States: 1 year $85.95. Elsewhere: 1 year $87.95. Single copies $10 (Canada), $16.50 (U.S.), $21.50 (other). Add applicable taxes to all rates. On occasion, our subscription list is made available to organizations whose products or services may be of interest to our readers. If you would prefer not to receive such information, please contact us via one of the following methods – phone: 1-800-668-2374, e-mail: privacyofficer@businessinformationgroup.ca, fax: 416-442-2191, mail to Privacy Officer-Business Information Group, 80 Valleybrook Drive, Toronto, ON Canada M3B 2S9. ©2012. Contents of this publication are copyright and may not be reproduced in whole or in part in any form without written consent of the publisher. The publisher cannot assume responsibility for the validity of claims in items reported or advertised. Machinery & Equipment MRO is published by BIG Magazines LP, a div. of Glacier BIG Holdings Company Ltd. Bruce Creighton, President, BIG; Alex Papanou, Vice-President, BIG; Tim Dimopoulas, Executive Publisher, 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. 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.

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

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I N D U S T R Y

N E W S W A T C H

Machinery & Equipment MRO

December 2012

Chicago, IL — The 3Q12 PTDA Business Index for the third quarter of 2012 produced a reading of 50.3, which represents a deceleration from the second quarter 2012 reading of 54.2. This indicates that the power transmission/motion control (PT/MC) industry expanded for the 10th consecutive quarter, but at a slower pace compared with 2Q12. The index is compiled by the Power Transmission Distributors Association (PTDA) and Cleveland Research Company. Both distributors and manufacturers reported decelerated sales growth compared with the previous quarter. On average, sales rose 5% in 3Q12, down from the 7% growth seen in 2Q12. Distributor sales growth increased 5% in 3Q12, down from 6% in 2Q12. Manufacturers also reported decelerated sales growth of 6% in 3Q12, compared with 8% growth in the previous quarter. The index reading indicates the rate of change compared with the previous period. For example, a reading of 50 indicates no change from the prior period while readings above 50 indicate growth and below 50 indicate contraction. The further the index is above or below 50 suggests a faster or slower rate of change. PTDA members expect 2013 to be another year of growth, with an average forecasted increase of 6%. Notably, 83% of distributors and 78% of manufacturers surveyed expect positive growth in 2013. The PTDA Business Index full report is available through PTDA’s website at www.ptda.org/BusinessIndex.

MAINTENANCE ASSOCIATION PRESENTS AWARDS FOR CONTRIBUTIONS

Cliff Williams received PEMAC’s Sergio Guy Memorial Award.

By Steve Gahbauer Toronto — The annual MainTrain conference took place in November 2012 in Toronto in conjunction with IMEC, the International Maintenance Excellence Conference. It was the first time these two conferences were combined, the result being a ‘two-for-one’ fourday event at the same location. The merger was made to reduce costs, attract a larger audience, and present a more comprehensive asset management event for delegates. IMEC was convened by C-MORE, the Centre for Maintenance Optimization & Reliability Engineering, a collaborative industry-academia consortium headed by the faculty of Applied Sciences and Engineering of the University of Toronto. MainTrain, conceived, produced and delivered by PEMAC, the Plant Engineering and Maintenance Association of Canada, is one of Canada’s foremost an-

nual peer-developed maintenance, reliability and asset management events for knowledge transfer, professional development and networking. Each year, PEMAC gives out special awards at the conference’s annual banquet. One of them is the Sergio Guy Memorial Award, presented in memory of one of PEMAC’s pioneering members, who passed away in the middle of his career. His family, together with PEMAC, initiated a fund for this annual award, which is presented to a maintenance professional who has made an outstanding contribution to the maintenance industry. This year, the recipient of the Sergio Guy Memorial Award was Cliff Williams, a 30-year-plus veteran of the maintenance field, an international speaker and a long-term columnist for Machinery & Equipment MRO magazine. Williams has worked in the pulp and paper and steel industries, as well as with food giants Coca Cola, Kraft and Wrigley. Williams’ previous position at ERCO Worldwide saw him help drive the maintenance performance at plants in North and South America. He also teaches the PEMAC Maintenance Management Professional (MMP) certification program at local colleges. He’s currently a consultant with ARMS Reliability. He believes that maintenance is first and foremost about people and that problems cannot be solved with the same level of thinking that caused them in the first place. At its annual banquet, PEMAC also honoured three former association executives with Lifetime Membership Awards. They were presented to immediate past-president Brian Malloch; to immediate pastMMP registrar and former PEMAC president Colin Carrington; and to retiring Photo: Bill Roebuck PEMAC executive director Norm Clegg. The new executive director of the association is Cindy Snedden. The MMP is the eight-module Maintenance Management Professional program/ course that provides training and accreditation for aspiring maintenance professionals. It was developed by PEMAC and is administered across Canada by many universities and colleges, and also is available online.

NEW IPHONE SAFETY APP FOR METALWORKERS LAUNCHED Montreal, QC — Walter has launched a new application for iPhones called the Walter Safety App. It has been designed to provide metalworkers with easy access to essential safety information when working on factory floors, jobsites, etc. The applica-

WHAT VIBRATION PENS WANT TO BE WHEN THEY

GROW UP.

Photo: Walter

Survey of power transmission business sees positive growth in 2013

App targets metalworking safety.

tion is an extension of the Mechanical Safety Seminars offered by Walter. The Walter Safety App includes • Abrasives speed chart: provides Max RPM info for all Walter abrasive discs based on their diameters • Grinding angles: provides minimum and maximum grinding angles according to type of grinder and choice of abrasive • Drill bits speed chart: provides optimal drilling RPM according to drill bit diameter and type of material to be drilled • Annular Core Cutter speed chart: establishes the recommended RPM based on the cutter diameter and the type of material to be cut • Unit converter: converts hundreds of unit measurements — length, area, volume, speed, mass, and temperature • Flashlight: use your smartphone as a flashlight • Level: determine the angle of any surface. It also includes quick links to instructional Walter videos and a link to the walter.com website. The app can be downloaded from the App Store on your iPhone or from the iTunes store. It is compatible with the iPhone 3GS, 4, 4S and 5; and the iPod Touch 3rd , 4th and 5th generation (iPad requires iOS 5.0 or later).

NEW CANADIAN WEBSITE TO PROMOTE CAREERS IN TRADES Ottawa — Two national organizations, the Canadian Apprenticeship Forum and Skills Canada, have partnered to revamp the Careers in Trades website to help Canadian youth have access to up-to-date information on skilled trades careers. “Apprenticeship stakeholders across trades,

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Online Reader Inquiry No. 120

BC ENCOURAGES STUDENTS TO CONSIDER TRADES

Delta, BC – The British Columbia government is investing an additional $1.1 million to encourage students to pursue a future in skilled trades, says John Yap, minister of advanced education, innovation and technology. “We want young people to see that a life-long career in the trades is a very smart choice, offering a secure future in a rewarding, respected, skilled and wellpaying career,” said Yap. “Under the BC Jobs Plan, and as part of our new Skills and Training Plan, we want to encourage more students in the K-to-12 system to be thinking about – and training for – careers in the trades. Raising the profile of careers in the skilled trades and engaging employers for the critical role they play in industry training will benefit BC, industry, today’s apprentices and the skilled trades learners of tomorrow.” A Discover Trades BC website – www. discovertradesbc.ca – has been launched that includes testimonials from fellow students and has workbooks and resources for primary, middle and secondary teachers to use in getting more students excited about trades work. Skills Canada BC will receive an investment of $125,000 to prepare BC secondary and post-secondary students and apprentices for the Skills Canada National Competition 2013, taking place in Vancouver, June 5-8, 2013. Website explores careers in trades. An investment of $300,000 will support the Industry Training Authority (ITA) to engage employers and improve their participation in training and hiring apprentices from postsecondary trades training programs. The ITA works with employers, employees, industry, labour, training providers and government to manage apprenticeships, set program standards, and increase opportunities in the trades.

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across sectors and across Canada tell us promoting careers in the skilled trades is a fundamental priority,” said Sarah Watts-Rynard, executive director of the Canadian Apprenticeship Forum. “With skills shortages looming in many trades, ensuring youth and students have opportunities to explore career options in the trades is as important to the Canadian economy as it is to individuals suited to hands-on, well-paid and highly-satisfying work.” The revamped website features stepby-step information on how to take up an apprenticeship, lists the advantages of a career in the trades, and offers youth, educators and parents stories from real apprentices across Canada. Over the next few months, additional resources for educators and students will also be updated. “It will be a valuable resource for thousands of career seekers looking for a rewarding future in the trades and technologies,” said Shaun Thorson, CEO of Skills Canada. “Supporting and promoting apprenticeship and training is essential to meet the demand for qualified skilled trades professionals.” The revamped website can be found at www.careersintrades.ca.

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NS fea str ma

NEW JOURNEYPERSONS HONOURED IN NOVA SCOTIA Halifax, NS — More than 400 of Nova Scotia’s newly certified journeypersons are taking advantage of the many careers Nova Scotia has to offer in the skilled trades. Marilyn More, Minister of

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I N D U S T R Y

N E W S W A T C H

December 2012

Machinery & Equipment MRO

Labour and Advanced Education, met with the journeypersons, their mentors, teachers and employers at a celebration event in Dartmouth, NS, on Nov. 3, 2012. “With the thousands of good jobs on the horizon connected to big contracts, we’ve never had such a great need for skilled workers,” said More. “This province’s tradespeople have the right skills to help engineer the world’s best navy ships and lay the concrete for the new trade centre. We need their talents now more then ever to fill some of the best jobs in this province’s history.” More presented two awards of excellence to an outstanding mentor and an apprentice. Workplace performance earned Keigan Moore and Jonathan Noel the Apprenticeship Award of Excellence. The award recognizes newly certified journeypersons who have made outstanding contributions to the industry and their employer, supporting others in the workplace and demonstrating a strong work ethic. Moore is a newly certified truck and transport mechanic working with the Halifax Regional Municipality’s emergency fleet. Noel is a newly certified automotive service technician working with Newfie Automotive in Dartmouth. The mentor-coach award of excellence was presented to Arthur Cole, certified mechanic with A.W. Cole Construction in Dartmouth. The award recognizes an employer, supervisor, instructor or other mentor who has served as a role model and demonstrated qualities of superior teaching, enthusiasm for the trade and a strong commitment to the progress of apprentices in their program. For more information, visit the website at http://www.nsapprenticeship.ca.

LUBRICANT DEMAND GROWTH STALLS IN MATURE MARKETS Parsippany, NJ — Despite the challenges of a precarious economic environment, the 2011 global lubricant market grew a resilient 2%, with global lubricant demand estimated at 38.6 million tonnes. This growth was largely fuelled by the BRIC countries’ resurgent industrial activity and expansion in the commercial and passenger vehicles sales, according to the recent Global Lubricants: Market Analysis and Assessment report by international consulting and research firm Kline & Company. The United States remains the largest lubricant market, but its near 22% global share continues to decrease. China and India are the next biggest markets with a combined total of over 26%, with Russia’s consumption expected to surpass Japan’s and consequently be the fourth largest market. Aside the BRIC countries (Brazil, Russia, India and China), strong growth is also expected in Indonesia, South Africa, and Malaysia, driven by an increase in new vehicle ownership and production, construction, and industrial activity, especially in the power-generation and oil and gas production sectors. The core of competition has evolved to be on a value chain basis and is most intense between multinationals and local majors in most developing countries. On the global level and an overall volume basis, Shell has maintained its leadership position in 2011 with a 13% market share, as well as leading in the branded lubricants category. The company continues strengthening OEM relations, critically with Chinese OEMs, and is successfully promoting its products

©iStockphoto/Thinkstock

through OEM service fill recommendations. ExxonMobil and BP follow with 10% and 7% shares, respectively. Through various national ‘cash for clunkers’ programs, older, higher lubricant-consuming cars were replaced by new, often down-sized models, with both smaller crankcase capacities, longer oil drain intervals, and growing OEM recommendations for synthetic engine oil, resulting in a decrease in lubricant volume demand, compensated by an increase in lubricant quality and higher revenues. Group I basestocks are continuing their long-term decline, primarily due to technical obsolescence for automotive applications. The impending scarcity of Group I provides opportunity for other products like naphthenics in metalworking fluids, process oils, and rubber oils, and is abetted by a supply push from Group II suppliers. George Morvey, Kline’s Energy Practice project manager, cautions, “While Group II penetration into automotive formulations is happening relatively quickly given the sector’s fewer product variations, penetration into industrial applications is likely to be slower as there are many more product categories with small individual volumes, so the payback period for converting an application to Group II is longer.” Strong pre-recession basestock prices

have rendered re-refining a more compelling economic argument and combined with new regulations in Europe and increasingly in North America, the use of rerefined basestocks is encouraged. However, logistic issues and a lack of consumer conviction remain obstacles to their greater acceptance. Globally, supply of re-refined basestocks is projected to grow at over 6% per year to exceed 3 million tonnes by 2021. Kline’s report combines regional market analyses into a comprehensive program to provide finished lubricant formulators, additive and basestock suppliers, and end users with the latest information on products, services, applications, and trends in the leading lubricant-consuming regions of the world. For more information, visit www.klinegroup.com.

US DEMAND FOR SYNTHETIC LUBRICANTS AND FUNCTIONAL FLUIDS TO EXCEED $7 BILLION Cleveland, OH — Demand for synthetic lubricants and functional fluids is forecast to climb 8.6% per year to $7.4 billion in 2015, with volume reaching 625 million gallons on annual gains of 3.4%, according to Synthetic Lubricants & Functional Fluids, a new study from The Freedonia Group Inc., a Cleveland-based industry market research firm. Synthetics will expand their share of the overall lubricant market, propelled by the higher-performance requirements of modern equipment, as well as increasingly stringent environmental standards. Gains will also be fueled by the expanding availability of high-quality basestocks due to growing investment in new basestock capacity, both in the US and overseas. continued on page 10

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I N D U S T R Y

N E W S W A T C H

Machinery & Equipment MRO

December 2012

Business Briefs

pany that provides innovative, turnkey energy-reduction solutions to industrial and commercial facilities. These solutions can deliver up to 20 years of maintenancefree performance through the application of energy-saving technologies for motors, compressors, lighting, refrigeration and air-conditioning systems. Canadian Bearings itself has installed a range of Eco-Watt’s products in its head office and central warehouse facility in Mississauga to decrease electricity consumption in its motors, compressors, airconditioning systems and lighting. “We are very pleased to be able to offer Eco-Watt’s unique energy-saving approach and guaranteed savings to our customers,” says Sergio Restagno, vice-president of enterprise solutions at Canadian Bearings. “This agreement further extends Canadian Bearings’ offering of bottom-line improvement to industry in Canada.” Vivian DoyleKelly, Eco-Watt’s president, concurs. “This is a great opportunity to improve manufacturers’ operating results and increase their competitiveness by converting inefficiencies to positive cash-flow,” he says. For further information, contact Sergio Restagno at 905-670-6728 or Vivian DoyleKelly at 514-704-8996, or visit www.canadianbearings.com and www.ecowatt.ca. • Reliable Controls, Victoria, BC, held a ribbon-cutting ceremony in October to mark the official opening of its new corporate headquarters. The event was attended by local dignitaries and individuals close to the project. The $8-million annex to the existing Reliable Controls building is a targeted LEED Platinum facility. For more details, visit www.reliablecontrols.com/corporate/facility/. • ITT Corporation, White Plains, NY, has completed the acquisition of Joh. Heinr. Bornemann GmbH (Bornemann Pumps), a global provider of highly engineered pumps and systems for the oil and gas industry, as well as the industrial, food and pharmaceutical sectors.

The transaction was valued at EUR 206 million. Information related to the acquisition is available on ITT’s website at www.itt.com\IR. • Automatic lubrication systems specialist FLO Components Ltd., Mississauga, ON, has appointed Marc Savage as territory sales manager for Sudbury as it continues to expand its resources to Marc better serve mining, Savage construction, road building, aggregate, manufacturing and trucking companies in the Nickel Belt. A resident and native of Sudbury, Savage studied business administration at Cambrian College there. • Wajax Industrial Components, Montreal, QC, has acquired Ace Hydraulic Ltd. of Bathurst, NB, in a transaction that will enhance Wajax’s hydraulic repair and service capabilities. The strategic acquisition will also augment Wajax’s ability to support mining, forestry and other industrial businesses throughout Atlantic Canada and the Quebec North Shore. Ace Hydraulic was founded in 1987 and has steadily evolved into a fully integrated hydraulic facility, repairing hydraulic pumps, valves and motors, as well as rebuilding and fabricating cylinders with 1-to-24 in. bores. Hydraulic power units of all sizes are also built on demand. The Bathurst facility has doubled in size as recently as November 2011, adding 6,000 sq ft space. It features an array of modern equipment, including a Lagun 1600 horizontal-vertical milling machine, several Tos high production lathes and a 34 x 160 Mazak lathe capable of handling some of the biggest machining jobs in the industry. In addition, the facility has a nut buster that will deliver 150,000 in.-lb of torque, allowing large hydraulic cylinders to be disassembled and assembled with ease. • The Swagelok Company, Solon, OH, has acquired the assets of Innovative Pressure Technologies (IPT) as part of its strategy to broaden the company’s offering of products and services for fluid

tions in 2010 and the development of General Motors’ proprietary DEXOS1 certified engine oil will further promote gains. In addition to GM, which now requires at least a synthetic blend motor oil for nearly all of its vehicles, other leading vehicle manufacturers such as Toyota and Honda are also making the transition. This will drive demand for synthetics in the engine oil market through the forecast period. Among the various materials used to formulate synthetic lubricants and functional fluids, glycol fluids represented the leading category in 2010. However, glycol’s share of the market is forecast to decline

due to maturity in the large antifreeze segment, along with a shift toward extended flush intervals and fill-for-life components in automotive design technology. Group III base oils and polyalphaolefins (PAOs) are also key materials, and are projected to expand at the fastest rates through 2015. The enhanced performance properties and environmentally friendly profile of PAOs will boost demand, as will the extended drain capabilities and customizability of PAO basestocks. The report is available for US$4,900 from The Freedonia Group. For details, visit www.freedoniagroup.com. MRO

News and views about companies, people, product lines and more • Acklands-Grainger of Richmond Hill, ON, a distributor of industrial, safety and fastener products, was recently recognized as having one of the most admired corporate cultures in Canada in a study administered by Waterstone Human Capital. Waterstone recognizes companies with the three-year distinction annually. Acklands-Grainger first earned this award in 2009 and is the only company in the maintenance, repair and operations (MRO) industry to be so recognized. • KSB Canada, Mississauga, ON, has appointed Dirk Ruppert as its new national sales manager. Ruppert, a globally experienced strategist and business development professional, has been recruited from KSB’s Dirk global headquarters Ruppert in Frankenthal, Germany, where he held key positions developing offshore markets for the company. He holds an MBA from the University of Applied Sciences in Ludwigshafen, Germany. • Koyo Canada, Burlington, ON, reports that JTEKT Corporation, the parent company of Koyo in Japan, which acquired the Torrington needle roller bearing division from Timken in 2010, will implement a full integration of the brand starting on January 1, 2013. Needle roller bearings, branded Koyo-Torrington until the end of 2012, will then bear the Koyo logo exclusively. • Canadian Bearings Ltd., Mississauga, ON, and Eco-Watt Inc., Montreal, QC, have reached an agreement where Canadian Bearings will offer Eco-Watt’s Energy Efficiency services and products to its industrial client base. Canadian Bearings is an industrial distributor serving large and small manufacturers. EcoWatt is a Canadian energy efficiency com-

Synthetic lubricants

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As the supply of these materials expands, original equipment manufacturers (OEMs) are becoming more willing to recommend the use of high-performance synthetic products, particularly as OEMs take steps toward global specifications. Engine oil will remain the fastestgrowing product type through 2015. These lubricants primarily find use in automotive applications, and will therefore benefit from a rebound in motor vehicle output from the declines of the 2005-2010 period, as well as continued gains in the number of motor vehicles in use. The adoption of the GF-5 and API SN engine oil specifica-

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system technology customers around the world. Located in Erie, PA, IPT is a manufacturer of high- and medium-pressure and sub-sea valves, fittings and fluid control devices used mostly in oil and gas, chemical/petrochemical, waterjet cutting, automotive, water blasting, and other demanding applications. • Omega Engineering Inc., Stamford, CT, which has sales and distribution offices in Canada, the UK and Germany, and which has been a supplier in the process measurement and control market for 50 years, opened a new office in Shanghai, China, at the end of September 2012. Omega was recently acquired by Spectris plc, Surry, England, a supplier of productivity-enhancing instrumentation and controls. MRO More detailed versions of these stories, along with many additional news items, can be found online at www.mromagazine.com.

Mr.0 The Practical Problem Solver

Solving lubrication troubles Problem: We’re having trouble making our lubrication routine consistent. Solution: Lubrication is an important area where preventive maintenance techniques can be applied, says Paul Michalicka, head of maintenance products, North America for SKF. “One of the biggest problems in maintenance is incorrect lubrication intervals. You know you’ve got trouble if you hear comments such as, ‘Did the morning shift grease the machine? We don’t know, so let’s give it another shot’; ‘When’s the last time we went up on the roof to grease that fan?’ ‘We ran out of the red can of grease, so let’s use the green.’ ‘I’m not walking back to stores, so let’s use this shovel to fill the bearing housing’. ” There are ways of dealing with such troubles, he says. One solution for lubrication problems is to use grease guns: “One shot and its Bob’s your uncle; it’s done right,” says Michalicka. Another solution is the use of single-point automatic lubricators. “You screw it in, turn the dial and you are good to go. They deliver the right grease at the right time at the right amount, and save on energy costs too.” Automatic lubricators also reduce waste. For every $1 of lubricants used, it costs $3 to dispose of the lubricants, Michalicka noted. “Lube software makes lube planning easy,” he said. “You mark the points, select the right grease, and the software tells the user the best way to deliver the lube.” Mr. O thanks SKF Canada’s Paul Michalicka for these suggestions. Do you have a solution for a maintenance problem? Send it in and if it’s published, we’ll send you $25 and a Mr. O Problem Solver T-shirt. Include your address, telephone number, complete details and, if possible, add a sketch to help explain your tip. Send your tips to Mr. O, Machinery & Equipment MRO, 80 Valleybrook Dr., Toronto, ON M3B 2S9.

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Fig. 1

Fig. 2

BY CARROLL MCCORMICK

Photos: Carroll McCormick

WEIGHING IN ON

WARRANTIES

Fig. 3

WHAT YOU GET AND WHAT YOU DON’T

n the consumer world, warranties cover defective workmanship and service life for periods ranging from months to several years. Industrial warranties, however, cover workmanship but they do not necessarily cover performance. On the plus side, industrial component users can expect excellent warranty support from distributors, failure analysis, repair service and more. For guidance on warranties and how well they are understood, Machinery & Equipment MRO contacted Motion Industries Inc., a distributor, RotoPrecision Inc., a master distributor, and SKF Canada Ltd., a manufacturer. Each company felt that users are generally knowledgeable about what warranties cover, but that there are some misconceptions about what they do not include. “In most cases, warranties are quite simple: We warranty the product against manufacturing defects,” states John Melanson, engineering manager at SKF. “I would say that end users are appropriately knowledgeable on warranties.” However, he observes, “Most claims are confused with application-related failures.” An expectation that products will arrive in 100% functional condition and be fully operational when they are installed is reasonable. But, says Gregg Robinson, president, RotoPrecision, “Where confusion enters is when the life of the product does not meet user expectations.” Randy Breaux, senior vice-president, marketing, strategic planning and product support, Motion Industries, says, “If the product fails because it is improperly installed or misused, the manufacturer will not honour it as a warranty.” The terms of warranties can vary, depending on factors such as products, applications and maintenance schedules. Three points in a warranty from a gear-

Fig. 4 Fig. 1: Some warranties require proof of appropriate operation and maintenance schedules. Fig. 2: Proper maintenance is part of keeping warranties valid. Fig. 3: Warranties might not cover equipment in harsh environments, like this waterdrenched equipment. Fig. 4: The warranty clock might be ticking on parts sitting in your spares room.

box and electric motor manufacturer illustrate some possibilities: (1) Products are guaranteed for two years from the date of delivery, considering 16-hour per day shifts; (2) The warranty is limited to free repair or replacement of defective parts; and (3) The warranty does not include natural wear or deterioration; e.g., from oil seals or lubricant leakages, nor from damages, defects or malfunctions caused by external components. How might this translate into action on the ground? A warranty may cover a component against defects for a certain amount of running time, but this should not be confused with normal wear of the product. “We cover ma nu fac tu r i ng, not the use of the product. Some people think warranties are about performance, but they are not. For example, the warranty does not guarantee you will get 40,000 hours out of a bearing in a critical fan that fails and causes lost production,” says Melanson. Freedom from defects in workmanship or material is an absolute, says Robinson. “In some cases, these defects can be identified by visual inspections of incoming products, but sometimes [it’s] only after products have been in operation. Where the ambiguities arise is when products fail prior to the user’s life expectations.

Distributors are important advisors regarding warranty expectations.

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“The industrial distributor who sold you the product, with the backing of the manufacturer, can be a key resource in determining if the failure is due to a manufacturing defect, conditions external to the failed product or if it has simply met its life expectations.” The amount and severity of use, including pushing equipment beyond its design capacity and the quality of the maintenance, is beyond the manufacturer’s control. This may be addressed in a warranty. One manufacturer, for example, specifies in its limited warranty on remanufactured major components, that the purchaser must “… properly operate, maintain, and care for the components,” and “… keep maintenance records as in some cases it may be necessary to show that required maintenance was performed.” Breaux comments, “You have to provide operational data to help the manufacturer determine if the product failed in an application it was intended for or if the product was installed in an application that it was not designed for and failure occurred because of such.” One way to head off this scenario, though, is to

learn the limitations, design specifications and service factors of products. “That is the expertise distributors provide prior to the sale,” Breaux adds. There is another warranty detail worth mentioning to maintenance departments that keep critical, hard-toreplace spares on hand, or that do not have good control over their parts inventory. A warranty period can start on the date equipment is manufactured, the date it is sold or the date it is put into service. There is a story of a crew installing a brand new motor that had sat on a shelf for several years, only to find that it would not work. Was it covered by the warranty? Robinson suggests, “I cannot recall a case where there was a defect in material or workmanship where we declined a warranty based on age of product.” That said, the amount of time a product sits on a shelf can render it unusable due to the shelf life of lubrication or other age-related breakdown in materials, such as seals. The environment in which products are stored will also have significant effect on shelf life. continued on page 12

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December 2012

If a user thinks he has a legitimate warranty claim, he should first contact the distributor that sold the product. The distributor will first determine whether the warranty period has expired, then facilitate the repair or replacement with the manufacturer. A user might also contact the master distributor or manufacturer directly. “We would then work with the end user and the distributor that sold them the product to develop a solution,” Robinson says. Since many manufacturers are located outside Canada, master distributors stand in as their representatives. “RotoPrecision fully honours the manufacturer’s warranty. We also provide full services to help a customer determine the reason for a failure,” Robinson says. Breaux adds, “Helping our end-user customer, and representing the manufacturer and selling their product, is what

Photo: Carroll McCormick

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Is yours a 24/7 production schedule? Some warranties distinguish between running time and calendar time.

we do. As the key link in the chain, we are often called upon for assistance and interpretation with the warranty claim.” If Shakespeare were a maintenance man, he might have asked, “To ship or not to ship? That is the question.” As a rule, the manufacturer will want the failed equipment back, to perform an autopsy, for example, but a manufacturer’s representative might want to see the offending item in-situ. “In many ways, this is the preferred method to first evaluate a potential claim. Certain sizes make it very difficult or expensive to transport and therefore the first evaluation is sometimes best done on site,” Melanson explains. Emailing photos and videos is efficient and fast, but examining the scene of the failure can be the ticket to resolving a problem. Consider a bearing that fails after two happy years. The user replaces it, only to see the new bearing rapidly fail. But say the shaft had, unnoticed, become misaligned (perhaps the reason the first bearing failed). “The resulting assumption of the maintenance worker would be that the new bearing was of poor quality and it should be a case for warranty. But only a detailed inspection of the failed equipment would uncover the failure’s underlying cause,” Robinson offers. Who pays the cost of shipping? As a very rough rule, the manufacturer is likely to cover the cost if the preliminary analysis suggests there may be a manufacturing defect. If the preliminary analysis suggests that the customer’s handling of the product or the application is responsible for the failure, the customer could be on the hook for shipping costs. Melanson offers this general rule: “If it is something very obviously qualityrelated, we will take it back [at our cost]. If it is questionable — for example, a dimensional evaluation — we will ask for a purchase order to cover the analysis. If it is a quality-related issue, we will not charge; if it is not, we will charge for the analysis.” One more thing: Beware of counterfeits. There is no warranty on counterfeit bearings, Melanson warns. “This is why people should be careful of where they buy their bearings.” Users have shown up on distributors’ doorsteps with warranty claims on counterfeits, including their fake OEM boxes. But it’s a no-go. Users with a long view should buy only from authorized distributors to avoid such trouble. MRO

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Machinery & Equipment MRO

2. Which of these are forms of personal protective equipment you may need while using a grinder? A. Eye protection. B. Respirator. C. Ear plugs. D. All of the above. 3. Why shouldn’t you wear jewellery while operating a grinder? A. The sparks will tarnish silver or gold. B. It could get caught in the equipment. C. The fumes will cause gems to become cloudy. D. It’s considered bad luck in many workplaces. 4. Why would you want to tap a grinding wheel with the non-metallic handle of a screwdriver? A. You would never want to do that. It could hurt the wheel. B. If the wheel makes a ringing noise, you will know it is not fit for use. C. It’s part of a test to check the usability of the wheel. D. Tapping a grinding wheel shakes any impurities out of its pores.

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DAILY

GRIND

This quiz will let you know when an operator can safely run a pedestal or bench grinder. Improper use of a grinding wheel, or the use of one that is defective or damaged, can cause the wheel to break up, sending deadly fragments flying around a shop.

5. When gauging the compatibility between a grinder’s RPM and a grinding wheel’s RPM, remember: A. The two numbers must be exactly the same. B. The two numbers are not connected. C. The RPM of the grinder is always twice that of the grinding wheel. D. None of the above.

8. If your grinder requires repairs, what kind of replacement parts should you use? A. Any kind that will fit. Parts for most brands of grinders are interchangeable. B. Only manufacturer-recommended replacement parts. C. Only parts purchased from the same store as the grinder. D. None of the above.

6. When you need to put a new wheel on your grinder, what should you do with the wheel first? A. Nothing. If it’s a new wheel, straight out of its packaging, just put it right on the grinder. B. Give it a ‘ring test’ to make sure it is suitable for use. C. Prepare it for use by soaking it in water for no less than three minutes. D. Roll it across the floor to make sure it is perfectly round.

The

| 2. D | 3. B | 4. C | 5. D | 6. B | 7. A | 8. B | 9. A | 10. D

1. Why should eye protection be used when operating a grinder? A. To protect the worker’s eyes from sparks. B. To protect the worker’s eyes from flying fragments, if the wheel breaks. C. To protect the eyes from ultraviolet rays created by the hot metal. D. A and B.

7. How much of a gap should there be between the work rest and the face of the grinding wheel? A. 1/8 in. or less B. Less than 1/8 in. C. 1/4 in. D. 1 in.

QUI Z A NS W E R S  1. D

Photo: Carroll McCormick

worker steps up to an abrasive wheel grinder and places a piece of metal against the wheel’s spinning surface. But because the machine was not adjusted correctly, the metal catches in the grinder. A split-second later, the grinding wheel explodes, sending stony chunks, as deadly as shrapnel, shooting through the shop. The worker drops lifeless to the floor. “Because abrasive wheel grinders are everyday equipment in workplaces, many workers become complacent about their hazards,” said Benjamin W. Mangan, founder and president of Mancomm, a company that develops and publishes regulatory compliance products. “Improper use of a grinding wheel, or the use of one that is defective or damaged, can cause the wheel to break up. And those flying fragments can be deadly.” To help workers stay safe, Mancomm developed a Grinder Safety Training CD. It can help workers to improve safety and minimize risk by focusing on a personal protection system for pedestal and bench grinders. Topics covered include personal protective equipment, grinder and grinding wheel RPM compatibility, ring tests, grinding wheel installation, guard adjustment and aluminum oxide grinding wheels. How familiar is your staff with abrasive wheel grinders and their safe operation? Let them take this quiz and find out. These questions were derived from the audio portion of the Mancomm Grinder Safety Training CD. This print quiz offers an answer selection for each question. The skill checks on the actual Grinder Safety Training CD are not ‘multiple guess,’ but multimedia demonstrations. Once the employee passes the CD’s interactive skill checks, you will know he can operate a pedestal or bench grinder safely.

9. The wheel hole diameter and the grinder arbour size are not the same. What can you do to make the wheel workable? A. The wheel is not compatible with the grinder. Do not install it. B. Go ahead and install it, even if you have to force the wheel onto the spindle. C. Screw on the wheel nut especially tight. D. B and C. 10. What kind of material can you grind with aluminum oxide grinding wheels? A. Only aluminum. B. Any type of metal. C. Any metal with a yellow, gold or amber hue. D. Ferrous or iron-based materials, like iron or steel. How many wrong answers are permissible? In the workplace, none. Whenever workers operate an abrasive wheel grinder incorrectly, such incidents raise the possibility of accidents, injuries or death, which in turn can lead to workers’ compensation expenses, raised insurance premiums, lost productivity, lowered employee morale and regulatory penalties. MRO See the correct quiz answers in the upsidedown text under the photo. For more information, visit www.mancomm.com.

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December 2012

Curing Conveyor Stick-Slip

Molten ingots cool on an incline conveyor in this aluminum processing plant.

Photo courtesy Tsubaki of Canada

BY KEVIN BREADNER

On extra-long conveyors, bearing roller chain prevents the friction associated with the troublesome stick-slip phenomenon.

ith extra-long conveyors come extra operational obstacles that need to be overcome. One major area of concern with extra-long conveyors running at slow speeds (less than 10 m/min.) is stick-slip. Stickslip can be described as longitudinal vibration of the chain. Stick-slip is caused when surfaces alternate between sticking to one another and sliding on one another. Understanding what is happening with the conveyor chain is the first step in finding a solution to

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eliminate the problem. Let’s look at stickslip within a large roller conveyor chain. There is elasticity within any chain drive. When the drive is started, load is applied to the outer surface of the bushing and the inner surface of the roller. The load increases between the two parts until the static friction (where the parts ‘stick’ on one another) is overcome and they begin to slide (‘slip’) on one another. At this point, and for a brief moment, the load on the parts decreases and the roller rotational speed increases. This energy then dissipates and the cycle starts all over again. With this happening over and over, it literally looks like the chain is vibrating in a linear fashion. This can become quite costly from an operational point of view, as lines are stopped at this point to inspect equipment, as maintenance staff try to figure out how to fix the problem. Industry example The stick-slip phenomenon can be very troublesome in lines that carry metals that are still in a liquid state and need to cool uniformly. This is very important when cooling aluminum ingots to be used in the manufacture of vehicle engine blocks. The constant vibration of the chain causes waves in the cooling metal, resulting in imperfect ingots that cannot be used for engine block manufacture and are therefore rejected. To scrap a few ingots may not sound like much, but imagine a line with 100 or more pots on it and each one weighing in at 100 lb or more each. Rejection costs can spiral out of control quite quickly. Initial tendencies are to add lubrication or increase the number of sprocket teeth, which can have some effect (albeit very minimal) in the reduction of the stick-slip, but those are short-term solutions at best. A couple of ways to overcome stick-slip are to increase the conveyor speed or split the conveyor into sections to reduce chain length. A decrease in the friction of the chain internals is the best long-term solution if a reduction in conveyor length is not possible. Bearing roller chain prevents the friction associated with the stick-slip phenomenon, allowing long-length, slowspeed conveyors to run virtually free of any stick-slip. Other great features of bearing roller chain include the reduction of chain tension and in some cases the required motor capacity, lower energy consumption, a reduction in rail wear, and an increase in chain wear life. The initial cost of installing a bearing roller chain is greater than a standard alternative, but with all the benefits it can provide, this will more than overcome costly rejections and possible damage to a company’s reputation for supplying quality goods. In today’s ultra-competitive manufacturing landscape, every penny and every second can contribute to success, so don’t let a sticky conveyor get in the way of smooth profits. MRO Kevin Breadner is a technical sales representative with Tsubaki of Canada Ltd., Mississauga ON. Online Reader Inquiry No. 607

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Improving efficiency in belt drive systems When it comes to air-handling in HVAC equipment, synchronous belts can offer energy savings. BY CRAIG ROOZEN

eplacing V-belts with synchronous belts in air handling applications has been recognized as a best practice to reduce energy requirements in industrial and commercial applications, according to a recent report from the US Department of Energy. Why are synchronous belts are considered ‘green’? At the time of installation, V-belt drives run at 95%-98% efficiency. Those percentages will decline to approximately 93% over the life of the belt if it is properly maintained. Most efficiency losses occur in the first 24 hours of operation, creating the need to re-tension the belt. If V-belt drives are not re-tensioned as part of a preventive maintenance program, they can drop to as low as 80% efficiency during the life of the belt. Efficiency as applied to air-handling equipment is the rate of the motor’s energy as transferred to the driven fan. The lower the efficiency rating, the slower the fan speed, which results in less air movement and longer cycle/run times for the HVAC equipment — thus increasing electrical energy consumption. Once properly tensioned, synchronous belts will maintain a 98% efficiency rating throughout the life of the belt, without the need for costly maintenance. Electrical savings due to the constant 98% efficiency standard of a synchronous belt are significant in many applications. What is the annual energy and dollar savings if a 93% efficient V-belt is replaced with a 98% efficient synchronous belt? The Department of Energy report compares a continuously operating, 100hp, supply-air fan motor at 93% efficiency, which runs at an average load of 75% while consuming 527,000 kWh annually. Electricity is priced at $0.05/KWh.

surface that improves torque-carrying capacity and tooth shear resistance. Jason offers a drive design manual to assist with the procedures and calculations required to convert V-belt drives to synchronous belts, as well as a design engineering group to help with the process. Craig Roozen is director of diversified products with Jason Industrial.

Above: Synchronous belts reduce bearing and shaft loads up to 15% for longer life and less wear. Right: Jason Industrial Platinum belts offer Dual Core Cord technology, which maintains extreme dimensional stability under tension, allowing narrow widths that fit within existing belt-drive applications.

Online Reader Inquiry No. 609

Energy Savings = Annual Energy Use x (1-93%/98%) = 527,000 kWh/year x (1-93/98) = 26,888 kWh/year. Annual Cost savings = 26,888 kWh x $0.05 = $1,345.

Not all synchronous belts are the same. For example, Jason Industrial Platinum offers Dual Core Cord technology, which maintains extreme dimensional stability under tension, allowing narrow widths that fit within existing belt-drive applications. Also, its RPC tooth profile supplies a 98% efficiency rating under less tension than V-belts. Synchronous belts improve efficiency and save energy on most drive setups, however, they will not produce energy savings in every application. Smaller drive applications with short centre distances tend to use V-belt slippage to ramp up fan speed. Switching to synchronous drives in these applications can possibly increase electrical consumption. Synchronous belts reduce bearing and shaft loads up to 15% for longer life and less wear. They run cooler than V-belt drives, increasing bearing life. In addition, Jason’s Platinum belt features HNBR rubber-based technology to reduce noise levels; offers a wide range of operating temperatures, from minus 30°F to +240F°; and has a fabric-covered tooth

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T H E

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F I L E December 2012

THEY DIDN'T HAVE TO DIE

BY SIMON FRIDLYAND

©iStockphoto/Thinkstock

Machinery & Equipment MRO

HOW TO REDUCE DANGER AND AVOID LIABILITY WHEN HANDLING FLAMMABLE AND COMBUSTIBLE LIQUIDS.

n November 15, 2012, British Petroleum (BP) agreed to plead guilty to 14 criminal counts, including manslaughter, and will pay $4 billion over five years in a settlement with the US Justice Department over the April 20, 2010, drilling fire and explosion disaster in the Gulf of Mexico that killed 11 people and unleashed the worst offshore oil spill in US history. The settlement includes a $1.256-billion criminal fine, the largest such levy in that country’s history. Two BP supervisors on the Deepwater Horizon drilling rig — Robert M. Kaluza and Donald J. Vidrine — were indicted on 23 counts, including involuntary and seaman’s manslaughter, for ignoring warning signs of the blowout that set fire to the rig. The rig later sank. The head of criminal investigation, assistant attorney general Lanny A. Breuer, said, “In the face of glaring red flags indicating that the well was not secure, both men allegedly failed to take appropriate action to prevent the blowout.” November marked a deadly month in Canada, with three people killed and 19 injured by an explosion and fire at the Neptune Technologies & Bioresources plant in Sherbrooke, QC. A second blast on the same day hit a Bombardier Recreational Products complex in Valcourt, QC, leaving two people with serious burns; one worker later died. Both Quebec explosions are being investigated by the authorities, but flammable/combustible liquids are suspected in both of these disasters.

The BP employees and the workers at the Quebec plants did not have to die. There is a lot of knowledge in industry about how to handle, store and process flammable and combustible liquids. Existing regulations state that companies shall make sure that their facilities meet the minimum requirements stipulated by various codes and standards. The best way to make sure that facilities meet the minimum requirements is to hire a professional engineer specializing in fire and explosion issues to assess the facilities. The first step in this process is to identify and classify flammable and combustible liquids. The classification is based on the liq-

but not exceeding 93.3°C. Liquids under these categories include kerosene, Varsol and No. 1 fuel oil. Flammable liquids themselves do not burn; it is their vapours that burn. The rate at which different liquids vaporize varies greatly, depending on the vapour pressure characteristics of each individual liquid. Vaporization increases as temperature climbs. As such, a flammable liquid at an elevated temperature can ignite more easily than the same liquid at a normal temperature. Because flammable vapours tend to accumulate in low areas, proper low-level ventilation is a must whenever liquids are being handled or stored. Exhaust

If the mix of air/fuel falls below the lower flammable limit, there will be no risk of an explosion or fire. uid’s flash point, defined as the minimum temperature at which a liquid in a container gives off vapour in sufficient concentration to form an ignitable mixture with air near the liquid’s surface. All rules for the safe storage, handling and dispensing of flammable and combustible liquids flow from this classification. Class I liquids are flammable liquids, examples of which include acetone, ethyl alcohol and xylene. These liquids have a flash point below 37.8°C when tested in a closed-cup vapour pressure of below 275 kilopascals (kPa) absolute at 37.8°C. Class II or III liquids are combustible liquids, and have a flash point above 37.8°C,

ventilation is used to reduce the fuel/air mixture to below the lower flammable limit (LFL). All flammable vapours have lower and upper flammable limits. For example, acetone’s LFL is 2.6 % in air by volume, methyl alcohol is 5%. If the mix of air/fuel falls below the LFL, there will be no risk of an explosion or fire. Methods of ventilation There are two basic methods of ventilation — natural and mechanical. Natural ventilation relies on convection currents and vapour diffusion. Although natural ventilation has the advantage of reliability, for example during power failures

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and breakdowns, it is, in general, not as effective as mechanical ventilation. Mechanical ventilation must be interlocked to provide an audible alarm should a situation occur where there is no air flow. It is crucial to pay particular attention to make-up air (replacement air to compensate for the exhausted air). If not enough make-up air is provided, strong negative pressure is created. This can cause a reverse-flow situation. If this were to happen, instead of exhausting, vapours would be pulled into the work area. As well, any gas-burning appliance may be bringing gases into the room. A lack of make-up air, and ventilation that is out of balance, could prove extremely dangerous. Controlling ignition sources is one of the important components in explosion and fire prevention. As such, it is necessary to address the following issues: Bonding and grounding – the control of static electricity. Control of open flames, welding equipment, etc. Control of mechanical operations that may produce sparks and heat, e.g., grinding. Using only forklift trucks and other moving equipment rated for use in flammable atmospheres, as liquids may be spilled when a forklift truck drops or punctures a drum. Ensuring that all electrical equipment, such as switches, lights and motors, are appropriately rated for use in flammable atmospheres (e.g., Class I, Zone 0, 1 or 2 electrical equipment — depending on location). Control of or elimination of hot surfaces (e.g., hot bearings, etc.). Reducing the likelihood of spontaneous combustion as a result of oils and wastes reacting with oxygen to generate heat and flame. Minimizing the possibility of mixing incompatible chemicals that may react explosively and generate heat and flame Spilling flammable or combustible liquids can present a significant hazard. As they are able to spread very rapidly, spills can expose a large area and produce vapours that can be ignited. A containment system is required to ensure that the maximum spill can be safely contained or drained to a safe location. Dikes, drainage ditches, curbs, site grading and raised doorsills are just a few examples of a containment system. Fire separations are designed to contain a fire in the fire compartment and prevent its spread. One- or two-hour (depending on the location, fire load and whether dispensing is taking place) fireresistant-rated walls are used. For example, an 8-in. hollow concrete masonry wall does not provide a two-hour fire-resistant wall. Fire doors, fire dumpers, service penetrations, etc., must also be rated. Rooms where flammable liquids are dispensed require that explosion relief is built in, in accordance with the NFPA-68 standard. Canada’s Criminal Code imposes a positive duty on employers and those who direct work to take reasonable measures to prevent bodily harm to employees and members of the public. It’s either that or face a charge of criminal negligence if the duty has been carelessly disregarded. The BP ruling is a clear example of that. MRO

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Simon Fridlyand, P.Eng., of SAFE Engineering Inc., specializes in industrial health and safety concerns and PSR compliance. For more information, visit the website at www.safeengineering.ca.

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M A I N T E N A N C E

1 0 1

December 2012

Machinery & Equipment MRO BY PETER PHILLIPS

This is the seventh segment of an eight-stage program on achieving world-class maintenance. Stage 6 was described in the November 2012 issue of Machinery & Equipment MRO and examined the building of a maintenance cost management system.

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Establishing a Maintenance System

rather than drive it at full speed, production volumes are set at 1,000 widgets per hour. Output is monitored as a KPI on a one-hour basis. In this example, we could turn on a warning light when volumes drop below 950 units per hour. At this point, a maintenance technician would be called to address the problem. The significant thing is that the KPI is set at 950 and this is defined as the trigger level at which some action is required. The same principle can be applied to less-obvious KPIs, such as the planned maintenance backlog. For example, it may be decided that when the PM backlog reaches a total of 100 hours, then overtime must be used to reduce the backlog. Once again, the key point is that a trigger level of 100 hours has been set. Technicians and first-line supervisors should be heavily involved in setting targets for performance indicators, since they are usually best placed to decide what are acceptable targets and because management-driven schemes often fail to work in the long term. While it may be possible to create a metric for a particular factor, it is not always practical to do so. We must balance the effort involved and the cost of collecting the data with its actual or potential value. For example, we may consider that it would be useful to develop a metric that indicates the number of work orders completed against the number issued. Poor performance on this metric would indicate a reduction in commitment on behalf of the technicians to input data to the CMMS. For this to be useful, however, would entail a very significant amount of work in scanning the CMMS for each work order that was not completed and then trying to determine to whom it was issued, etc. Here some typical maintenance key performance indicators:

• Overtime worked against plan • PM schedule compliance • Time taken to answer maintenance calls • Budget compliance • PM backlog man-hours • Critical equipment availability • Number of breakdowns (unplanned maintenance) • Production equipment performance (by output volume levels) • Equipment performance (with respect to quality).

©iStockphoto/Thinkstock

ow that we have a maintenance system in place, it’s time to review our plan and to measure our success. It is important to set goals you want your maintenance team to achieve, yet many maintenance departments start maintenance improvement strategies but never take the time to review their results. First of all, before you start any type of improvement plan, you need to take a ‘before picture’ of just where you are now. You must have reasons to want to make improvements. Perhaps it is the number of failures and interruptions to production. Maybe you want to improve the use of your maintenance hours. Or it might have been a corporate initiative that meant you had no choice but to implement new ways of doing maintenance. Whatever the reason, you need to know what to measure in order show improvements. Measurements come in the form of specific parameters we need to measure before we start our efforts and then measure again as we implement new maintenance procedures and practices. Many companies call these measure KPIs (Key Performance Indicators) or maintenance metrics. Many of the measurements are simple to analyze, while others rely on calculations. Listed below are some typical KPIs. First of all, we need to evaluate reliability: • What is the total number of failures? • What is the total number of minor stoppages? • What is the MTBF (Mean Time Between Failures)? • What is the failure frequency? Second, we need to evaluate maintainability: • What is your maintenance ratio? • What is your predictive maintenance ratio? • What is your MTTR (Mean Time To Repair)? Although we can measure many things and every company will have its own set of metrics, they all boil down to telling us the same thing: the uptime of equipment versus the downtime. Lets have a closer at KPIs and maintenance metrics so we can better understand what they are and how to decide which ones to use. Effective key performance indicators or metrics are a valuable tool for triggering corrective maintenance actions. Often however, maintenance metrics are worthless, since they do not provide worthwhile indications of maintenance performance, particularly when this performance is below acceptable levels. The key to this is that a KPI should normally have a trigger level set on it that is used to initiate some corrective maintenance action. If no trigger has been set, then your maintenance metric is ineffective. If no one has defined the level on the metric where performance becomes bad enough to require corrective action, then there is no point in recording it. A realistic period must also be used for each metric; in some cases this may be one hour while in others it could be one year. Let’s say that we are monitoring the production output from a critical machine. Maximum output volume from the machine is 1,250 widgets per hour, but

USING KPIs AND MAINTENANCE METRICS TO MEASURE IMPROVEMENTS.

Whatever you decide to measure, you need to meet with technicians and production personnel to determine the triggers. Once this is done, you can measure your current state of affairs and decide on a plan to establish a performancedriven maintenance system. As you progress through your improvement plan, you should periodically measure your progress using the same KPIs or metrics. We need to make sure our original aims and goals are being satisfied. To get accurate data from your CMMS, you need to make sure the data recorded in the software is complete. Every work order must be treated the same, so that the KPIs display a true picture of what’s going on. Measure your progress and then develop corrective actions to put you back on track if necessary. Finally, share your results with everyone. Post graphs of production output and reductions in breakdowns — whatever you are measuring. Show the results of everyone’s efforts and bring the team together, working toward a common goal to reduce downtime costs and increase output so the organization’s jobs can be secure now and in the future. MRO Peter Phillips of Trailwalk Holdings, a CMMS consulting and training company, can be reached at 902-798-3601 or by e-mail at peter@trailwalk.ca.

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Industrial Lubrication

December 2012

Lubrication, Tribology and Hydraulics ©iStockphoto/Thinkstock ©Hemera/Thinkstock

BY ROBERT ROBERTSON

n ineffective lubrication game plan is taking a chunk out of your company’s bottom line. The good news, however, is the situation could be worse. One company in the automotive industry had a scheduled gearbox replacement, but recommendations based on oil analysis results were overlooked. Six months later, the gearbox suffered a catastrophic failure and the plant was shut down for 12 hours at a cost of $15 million. At the Blueprint to World-Class Lubrication workshop held in Burlington, ON, by Lubrigard Ltd. (division of WearCheck Canada Inc.), the above production-related stoppage blow was anecdotally in the mix, along with an offering

of solid lubrication advice and tips. Participants included 25 reliability professionals who spent the day on site with instructors. Lubrigard plans to hold between six and eight of the free learning workshops in 2013. In this workshop, attendees were walked through an assessment process to help them evaluate the current status of their plant’s lubrication protocol relative to best-in-class programs; build a business case for lubrication improvements; and create a customized action item list to help transform lubrication management. Workshop discussion topics comprised lubricant storage, handling and dispensing; lubricant application procedures; equipment maintain-

Lubricant storage and handling mistakes

Photos courtesy Lubriguard Ltd.

According to Lubrigard’s Paul Dumont, it’s easy to find examples of bad lubrication practices. He says oil is the lifeblood of equipment, but many organizations unfortunately pay little or no attention to the proper storage and handling of oil. And today’s typical lube room can repeatedly be in a tragic state of neglect and this isn’t the best option, Dumont explains. “Depending on the individual plant application, proper lubricant storage and handling is often nowhere to be seen. Keep in mind, however, the lube room can always be transformed with improvements,” he says. “Drums are the most common oil container. They’re generally stored upright, or tipped on their sides when in use and often support open bungs. Fluid storage racks allow you to dispose of oil drums. Oil is transferred directly from the drum to the storage containers with the use of an integrated (and timed) pump and suction wand. “Suddenly, 200 square feet of random drums then becomes a neat and organized 20 square-foot integrated oil solution. Lubricants that are filtered and free from gross particulate and water contamination will last longer and serve to increase the life of your equipment. “By investing in proper lubricant storage/handling practices and procedures, companies will have an investment that improves the reliability of lubricated equipment.” Fig 1.

Fig 2.

Fig 3.

Fig 4.

Fig 1. The result of storing oil drums outdoors, water and rust can be drawn in through the bung when the barrel expands in the summer. Fig 2. Don’t do this: Barrels of new oil are stored upright with open bungs in a high-contamination production area. Here, the dispensing containers are old coffee cans. Fig. 3. An inspection hatch left unsealed on a turbine reservoir means easy access for contamination. Fig 4. This inspection hatch is permanently propped open with a fill wand for top-ups on a turbine reservoir, without concern for the debris scattered on top of the container.

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Left: “You want to avoid the machine failure cycle,” says Lubrigard vice-president Bill Quesnel.

Photos: Robert Robertson

Curb poor lubrication practices to reduce operating costs

Far left: Lubrigard business development manager Paul Dumont advises you look into oil filtration using the proper air breathers.

ability; contamination control; oil sampling practices and analysis; and training and education. At the end of the workshop, the group had the opportunity to take away detailed action item lists that were customized to specific lubrication needs. Participants also received an estimate of present financial losses attributed to the use of poor lubrication at their plants. Everyone could then schedule a one-hour, follow-up session with the workshop instructor at a later date to review their lubrication action plan with essential team members back at their facilities. “A recent study by Machinery Lubrication magazine asked 350 maintenance professionals what importance they placed on precision lubrication in relation to overall equipment reliability. An overwhelming 99% of respondents agreed that lubrication is either critical or very important to equipment reliability,” says Bill Quesnel, OMA-II, vice-president of Lubrigard. “Only 32% of respondents felt they had achieved a level of performance that comes close to world-class lubrication. In terms of lubrication fundamentals, why then are the other 68% of surveyed maintenance professionals left out in the cold? “I believe the three main stumbling blocks are lack of knowledge or education, lack of top management support or buy-in, and maintenance staff that are too busy ‘fire-fighting’ to sustain a concerted lubrication improvement plan.” Quesnel added that the one-day lubrication workshops address these obstacles “and provide attendees with insight into our program and tools. Lubrication is the cornerstone of any reliability-driven maintenance department. Done correctly, lubrication can eliminate equipment failures and increase uptime. Done poorly, it can result in losses as high as 30% of a plant’s maintenance budget.” According to Quesnel, implementing a successful oil analysis program starts with a desire for optimum maintenance performance. This involves setting key targets and goals, determining responsibilities and machines to be sampled, establishing sample points, collecting equipment information, selecting a laboratory, performing correct testing and taking affirmative actions. He further says it’s important for companies to build a business case for world-class lubrication. “In terms of oil analysis and basic inspections, you want to monitor for abnormal wear modes, identify proper oil change intervals and detect environmental and process contamination. “It’s crucial to evaluate filtration upgrades, lubricant type and brand changes, as well as the effectiveness of reliability improvements,” says Quesnel. “Don’t forget to confirm maintenance activities and undertake root-cause failure analysis. A maintenance environment prevents contamination ingress and improves equipment reliability.

You want to avoid the machine failure cycle. “Maintenance managers don’t care about poor lubrication, but they care about the financial impact of poor lubrication. You want to estimate the dollars lost per year due to failing lubrication and establish an action plan that closes the gap on the most common reasons behind it. “Next steps include estimating upfront and ongoing costs to achieve lubrication excellence, as well as calculating your five-year Net Present Value (NPV) and Internal Rate of Return (IRR) for total improvements.” Paul Dumont, the OMA-certified business development manager for Lubrigard, says it’s difficult to gain appreciation for the extremely small scales of destructive particles that wreak havoc on lubricated equipment. To give your lubricants the best possible chance to succeed, Dumont recommends monitoring for abnormal wear modes, determing proper oil change intervals, as well as guarding against environmental and process contamination. Dumont also says proactive maintenance and plant operations staffs need to prevent the oil from being contaminated while it’s circulating through their machines. “If your equipment is like 95% of all lubricated equipment in North America, then that oil is getting dirtier and wetter by the minute. To become proactive with a lubrication management program, it’s fundamental to focus on ingression control,” says Dumont. “Contaminant ingression control involves the prevention of the entry of dirt and water into the lubricant during machine operation. Ensure that proper air breathers are installed on equipment. A proper air breather will employ 3-, 5- or 10-micron filtration to prevent dirt and dust from entering the oil. This will keep the oil clean.” According to Dumont, implementing a lubrication management program — especially one that includes oil analysis — just makes sense. He says oil analysis is a useful predictive maintenance tool and provides a high return on investment (ROI). “Companies continue to manage their costs using oil analysis. Taking the time to lay the groundwork for a successful program will ensure that you maximize your ROI from oil analysis,” he says. “It’s about using oil analysis information to improve your reliability decisions and better enable trades people. It’s also about putting your organization on the right track to world-class maintenance excellence.” For more information about this series of lubrication workshops, contact Lubrigard at (800) 268-2131 or visit www.lubrigard.com. IL Robert Robertson is a contributing editor at Machinery & Equipment MRO and a Mississauga, ONbased freelance writer.

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Machinery & Equipment MRO

December 2012

controllers to keep temperature swings at a minimum, premium hydraulic fluids with antiwear additives help to prevent excessive wear rates in the face of any temperature fluctuations and service demands. “At its core, a good hydraulic fluid will efficiently transmit force from one point to another while at the same time protecting all of the critical components of a hydraulic system, such as the housing, seals, pumps and valves,” explains Purificati. He suggests that operations need to first understand the direct effect of the fluid on the equipment itself throughout its life cycle, as opposed to basing performance quality on the length of the life of the fluid alone. “The best way to check the quality of hydraulic oil is through laboratory testing. This should be done regularly to ensure prevention of longerterm damage. Premature wear within the equipment, where the fluid is supposed to provide protection, will lead to shorter overall equipment life and cost you more money in the long run.”

Choosing the right hydraulic fluid for the job

Examine what it is that your current fluid is it not delivering.

ydraulic fluids are a crucial component of many operations. You rely on them every day to protect your equipment and maintain proper workings of hydraulic systems. But when the hydraulic fluid you’re using isn’t the right fluid for the job, you can run into longterm issues such as premature wear, increased sludge and loss of equipment productivity. These factors all can lead to shorter equipment life and overall increased costs. So how do you choose the right hydraulic fluid? As Marc Bouchebl, the hydraulic oils category portfolio manager for Petro-Canada Lubricants Inc., explains, it’s all about knowing the ins and outs of your business and your machinery. “Every sector is different, and every operation within each sector presents its own unique challenges. When looking for the right hydraulic fluid, you need to start by looking at your own business needs. What are the demands of your operation? Which fluid are you currently using and what is it not delivering? Essentially, what do you want to get out of your hydraulic fluid?” When you choose the right hydraulic fluid, it should ultimately improve your productivity and your bottom line. If this doesn’t sound like your fluid, perhaps it’s time to revisit your needs.

What to look for in hydraulic fluid OEM specifications: The first step is to research your Original Equipment Manufacturer’s (OEM) requirements. Each OEM has its own specifications regarding optimal viscosity levels and other characteristics to ensure the best performance for its equipment. Darryl Purificati, technical services advisor

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for Petro-Canada Lubricants, knows about the hydraulic fluid demands of today’s industries. “OEMs provide guidelines for a reason, so it’s important to refer to these as a core starting point, especially if under warranty,” he explains. “Using a fluid that does not meet equipment manufacturer guidelines may affect your warranty and equipment performance. At Petro-Canada, we work closely with our clients and equipment manufacturers to ensure requirements are met.” Oxidative stability: Oxidation is the most common cause of hydraulic fluid degradation in today’s plants. The three most important accelerators of oxidation are: • High temperatures • Contamination with catalytic metals, such as iron and copper • Exposure to oxygen. Unfortunately, these causes are troublesome for plants using smaller reservoirs. With the smaller systems now in operation, air and heat are not able to escape as easily as with larger reservoirs. Water cannot separate as effectively, contaminants accumulate faster and, as the rate of oxidation rises, so does the risk of harmful sludge build-up. “Sludge can be incredibly damaging to hydraulic components. Even with a good filtering system, excessive sludge can plug filters, which can decrease fluid flow rates, increase system pressures and seriously damage the hydraulic pump. In the end, it makes the system work harder for less result,” explains Purificati. “Using hydraulic fluid with good oxidative stability will help prevent harmful sludge build-up.” By minimizing oxidation and consequently reducing sludge build-up, a high-performance hydraulic fluid can safely provide longer lubri-

cant life, while still providing optimal protection and performance. This results in fewer change-outs, reduced equipment wear and less downtime for operations. Thermal stability: High temperature swings can cause hydraulic fluids to degrade or break down. A fluid with good thermal stability will resist degradation in high temperatures, and reduce the need for fluid top-ups and/or system cleaning. Together, oxidative and thermal stability promote longer oil life, which helps plants to safely extend drain intervals for reduced change-outs. When plants are able to reduce change-outs, it can not only help to decrease costs and unnecessary downtime, it also helps to lessen a system reservoir’s exposure to external contaminants, which can be harmful to the fluid and the system as a whole. Rusting and corrosion prevention: Corrosion is the degradation of metals, and rusting is the degradation of ferrous metals. Though different by definition, their effects on hydraulic systems can be equally detrimental. When hydraulic surfaces are not properly protected, rusting and corrosion can occur that can negatively affect system integrity, leading to metal fatigue and, in some cases, system seizing. As Purificati explains, the best way to prevent rust and corrosion is to select a fluid with excellent water separability, hydrolytic stability and rust-inhibiting additives to prevent water damage and effectively protect against the negative effects of corrosion and rusting. Advanced wear protection: Today’s hydraulic systems can be expected to operate for long intervals, and at high pressures and temperatures. While many modern systems may have

Photo: Petro-Canada Lubricants Inc.

Oil monitoring Many operations have heard of oil monitoring, but what can it do for your hydraulic systems? “For our customers, and anyone using hydraulic systems, we recommend participating in an oil-monitoring program,” explains Purificati. “It helps to understand how systems are performing, whether they could work better, and ensures minor mechanical problems are discovered before they become serious and expensive to fix. Simply said, it’s the difference between preventive maintenance and reactive maintenance.” Oil-monitoring programs, such as PetroCanada Lubricants’ Lubri-Test, are low-cost, preventive maintenance programs, used to evaluate the condition of lubricants and equipment on a routine basis. The programs monitor oil properties, such as viscosity, oxidation levels and metals content, to help detect abnormal equipment wear and unwelcome contaminants like dust, dirt and water. Some of the major benefits of oil monitoring programs include: • Reduced unscheduled downtime • Improved equipment reliability • Effective maintenance schedules • Extended equipment life • Reduced maintenance costs. “Our Lubri-Test, for example, uses viscosity and other fluid properties to determine the condition, and decide if the fluid is still suitable for use or if a change is required,” explains Purificati. “Oil-monitoring programs help plants to extend their drains safely and effectively, avoiding additional costs and increased downtime.” When implementing an oil-monitoring program, it’s always important to work with a professional. Unsafely prolonging an oil drain interval can lead to equipment damage. Over time, hydraulic fluids will lose their effectiveness and continuing use of these fluids can seriously compromise the system components and eventually the entire system. When used properly, an oil monitoring program can make a big impact on your uptime and equipment productivity. Once you understand your needs, your best solution is to work with knowledgeable suppliers who know the products, their specifications and benefits, and can work with you to deliver the best results for your plant. “When you get it right, it shows,” concludes Bouchebl. “When you use the right hydraulic fluid for the job, it can increase your equipment productivity, reduce downtime and improve your bottom line.” IL The article was prepared by Petro-Canada Lubricants Inc., Mississauga, ON. The company supplies Hydrex AW, a high-performance hydraulic fluid, as well as the Lubri-Test oil-monitoring program. Online Reader Inquiry No. 608

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December 2012

Machinery & Equipment MRO

Centralized lube systems enhanced

Manufacturers develop an improved pump unit for centralized lubrication systems on wind turbines that offer better efficiency and machined sealing. BY STEVE GAHBAUER

ubrication requirements for bearings in wind turbines have triggered a series of developments that improve the operation of centralized lubrication systems. Some bearings in wind turbines require lubrication at predetermined intervals. Automatic centralized lubrication systems achieve that. But now a bearing manufacturer and a pump manufacturer have combined efforts to develop a lubrication package for these units that increases the lifetime and reliability of wind turbine bearings and elevates centralized lubrication systems to a new level. The new system consists of a KFG series pump unit, an electric filling pump, a pressure switch, and a pump for the used lubricant. Unlike in earlier pump versions, the lubricant can be fed into the modified KFG pump from the top, avoiding an accumulation of unused grease in the upper part of the pump. This improvement in the design is a key component of this pump. It allows for a homogenous exchange of the lubricant, based on the ‘first-in, first-out’ principle: the topfed lubricant is pumped out at the bottom, as opposed to the system used in earlier versions. Another advantage is that this modular concept pump can be used in a wide temperature range and is easy to install. And the pump can be refilled with a specially designed portable electric filling pump, which significantly improves the ease of service and maintenance operations. The pump unit also contains a new machined sealing arrangement for the grease follower piston. This new sealing concept was developed by SKF Economos Deutschland GmbH in cooperation with SKF Lubrication Systems in Germany. The new design and the customized sealing system enable the grease follower piston to operate using various viscous lubricants suitable for different temperature ranges. The benefits of the new design are obvious. The modular pump concept allows easy pump installation. The redesigned reservoir enhances reliability, even when used in extreme operating conditions. Forcibly actuated pistons supply adequate and controlled volumes of lubricant. Maintenance requirements are reduced and bearing reliability is increased. An efficient and successful cooperation between SKF Sealing Solutions and SKF Lubrication Systems and collaboration with KFG Pumps has resulted in developing an improved and more reliable central lubrication system for wind turbine bearings, contributing to longer service life and less maintenance, says Stefan Schürmann, manager of the Development Centre Hockenheim at SKF Lubrication Systems. Also contributing to this development were Peter Beckenbach, technical sales representative of SKF Economos Deutschland in Erbach, Germany, and Thomas Mayer, seals business manager of the SKF Service Division in Judenburg, Austria. IL Steve Gahbauer is an engineer, a freelance writer, and a contributor of technical articles to Machinery & Equipment MRO.

Above: The design of the piston pump allows it to be used reliably in the rotating area of a wind energy system. Inset photo: The SKF piston pump unit KFG for wind turbines is specifically designed for the demanding requirements of the wind industry. The pump design has several advantages, including a reinforced grease reservoir available in various sizes to meet the requirements of any lubrication circuit.

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December 2012

The Beast of Lyon Bests Friction Photos courtesy INSA

The Tribogyr is the largest and most sophisticated test machine ever, built to allow new insights into the behaviour of friction in rolling elements. By Steve Gahbauer

he Tribogyr test machine at the National Institute of Applied Sciences (INSA) in Lyon, France, is breaking new ground in tribological research, the study concerned with interacting surfaces in relative motion, and the behaviour of lubricants under friction and wear that influences bearing design. Lubricants provide the film between contacting surfaces, and lubrication knowledge goes hand-in-hand with bearing technology. That’s why developments at INSA are important. Established in 1957, the Institute is one of the largest engineering schools in France. It provides a fully integrated approach to education, research and innovation. Lyon collaborates with other leading universities internationally and fosters strong relationships with industry, to wit its partnership with Swedish bearing designer and manufacturer SKF. INSA offers experience and competency in tribology dynamics, mechanical transmissions, and forming processes. One of its focus areas is the multi-stage analysis of lubricated contacts. This analysis is performed by the Tribogyr test machine, also often referred to as “the Beast of Lyon,” a complex, colossal six-tonne contraption of metal alloys, sensors and computers, sitting on a special pad to isolate it from outside vibration and housed in its own environmentally controlled room. It is the largest and most sophisticated test machine ever built to measure fric-

tion and lubricant film thickness in heavily loaded bearing applications. The machine was designed by the Contacts and Structural Mechanics Laboratory (LaMCoS) at INSA. Operating since 2005, the Tribogyr test machine is the result of a long process of development. It provides new insights into the behaviour of friction in rolling elements, so important in meeting the trends toward higher power density and friction reduction in bearings. Over the years, LaMCoS has acquired a considerable reputation for developing experimental machines and numerical models to study friction in loaded lubricated contacts. Senior researcher Philippe Vergne points out that a better understanding of friction and the dissipation of heat that friction creates leads to improvements in the efficiency of large bearings. Tribogyr simulates the behaviour at full scale, which means that it can handle forces up to 3,000 N and operate at speeds of up to 22,000 rpm. Tribogyr can measure frictional forces and moments in different directions

Top: Thomas Doki-Thonon (left) and Nicolas Devaux with the Tribogyr test machine. Above: The Tribogyr can handle forces up to 3,000 N and operate at speeds up to 22,000 rpm. Far left: Engineer Nicolas Devaux makes adjustments to the Tribogyr test machine. Left: Phillippe Vergne is the director of research for LaMCoS.

given independently by the two contacting surfaces – the rolling elements and the flange. The gap of the contact can be in the order of five millimetres, which is huge for heavily loaded lubricated contacts. “At full operating conditions, the contact could generate more than 10 kW of heat dissipation, compared with a large commercial test machine of less than 1 kW,” explains Guillermo Morales-Espejel, a visiting professor at INSA and a senior scientist at the SKF Engineering and Research Centre in the Netherlands. “Large-size spinning contacts do not behave like small-size spinning contacts; they are truly unique entities,” he says. “The larger the contact, the larger the surface velocity asymmetry within it. Film thick-

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ness and friction are very much determined by the speed of [the moving] surfaces. Thus, asymmetry in the speed means asymmetry in the film thickness and the created friction, and this cannot be easily calculated.”

Measuring friction But it can be measured. The major benefit of the Tribogyr is that it can accurately measure friction. New research has resulted in an ability to measure film thickness as well. This supplies an image of lubricant flow, which provides

Large-size spinning contacts do not behave like small-size spinning contacts; they are truly unique entities. qualitative as well as quantitative information about lubricant behaviour. From the viewpoint of bearing company SKF, there are clear benefits deriving from collaborating with LaMCoS. The bearing designer and manufacturer has access to the whole picture of the behaviour of large-size spinning contacts. The company can very precisely model temperature distributions in and around the contact area. This enables design engineers to continuously improve bearing designs and make bearings more reliable and efficient. Looking to the future, Tribogyr is undergoing continuous improvement, opening up new testing and simulation opportunities. This machine delivers new insights into the behaviour of large bearings and the lubricants that provide the film between contact surfaces in relative motion. The Tribogyr story is proof of how collaboration between research and industry delivers worthwhile results for both. IL Steve Gahbauer is an engineer, a freelance writer, and a contributor of technical articles to Machinery & Equipment MRO.

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Online Reader Inquiry No. 133

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I N D U S T R I A L

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Machinery & Equipment MRO

December 2012

What’s new in lubrication products Easily installed singlepoint lubrication system is versatile Flo Components’ Perma Flex is a single-point lubrication system for all types of applications and industries. This gas-generating unit produces the required pressure to continuously supply the lubrication points with fresh lubricant for the selected discharge period (one to 12 months). Features include ingress protection to IP 68 level, wide operating temperature range of minus 20°C to plus 60°C, and a small size that fits into tight applications. If necessary, the discharge period can be adjusted after activation, and the system can be switched off during longer non-operation periods. The user-friendly system comes fully assembled and can be activated quickly and easily without tools. Flo Components Online Reader Inquiry No. 588

Automatic lubricator system assures continuous supply to components The latest generation of SKF System 24 single-point automatic lubricators provides a reliable and cost-effective way to deliver a continuous supply of lubricant to plant machinery components. Improvements to the previous system include: no tool required to set up the unit, easily detachable batteries, improved dial readability, redesigned top ring for better grip, and a deactivation mode. These easy-toinstall and -use devices deliver premium-quality SKF lubricant, even in applications subject to high levels of contamination, or in demanding, hardto-reach, remote and hazardous areas. Applica-

tions include bearing housing lubrication, electric motors, fans and pumps, conveyors and cranes. SKF Canada Online Reader Inquiry No. 592

Lubricant provides both water spray-off and wear resistance Dow Corning’s Molykote G-1502FM synthetic bearing and gear grease has been formulated to simultaneously resist water washdown and sprayoff and help prevent wear and corrosion, minimizing both grease loss and wear scar. Offering long service life at wide service temperature ranges in water-rich environments, the product is designed to reduce costs and extend equipment life. It delivers effective results even at low speeds. Dow Corning Online Reader Inquiry No. 366

System manages custom-mixed lubricant for piping networks Industrial Innovations has introduced a line of Pro-Mix lubricating systems designed to mix the desired content of lubricant concentrate and water for distribution through an in-plant piping network. Each machine connected to the network automatically receives a continuous supply of pressurized lubricant mixture. Additionally, the systems can be manufactured to supply up to three different lubricant mixtures to each press, allowing flexibility for various material applications. The systems come in Pro-Mix I, III and V models. The Pro-Mix III and V are larger units that use pump/valve assemblies to refill the reservoirs. The Pro-Mix I has all the standard design features of the larger systems on a smaller scale and relies upon gravity, using mechanical ball float switches for reservoir refill. Industrial Innovations Online Reader Inquiry No. 593

Industrial leak detection kit uncovers oil-based fluid leaks Spectronics has introduced the OPK-341 industrial leak detection kit for pinpointing the exact source of all fluid leaks in hydraulic equipment, compressors, engines, gearboxes,

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fuel and other synthetic and petroleum-based industrial systems. At the core of the kit is the Optimax 3000, a cordless, rechargeable, superpowerful, blue-light LED inspection flashlight featuring an inspection range of up to 6.1 m (20 ft). Powered by a rechargeable NiMH battery, the flashlight has an LED life of 50,000 hours. Also included in the kit are a 473-ml (16-oz) twin-neck bottle of Oil-Glo44 concentrated fluorescent oil dye, a 237-ml (8-oz) spray bottle of Glo-Away dye cleaner, smart AC and DC chargers, dye treatment tags and fluorescence-enhancing glasses. All components are packed in a rugged carrying case. Spectronics Online Reader Inquiry No. 595

Electro-graphite grade material is approved for food contact Metcar Grade M-58 electro-graphite base material from Metallized Carbon has received approval from the US Food and Drug Administration (FDA) for use in food contact applications, such as dry-running food mixer seals. Dry-running mechanical seals are used on large, vertical mixers to seal the clearance between the agitator shaft and the mixer housing at the location where the shaft enters the top of the mixer. The material contains an additive to reduce friction and improve the dry-running wear rate. Available fully machined to the customer’s drawing specifications, these primary seal rings can be used in temperatures between minus 30°F and plus 800°F. FDA-approved bearings, seal rings, vanes, rotors, end plates, piston rings, valve seats and other machine parts that must run submerged in beverages or liquefied foods use Metcar carbon-graphite grades that are impregnated with thermal-setting resin, copper, tin-bronze or nickel-chrome. Metallized Carbon Online Reader Inquiry No. 596

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I N D U S T R I A L December 2012

Metal-detectable lube stops contamination in food processing LPS has introduced Detex metal-detectable plastic aerosol components for the food industry, which guarantees that all plastic components on an aerosol can for the company’s NSF H1 food grade lubricants are metal detectable. Blue coloured caps, actuators and extension tubes signify the Detex components that are metal detectable and can help prevent food from being contaminated. This assists food processing plants in meeting strict HACCP requirements regarding the use of LPS NSF H1 aerosol products in the food processing area. The LPS NSF H1 products with the Detex components are Belt Dressing (#02216), Clear Penetrating Grease (#06716), Food Grade Chain Lubricant (#06016), Food Grade Machine Oil (#01316), Food Grade Silicone Lubricant (#01716) and Heavy-Duty Silicone Lubricant (#01516). LPS Laboratories Online Reader Inquiry No. 598

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dirt or small particulates. The system includes retractable hose reels with metered dispensing control handles. A large steel tool box with cabinets underneath the reels provides convenient storage of tools, greases, rags, etc. The IFH Group Online Reader Inquiry No. 360

Lubricant complies with international food safety standards Sprayon’s NSF-H1-rated food grade lubricant line features 12 lubricants developed specifically for the food processing industry. Consisting of high-quality food-grade basestocks, including synthetics, renewable oils and silicones, these lubricants feature heavy load pressures, good resistance to water washout, low flammability ratings and wide temperature

system pressure of up to 206.7 bar (3,000 psig). Available in a wide variety of ranges up to 30 gpm, the flowmeter measures oil rates with plus or minus 2% of full-scale accuracy. It comes with a choice of 1/4-in., 1/2-in. and 1-in. connections for a wide variety of applications, and is calibrated for horizontal in-line mounting. ITM Instruments Online Reader Inquiry No. 359

Motor oil reduces fuel consumption Delo 400 LE Synthetic SAE 5W-30 gasoline and diesel motor oil can deliver over 4% fuel economy improvement in various trucks and duty cycles when compared to SAE 15W-40 reference oil in SAE J1321 fuel consumption testing, according to Chevron Lubri-

cants. The product is designed to provide maximum fuel economy improvements while meeting industr y and engine manufacturers’ per formance requirements and is suitable for heavy- and medium-duty trucks operating both on- and off-highway. The product is recommended for engines in which the API CJ-4 or API SN service categories and SAE 5W-30 viscosity grade are recommended. The oil is designed to meet the demands of EGR and EGR/SCR engines, while also performing in other diesel engine technologies. Chevron Lubricants Online Reader Inquiry No. 594 IL Obtain free additional information about any of these items by using our online reader reply card at www.mromagazine.com/rsc.

Lubrication system keeps rack and pinion systems running smoothly Wittenstein has developed a complete lubrication system, specially designed to work with any type of rack and pinion system, that ensures these systems are running smoothly with long service life. The lubricator supplies a preset quantity of grease to the felt pinion ranges. They meet the formulation hygiene requirements for the use and handling of lubricants that may come into contact with food, cosmetics or animal feed products during manufacturing or processing. Sprayon Online Reader Inquiry No. 367

Lubricant line can offer energy-efficiency benefits and guarantees a constant film of lubrication on the rack and pinion. Multiple components make up the lubrication system. The lubrication canister, which comes in two sizes, houses the lubrication. To this is attached a sensor kit, which notifies when the lubrication is running low. The lubrication flows from the canister to the mounting shaft through a plastic hose connection. The mounting shaft contains holes that allow for the lubrication to pass through to a felt pinion which disburses lubrication onto either the pinion or the rack. Wittenstein Online Reader Inquiry No. 365

ExxonMobil’s machine shop lubricants are formulated for performance and energy efficiency. The line includes: Mobil DTE 10 Excel series of high-viscosity-index, shear-stable, anti-wear oils for hydraulic systems; Mobil SHC 600 synthetic circulating and gear oils that deliver good equipment protection; and Mobil SHC Gear fully synthetic industrial gear oils that help enhance equipment performance, and deliver good oxidation resistance and low-temperature fluidity. All products offer potential energy efficiency benefits. Exxon Mobil Online Reader Inquiry No. 597

Portable lubrication system goes anywhere in large industrial plants

Variable-area flowmeter for oil features durable metal construction

A mobile lubrication system from the IFH Group provides storage and dispensing of lubricants, cutting oils, bearing oils, hydraulic fluids, transmission fluids and engine oils for plants requiring lubrication maintenance at multiple locations over a large area. The

Dwyer Instruments has announced the release of its series DTFO variable-area flowmeter for oil. This compact series allows for the accurate measurement of compatible oils at an affordable price. The rugged brass or available stainless steel construction helps withstand

Online Reader Inquiry No. 137

SEE BEYOND

TEMPERATURE The NEW Fluke VT02 Visual IR Thermometer. system, which is delivered on a pallet, can be placed in the bed of a heavy-duty pickup truck for easy mobility anywhere within a plant. It includes two 50-gal and two 25-gal steel containers with PVC sight gauges. Air-operated piston pumps on top of each container provide a 5:1 pumping ratio, and filters remove any

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The first low cost IR thermometer with a visual advantage! Scan for hot and cold across a surface and blend the infrared and digital image. Done. flukecanada.ca/beyondtemp

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Machinery & Equipment MRO

December 2012

What’s new in belt drives Narrow-profile V-belt withstands demanding applications

Goodyear has introduced the long-lasting Wedge TLP V-belt. This narrow-profile belt is suitable for rigorous, highhorsepower drives, particularly where high shock loads are present. Since the product can also be used in tandem, it can be used in various industries, including forestry, metal mining, oil and gas extraction, heavy construction, lumber and wood products, primary metal, and industrial and commercial machinery. Its greater horsepower capacity enables it to deliver the same amount of horsepower with a smaller number of belts. Fewer belts mean fewer

sheave grooves, and the combination of the two means a lower initial price and less cost of operation. For additional details, visit GoodyearEP.com/WedgeTLP. Goodyear Engineered Products Online Reader Inquiry No. 555

Heavy-duty timing belt is designed for large, high-tensile loads

The ContiTech Power Transmission Group has developed a polyurethane heavy-duty timing belt with a carbon tension member, the Conti Synchrochain Carbon. Carbon fibres stretch only half as much as aramid under the same load and offer increased pitch precision under high-tensile load. This characteristic, combined with the hard polyure-

Raw-edged, heavy-duty V-belt gets performance boost

The performance of the raw-edged Conti-V FO-Advance heavy-duty V-belt has been increased by up to 15%, according to ContiTech Power Transmission Group. The belt provides drive solutions in many industrial applications, including in machine and systems constructions and ventilation technology, as well as in pumps and compressors. Using these belts, drives will be more cost-efficient and be able to transmit more power with the same footprint or the same power in a smaller footprint. The smooth-running belts are currently available in profiles XPA, XPB, XPC and XPZ from 1,250 mm to 3,550 mm. ContiTech Online Reader Inquiry No. 559

thane teeth, substantially reduces the risk of tooth jumping. Also, the high stiffness of the cord minimizes the prestress loss, thus boosting the efficiency of the drive. The smooth-operating

belt requires no lubrication and virtually no maintenance. ContiTech Online Reader Inquiry No. 557

Reducing play at pulley tooth gaps increases positioning accuracy

Most linear drives and systems require precise positioning, not allowing for timing belt backlash. Repeatability tolerances can be improved by reduced backlash (SE) or zero backlash (0) tooth gap designs. Brecoflex offers timing belt pulleys with normal tooth gap design (most backlash), reduced backlash design and zero backlash design, while maintaining the

accuracy of the respective pitch diameter. In addition, the company offers reduced backlash and zero backlash pulleys in T and AT tooth configuration. The pulley lead time is eight working days. For additional details, visit www.brecoflex.com. Brecoflex Online Reader Inquiry No. 556

Plastic components replace metal in corrosive environments

Martin Sprocket & Gear offers both injection-moulded plastic and machined plastic manufacturing. Well-suited for demanding and diverse applications such as food and beverage, wastewater treatment, printing, chemical processing, and forest industries, plastics are used in

areas where contamination, corrosion or caustic environments prevent the use of metals, and where weight reduction is a concern. The company manufactures FDA-approved plastics to meet the needs of such industries as the food industry. It can produce plastics in a variety of�� colours�� to make it easy for machine operators to find the correct parts quickly and easily, avoiding downtime. Martin Sprocket & Gear Online Reader Inquiry No. 560 MRO

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December 2012

Machinery & Equipment MRO

What’s new in electrical and electronic components t

Thin panel bushing protects cables, utility lines

Covers provide mechanical and electrical protection

Online Reader Inquiry No. 582

Pre-assembled connector cuts installation time

Appleton has added a pre-assembled KO sealing ring with lock nut to its Liquidtight ST series of electrical cable and conduit connectors, eliminating the need for additional purchasing. The simplified three-piece design allows fast installation and easy field assembly. Constructed from bar stock steel or malleable iron, the connector provides longterm protection from water, dust, oil, grease, fumes and hostile contaminants.

Dwyer Instruments Inc. has introduced the 15-A Series 861H hermetic solid-state relay, featuring an internal heat sink, an internal snubber, finger-safe terminals, DIN or panel mounting and LED indicator light. It is a complete solid-state relay in a modular package with no moving parts. The intrinsically safe relay incorporates integrated heat sink and sealing technology to achieve a UL Class 1, Division 2 rating for approved use in Groups A, B, C and D hazardous locations. The device provides reliable switching and long-life operation in demanding applications such as mining, oil and gas. ITM Instruments Inc. Online Reader Inquiry No. 577

Coils suit high-current metering applications

Harting has extended the application possibilities for its Han-Inox stainless steel product series with covers for hoods and bulkhead housings in size 10 B. In addition, a bulkhead housing with integral cover and coupling housing, also for size 10 B, has been introduced. Designed for rugged, highly sensitive applications where a high-grade stainless steel exterior is required, the IP-65 compliant product provides resistance against chemical and other aggressive substances in industries such as oil and gas, petrochemical production, water filtration and wastewater systems, as well as for food, beverage and pharmaceutical production. Harting North America

Low-cost solid-state relay stands up to hostile environments

Online Reader Inquiry No. 584

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Standex Electronics manufactures highly accurate Rogowski coils and modules in custom configurations to meet high-current metering applications. Suitable for use within hybrid circuit breakers and other components used in smart metering, the coils are wire wound air core toroids used to measure AC current. Among the benefits are low cost, good linearity over the measurement range, good high current measuring capability, low power consumption, no DC/high current saturation problem, low output variation with temperature, no DC offset problem, and no saturation and hysteresis problem. In-house moulding means that the coils can be packaged to suit particular requirements. Standex Electronics Online Reader Inquiry No. 579

Mississauga, ON-based Carlo Gavazzi has introduced the RG series of AC and DC solid-state relays and contactors, designed for switching resistive, slightly inductive and motor loads. The RGS solid-state relay provides a slim 17.5 mm of width. Maximum output voltage is 600 VAC with a current rating of 90AAC (with proper heat sink). Both the AC and DC control versions are available covering a wide range of input voltages. The RGC solid-state contactor offers an integrated heat sink with a small frame size rating of 20 and 23AAC/3 hp in the same 17.5-mm width, 30AAC/5 hp (22.5 mm wide), 40AAC/7.5 hp (35 mm wide) and 60AAC/10 hp and 85AAC/15 hp (70 mm width). Also available is the series of RGS1D/RGC1D DC output solid-state relays. Applications can be found in the HVAC, food and beverage, packaging, plastics, printing, glass and transportation industries. Carlo Gavazzi Online Reader Inquiry No. 581

Explosion-proof pressure switch withstands extreme temperatures

Designed for use in panels as thin as 0.5 mm (0.020 in.) and made from nylon 6/6, Heyco’s thin panel bushings are available in multiple sizes for use in 5.5-mm (0.218-in.) to 22.2-mm (0.875-in.) diameter holes, and easily convert raw-edged holes into smooth, neat, insulated holes. They also insulate and mechanically protect electrical and telecommunications cables, tubing, hose, rope and utility lines. Features include locking fingers that snap into holes with fingertip pressure in fractional increments up to the maximum panel thickness; they can withstand a push-back force of greater than 35 lb. Heyco Products

It features a compact, slim profile with a small turning radius for easy installation in tight spaces. The connectors are UL Listed for use in Class 1, Division 2 hazardous and wet locations and are offered in sizes ranging from 3/8 in. to 5 in. in most straight, 45-degree and 90-degree configurations, with or without insulated throats, external ground lug or wire mesh strain relief. Appleton/Emerson Industrial Automation

Slim solid-state relay/ contactor series switches motor loads

An explosion-proof pressure switch has been released by American Sensor Technologies. The AST46SW switch offers a single-pull, double-throw configuration with factory-set switch points and hysteresis. Using the company’s Krystal Bond technology, the one-piece, stainless steel sensing element of the unit measures pressure in extreme temperature conditions. Standard models are configured with 316L, 17-4 PH, or Inconel 718 materials. With a maximum operating pressure range up to 1,378 bar (20,000 psi), the switch maintains high performance with zero signal drift due to an extremely thick and robust sensing diaphragm, and is CSA-approved for use in hazardous areas including Class 1, Division 1 explosion proof Groups A, B, C and D, and for mining applications, Class 2, Divivsion 1 Groups E, F and G. American Sensor Technologies Online Reader Inquiry No. 578

End-of-line terminator aids communication between devices

The Reliable Controls End Of Line terminator optimizes communication between the company’s devices and devices from other manufacturers that are connected on a common EIA-485 network, using BACnet or Modbus protocol. It provides the ability to properly terminate EIA-485 twisted pair networks, has 24-VAC input power and is a biased terminator similar to those found on all of the company’s controllers. Housed in a robust plastic case, the device has a red power LED to indicate the device is

powered correctly and comes with convenient mounting screws and removable 5-mm rising cage terminal blocks. For more information from the Victoria, BC company, visit the website at www.reliablecontrols.com. Reliable Controls Online Reader Inquiry No. 580

Stainless steel enclosure is built for rugged, corrosive environments

Hammond offers a number of floor-mounted and freestanding stainless steel enclosures designed to house electrical, electronic, hydraulic or pneumatic controls and instruments for installation in oil and gas facilities, water treatment plants, food manufacturing plants, pharmaceutical produc-

tion plants and more. The 1418, 1422 and HN4SS series enclosures are manufactured from 304 or 316 grade stainless steel with a smooth, brushed finish. All seams are continuously welded and ground smooth and the units are sealed to NEMA 4X rating. Features include heavy-duty, stainless-steel lifting eyes and doors mounted on continuous hinges and sealed with a seamless, poured-in-place gasket. A wide range of accessories such as windows kits, breathers, anti-condensation heaters, thermostats and drip shield kits is available. Hammond Manufacturing Online Reader Inquiry No. 585

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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. 139

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December 2012

What’s new in grinding and cutting Trimmable flap discs designed for hard-to-grind applications

A line of trimmable C3 ceramic flap discs has been introduced by CGW-Camel Grinding Wheels. The discs have a backing designed to be trimmed down to expose ceramic flaps for extended working life, allowing for fewer disc changes and longer production times. Also, the hybrid compact flap design compresses and compacts flaps at a four-degree angle for addi-

tional edge strength and more material. Manufactured from self-sharpening ceramic grain and a strong polyester flap backing, the discs are recommended for aggressive cutting action on hard-to-grind materials such as stainless steel. They are available in 4-1/2-in. and 5 -in. diameters, with 7/8-in. arbor holes or 5/811 hub and grit sizes of 40, 60 or 80. CGW-Camel Grinding Wheels Online Reader Inquiry No. 568

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Grinder/sander model line suits wide range of light applications

Chicago Pneumatic has introduced 18 models in its CP3000 series of straight industrial die grinders and 18 models in its CP3030 series of angle industrial die grinders and sanders. They range in power from 300 W (0.4 hp) to 500 W (0.7 hp) and in speeds from 15,000 rpm to 30,000 rpm. Designed for use with 6-mm (1/4-in.) carbide burrs and mounted points, these tools are suitable for a wide range of light metalworking operations, including contouring, de-burring and light chamfering, as well as sanding with 76-mm (3-in.) sanding pads, in industries as diverse as energy, metal transformation and manufacturing. The models feature a compact composite body, industrial grade durability and a low cost of maintenance, and are ergonomically designed to offer very low vibration (close to or below 2.5 m/s2), low weight (starting as low as 0.4 kg/0.88 lb) and low noise. Chicago Pneumatic Tools Online Reader Inquiry No. 562

Feed belt moves workpieces to grinding machine with precision

ContiTech Conveyor Belt Group’s feed belts offer a flexible, economic and reliable solution for the wood, paint, plastic or metal grinding process. An important

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precision element between the feed table, work piece and grinding unit on cylinder and belt grinding machines, the Contact feed belt features a material composite consisting of rubber and tensile members of synthetic fabric that does not impart colour. Its profiled surface has a high adherence friction, and a variety of profiles with rubber compounds of varying hardness allow the belt to optimally absorb grinding pressure. Features include high load capacity, good plan parallelism, straight tracking, low take-up and low sliding friction between the belt underside and the feed table. ContiTech Online Reader Inquiry No. 563

Premium abrasive grinding wheel comes in many sizes

A full line of abrasive grinding wheels that come in various grits and sizes is available from Rex-Cut Abrasives. RexCut Sigma Green Premium Grinding Wheels are designed for aggressive

Kenneth A. Miko Director Strategic Accounts BDI Worldwide

• New chapter on technical and engineering data for easy reference • Individual chapters available for purchase

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

grinding applications on stainless steel, mild steel, hard face, titanium, Inconel and aluminum. Available in 36, 46 and 60 grits in 4-in., 4-1/2-in., 5-in. and 7-in. diameter sizes, with 36 grit at 3/16-in. thick and 46 and 60 grit at 1/8-in. thick, they have a zirconia/ceramic grain with a proprietary bonding and wheel design. The wheels provide smooth, quiet and controlled grinding action. Designed to remove heavy welds fast, they prevent the discoloration and warping of stainless steel and other highly alloyed materials. Rex-Cut Abrasives Online Reader Inquiry No. 565

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P R O D U C T

N E W S

December 2012

Machinery & Equipment MRO

Instant-brake angle grinder keeps workers safe while on the job

Online Reader Inquiry No. 570

Four deep-cut corded band saws that provide increased durability over previous models are available from Milwaukee Tool. The increase in durability is achieved externally by Job Site Armor technology, which comprises a proprietary composite material and crush zone barriers to absorb impacts, and internally by an all-metal direct drive system that provides long tool life and requires less servicing than chain drives. A gear-protecting clutch extends gear and motor life by absorbing high-impact forces caused by blade lockups, and the completely sealed design of the direct drive protects the internal gears from water and debris

Two angle grinders from Metabo are designed to stop wheel rotation in two seconds or less when the Deadman safety switch is released, greatly reducing the likelihood of injuries. Suitable for heavy-duty grinding and cutting applications, the WEPBA14-125 Quick offers a no-load speed of 10,000 rpm and a maximum wheel diameter of 5 in., while the WEPBA14-150 Quick provides a no-load speed of 9,000 rpm and a maximum wheel diameter of 6 in. Both models feature a 12.2-A motor and 1,400 watts of power. The tools also include the company’s autobalance technology, which replaces a traditional backing flange with an auto-balancing flange pressed onto the spindle. Metabo

Deep-cut bandsaw is built for longevity

Improved disc for metal finishing enjoys long product life

Walter Surface Technologies has announced the improved, longer-life, Enduro-Flex metal finishing disc, featuring a new design and f lap configuration. The backing can be trimmed down, which adds total longevity to the product. The improved offering provides a more consistent surface finish and removes more material. A 5-in. disc with Grit 40 removes up to 2,500 g over its lifespan. The longevity of the new design lowers costs and results in fewer disc changeovers, as well as less waste over the long term, making it suitable for finishing steel and stainless steel, aluminum and other alloys. For more information, visit www.walter.com. Walter Surface Technologies International Online Reader Inquiry No. 564

contamination over time. The saw can cut up to 5-in.by-5-in. material in one pass,

while the adjustable shoe allows for less tool rotation when cutting material above 5 in. Milwaukee Tool Online Reader Inquiry No. 573

MRO

Metal cutting saw/blade combination makes light work of tough jobs

Hilti’s SCM 18-A cordless metal-cutting circular saw delivers fast, smooth cuts for most metal-cutting applications. Designed with cold-cutting technology for a clean, cool cut and an optimized blade that increases tool life, the SCM 18-A is built to withstand the toughest jobsite

EXPLORE REAL RESULTS at www.realPTPresults.com.

WE’RE

conditions. Using the SC-C MU 6-1.2-in. by 5/8-in. z40 A 40T ferrous metal cutting blade with the saw provides more cuts per charge. This blade has tungsten carbide and titanium carbide tips brazed to the teeth for good wear resistance. The tool and blade combination cuts everyday materials such as strut, threaded rod and rebar, plus demanding applications such as back-to-back strut or thick steel, with ease. Hilti (Canada) Online Reader Inquiry No. 571

DRIVING

REAL RESULTS.

Metal hole cutter kit includes cutters for wide range of jobs

Hougen Manufacturing has i nt ro duc e d two RotaCut sheet metal hole cutter master kits. Each kit is an all-in-one set containing 16 sizes of hole cutters for drilling holes in materials up to 1/4-in. thick. The fractional kit includes cutters from 1/4-in. to 3/4-in., while the metric kit includes sizes from 6 mm to 20 mm. The cutters are for use in all types of metal fabrication, maintenance and electrical applications, spotweld removal, plug holes for welding, and production environments. Packaged in a sturdy plastic storage case, the kits include an arbor assembly, extra pilots, centre punch, washers and instructions. The cutters can be used in hand-held electric drills with 3/8-in. chucks and in drill presses. Hougen Manufacturing Online Reader Inquiry No. 572

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Upgrade your belt drive system with Goodyear Engineered Products, and drive toward increased energy savings, productivity and more. Need to see it to believe it? Visit www.realPTPresults.com for success stories from operations just like yours.

The GOODYEAR (and Winged Foot Design) trademark is used by Veyance Technologies, Inc. under license from The Goodyear Tire & Rubber Company. Goodyear Engineered Products are manufactured and sourced exclusively by Veyance Technologies, Inc. or its affiliates. ©2012 Veyance Technologies, Inc. All Rights Reserved.

Online Reader Inquiry No. 140

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M R O

O N

T H E

R O A D

Machinery & Equipment MRO

December 2012

PTDA Industry Summit sees attendance jump BY BILL ROEBUCK

Photos by Eric Achilles Cousineau

Dallas, TX — The power transmission/ motion control industry gathered in October in Dallas, TX, at the 2012 PTDA Industry Summit to network, share solutions and help build business. More than 700 participants convened for twoand-a-half days of business sessions and fun events. “The 2012 Industry Summit delivered big, bold ideas participants could use right away to make a difference in their business,” said Ann Arnott, PTDA executive director. The theme of the conference was ‘Big Ideas to Steer Your Business’. In addition to an overall delegate participation rate that was up 9% over 2011, distributor attendance showed an increase over the previous year of 12% for individual delegates and 10% for companies represented. International delegates from Argenti-

na, Belgium, Canada, France, Germany, Italy, Japan, Mexico, the Netherlands, Trinidad and Tobago, and the United Kingdom attended. Total attendance was 715, which included 570 industry delegates. The event featured two keynote addresses, three workshops and a market briefing on the oil and gas industry, as well as a Motion Control Showcase featuring 18 exhibitors. During the Summit, PTDA named Barbara J. Ross, vice-president, sales and marketing, Timken Drives LLC, as the 23rd recipient of its Warren Pike Award for lifetime achievement in the power transmission/motion control (PT/ MC) industry. The award was established in 1984 to honour individuals who have demonstrated outstanding, continuous, long-term support of PTDA and the PT/MC industry.

To better promote peer-to-peer networking, the Summit featured a Distributor Forum and a Manufacturer Forum. In each of these, distributors and manufacturers separately tackled issues that affect the distributor-manufacturer relationship. Each forum addressed four identical questions; a fifth unique question was addressed separately by distributors and manufacturers. Nearly 120 manufacturers exhibited at the MD-IDEX (Manufacturer-Distributor Idea Exchange) event, where supply chain partners met face-to-face in over 600 scheduled and open appointments and engaged in focused, one-on-one group discussions about how to work together. PTDA also elected its 2013 Board of Directors and Manufacturer Council at the Summit. Chris Bursack, director of marketing, Industrial Supply Co. Inc., Plym-

outh, MN, will become PTDA’s president in 2013. He will succeed Mitch Bouchard, secretary-treasurer, General Bearing Service Inc., Ottawa, ON. Michael Dolpp, vicepresident sales, Americas, Thomson Industries, Amherst, NY, will assume the duties of the PTDA Manufacturer Council chair in 2013, succeeding George Rizza, president, Rossi Gearmotors Division, Habasit America, Suwanee, GA. The conference came to a close with a visit to the Dallas Cowboys Stadium, giving delegates a viewpoint usually reserved for NFL players — from the field. Some attendees showed off their team pride by wearing jerseys from their favourite teams. PTDA’s 2013 Industry Summit is scheduled for October 3-5, 2013, at the J.W. Marriott Desert Springs in Palm Desert, CA. For more information, visit www.ptda.org. MRO

C lo o lo

O p b

1. Todd Lucich, Bison Gear; Tom Tesoro, Jason Industrial; and Dennis Tanrikulu, NTN. 2. Denys Bolanos, Lafert North America; Mitch Bouchard, GBS; Chris Curran, Climax; and Rob Galarneau, RG Speed Control Devices. 3. Hans Hanegreefs, EPTDA; Dan and Marie Racine, Gopher Bearing; and John Masek, Bearing Service Inc. 4. A PTDA delegate dances on the 150-yard line

at the Dallas Cowboys golf course. 5. John Davis, Tsubaki Canada; Tom Dielschneider, Motion Industries; and Oswaldo and

Claudia Almeida, NSK Canada. 6. Ann Arnott, PTDA executive director, presents a surprised Barb Ross of Timken Drives with

the Warren Pike Award for lifetime achievement. 7. Bob and Cheryl Ruland, Ruland Manufacturing. 8. Sean and Helen Hickey, Lafert North America. 9. Brent Pope, Motion Industries; Marci Reuby, Toronto Gear Works; Jody Pope, Motion Industries; and

Jos Sueters, Tsubaki Canada. 10. A Jeopardy-style game helped show the audience the benefits of being a member of PTDA.

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A Case for NTN Tapered Roller Bearings

Special Features

Crowned rollers provide lower friction and smooth operation through even load distribution.

Case carburized steel enhances long life operation and improves shock loading capabilities.

Preferred by leading manufacturers, NTN tapered roller bearings are renowned for their ability to operate reliably in some of the world’s harshest environments. NTN tapered

Soft Core

roller bearings are ideally suited for heavy duty applications ranging from rail to aggregate and mining equipment, where marginal lubrication, vibration and impact loads are considered

Hardened Surface Layer

the norm. NTN tapered roller bearings are made to meet or exceed industry standards and feature case carburized steel.

Optimized roller/rib interface promotes lubrication and lowers bearing running torque.

Honed raceways ensure low friction for trouble free operation.

Carburizing hardens the steel from the surface to the proper depth, leaving a relatively soft core, improved durability and longer life. These results make the material ideal for shock loading and extreme conditions. Like all our products, NTN tapered roller bearings are backed by our knowledgeable technical support team, competitive pricing, 24/7 service and

Creative Solutions... Delivering Value

unmatched inventory capability.

Better Support Makes a Better Bearing

• In depth bearing failure and machine troubleshooting

As an integral part of after-sales service and support, NTN provides

• Bearing (re)selection and machine redesign to prolong bearing life and up time

an engineering and service staff across Canada to assist customers

• Liaison with original equipment manufacturers and third party suppliers

in gaining maximum service from the life of their bearings

• Preparation or review of maintenance schedules and procedures • End user in-house training seminars

www.ntn.ca

• Accurate part number crossover to one of NTN’s complete range of products Online Reader Inquiry No. 141

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MRO Ad_Dec_2012_PulpPaper_Focus_Schaeffler 11/19/2012 8:01 AM Page 1

Of course not. With the high cost of running todayâ&#x20AC;&#x2122;s pulp and paper mills, downtime is not an option. The highly competitive nature of this vital industry makes efficient operation and reduced maintenance more critical than ever. This means that every bearingrelated aspect of the process - product selection, inventory control, technical service, training and support - must bring value directly to the mill; value that translates into efficiency and increased productivity. Schaeffler, with our INA and FAG brands, has set a standard that is unrivaled throughout the industry by offering a complete range of products and support services for pulp & paper mills that can help dramatically improve equipment performance. Case in point: our FAG split spherical roller bearing. In hard-toreach areas, its split design allows for quick removal and replacement without removing gears and couplings or cutting off the old bearing. From fiber production to processing stations, providing costeffective solutions and preventing downtime is our commitment to the pulp & paper industry - it is our commitment to you. Anything else is just run of the mill.

www.schaeffler.ca ÂŠ2012

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Superior-quality products. Comprehensive reliable solutions. Online Reader Inquiry No. 142

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