Machinery & Equipment MRO June 2013 by Annex Business Media

MACHINERY AND EQUIPMENT

Forestalling belt and chain drive failures The myth of chain stretch The importance of machine base flatness

Vol. 29, No. 3

JUNE 2013

Domtar gives ‘near misses’ their due Measuring and analyzing drive vibration Adding up the real cost of run-to-failure

Tools for Tough Jobs WHAT’S NEW p01 June13 MRO Cover1_HiRes.indd 1

HAND & POWER TOOLS

GRINDING WHEELS

FLUID POWER 13-06-03 8:05 AM

P R O D U C T

SP TLIGHT

Machinery & Equipment MRO

Washdown-duty motor specially designed to resist humid environments

Added ratios expand worm gear speed reducer series

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Boston Gear has expanded the ratio offering of its 700 series worm gear speed reducers with the addition of 80:1 and 100:1 ratios. These models provide the compact size of a single-reduction reducer with a low purchase price. Units are backwards compatible with all 700 series industry-standard mounting dimensions.

Synchronous belt stands up to the most arduous applications

The Jason Platinum belt by Megadyne is an ultra-high-performance, rubberbased synchronous belt with Dual Core hybrid cord technology capable of handling the most demanding drives. This technology maintains extreme dimensional stability under tension, allowing nar-

row widths that fit within existing beltdrive applications. In select high-horsepower air handlers, the product assures 98% efficiency in horsepower transfer throughout the life of the belt, with up to 15% less tension. This produces more efficient air movement, with less stress on component parts. Operating temperatures range from minus 31°F to plus 239°F. HNBR rubber-based technology reduces noise levels, while a fabric-covered tooth surface improves torque-carrying capacity and tooth-shear resistance. Jason Industrial

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Suitable for low-torque, light-duty material handling, food processing and packaging applications, the reducers are available with projecting, quill or coupling input options. Hollow and solid (projecting) output options also are offered. The reducers are available with standard paint, BK/SBK coatings or rugged stainless steel housings and feature high-strength bronze worm gears mounted between heavy-duty tapered roller bearings. Altra Industrial Motion

Baldor Electric has introduced the Super White Washdown Duty motor, designed for humid and moist environments in the food and beverage industry where motors receive sanitary washdowns on a regular basis. The autophoretic autodeposition exterior surface preparation method makes the white epoxy finish coat of this motor five times more resistant to corrosion and chipping than previous methods. The shaft, hardware and nameplate are made from 300 series stainless steel. Features include labyrinth seals on each end of the motor, enhanced sealing around the lead exit, same-size bearings on each end, and a moisture-resistant insulation system. Neoprene rubber gaskets on the conduit box ensure a tight, waterproof seal. A mainte-

nance-friendly drain design, with four easy-to-remove condensation drain plugs, allows thorough drainage regardless of the motor’s mounting position. The motors are NEMA Premium efficient and are available from 1 hp to 20 hp, 56C through 256TC. Baldor Electric

June 2013

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Wireless thermal imaging camera captures critical measurements

The Fluke CNX wireless system now includes Fluke thermal imagers. The thermal imaging camera captures current measurements from up to five wireless modules at once. The wireless modules communicate with wireless thermal imagers and store both absolute and rela-

The First Name in Power Transmission tive current readings right along with the thermal image. The system can be used to inspect motors and switchgear, breaker panels, fuses and other equipment more thoroughly, and to figure out whether temperature differences are normal, and it can start uncovering potential causes of problems immediately. Fluke Electronics Canada Online Reader Inquiry No. 432

Vegetable-derived cleaner delivers industrial-strength cleaning power

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

• Unmatched Quality

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

• Improved Uptime

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Download a QR reader app and scan this code for more information. http://qr2.it/Go/1031260

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Walter Surface Technologies has developed an eco-friendly solution for heavyduty industrial cleaning. Nature Boost is an additive derived from vegetable extracts and obtained from a byproduct generated in the vegetable processing industry. This raw material, which has good solubility of oils, greases, inks, adhesives and paint, is not f lammable, does not emit VOCs, is non-toxic and is bio-renewable. The addition of Nature Boost to the Bio-Circle Environmental Solutions product line means industrial workers can choose from three efficient and green cleaning alternatives. CB 100 is an aqueous-based micro-emulsion of Nature Boost additive with surfactants designed for bulk cleaning and degreasing, while GS 200 contains the additive in its undiluted form and is designed to remove glue, ink, paint, sealant and wax from metallic surfaces. Bio-Circle Ultra is the heavy-duty version of BioCircle L. When used with the Bio-Circle parts cleaning system, it removes crude oil, bitumen, heavy grease and even baked-on contaminants. Walter Surface Technologies Online Reader Inquiry No. 434

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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.

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p02-03 MRO June13 Spotlight.indd 3

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C O N T E N T S

Machinery & Equipment MRO

June 2013

in this issue Climbing the safety ladder / 10

Domtar’s great maintenance safety record is built of many small improvements, such as paying attention to ‘near misses’ as well as actual accidents. Bearing up: Part 2 of 2 / 13

Here are more eight practical methods for keeping your bearings cool, calm and collected. What’s shakin’ with your mechanical systems? / 15

Powerful yet affordable portable vibration measurement and analysis tools provide considerable benefits for troubleshooting. The myth of chain stretch / 16

How to measure and manage roller chain wear.

p10

departments

Using synchronous belts for air-handling systems / 18

Editor’s Notebook / 6

How proper tension maintains consistent belt efficiency. The importance of machine base flatness / 19

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Shaft movement can play tricks when trying to align pump and motor systems.

columns

Maintenance 101 / 20 MRO on the Road / 26

Product Spotlight / 2

Maintenance 101: Cost catastrophes / 20

Focus on Tools / 21

Adding up the real expense of a run-to-failure maintenance strategy.

Focus on Grinding / 22 Focus on Fluid Power / 23

MRO on the Road / 26

Focus on MRO

The Bearing Specialists Association presents a Lifetime Achievement Award at its annual convention.

Components / 25

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editor’s selections ‘Think of the safety sphere as an imaginary, three-metre-diameter bubble that travels around with you, the interior of which you constantly analyze for danger.’ Michel Cloutier / 10

What you need to know about belt and chain drive maintenance / 17

Diagnose and forestall drive failures with these tips from experts at Tsubaki of Canada and Gates Canada.

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Here are the energy-efficiency benefits of maintaining proper belt tension in an air-handling unit.

Business Briefs / 9

Product News

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Relieving the tension / 18

Industry Newswatch / 7

‘‘The temperature is a monitor of the happiness of the grease.’ Chris Mackenzie / 13

p15

‘The major reasons for chain drive failures are elongation, corrosion and erosion, fatigue, overload, lack of proper lubrication, misalignment, pin wear, and plate fracture.’ Jeff Murray / 17

p24 Cover Oversize wrench has a jaw capacity of 3 in. For details, see p. 21. Photo © Channellock.

We realized very quickly that the maintenance departments in these facilities did not have enough maintenance personnel to complete the scheduled PMs.’ Peter Phillips / 20

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June 2013

Flagging the ‘near misses’

f you only have time to read just one article in this issue today, I highly recommend Climbing the Safety Ladder on page 10. This case study of Domtar’s maintenance safety practices is an eye-opener, explaining why the company’s Windsor, QC, mill has such a great safety record. Of particular importance – and uncommon – is the mill’s tracking of ‘near misses’ – close calls or near accidents. Recognizing such potential hazards like near misses goes a long way to preventing future incidents and injuries. The article also contains many more tips and ideas – some quite simple to implement – for improving your own maintenance safety.

Of course, I’d really hate to believe you’re only going to read just one story of the two-dozen or so within. Almost everybody is interested in optimizing uptime for the lowest maintenance cost possible – and that often leads to using a run-to-failure strategy – you know, based on the thinking that, if it ain’t broke, don’t fix it. Yet there is strong evidence that run-to-failure is a foolish attempt at saving money. Check out the math for this in the example that’s part of our Maintenance 101 column on page 20, or read about the cost-saving benefits of condition monitoring that are discussed on page 15 in What’s Shakin’ With Your Mechanical Systems?

Avoiding unexpected failures is important with all kinds of industrial systems, but especially with belt and chain drives, which we focus on specifically in this edition. Our articles on this section include content from experts at companies such as Tsubaki of Canada, Gates Canada, Diamond Chain, Fenner Drives and Jason Industrial. Four of the features in this issue offer guidelines for troubleshooting belt and chain drive systems. And, so you won’t miss it, I should mention there’s a free offer on page 16 for a handy roller chain wear gauge. You also might find it interesting that some companies do a lot of testing on their systems and products even before you get a chance to use them. One example, discussed on page 18, references a lack of hard data on the subject of V-belt drive efficiency. That’s why Fenner Drives built a dynamometer test cell to measure the true impact of belt tension on HVAC fan systems. The test cell in-

corporates two identical but fully independent fan and measurement systems for accurate comparisons. System testing also was done by Benchmark Maintenance Services, as described in The Importance of Machine Base Flatness. Here, to evaluate the accuracy of laser shaft alignment, the base for a pump and motor setup was purposefully misaligned to determine the effectiveness of the alignment procedures. Details are on page 19. All of these tips, suggestions and ideas can be thought of as ways to boost the overall level of asset management in any kind of industrial operation. Recognizing the importance of this field, the Plant Engineering & Maintenance Association is to be lauded for working to establish new courses and a new professional designation in this field. You’ll find details in our Industry Newswatch pages. Bill Roebuck, Editor & Associate Publisher

MACHINERY AND EQUIPMENT

MAINTENANCE, REPAIR AND OPERATIONS

JUNE 2013 Volume 29, No. 3 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. ©2013. 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 Dimopoulos, 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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N E W S W A T C H

June 2013

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Chicago, IL – The Power Transmission Distributors Association’s 1Q13 Business Index for the first quarter of 2013 produced a reading of 61.1, which represents a substantial increase over the previous quarter’s reading of 50.7. This indicates that the power transmission/motion control (PT/MC) industry expanded for the 12th consecutive quarter at a slightly faster pace compared with 4Q12. However, the 1Q2013 index is significantly lower when compared against the same quarter in previous years (with the 1Q2011 index at 85.5 and the 1Q2012 index at 75.4). 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. The entire 1Q13 PTDA Business Index report is available through PTDA’s website at www.ptda.org/Index.

PEMAC TO ESTABLISH PROFESSIONAL DESIGNATION IN ASSET MANAGEMENT Mississauga, ON – The Plant Engineering and Maintenance Association of Canada (PEMAC) has been awarded a significant grant by the Ontario ministry of Training, Colleges and Universities to invest in skills development initiatives in the field of Physical Asset Management. Asset management is a growing career field around the world that is attracting not only engineers and tradespeople, but also business professionals and IT professionals. It takes a holistic view of managing large-scale physical assets and seeks to break down barriers between departments so that rational, long-term, risk-based, decision-making processes become entrenched in an organization. An international standard, ISO 5500x in Asset Management, is currently in development. PEMAC intends to establish a national professional designation and has entered into a partnership with Humber College to develop the supporting certificate program, as well as a course for senior managers. Using a similar funding opportunity in 1998, PEMAC developed the Maintenance Management Professional certificate program, which leads to an MMP professional designation. Since that time, the MMP program has grown consistently and is now offered at 14 teaching institutions from coast to coast in Canada, and attracts over 1,000 course enrolments per year.

Photo: Claude-Simon Langlois

PT industry continues to see growth INDUSTRIAL CATALOGUE PHOTOGRAPHER AN AWARD WINNER Montreal – Walter Surface Technologies Canada, a supplier of surface treatment technologies, says Montreal-based photographer Claude-Simon Langlois has won the 2013 Applied Arts Award in the Corporate Photography category for his outstanding images of innovative metalworking and finishing disc products in action, as featured in the 2013 Walter Canada products catalogue. Langlois is an award-winning professional photographer selected by Walter to artfully contrast the harsh, physical world of Canadian welding, metal fabricating and finishing shops with the sensual, soft world of creative photography, in its most recent catalogue. Langlois visited shops in the Ontario and Quebec area — including Cornwall, ON, Trois-Rivières, QC, Joliette, QC, and Saint-Polycarpe, QC — to capture the striking behind-the-scenes images of workers using Walter products in their everyday operations and workflow. The Applied Arts Awards are one of the industry’s most prestigious recognitions of creative excellence and are presented annually by Canada’s Applied Arts Magazine, with over 20 countries participating. Langlois’ winning work, featuring Walter customers in action represents some of the very best photography produced internationally over the past year. The winning entries are displayed at www.appliedartsmag.com.

GLOBAL BEARING MARKET TO SURPASS $100 BILLION BY 2018 San Jose, CA – According to the forecasts of the US consulting firm Global Industry Analysts Inc. (GIA), the volume of sales in the global bearing market will reach US$101 billion in 2018. According to analysts, the bearing market will reach new heights because of the recovery of the basic industries in combination with favourable trends on the investment front. The demand for bearings is dynamic because bearings are closely linked to global GDP trends through their extensive use in production and engineering. However, because of the financial crisis that began in 2008, the turnover in the market dipped seriously both in value and in types. Despite the attempts of recovery in 2010, as well as at the beginning of 2011, combined with the debt problems of the Euro area, the slow

©iStockphoto/Thinkstock

Industrial facility photographs such as this impressed the judges.

recovery of the US economy and the contraction of the Japanese economy, the growth prospects of the bearing industry began to restrain in 2012. This negative effect of reduced growth in major developed countries also seeped into emerging economies such as China and India. The greatest future growth will be in the Asia-Pacific region, in the period between now and 2016. The market will rise there by an average of 10% per year and will reach $54 billion. That will be more than half of the global total demand. In 2016, sales in China will amount to one-third of the world total, and in 2021 will exceed the sales in North America and Western Europe combined. Demand for bearings in developed markets, including large regions such as Japan, Western Europe and the US, will grow faster than in the period 2006 -2011. The growing demand for industrial equipment and a variety of durable goods will contribute to rapid acceleration of sales for bearings by original equipment manufacturers operating in Japan, the US and Western Europe. According to GIA, there are currently 235 large bearing companies in the global market.

MANUFACTURING JOBS INCREASED IN APRIL, FINALLY Ottawa – Following a decline the previous month, employment was little changed in April 2013 and the unemployment rate remained at 7.2%, according to the latest Labour Force Survey from Statistics Canada. Compared with 12 months earlier, employment increased 0.9% or 163,000, all in full time. The total number of hours worked rose by 1.5% over the same period. In April, there were employment gains in manufacturing and public administration. These gains were offset by losses in transportation and ware-

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housing; ‘other services’; and business, building and other support services. Employment in manufacturing increased by 21,000 in April, the first monthly gain following a downward trend that began in June 2012. Employment in this industry was down 2.9% or 52,000 from 12 months earlier. Employment in April increased among people aged 25 to 54 and declined among youths. For people aged 55 and over, employment was little changed. Provincially, employment grew in Alberta, while it fell in Manitoba, New Brunswick and Newfoundland and Labrador. Employment in Alberta increased by 15,000 in April, offsetting the loss in the previous month and pushing the unemployment rate down 0.4 percentage points to 4.4%. Compared with 12 months earlier, employment in Alberta grew by 1.9%. In Manitoba, employment declined by 11,000 in April, pushing the unemployment rate up 0.8 percentage points to 5.8%. With this decline, employment returned to a level similar to that of 12 months earlier. Employment in New Brunswick fell by 3,200 and the unemployment rate was 10.9%. Compared with 12 months earlier, employment in the province was little changed. Following three months of little change, employment in Newfoundland and Labrador declined by 3,000 in April and the unemployment rate was 12.4%. This decline brought employment back to its level of 12 months earlier. Employment in Ontario was little changed in April, and the unemployment rate remained at 7.7%. On a year-overyear basis, employment growth in this province was 1.0%, with the bulk of the gains in the fall of 2012. Following a decline in March, employment in Quebec was little changed in April and the unemployment rate was 7.8%. Compared with 12 months earlier, employment in the province rose 1.1%, with most of the growth from August to November 2012. MRO

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June 2013

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Business Briefs

News and views about companies, people, product lines and more • Baldor Electric Co., based in Fort Smith, AR, and a member of the ABB Group, is moving pulley production to Ste-Claire, QC, from Mexico. The decision was made after Investissement Québec agreed to provide a $600,000 non-refundable contribution from the Québec government to Baldor Electric Canada for its St-Claire facility. The money will go towards upgrading equipment at the plant to increase its production capacity. Already, about half of the production from the Mexico plant has been transferred to Ste-Claire. Those with good memories will recall that Baldor acquired Maska Pulleys of Ste-Claire, in November 2008. (Baldor itself was acquired by the ABB Group in January 2011). ABB Canada is based in Ville Saint-Laurent, QC. • MSC Industrial Direct Co. Inc., Melville, NY, a distributor of metalworking and MRO supplies in the US, will enter the Canadian market with the acquisition of Barnes Distribution North America (BDNA), Cleveland, OH, the North American distribution business of the Barnes Group Inc. In addition to gaining access to the Canadian market, with this acquisition MSC will double the size of its sales force and expand its portfolio of inventory management solutions and other metalworking and MRO products and services. BDNA is a distributor of fasteners and other consumables. In addition to its three

Canadian distribution centres in Ontario, Alberta and New Brunswick, it maintains seven facilities throughout the United States. It has about 1,400 associates and offers more than 55,000 SKUs of products. • Harting Canada Inc. of Montreal has named Randolph Froude to the new position of area sales manager for Ontario and Western Canada, as part of the second stage in the company’s plan to establish a strong sales presence in the CanadiRandolph an market. The first Froude stage of the company’s plan, completed in 2011, was the opening of a national sales office in Montreal, headed by Claude Gravel. Harting develops, manufactures and sells electrical and electronic connectors, device terminations, network components and cable harnesses. • Acklands-Grainger, Richmond Hill, ON, a distributor of industrial, MRO, safety and fastener products, is in the midst of its largest-ever product expansion, adding 200,000 new products to its online offering. With this expansion, the company will offer more than 300,000 products to help keep businesses across Canada safe and productive. “We en-

hanced our selection in several key categories to help ensure that when customers have a need, we are ready to offer solutions,” said Acklands-Grainger president Eric Nowlin. Much of this product expansion comes from the company’s private brands, such as Westward, Profast’ners, Condor and Tough Guy. • With the arrival of the latest generation of KSB’s Movitec pumps, KSB Canada, Mississauga, ON, has widened its portfolio of small-size centrifugal pumps. Geared to the commercial market, the Movitec vertical multi-stage pumps line is available in stock. Applications range from fluid transfer to instant pressure boost, making Movitec suitable for many industries and sectors. The pump maker’s latest partner is Calgary-based CanDyne Pump Services Inc. • Lubrication systems specialist FLO Components Ltd., Mississauga, ON, has received a letter of intent from the SKF Lubrication Business Unit (LBU) designating the company as a SKF LBU System House for both Lincoln and SKF brands. FLO is the first official SKF LBU System House able to offer the entire spectrum of Lincoln and SKF Lube Solutions for all applications. According to FLO’s marketing specialist, Gabriel Lopez; “The ‘SKF branded’ lube product complements the ‘Lincoln branded’ lube product, filling in gaps that existed in the Lincoln line for some special applications. With the addition of the SKF line, we can now offer complete cradle-to-grave lubrication solutions for large operations with several diverse requirements, such as sand and gravel pits, cement plants and paving plants.”

• Wajax Industrial Components, Mississauga, ON, has relocated three of its branches. The Wajax Industrial Components’ Bearing and Power Transmission (BPT) staff located at 2250 Argentia Rd. in Mississauga, ON, has moved into the former Kaman Industrial Technologies office at 5080 Timberlea Blvd., Unit 45, in Mississauga. The move will result in more local inventory, a dedicated local driver, along with additional resources gained through the acquisition of the Kaman Canada Mississauga team. The company’s branch at 2030 St. Peter Ave., Bathurst, NB, has moved into the Ace Hydraulic facility (which was acquired by Wajax) in Bathurst at 955 Riordon Dr. And the former Kaman Industrial Technologies office at 19358 - 96th Ave. in Surrey, BC, was moved into the nearby Wajax Industrial Components’ branch in Surrey at 19269 96th Ave. As well, the distributor has opened its 66th branch in Canada, in Redcliff, AB. • Standard Machine of Saskatoon, SK, has been acquired by The Timken Company of Canton, OH. The agreement brings Timken Industrial Services additional gearbox repair capabilities and a new regional service centre location for bearing reconditioning. Standard Machine provides new gearboxes, gearbox service and repair, open gearing, large fabrication, machining and field technical services to end users in Canada and the western United States. MRO More detailed versions of most of these news items can be found on our website at www.mromagazine.com.

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CLIMBING THE SAFETY LADDER

Fig. 1

BY CARROLL MCCORMICK

Fig. 2

Domtar’s great maintenance safety record is built of many small improvements, such as paying attention to ‘near misses’ as well as actual accidents.

Fig.3 Fig. 4

Fig.5

Photos: Carroll McCormick

alking along a mill’s machinery-lined corridor on a tour, I stumbled on an asphalt ramp between the floor and a fiveinch high doorsill. Once painted yellow, little of the warning colour remained. I turned to Michel Cloutier, my host and the maintenance superintendent at Domtar’s pulp and paper mill in Windsor, QC, and said, “I think that was a near miss.” He whipped out a notebook and scribbled a few words. I was at the mill to learn some of the techniques Domtar uses to improve worker safety in its maintenance practices. Reporting and analyzing near misses, that is, close calls or near accidents, is one of the ways Domtar improves safety and I had just treated myself to an example. “With a near miss, we do the same report as with an accident, including corrective measures,” Cloutier explains. “We have had near miss reporting for a while, but put additional focus on it in 2012. We’ve tripled the number of reports compared to three years ago.” Near misses help management and employees recognize, report and then communicate potential hazards to all employees. “Reporting near misses is a good thing. You know your culture is going in the right direction,” says Eric Ashby, the Windsor mill manager. Domtar won the 2012 Paper Week Canada Safety Leadership Award, with just five recordable incidents in the course of 1,483,056 hours worked. Achieving such a record and creating a positive safety culture is a continual effort. “There are a multitude of items we are working on, on a daily basis, to move from a reactive to a proactive culture. People that tell themselves that it is one thing will miss the boat,” Ashby explains. In 2009 Domtar introduced the concept of the sphere de sécurité, or safety sphere. Think of it as an imaginary, three-metre-diameter bubble that travels around with you, the interior of which you constantly analyze for danger. “It’s quite basic, but when you are reminded of it every day, it becomes second nature. That is what we are trying to do. Look up, look down, look for traffic, etc.

Fig. 1: This pocket-sized checklist reminds workers to look for hazards whenever they go out on a job. In the background is a safety sphere poster. Fig. 2: A formal sling inspection program is reassuring, especially when lifting equipment such as this 57,500-pound roller. Fig. 3: Many small considerations, such as this ladder tie-off, contribute to Domtar’s award-winning safety program. Fig. 4: Hundreds of beefy new guards improve protection at drive coupling pinch points found throughout Domtar’s Windsor mill. Fig. 5: Scores of padlocks reflect the mill’s attention to lockout procedures.

The safety sphere is part of our basic safety analysis,” Cloutier explains. Domtar produced another aid in late 2011 that helps workers remember to analyze the safety sphere and perform other safety checks as they prepare for a job. It is a pocket-sized booklet, called ‘J’analyse la tâche’ (‘I am analyzing the task’) and everyone carries one with them. On the front of each page is a yes/ no checklist of 11 items; e.g., are there any risks associated with my safety sphere; is there a risk of being distracted or losing my balance; am I working with

a new colleague; do I need to coordinate with another team; do I need to control any sources of energy? On the back of the page, workers can note dangers they spot and the controls they put in place. “We specify that the pages be filled out when going on a job that is not common or done every day. Filling out a page in the booklet is not mandatory, but we want to get people into the habit of doing it,” Cloutier says. Domtar’s management promotes these habits. For example, the maintenance supervisor discusses the safety sphere at

safety meetings. Before someone goes out on a job, a supervisor will review the safety checklist and protocols. “We have it set up from the top down. The supervisor has a big role in this. Our safety coordinator and our safety guy from the union, their roles have been refined to focus just on safety,” Cloutier explains. New employees are taught to think about safety during a four-day introduction to the mill. They spend two of those days on health and safety, and lock-out procedures. “Let’s say a millwright comes into my area. There is a specific introduc-

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tion into that area. We started doing that last year. We discuss things like lift trucks, specific machines, heat and pinch points. We discuss winders, overhead cranes (you can’t walk under a loaded crane) chemicals and heights (you need three points of support or to be attached with a harness).” Risk assessment Risk assessment is a big deal at Domtar. Noting that workers were cutting their hands with utility knives, for example, the mill banned them and purchased safer cutting tools. “Banning them was a big change, but the new workers [of the future] will privately think, ‘I don’t believe they ever used those razor-sharp things’,” Cloutier predicts. Three years ago, Domtar banned safety shoes and mandated six-inch safety boots. There is more emphasis on wearing gloves. For instance, Cloutier says, “We have a rule that you have to wear gloves when you use knives or doctor blades (blades used to scrape rollers).” Special clothing or equipment may be specified in work orders. Before doing certain electrical tasks, for example, specialized safety equipment may be required, such as Level 2 arc flash clothing for electrical hot spots and hearing protectors, glasses and shields for protection against arc flash. “There is a companywide program to promote electrical safety according to Canadian and US norms. There is a lot of auditing,” Cloutier says.

Machinery & Equipment MRO

mission de la santé et de la sécurité du travail (CSST) — the province’s workplace health and safety commission, and a company that makes safety videos. Drive coupling guards Based on a CSST province-wide pinch points program, about five years ago the mill began replacing the guards on drive couplings. This was not because of any accidents or complaints, but rather, the initiative recognized that couplings are one of the biggest pinch point areas. Domtar has an ongoing program to install beefy bright red guards during every shutdown. The mill has installed hundreds of them so far, with more to come. Getting workers talking about safety helps change a safety culture. At Domtar, safety videos have been a great catalyst for discussion. A union safety representative by the name of Sam Lussier produces safety videos for Domtar, using union members as actors. His company, Sam Sécure,

has produced videos on topics such as hearing protectors, hand tools, burn out, distractions and forklift forks. The maintenance workers have seen them all, Cloutier says. “They are done from the point of view of worker safety, not management or unions. I think they are very well perceived. There is normally a lot of interaction during the presentation of these videos.” The videos also speak to corporate initiatives such as the courage to intervene if a worker sees a potentially dangerous situation or recognizes that a colleague might be in the wrong frame of mind to do a job safely. A worker’s state of mind “Rushing, frustration, fatigue and complacency are related to safety performance. The likelihood of incidents is higher if employees are not on task. We have people acknowledge that these four states of mind can affect performance,” Ashby explains.

Cloutier comments, “We have said that when a supervisor is assigning someone a task, make sure he is up to it. If the person says he is not, our response will not be, ‘go out and do the job anyway’.” Most people of a certain age are well aware of how macho work environments reward bravado, but this attitude is changing, according to Cloutier. Take the sharing of accident stories, a proven way to prevent the same mistakes from recurring in different mills. “I shared a story a couple of weeks ago about a death in St-Jérôme. People listened. Years ago they might have walked out of that talk, but not now. The culture is changing.” By the way, Cloutier wrote up a work order, and the ramp I stumbled on has been repainted. MRO Carroll McCormick, our senior contributing editor, is based in Montreal. He has been writing award-winning articles for us for the past 15 years.

Proper tool use Using the proper tools is another focus. Maintenance workers are already discouraged from using adjustable wrenches for big bolts, and a more comprehensive tool inspection is under development. “We have had some in the past but it wasn’t anything formal. Formal is ‘if you do a tool inspection, what do you look for?’ This new process came from a corporate health and safety audit,” Cloutier explains. Also, three years ago, the mill introduced a formal, documented sling inspection program. A corporate health and safety audit led to a simple, effective aid the company adopted last year to identifying slings that have passed inspection: a blue inspection tag to show that it has been independently tested. Lockouts Lockouts and paper machine shutdowns are a big topic of conversation, Cloutier says. “We are always working to refine our procedures and have done a lot of work in the past few months on lockouts and shutdowns. On the last paper machine shutdown, for example, the lockout team spent about 40% more time preparing for and executing the lockout – about 24 hours in all. One change is to restrict access to the paper machine when installing press felt because the rolls can turn. “We are installing additional mechanical stoppers to prevent dryer rolls from turning when we install dryer felts. Another important lockout procedure that the mill has improved is the verification of the drainage of pipes. We have had a few near misses with that,” Cloutier says. With the help of the Associations de la santé et de la sécurité des pâtes et papiers et des industries de la forêt du Québec (there is no official English version, but it translates as Quebec associations of health and safety of the pulp and paper and forest industries) the mill is looking to improve the ways motor test starts are done. Other outside sources the mill has tapped for assistance include the Com-

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BEARING UP F O C U S

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June 2013

Machinery & Equipment MRO

Photo: SKF Canada

BY CARROLL MCCORMICK

Here are eight more hot tips for keeping your bearings cool, calm and collected (Part 2 of 2).

ur previous issue (April 2013, page 11) offered up eight practical, field-proven tips for keeping your bearings and seals happy. In this issue, we offer Part 2 of that feature, with another eight great tips to keep your bearings turning and for avoiding unpleasant surprises.

TIP 9

TIP 12 |

Proper seal installation orientation: “There are two possible seal orientations,” Jennifer Moritz explains. “Grease-purgeable, where the primary intent of the seal is to lift

under internal pressure and let excess grease out. Under external pressure it sits tighter, keeping contamination out. “Grease non-purgeable seals sit continued on page 14

The right orientation: The grease-purgeable seal orientation (top), lets excess grease out and keeps contaminant from getting in. The grease non-purgeable orientation (bottom) keep grease in, but can admit contaminants, for example, from high-pressure washes.

Te m p e r a t u r e a l a r m settings: “I am frequently asked what the alarm shutoff temperature should be,” says Jennifer Moritz, training manager, SKF Canada. “A 10° Celsius rise above normal operating temperature indicates that a problem is developing, perhaps the need for lubrication. A 20°C rise is clear evidence of an application that is ready to go south fast. You need to plan a shutdown fast. “Take a typical industrial motor, with an operating bearing temperature of 90°C. At 100°C, there is a problem. If you re-grease and the temperature drops to 90°C, you have established a new lubrication frequency. If the temperature goes back up, to 110°C, the motor is about to fail. Set the alarm at 10°C to look at it. Set the alarm to shut the equipment down at 20°C above the normal operating temperature.”

TIP 10 |

Breaking in high-speed b e a r i n g s : D o n e wly greased bearings need breaking in? Absolutely, says Chris Mackenzie, owner, Advanced Machine Services LLC, Oxford CT. “It can take up to a week to bring the spindle up to speed. It is a question of getting the grease distributed. I will build a spindle and run it at 20% of rated speed, monitor it for temperature and vibration, and gradually increase the speed. “The temperature is a monitor of the happiness of the grease. A rule of thumb for the temperature is 110° Fahrenheit. When we build a spindle and break it in right, we consider it greased for life. We don’t recommend ever greasing it again.” Once broken in, the machine can be turned on and immediately run at normal operating speed, although turning a machine on and letting it warm up at lesser speeds is preferable.

TIP 11 |

Is this the correct bearing? Speaking of rebuilds and new bearings, do you assume the new bearings that shops install in your motors are the correct size? While at a pulp and paper mill recently, I saw a great tip in action. Jonathan Walker, an electrician at Domtar’s Windsor, QC, mill, was getting ready to fire up his torch to heat up a bearing for removal. This is what he said: “We just got this motor back from an outside shop. I always check to make sure the right bearing was installed, and this time, it was the wrong bearing.”

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tighter under internal pressure, keeping grease in. But if contamination exclusion is a big concern, especially with highpressure washdowns, remember that seals mounted in the non-purgeable direction can lift, letting contamination in. This is a fast route to premature bearing failure,” Moritz advises.

TIP 13 |

Take care of your lubricant: Lubricants are carefully formulated and prepared to exacting standards of cleanliness to extend bearing life. Yet, observes Marcus Wickert, engineering division manager, NTN Canada, “Poor storage or handling practices can frequently allow them to become contaminated prior to use. “Likewise, poor sealing or movement of a bearing and its mating components — for example, between a shaft and its housing — can create a way for dirt to get in and contaminate the lubricant, which

is the core substance that keeps our machinery moving. Keeping lubricants free from contamination is the ultimate priority in achieving bearing performance.” On this topic, Chris Mackenzie comments, “I’d also say that the leading cause of bearing failure is contamination. A common example of that is if you aren’t very careful to wipe contamination off the fitting and grease gun.”

TIP 14 |

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Left: Jonathan Walker, an electrician at Domtar’s Windsor, QC, mill, removes a wrong bearing that an outside shop installed.

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June 2013 Photo: Carroll McCormick

Machinery & Equipment MRO

bearings, but in precision and high-speed applications, too much grease in a bearing can fail it. High speeds; e.g., from 10,000 to 50,000 rpm, will generate heat that can burn up the grease and bearing. I will fill as little as 15% of the void space of the bearing.

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Above: Automatic lubricators grease bearings for weeks or months at a time. Between replacements, they solve the problem of contamination via dirty grease fittings.

“Use 15-25% as a typical rule of thumb when you want to run a bearing at its rated speed. It’s the wrong hope that the excess will squeeze out the other end. This is the kiss of death.”

TIP 15 |

Lubrication type: This is a book-worthy topic, but Chris Mackenzie offers these thoughts as a starting point for more research. “In any given application, you are looking at speed, temperature, cleanliness of the environment, sealed or open bearings, exposure to pressure wash, steam cleaning, acids …. Some greases are very resistant to wash out and others will wash out right away. You will see greases with EP (extreme pressure) on them. Not using them in a high-load situation will lead to bearing failure.” Do you have the need for speed? Mackenzie offers a quick primer on how speed is rated. “In the bearing and grease industry, we look at ‘speedability’. Bearing catalogues give a rated speed for the size of the bearing. A grease rating (dN) is the product of the bore of the bearing in millimetres multiplied by the RPM. If a grease is rated for 200,000 dN, do not use it in a 500,000-dN application. “It absolutely happens that the wrong grease is used. My general sense is that as plants get leaner, the guys that are into PM and have all those interests are fewer. The expertise may not be there. Ask your lubricant suppliers or distributors. They are pretty knowledgeable,” Mackenzie advises.

TIP 16 |

Consider automatic lubricators: These clever devices may be the ticket to making all of your greasy dreams come true. Installation is as simple as screwing out a grease fitting and installing an automatic lubricator. The delivery schedule is adjustable on the unit. “You can set it to exhaust itself in anywhere from a month to a year. The lubrication schedule depends on load, speed and bearing size,” Chris Mackenzie says. Manufacturers have various ways of powering them. The lubricators that Mackenzie sells, made by Simatec Smart Technologies, are powered by gas cartridges. These sealed, disposable units can even be installed under water. “They are particularly advantageous in hard-to-reach places, such as high up. Those places tend to get ignored,” he says. MRO Carroll McCormick is MRO Magazine’s award-winning senior contributing editor. He has been writing for us since 1998.

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Today’s powerful, portable, affordable and easyto-use vibration measurement and analysis tools enable even smaller organizations to enjoy the considerable benefits of vibration analysis.

What’s shakin’ with your mechanical systems? BY COLIN PLASTOW

ost machines have rotating parts, and rotating parts vibrate. Measuring how and how much those parts vibrate can tell you a lot about the health of a machine. Whether it’s the rumble of worn bearings or the shaking, shimmying or thumping of loose, misaligned or unbalanced parts, machines have a tale to tell to those who are willing and able to listen. Vibration analysis — the art and science of measuring and interpreting those tell-tale rumbles and shakes — has been around for decades, but mostly in the domain of specialists operating exotic instruments for corporations and government agencies with mission-critical equipment and very deep pockets. For everyone else, vibration analysis was typically performed by a mechanic using a makeshift stethoscope fashioned from a screwdriver — the tip held to the machine, the handle held to the ear — or, more often, not done at all. Recent developments however, are making vibration analysis cheaper, easier, and more widely available. Common mechanical faults revealed Measuring the vibrations of motors, pumps, and other common machines can reveal valuable information about machine health — or impending failures. Easier measurement procedures combined with automated vibration analysis enables personnel with minimal training and experience to use vibration to evaluate machine health and determine required maintenance. Vibration analysis can reveal four of the most common mechanical faults. • Imbalance – A ‘heavy spot’ in a rotating component causes vibration when the unbalanced weight rotates around the machine’s axis, creating a centrifugal force. As machine speed increases, the effects of imbalance become greater. Imbalance can severely reduce bearing life as well as cause undue machine vibration. • Misalignment/shaft runout – Vibration can result when machine shafts are out of line. Angular misalignment occurs when the axes of (for example) a motor and pump are not parallel. When the axes are parallel but not exactly aligned, the condition is known as parallel misalignment. Misalignment may happen during assembly or develop over time, due to thermal expansion, components

shifting, or improper reassembly after maintenance. The resulting vibrations may be in the direction of the rotation, along the shaft axis, or both. • Wear – As components such as bearings, drive belts or gears become worn, they may cause vibration. When a roller bearing race becomes pitted, for instance, the bearing rollers will cause a vibration each time they travel over the damaged area. A gear tooth that is heavily chipped or worn, or a drive belt that is breaking down, can also produce vibration. • Looseness – Vibration that might otherwise go unnoticed may become obvious and destructive if the component that is vibrating has loose bearings or is loosely attached to its mounts. Such looseness may or may not be caused by the underlying vibration. Whatever its cause, looseness can allow any vibration present to cause damage, such as further bearing wear, or wear and fatigue in equipment mounts and other components. How to measure vibration Vibration sensors have advanced far beyond the mechanic’s screwdriver. There are a variety of sensor types, but the accelerometer is the most common. To take a measurement, a small metal sensor is attached to the appropriate location on the equipment to be tested. The attachment, which can be permanent for continuous monitoring or temporary for machines that are evaluated

only periodically, must be at a position on the machine that reveals the best information about the vibration that is being investigated (at the bearings of a motor, for example, or close to a rotating shaft). Inside the sensor, an array of tiny electronic accelerometers convert movement along any of the three axes (up and down, back and forth, side to side) into an electrical signal that is fed to a recording device. Recorded vibration data can be analyzed at the test site for an immediate diagnosis, and can also be saved for later analysis or comparison with earlier recordings to monitor trends in machine health. Benefits of vibration analysis Predictability – Vibration analysis can provide early warnings of impending machine failure, giving maintenance staff time to schedule required repairs and acquire needed parts. Safety – Having information about machine health enables operators to take faulty equipment offline before a hazardous condition occurs. Revenue – Well-maintained machines have fewer unexpected and serious failures, helping to prevent production stoppages that cut into the bottom line. Increased maintenance intervals – When machine health is being tracked, maintenance can be scheduled by need, not just by accumulated hours of operation. Reliability – Monitored machinery has fewer unexpected or catastrophic failures.

Cost savings – Running machinery until failure often results in more expensive repairs, overtime, and forced purchases. ‘Run to failure’ maintenance programs, while simple, often have costlier repairs, loss of revenue from production stoppages, and expensive overtime. Preventive maintenance programs, in which machinery is serviced after a certain number of hours of operation, can result in unnecessary work being performed, and unmonitored machinery can still fail before the maintenance interval elapses. When vibration analysis is incorporated into a maintenance program, however, the condition of monitored machines is known, so unnecessary maintenance work is avoided, and required work can be scheduled for convenient times and when parts are available. Advances in vibration sensor, data acquisition and analysis technologies have enabled the introduction of powerful, portable, affordable, easy-to-use vibration measurement and analysis tools that enable even smaller organizations with limited training and hardware budgets to enjoy the considerable benefits of vibration analysis. MRO Colin Plastow is the industrial product manager for Fluke Electronics Canada. He has been with the company since 1987 in various support and product management positions. He can be contacted by e-mail at colin.plastow@fluke.com. Online Reader Inquiry No. 500

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Photo: Fluke Electronics Canada

June 2013

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June 2013

The myth of chain stretch D How to measure and manage roller chain wear. id you know that drive chain does not actually ‘stretch’? Its elongation is caused when material is removed from the pins and bushings. The individual joints in a roller chain articulate as they enter and leave the sprockets. This articulation results in wear on the pins and bushings. As material is worn away from these surfaces, the chain will gradually elongate. So what can you do about it? Elongation is normal and may be minimized by proper lubrication and drive maintenance. The rate of wear is dependent upon the relationship between the load and the amount of bearing area between the pin and bushing, the material and condition of the bearing surfaces, the adequacy of lubrication, and the frequency and degree of articulation between pins and bushings. The latter is determined by the quantity of sprockets in the drive, their speeds, the number of teeth, and the length of the chain in pitches. Check chain wear Roller chains should be replaced when worn (elongated beyond 3%) or when the chain rollers begin to ‘ride high’ near the tips of the teeth on relatively large sprockets. Do not connect or splice a new section to a worn chain. Do not continue to run a

chain worn in excess of 3% (or less in some applications), as the chain will not engage the sprockets properly and increased damage to the sprockets may occur.

Roller chain wear gauge instructions 1 | As a safety precaution, shut off the power to the drive and lock out gears and sprockets before attempting to measure chain wear. 2 | Determine the pitch of the chain. This is typically stamped on the outer link plates of the chain. It can also be determined by measuring the distance from the centre of one pin to the centre of the next pin. Refer to a product catalogue for a list of ANSI standard chain models and correlating pitch measurements. 3 | For reliable linear measurement, a taut span of chain must be used. Using slack chain will result in inaccurate measurements. 4 | Choose either a 1.5% or 3% wear elongation limit to check your span of chain. Each percentage correlates to a different side of the scale. The maximum allowable wear elongation is typically 3% for most industrial applications, depending upon sprocket design. In drives having fixed centre distances, chains running in parallel, or where smoother operation is required, chain wear should be limited to approximately 1.5%. 5 | Refer to the table on the wear gauge for

Step 5 the number of pitches to inspect. The more pitches (pins) that are included in the measurement, the more true the representation will be of the average amount of wear distributStep 6 ed throughout the chain. 6 | Place the inside corner of the wear scale around one pin, using that pin as ‘0’, your starting point. This corner is the zero Step 7 point on the scale. 7 | Starting at ‘0’, count the number of pins/pitches to be measured for your chain’s length. 8 | If the centre of the indicated pin does not Step 8 reach the wear line for the corresponding chain size, the chain has not reached the wear limit. 9 | If the centre of the indicated pin is at or beyond Step 9 the indicated line, the chain is worn to the wear limit (1.5% or 3%, depending on the scale used) and may need to be replaced. MRO

This article was prepared by the Diamond Chain Company Inc., Indianapolis, IN.

Chart: Diamond Chain Co. Inc.

For more information, visit the website at www.diamondchain.com. For a free roller chain wear gauge, e-mail the company at marketing@diamondchain.com. Online Reader Inquiry No. 501

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What you need to know about belt and chain drive maintenance

How diagnosing and forestalling failures of mechanical drive components reduces expensive downtime. BY STEVE GAHBAUER

n any plant, the efficient and reliable transmission of power depends on the proper f u nction of d r ive components. When they fail, the resulting work stoppage can be costly. Chain and belt drives are vulnerable, and diligent maintenance pays sizable dividends. In a day-long education seminar last November, convened by the Hamilton, ON, Section of the STLE, the Society of Tribologists and Lubrication Engineers, presenters from Tsubaki of Canada Ltd. and Gates Canada Inc. provided some useful insights and points to consider about mechanical drive component maintenance. Jeff Murray, district sales manager for Tsubaki of Canada in Mississauga, ON, says the major reasons for chain drive failures are elongation, corrosion and erosion, fatigue, overload, lack of proper lubrication, misalignment, pin wear and plate fracture. Over a period of time, all chain drives stretch about 1.5%. In very long drives, that can add up to a substantial elongation that can be corrected by removing one or more links. Corrosion is evident when bush and roller have worn wafer-thin, pins exhibit excessive wear, and plates show side wear and pitting. The solution is to improve lubrication or to switch to a corrosion-resistant chain material. Bush fatigue failures and permanently stretched outer plates are the result of severe overload. Misalignment causes rubbing wear on the side plates and the pin faces. To correct misalignment, realign the chain drive before the damage to the chain becomes too severe and the chain has to be scrapped. The most common failure is pin wear. Over a period of time, pins gradually wear until the 1.5% chain elongation is reached. Plate fracture is common as well when excess working loads are applied repeatedly. Belt drives often fail prematurely, too. Tony Lavalle, industrial district manager, Ontario, of Gates Canada Inc. in Brantford, ON, says that analyzing belt failures does not require a lot of tools. The resulting benefits include better drive performance, longer belt life, greater efficiency, energy cost savings and reduced downtime. When properly installed and tensioned, V-belt drives operate at 93% to 97% efficiency. This efficiency level can be sustained as long as all drive components are properly maintained. Belts can deliver up to five years of service when well looked after. When a V-belt has reached the end of its useful life, it will pull apart or break. The major factors affecting V-belt life are poor maintenance (42%), improper installation (20%), incorrect handling (2%) and defective components (1%). Poor maintenance is the most com-

ÂŠiStockphoto/Thinkstock

June 2013

mon cause of premature belt failure. V-belts need a large surface area of contact and a high coefficient of friction and tension. Time and neglect can easily compromise these requirements. Too much or

too little tension, worn pulleys, and misalignment are key indicators of improper maintenance. To keep a belt drive performing as it was designed requires regular inspection, proper alignment and correct tensioning. Improper installation is the next major reason for belt failure. The drive must be properly aligned. Misalignment causes drive instability and shortens belt life. Common causes of misalignment include non-parallel driver and driven shafts, out-of-line sheaves, and sheaves that wobble or tilt while running. Check correct alignment by using a straight edge and string, or a laser alignment tool. It is also vital that belt drives are properly mounted. Avoid prying or rolling the belt onto the sheave as this can damage the tensile cords and reduce belt life. Always check sheaves for wear or damage before mounting a belt. Nicks, worn sheaves and sharp edges can damage belts. Excessive heat and contamination are

two additional causes of abnormal belt wear. The ideal operating temperature is approximately 60Â°C. Also remember that belts should be stored on a flat surface to avoid crimping. Hanging V-belts on hooks can shorten service life. Detailed troubleshooting requires shutting down the drive and conducting a thorough inspection of all drive components. Stiff belt surface and surface flaking are indicators of excessive wear. Sheave damage could result from incorrect installation or debris falling into the drive. Install a drive guard to avoid this problem. Competent installation, regular inspection for wear, and diligent maintenance are the keys to better-performing and lonMRO ger-lasting drives, says Lavalle. Steve Gahbauer is an engineer, a freelance writer, and an regular contributor of technical articles to MRO Magazine.

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June 2013 Photo: Fenner Drives

Relieving the tension The energy-efficiency benefits of maintaining proper belt tension in an air-handling unit. BY JEREMY BIGLER AND STEPHEN HESTON

savings of 1.9%. In the field, the expected energy savings for well-maintained and well-designed drives is between 1% and 3%. But in most cases, belt drives are not optimally designed, nor well maintained. In these systems, installing a T-Max Belt Tensioner can result in significantly higher energy savings. MRO Jeremy Bigler and Stephen Heston of Fenner Drives originally prepared this article as a white paper for the company and it is published here with permission. For more information, visit www.fennerdrives.com.

In the field, belt drives are not optimally designed, nor well maintained. In these systems, installing a T-Max Belt Tensioner can result in significant energy savings.

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Using synchronous belts for air-handling

How proper tension maintains consistent belt efficiency.

eplacing V-belts with synchronous belts in airhandling applications has been recognized by the US Department of Energy as a best practice to reduce energy requirements in industrial and commercial applications. At the time of installation, V-belt drives run at 95-98% efficiency, but the efficiency rating drops to about 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 and maintained, their efficiency can drop as to as low as 80% during the belt’s life. Efficiency as applied to air-handling equipment is the rate that the motor’s energy is transferred to the driven fan. The lower the efficiency rating, the slower the fan speed, which results in lower air movement and longer cycle/run times for the HVAC equipment, thus increasing electrical consumption. Once they are properly tensioned, synchronous belts maintain a 98% efficiency rating throughout their life, without the need for costly maintenance. Electrical savings due to the consistent 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 100-hp supply-air fan motor at 93% efficiency, which operates at an average load of 75%, while consuming 527,000 kWh annually. Electricity is priced at $0.05/KWh. 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. Note that synchronous belts will not produce energy savings in every application. Smaller drive applications with short centre distances tend to use the V-belt slippage to ramp up fan speed. Switching to synchronous in these applications can possibly increase electrical consumption. Consult a belt supplier for help with calculating the savings potential for your specific drive design. MRO This article was prepared by Jason Industrial Inc. staff in Mississauga, ON. Online Reader Inquiry No. 505

Photos: Jason Industrial Inc.

ith the recent focus by the heating, ventilation and airconditioning (HVAC) industry on green initiatives, the subject of V-belt drive efficiency has garnered much attention. Despite a lack of hard data, it is common knowledge among HVAC professionals that proper V-belt tension is critical not only to belt life, but also to optimal drive function. In order to add rigorous empirical data to this subject, Fenner Drives constructed a dynamometer test cell to measure the true impact of belt tension on HVAC fan systems. The test cell incorporated two identical, but fully independent, HVAC fan and measurement systems. Centrifugal blowers were used to provide the variable load, and high-accuracy sensors captured power readings at each energy conversion point. The results show that even in properly designed, well-maintained belt drives, tension decay causes efficiency losses. The results also show that these losses are largely eliminated with the use of a T-Max Belt Tensioner. (Editor’s Note: Because of space limitations, the four charts that are referenced below can be found online in the Feature Stories section of our website at www. mromagazine.com.) Chart 1 displays the typical degradation in performance observed in several brands of rubber V-belts as tension was reduced. These trends represent the combined data from many trials with each brand of rubber belt. It is evident that losses in belt tension correlate to reductions in drive efficiency. For a fan system controlled to a fixed motor speed, the reduction in drive efficiency causes a reduction in speed of the fan shaft and thus, a corresponding reduction in air flow. This is also shown in Chart 1 (online). However, in systems controlled to a constant flow rate or static pressure, the reduction in drive efficiency results in an increase in power consumption as the system works harder to maintain the same air flow. In order to estimate the energy loss in a given system, the time rate of tension decay must be known. Chart 2 (online) represents a typical maintenance schedule for an HVAC system where the V-belt is retensioned every six months. The shape and slope of the linear tension/time curve shown in the chart result from multiple long-term tests conducted in the Fenner Drives’ cell. As belt tension decays over the course of six months, the drive efficiency decreases from approximately 95% to 91%. The increase in power consumption required to maintain airflow as belt drive efficiency decreases is shown in Chart 3 (online). As can be seen, the drive efficiency and power consumption return to the optimal level when the belt is re-tensioned. A T-Max Belt Tensioner prevents tension decay from occurring in the drive and thus, maintains peak efficiency for the entire year. In Chart 4 (online), the shaded area represents wasted energy (energy that can be saved by installing a T-Max Belt Tensioner). In this test case, the shaded area accounts for an annual energy

Top: Electrical savings due to the consistent 98% efficiency standard of a synchronous belt are significant in many applications. Middle: Synchronous belts consist of several layers of materials. Bottom: Once properly tensioned, synchronous belts maintain a 98% efficiency rating.

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June 2013

Machinery & Equipment MRO

The importance of machine base flatness

Fig. 1

Shaft movement can play tricks when trying to align pump systems. Fig. 2

Fig. 3

Fig. 5

Fig. 4

Fig. 6

No shim

Fig. 1: Measuring for flatness on a two-level steel bed. Figs. 2, 3 & 4: The laser beam is zeroed to the first position, then adjusted to the second and third positions. Fig. 5: Before doing the installation, an experiment was conducted. Knowing the base is flat, three 10-thou shims were placed under three of the feet. Fig. 6: Laser display shows soft-foot result.

BY JOHN LAMBERT

ow, more than ever, I’m convinced that many machines are installed on bases that are not flat – especially large, newer and more flexible machines that have been set up on old bases. Recently, while doing some training for one of our customers, KSB Pumps Inc., we had an opportunity to do a little experiment with a base and motor. KSB Pumps is a large, well-known pump manufacturer that provides the complete units of base, motor and pump. For many of its customers, the company does the initial installation work. It also handles pump overhaul work, which in many cases includes the reinstallation of the pump. KSB uses an Easy-Laser E710 for shaft alignment and now it has added a D22 Swivel laser transmitter that will allow it to also measure the base for flatness. Many customers request complete units with the coupling installed and aligned before shipment. This makes sense, because if it is out of alignment, the unit could be damaged during shipping. Many more customers are now also asking that the bases be measured for flatness, as well as being levelled during installation. Here’s an example of a base we are going to measure for flatness. It is a two-level steel bed. The base specs are: length 104 in., width 38 in., height (upper level) 16 in., height (lower level) 10 in., weight 8,915 lb., motor RPM 3,600. Note: The base is sitting on adjustable chucks. It has been roughly levelled. With a two-level machine base unit, we start on the upper level by establishing a flat plane. This is done by adjusting the laser beam at three points to zero. This is a machined area, so there is no surprise that when we measure the fourth point, it is also zero. This means we know that the upper level is flat. Zero the laser beam to the first position. Adjust the laser beam to the second and third positions to find the reference. Next we measure the lower level in relation to the flat upper plane that we have established. For speed, we will only take one measurement per mounting area. However, normally we would take four readings to map out the complete foot pad area. The procedure is simple and we finish quickly, finding that the base does have a very small amount of twist. We have measured over the actual bolt hole and we easily place the small amount of shim need-

ed on the low points to make the base flat in relation to the upper level. We are now in a position to install the pump and motor. (Note: The customer could have requested a fully machined base, which would have been flat, but it has chosen a welded plate construction. We know that welded plate is not precise when it comes to flatness.) Before we do the installation, we conduct a little experiment. We know the base is flat, so if we place three 10-thou shims under three of the feet, we will be creating a twist in the motor because it is not on a flat surface. This actually creates an offset with the bearing – something I call internal misalignment. Once the pump and motor have been installed, we have misalignment because we have used 10thou shims on three pads only, giving it 5-thou offset at the centre (at the bearing housing). The motor is now sitting down on the base with the bolts loose and we do have a small gap of less than 2 thou. However, we cannot measure right across the foot pad. So we tighten the hold-down bolts, and then do a traditional measurement for soft-foot, loosening each bolt and checking for a gap under the foot with a feeler gauge. There is no gap detected with a feeler gauge, so we use the laser system to measure, and the laser gives us a result of a 1.5-thou gap across the diagonal plane where the 10-thou shim was missing. My conclusion is that with all laser systems, the soft-foot measurement result is based on shaft movement/deflection. Although we use and recommend it as a guide, you may not see a true result, because the shaft movement is transferred through the casing, which is flexible, then through the bearing — which has play to the shaft. The feeler did not work because the sheer weight of the machine pulled it down on to the base. Yes, on smaller, stiffer machines, the foot may spring up. But will the feeler measure all of the twist that is in the base, or just a portion of it? I think the only way to know for sure is to measure the base with the machines removed, using a D22 Swivel laser. MRO John Lambert is with Benchmark Maintenance Services, Pickering, ON. For more information, visit the website at www.benchmarkpdm.com. Online Reader Inquiry No. 503

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Photos: Benchmark Maintenance Services

F O C U S

M A I N T E N A N C E

1 0 1

Co$t Catastrophes Machinery & Equipment MRO

BY PETER PHILLIPS

his column in the previous issue talked about maintenance departments not having enough time to do preventive maintenance. This month, we expand on this subject by informing maintenance managers and directors on what is going on in their maintenance departments and what catastrophes are awaiting them right around the corner. When maintenance departments don’t have the time to faithfully carry out preventive maintenance (PM), unannounced failures and costly repairs are going to increase well above normal and the price tag for this trend is going to rock the maintenance budget. The previous column went into some detail on three topics on why PMs are not done: 1) Production is not releasing the equipment for maintenance work, 2) There are not enough available maintenance labour hours, and 3) Maintenance is too busy repairing breakdowns. The main issue we hear about repeatedly and see at many facilities and factories is number 2, not enough maintenance hours. Recently, we have been setting up new

computerized maintenance programs in several public sector facilities. These were turnkey implementations, where we did the complete maintenance plan for the whole facility. We inputted all the equipment and other necessary information into the program to make the maintenance software functional. As we developed the preventive maintenance plan and schedule, we realized very quickly that the maintenance departments in these facilities did not have enough maintenance personnel to complete the scheduled PMs. Realistically, they would not be able to complete any more than 30% of the scheduled PM work. This 30% included regulatory and safety-related preventive maintenance. After these PMs were completed, there would be no time left to inspect pumps, HVAC systems, or any other mechanical or electrical system. Already, there were stacks of preventive maintenance work orders that had been generated from the previous CMMS and that had not been completed over the past year. Without enough man-hours, these pieces of equipment would run to

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jasonindustrial.com

CHANGE OVER TO SUSTAINED EFFICIENCY

Unless periodically tensioned, cogged and standard V-Belts lose between 5-20% HP transfer efficiency over the life of the belt. A fan running at 80% capacity moves less air, causing increased equipment run time.

Introducing PLATINUM, the ultra-high performance synchronous power transmission belt! l

“Dual Core” hybrid with synchronous belt technology produces 98% efficiency with less tension.

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CANADA BRANCHES MISSISSAUGA, ONTARIO 905.602.4400

A MEGADYNE GROUP CO. 9135 COTE DE LIESSE EDMONTON, ALBERTA DORVAL, QUEBEC H9P 2N9 780.461.4400 514.631.6781 l FAX: 514.631.7408 Online Reader Inquiry No. 130

failure (RTF) and would be repaired only when they broke down. The electrician in one facility told us that there was absolutely no time to do any meaningful PMs, except for dealing with the backup generator, fire alarm and emergency light inspections monthly. The facility’s maintenance supervisor told us he had less than $100 left in his budget for the year due to fiscal cutbacks and unscheduled repairs. So how much is this style of maintenance going to cost in the long run? First of all, when equipment is left to a RTF scenario, it is going to cost a lot more to rebuild and repair it than if it was dealt with before serious problems occurred. For example, if the bearings in a motor are replaced when they first become noisy, then the cost is a couple of bearings and some labour to change them during a planned outage. If the bearings are allowed to run to failure, the cost will most likely be much higher, due to the additional damage to the motor housing and armature (known as collateral damage) that may result, and the cost of the machinery being out of service. In many cases, the cost of expediting parts from vendors is outrageous, which adds to the repair expense. The end result is unscheduled repairs that eat into and increase the maintenance budget. (See the cost example below.) This publicly owned facility, as well as many others, suffers from maintenance cutbacks both in personnel and maintenance budget dollars. When maintenance people retire, they are not replaced. When cost cuts are necessary, the maintenance department shares the burden with other departments. The inventory of spare parts is also kept to a bare minimum to help reduce the apparent overall maintenance cost. These types of non-production facilities, however, generally have tandem equipment. In other words, they have a parallel system ready to swing into action if the primary system fails. For example, if one pump fails, it simply involves shutting it off, turning on a couple of valves and switching on a backup pump. Then the primary pump is repaired — if and when there is time and money available. The question remains, though: Is this type of maintenance plan efficient? Publicly owned non-production environments usually handle breakdowns differently than production environments, because no loss of production takes place. However, critical equipment does need to be maintained. Practical example Here is an example of how a boiler pump allowed to run to failure affects and costs a production facility versus a non-production facility. For this, we’ll use a pump misalignment problem. If the boiler feed pump had been monitored for vibration, the misalignment could have been detected and the pump realigned during scheduled downtime. However, the plant did not perform condition-based

maintenance. Instead, the pump failed without warning for the second time in eight years. The effect of the undetected misalignment was to overload the bearings, resulting in premature failure and collateral damage to the pump and motor. There was no spare in stock to replace the pump, so the boiler was inoperable until the pump could be repaired and new bearings installed. Due to inventory reduction, no replacement bearings were on hand. Instead, a frantic scramble began, in order to locate a supplier that had the hard-to-find replacement bearings in stock, and who could courier them overnight (at a substantial charge on top of the cost of the bearings). The search was successful and the replacement bearings arrived the next morning, at which time the pump was repaired, realigned and put back in service. The boiler, which usually operated 24/7, was down for 32 hours, from 10 a.m. on the first day until 6 p.m. on the next day, resulting in lost production and revenues of $6,000 per hour. At the time the pump failed, $18,000 worth of products in process were ruined and had to be scrapped. ©iStockphoto/Thinkstock

Adding up the real expense of a run-to-failure strategy.

June 2013

Doing the math Here is how to calculate the overall cost of this scenario. Production environment – $0 for a replacement pump, which was not necessary because the failure could be repaired – $2,000 for bearings and labour to repair the pump (collateral damage) – $10,000 for spare motor swap-out and repair to original motor (collateral damage) – $280 for laser alignment, which still had to be performed after the pump bearings were repaired – $1,000 for expediting fees and air shipment to get the replacement bearings the next day – $192,000 for lost revenue from 32 hours of unscheduled production downtime – $18,000 to scrap products in process Total cost of this failure: $223,280. Non-production environment In a non-production environment, the same cost is incurred, except for the loss of production and scrap products, resulting in a total cost of failure of $13,280. A person could argue that this nonproduction facility repair cost is acceptable because of the money saved from the reduction of maintenance personnel and spare parts inventory. However, we need to realize that we have calculated the cost of one failure. Remember, there are stacks of PM work orders for the whole facility that have not been done. What will be the total cost when cascade failures begin to occur throughout the facility? What it all comes down to is that RTF costs money. Cutting staff and spare parts looks good on fiscal reports, but in the long run, it reduces the overall condition of the equipment and does not allow maintenance people to do their job. When the looming cost from this type of maintenance comes home to roost, it will definitely rock your maintenance world. MRO Peter Phillips of Trailwalk Holdings, a Nova Scotia CMMS consulting and training company, can be reached at 902-798-3601 or by e-mail at peter@trailwalk.ca.

P R O D U C T

N E W S

June 2013

Machinery & Equipment MRO

What’s new in hand and power tools Safety air gun with chip shield protects against flying debris

Exair’s family of safety air guns is available with chip shields to protect workers and to help businesses comply with OSHA safety standards. The shields,

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CP69 1-in. impact wrench series. Designed for heavy-duty industrial maintenance applications where power and tool reliability are critical, this powerful, durable and ergonomic series delivers up to 2,600 Nm (1,920 ft-lb) of torque, with 700 blows/min. Features include a pinless rocking dog clutch with a newly designed oil bath lubrication system, precision machined and finished steel rotor and end-plate components, light aluminum alloy clutch housing protected by a moulded rubber front cover, and a 1-in. industrial pistol and D-handle design. The series is suitable for any heavy-duty applications in the oil and gas, petrochemical, and mining sectors, including those with higher dust concentrations. Chicago Pneumatic Tools

which can be used with or without an extension pipe, are made of a durable polycarbonate and protect operators from flying debris often associated with blowing chips off machined parts. They also keep coolant from splashing everywhere during drying operations. Shields are available to fit models currently in use. The safety air gun line includes precision safety air guns, soft-grip safety air guns and heavy-duty safety air guns. Exair Online Reader Inquiry No. 418

Martin Tool & Forge’s adjustable spudend wrench has an adjustable 1-1/2-in. jaw capacity and a 12-in. alignment spud. The ground end spud allows for quick, easy alignment of holes and fasteners. In addition, the wrench features a

Online Reader Inquiry No. 416

Impact wrench series is built to withstand harsh, dusty conditions

Chicago Pneumatic has introduced the

Online Reader Inquiry No. 421

impact tools. The line has a 1/4-in. quick-change shank that is designed to work with all types of impact drivers and rotary drills. Screwdriving bits, which are forged rather than milled, are available in Phillips, square recess, Torx, and tamperresistant Torx bits. Nutsetters are de-

sions SID 18-A CPC impact driver, SIW 18-A 1/2-in. impact wrench, and the SIW 18-A 3/8-in. CPC impact wrench. All of these tools feature a highly efficient hammering mechanism, sealed electronics, intelligent power switch to prevent burn outs, and four LED lights for better visibility of the work surface. The compact versions of these tools come with a 1.6 Ah compact battery to provide lighter weight, while the B 18 3.3 Ah battery offers 25% more energy for the highest work per charge and ultimate run time. Hilti Online Reader Inquiry No. 419

Oversize adjustable wrench has the power to tackle the toughest jobs

Wrench gives workers four tools in one

The 8C ratcheting socket wrench from Lowell features four sockets that can handle the four most common nut sizes found in utility and construction work. Features of this durable tool include HiVis sockets and handle, ergonomic g rip and light weight of 2.5 lb. The stamped steel handle is 17 in. long and 1/2 in. thick, and the ratcheting action is easily reversed with levers at each end of the wrench head. For turning power, the tool is rated at 200 ft lb, strong enough not to break under hard use. The ratchets have 36 teeth, resulting in a 10-degree handle throw that is especially useful for working in tight spots. Bolts can pass entirely through the wrench head so that nuts can be secured on any threaded length. Suitable applications include guard rail assembly, levelling pad adjustment, mechanical joints, restraints, couplings, sleeves, repair clamps, saddles and flange bolts. Lowell Online Reader Inquiry No. 420

Line of accessories designed for use with impact tools

Irwin Tools has introduced the Impact Performance Series line of screwdriving bits, nutsetters, socket adapters and bit holders, engineered specifically for use in

signed to drive the fastener from the side, rather than forcing the corners to turn, maintaining the shape of the fastener and reducing breakage and damage from stripping. Socket adapters are available with a ball-lock retention design for quick-change applications. The body of the socket is forged for additional strength, and the black oxide finish resists corrosion and increases the life of the tool. Bit holders have a C-ring design with an external clip that fits into the retaining ring notch of the insert bit, as well as a powerful rare earth magnet. Irwin Tools Online Reader Inquiry No. 424

18-volt impact drivers and wrenches are powered by brushless motors

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large knurl with lead-in for easy access while adjusting. It is built for work in the oil and gas industry, military, government, factory maintenance, utilities, construction and iron work. The wrench’s black oxide finish provides corrosion resistance for an extended life. Martin Tool & Forge

The Milwaukee Fastback II utility knife includes magnetic blade storage that folds into the handle. The knife features a press-and-flip one-handed blade opening for easy activation. In addition, a tool-free blade change allows for fast and efficient adjustments, while a thin body design makes it easy for users to store the knife in their pocket. The magnetic blade storage holds one spare blade at a time to keep the profile of the blade as slim as possible. An integrated gut hook and wire stripper allows the user to make cuts without exposing the blade and eliminates the need to look for another tool to accomplish the task at hand. When the knife is not in use, a wire-form belt clip attaches to pockets without tearing the material. Milwaukee Tool

Online Reader Inquiry No. 415

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Adjustable spud-end wrench lines up bolt holes quickly

Utility knife has convenient magnetic blade storage

Hilti has introduced a family of impact drivers and wrenches with highefficiency brushless motors: the SID 18-A CPC compact impact driver, SIW 18-A 1/2in. compact impact wrench, SIW 18-A 3/8-in. CPC compact wrench and the high-capacity ver-

Online Reader Inquiry No. 131

Channellock has introduced the 30-in. 830 adjustable wrench, complementing the company’s existing line and adding 6 in. in length to the previous offering. It provides added power and leverage, as

well as a jaw capacity up to 3 in. These improvements, coupled with the fact that the wrench is forged from chrome vanadium steel for durability and performance, make the tool capable of handling the most demanding jobs in any industry. Features include a reinforced joint, with a 1.5-in. thickness and 6.3-in. width, as well as premium support behind the wrench’s 12-lb steel structure. With such a massive frame, the wrench was designed for professionals from the oil and gas, fleet maintenance, HVAC, rigging, farming, and industrial and commercial industries. Channellock Online Reader Inquiry No. 422 MRO

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Machinery & Equipment MRO

June 2013

What’s new in grinding and cutting ▼

Combination cutting/ grinding wheel saves money, increases productivity

Online Reader Inquiry No. 334

Finishing disc replaces plastic backing with eco-friendly plant fibre material

Walter Surface Technologies has announced enhancements to its line of Enduro-Flex and Enduro-Flex Turbo flap

speed Enduro-Flex Turbo cutting flap disc is said to remove 60% more material than before. It is designed for weld removal, edge breaking and blending applications. Built-in cyclone technology, along

CGW-Camel Grinding Wheels has expanded its flap wheel drum line for large-scale metal finishing with the introduction of wire flap wheel drums with keyhole arbours. The line includes abrasive nylon, stainless steel and brass-plated wire options. Abrasive nylon flap wheel drums are made of flexible nylon abrasive filaments that allow work to be accomplished at lower speeds with lighter pressure for applications that require a drum with flexibility. The high-temperatureresistant stainless steel models are made from 0.008-in.-thick stainless steel wire that does not leave an oxidizing deposit on work surfaces, while the brass-plated models are made from softer-than-standard wire, designed not to scratch harder metals or create sparks. A wide variety of models and sizes is available. CGW-Camel Grinding Wheels Online Reader Inquiry No. 567

with the flap configuration, enables operators to perform with a cutting rate of a grit 36 with the finish of a grit 60. Walter Surface Technologies Online Reader Inquiry No. 412

Grinding wheel works fast, quietly

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Metabo offers a combined cutting and grinding wheel, the Combinator, for cutting, deburring and light grinding. The combination eliminates the need to change abrasive wheels during cutting and grinding applications. At 5/64in. thick, the contaminant-free, heavy-duty wheel makes quick, clean and straight cuts in stainless steel, steel, alloy steels, hardened steels, pipe, tube and solids, while three full layers of glass-fibre enhance safety. Available in 4-1/2-in., 5-in. and 6-in. type 27 versions, the wheel employs an improved abrasive/resin formulation for fast cutting with increased wheel life, as well as strength and rigidity. Metabo

discs for metal-finishing applications. The discs have been ecologically improved with an Eco-Trim backing made from a base of natural and sustainable plant fibres. Designed for finishing steel and stainless steel, these flap discs require fewer changeovers, which helps reduce waste and ensures greater operational efficiency. In addition, they offer a long service life: a 5-in. disc with Grit 40 removes up to 2,500 g over its lifespan. The ultra-high-

Flap wheel drum line has added keyhole arbours for large jobs

CGW-Camel Grinding Wheels has introduced Green Grind, a high-performance, depressed-centre grinding wheel manufactured from a premium bond and zirconia-aluminum oxide grain mixture. The wheel coolly grinds metal extremely fast, will not discolour or warp stainless steel, and runs smoothly for a quieter working environment and less operator fatigue. Containing less than 0.1% sulphur, chlorine and iron, the wheels are suitable for tank fabrication, power plant maintenance and metal fabrication, and can be used on mild steel, hard face, titanium, stainless steel, Inconel and aluminum metals. They are available in 36-grit size, type 27 shape, with 4 1/2-in., 5-in. and 7- in. diameters, and with a 7/8-in. or 5/8-in.-11 arbour hole. CGW-Camel Grinding Wheels

Abrasive grinding wheel removes and blends heavy welds fast

Rex-Cut Sigma Green Grinding Wheels are abrasive wheels that provide fast, chatter-free grinding action to cleanly remove and blend welds without discoloration and warping on steel, stainless steel, Inconel, titanium and other alloys. Made from a zirconia/ceramic grain, these wheels cut up to 50% faster on 316 SS than aluminum-oxide wheels, run 20% cooler, and produce a better finish, says the company. They are available in 4-in., 4-1/2-in., 5-in. and 7-in. diameter sizes to fit right-angle

Online Reader Inquiry No. 332

Abrasive grinding wheels finish filet welds in one step

A line of type 27 cotton-fibre abrasive wheels that can remove filet welds on stainless steel and aluminum, and produce foodgrade finishes in one step, is available from Rex-Cut Abrasives. These grinding wheels feature multiple layers of cotton fibre that are impregnated with aluminum oxide grains and then pressed and bonded together. They constantly reveal fresh abrasives to provide smooth, controlled grinding action, and can grind with both the side

grinders and are offered with or without hubs. Virtually iron-free, these fast-cutting wheels contain only 0.035% iron, with less than 0.1% of iron, chlorine and sulphur combined, and a bonding that is formulated to help prevent corrosion. Rex-Cut Products Online Reader Inquiry No. 566

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Extra-thin cut-off wheel offers high-precision cutting on thin gauge metal

and face. Available in 4-1/2-in., 5-in. and 7-in. sizes, 3/16-in. and 1/4-in. thick, with A36 or A54 grit sizes, and a GFX latex bond, the wheels provide finishes with a fine grit size and are non-loading on aluminum. Optional 5/8-in.-11 throw-away adapters are offered. Rex-Cut Abrasives Online Reader Inquiry No. 132

Online Reader Inquiry No. 331

In response to requests for a thinner version of its current cutting wheels, Walter Surface Technologies has introduced Zip One, a high-performance, extra-thin yet durable 1-mm cut-off wheel. The wheel is designed for precision cutting in thingauge metal (up to 8 ga or 4 mm) and allows for accurate and burr-free cutting without overheating the work piece. Features include long wheel life, fast and cool cutting, heavy reinforcement for safety, easy metal penetration in plunge cutting, minimal heat, and straight and accurate cuts. It also works well on galvanized steel. Walter Surface Technologies Online Reader Inquiry No. 413 MRO

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June 2013

Machinery & Equipment MRO

What’s new in fluid power Flexible high-pressure PTFE hose makes tight bends

Rod clamp retains load on hydraulic power or pump failure

signed for pipe sizes from 1 in. to 12 in. and comes in three materials (stainless steel, brass and PVC). A variety of custom fittings ensures accurate fitting in the pipe. The series is useful for applications where moving parts would be a problem, such as dirty liquids. It can also handle applications where there are rapid changes in viscosity and flow, while other applications include small pipes and chemical metering pumps. Dwyer Instruments Online Reader Inquiry No. 402

tings. The hoses are braided for flexibility and tight bends, while maintaining high continuous working pressures. Both models are available in sizes ranging from 1/4 in. up to 1 in. I.D., and can handle temperatures ranging from minus 65ºF up to 400ºF. Assemblies only are supplied in lengths up to 25 ft with a carbon or stainless steel female JIC fitting on each end. Other sizes and lengths also are available. Parker Hannifin

Developed to provide power-off clamping of rods and shafts, the Amlok hydraulic series RCH rod clamp is actuated by a spring/ collet mechanism and unclamped by hydraulic pressure. The clamps, for locking axial motions only, are designed to clamp components after the motion has stopped and to hold the position securely as long as the holding force does not exceed the table value. The holding force depends upon the rod diameter and the amount of hydraulic pressure available for unclamping. The clamp is preset at the factory to release at the specified hydraulic pressure. The available holding forces are listed in a chart and can be multiplied by adding additional clamps to the same rod. The mountings apply to standard heavy-duty NFPA-style MF1 cylinders. Advanced Machine & Engineering

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Parker’s high-pressure PTFE hose assemblies can handle working pressures as high as 5,500 psi while maintaining peak flow rates. The 944B and 955B assemblies are manufactured with a heavy wall of PTFE that can withstand a variety of media, including corrosive chemicals such as acids and newer hydraulic fluids. In addition, the PTFE tube has a static dissipating liner that provides a path for static dissipation to the end fit-

Online Reader Inquiry No. 400

Flexible hydraulic hose can accommodate tight bends

Veyance Technologies, manufacturer of Goodyear Engineered Products, has introduced the XR16SC hydraulic hose. The hose is suitable for high-pressure service requiring abrasion resistance, the ability to accommodate tight bends

and flexibility. It is designed for use with petroleum- and water-based hydraulic fluids. Impulse performance and flexibility exceed SAE 100R2 and SAE 100R16 standards. Veyance Technologies Online Reader Inquiry No. 401

continued on page 24

Finding new customers shouldn’t be this difficult.

Online Reader Inquiry No. 406

Hydraulic hose is made for ultra-high-pressure applications

Kurt Hydraulics’ Kurt Tuff Spiral Flex hydraulic hose is engineered for rugged, high-pressure hydraulic applications up to 6,235 psi. Designed for applications w it h m i n i m a l space, the design provides bend capacity of 8.25 in. to 9.5 in., depending on hose diameter selected. Reinforced internally with four spiral layers of hightensile steel wire braid, the hose has a durable oil-, ozone- and abrasionresistant synthetic outer cover, withstands temperatures from minus 40°F up to 250°F, and meets flame-resistant MSHA designation. It meets or exceeds requirements of SAE DIN 20023. Applications include construction equipment, trucks and demanding injection moulding systems. The hose is available in diameters of 3/4 in., 1 in. and 1-1/4 in. I.D., and may be combined with many Kurt coupling styles that are designed for heavy-duty applications where shock and vibration are present. Kurt Hydraulics

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Online Reader Inquiry No. 407

Insertion flow sensor has no moving parts for easy maintenance

Dwyer Instruments’ series EFS2 insertion electromagnetic flow sensor is de-

PARTNERS IN YOUR SUCCESS Ref: SLRA13H

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Enhancements improve FRLs for AODD pumps

An improved line of air filter/regulators and lubricators (FRLs) has been introduced by Sandpiper. The line has been specifically developed for air-operated double diaphragm (AODD) pumps to reduce maintenance and lower operating costs. Features include a liquid-filled pressure gauge, as well as a full line of accessories such as lockout valves and mounting bracket kits. The addition of a filter/regulator helps prevent dirty, wet and contaminated compressed air from decreasing the performance of AODD pumps. Included are a cross-reference guide, updated service manuals and data sheets. Warren Rupp

June 2013

Air actuator can be disassembled into individual parts and replaced

ContiTech has added the D-type series to its air actuator product range. The series is designed so that each component can be quickly and easily replaced, simplifying the recycling process as rubber and metal parts can be easily separated. Connecting plates with diameters of up to 175 mm are produced from aluminum, which is lightweight, flexible and easy to take apart. The product range comes in eight sizes, each of which is available as a one-, two- or

Thermoplastic basket strainer withstands harsh chemicals

Hayward Flow Control has introduced the Platinum GF-PP (glass-filled polypropylene) SB series thermoplastic basket strainers. The series expands the range of piping applications for protecting critical piping systems components such as pumps, filters and flow meters from particulate and debris. Suitable for both robust chemical service and sensitive media systems, the strainers come in 1/2-in. to 4-in. sizes, with true union threaded or flanged end connections. They feature a maximum pressure rating of 150 psi at 70°F non-shock, with maximum service temperature of 240°F. Other features include FPM or EPDM O-rings and seals, an ergonomic hand-removable cover and a liquid-displacing cover design. Hayward Flow Control Online Reader Inquiry No. 411

three-convolution bellows and has dimensions of 80 mm/type 22 up to 435 mm/type 816. Without a piston rod, strokes of more than 400 mm are possible, while the lifting force range extends from 0.5 KN to

Online Reader Inquiry No. 405

80.0 KN. Applications include power collectors in trains (pantographs) and paper machines, and applications in automation, glass, wood and agricultural engineering. ContiTech Online Reader Inquiry No. 404

Medium- and high-pressure control products suit tough environments

Swagelok has expanded its medium- and high-pressure product line with the addition of the IPT series of precision valves, fittings and fluid control devices suitable for surface and subsea installation, instrumentation, injection and sampling

systems. Products are made standard from cold-worked, 316 stainless steel. Annealed 316 stainless steel and other corrosion-resistant special alloys are available to meet NACE MR0175/ISO 15156 requirements. The series includes check valves, ball valves, relief valves and needle valves, medium- and highpressure tubing and nipples, and coned and threaded fittings. Coning and threading kits contain everything needed to prepare tubing in 1/4-in., 3/8-in. and 9/16-in. sizes. Swagelok

Eaton’s Internormen full-line of hydraulic and lubrication products protect servo and proportional valves, hydraulic systems, and a wide range of low to high pressure applications by filtering dirt out and keeping system fluids cleaner. Keep your high performance systems running smooth and clean with Eaton filtration products. And, you can find Eaton Internormen filtration products at your local Motion Canada location. Our local sales and service specialists are experts in application and technical support, providing the parts and the know-how you need to stay up and running.

Online Reader Inquiry No. 408

Centrifugal pump line upgraded to offer improved efficiency

KSB has introduced an efficiency-optimized generation of its Etanorm family of centrifugal pumps. The pumps feature refined hydraulic contours inside the pump, resulting in improvements to intake suction and NPSH, with the result that cavitation under difficult operating

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MotionIndustries.com Online Reader Inquiry No. 133

conditions is reduced and pumps run more smoothly and reliably. Pump casings have been strengthened so that these models can withstand higher mechanical loads from piping systems. Other refinements that improve durability and maintainability include enlarged space around seals and more effective gaskets. The pumps come in 43 sizes, and special alloys are available for use with aggressive fluids, oils, etc. KSB Pumps Online Reader Inquiry No. 410 MRO

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June 2013

Machinery & Equipment MRO

What’s new…

Modular line of belt drive actuators suits wide range of machinery

Misumi USA has introduced the MSA series belt drive actuators. Designed to optimize performance and reliability at a modest cost, these actuators can be configured to carry loads up to 227 kg (500 lb), with travel speeds ranging from 1,200 to 10,000 mm/sec, and standard lengths up to 6.25 m, with custom lengths upon request. They are suitable for applications across many markets, including packaging, printing, machine tool, manufacturing automation, education, entertainment, aerospace and defence. Pulleys feature precision-machined, onepiece steel construction, nickel-plating for durability and corrosion protection, and an integral shaft for strength. The tough timing belts are made of specialty steel cords moulded into highly flexible polyurethane material to protect against damage and deformation. Misumi USA.

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

Truly endless belts are designed for long life and corrosion resistance

Belt Corporation of America offers a wide selection of technologically advanced belts, and mass-produces endless belts and base-belts of high-performance poly-

ends via carefully designed channel clamps. The leaked fluid then allows for fast hose failure detection. Equipment operators working within a 3-ft line-of-sight of a hydraulic system know the potential for problems: personal injury, fluid burns and injection, fires and explosions, electrical shock and mechanical failure. The double-layer sleeve effectively shields against these hazards. Gates Canada Online Reader Inquiry No. 438

Water transport pump comes in wide range of capacities mers such as polyimide and PEEK. These belts exhibit excellent strength, wear, chemical and radiation resistance, heat resistance, and compliance for use with food and medical applications. The company is mating these high-performance polymers with endless layers of other materials, including silicone, urethane or neoprene, creating performance characteristics for a wide spectrum of applications. The technology also produces thickwalled PEEK tubing for oil and gas, semiconductor and aerospace industries. Belt Corporation of America

KSB offers a comprehensive range of efficient and reliable water transport pumps, ranging from the versatile and easy-to-install Movitec family to the high-capacity RDLO line. These pumps are available in a wide range of sizes and

Online Reader Inquiry No. 439

Universal tension meter keeps all belt types running at peak performance

Brecoflex has introduced the New Generation SM5 universal tension meter, designed to measure the frequency of all belt types, regardless of the belting and tension member material. Providing a

Online Reader Inquiry No. 437

Upgrade enhances mobile app or power-transmission industry

dard pipes, permitting inspections in limited access areas. Full coverage of the weld enables inspectors to characterize and size diverse defects in inspections done in close to real time. Compared to radiography, most types of defects will be detected with a higher reliability, and only a few with a lower reliability. SGS

Version 1.2 of its PT Units mobile app has been released by Sumitomo. This powertransmission industry mobile app has an updated user interface and is now optimized for the latest versions of the Apple iOS and Google Android operating systems and displays. Version 1.2 expands the features of the app’s three main functions: converting units, contacting company sales reps, and connecting to its web resources. The unit converter quickly and accurately converts between commonly used units of power, torque, force, temperature, fluid volume, mass, length, and newly added units: linear velocity, pressure and stress, and moment of inertia. PT Units is available in English, Spanish, Portuguese, French, Japanese, Korean and Chinese. Sumitomo

Online Reader Inquiry No. 445

Bearing line reduces corrosion and wear

Part of the SKF BeyondZero portfolio, the range of SKF extended-life spherical plain bearings and rod ends is aimed primarily at applications in the farm, forestry and construction sectors. The products are phosphated and undergo treatment to reduce wear and practically eliminate corrosion, making them virtually maintenance-free. This means that they do not need to be re-lubricated, helping reduce cost of ownership and environmental impact. The bearings are equipped with heavy-duty triple-lip seals, which eliminate the ingress of contaminants and the resulting poor lubrication condition that causes premature bearing failure. SKF Canada Online Reader Inquiry No. 442 MRO

Online Reader Inquiry No. 441

ratings to offer a good match between the flow and head requirements of the application and the optimal duty point of the pump set. Optional features such as highly corrosion-resistant alloys and special seals are available, so that these pumps can be configured to handle demanding water conditions. The company provides support for selecting equipment for a particular application, including the EasySelect online software tool and the availability of experienced application engineers. KSB Pumps Online Reader Inquiry No. 444

Boiler tube weld inspection system uses phased array technology SGS has developed a weld inspection system using phased array designed specifically for testing boiler tube welds. The system covers pipes from 21.3 mm (0.84 in.) to 114.3 mm (4.5 in.) O.D. and operates within the 13-mm (0.5-in.) clearance on all stan-

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

PULL belt-frequency reading of 7 Hz to 450 Hz, the meter ensures correct belt tensioning for accurate measurement results of optimal belt performance and life. In addition, it saves production and downtime with quick readings, fulfills quality system requirements with traceable certification, and integrates with the company’s online calculation program. Brecoflex

Line-of-sight sleeving system protects operator from serious injury

Motor/Generator Rewinds & Repairs Up to 5000 H.P. & 30,000 Lbs Lifting Capacity When It Must Be Done Right!! 50 Years of Experience Working For You

Co. Ltd. 206- 1730 Coast Meridian Road, Port Coquitlam, B.C. V3C 3T8 Tel. 604-554-0120 www.electromotors.ca Online Reader Inquiry No. 134

Electro Motors Co. Ltd. is independently owned and operated and is not an affiliate of Kato Engineering Inc.

AND THEN

Online Reader Inquiry No. 440

Gates’ LifeGuard line-of-sight sleeving system contains bursts up to 10,000 psi and pinhole leaks up to 5,000 psi at 121°C (250°F) for up to five minutes. After redirecting the explosive force down the length of the hose, the sleeve disperses the energ y and fluids at the hose

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Online Reader Inquiry No. 135

M R O

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BSA presents Lifetime Achievement Award

June 2013 Photos: Eric Achilles Cousineau, MRO Magazine

Machinery & Equipment MRO

Bearing industry gathers for annual convention. Hilton Head Island, SC — Andrew Hall Nations, president and CEO of B&D Industrial, is the latest recipient of the Bearing Specialists Association (BSA) Lifetime Achievement Award. The presentation was made at the association’s 2013 annual convention, held May 4-7 at the Westin Hilton Head Island Resort at Hilton Head Island, SC. Nations is the first second-generation Lifetime Achievement Award recipient. His father, John Nations, was presented with the award in 2004. B&D Industrial (known to many as Bearings & Drives) was founded in 1947, when Nations’ father, John, purchased Travis Belting & Supply in Griffin, GA, for $9,000. Nations literally grew up in the company, learning the ropes by working in various positions, starting with shipping and delivery for Bearings and Drives, before he graduated from the University of Georgia with a degree in finance in 1971. From implementing the company’s first computer system in 1975 to managing various acquisitions and record growth in the 1990s, Nations has brought B&D to a new level. Nations has been an active BSA participant since 1974, serving on many committees over the years and as president in 1992-93. He was the 2013 convention committee chairman. 4

Also at the conference, BSA’s Past Presidents Council recognized the many contributions and support of participating manufacturer Bob Daniel, formerly general sales manager – North American Distribution at The Timken Company and currently its general manager – business communications. The convention heard the results of BSA’s 2013 Distributor Survey from Jack Simpson of Applied Industrial Technologies, who is the newly elected BSA president for 2013-2014. The survey documented a 5% increase in 2012 aggregate sales of all bearing products over 2011 aggregate sales. Total sales for 2012 surpassed the pre-recession high in 2008. In addition, survey participants estimated that 2013 will continue with an additional gain of 7% aggregate sales of bearings products over 2012, Simpson reported. BSA is an international service and educational organization of almost 100 companies distributing factorywarranted, anti-friction bearings, and invited manufacturers of bearings and related products. For more information, visit the website at www.bsahome.org. MRO

Visit www.mromagazine.com/gallery to view additional photographs from BSA’s 2013 convention. 5

10 1. Oswaldo Almeida, NSK; Nicolle and Ricardo Lugo, Lugo Hermanos; and Dave Strutt, C&U Americas. 2. Bob Ruland and Cheryl Desjardin, Ruland Manufacturing; and Kent Morgan, Randall Bearings. 3. Chris Nook, Nook Industries; Chris Curran, Climax Metal Products; Steve Durston, Jamaica Bearings; and JP Bouchard and Mitch Bouchard, General Bearing Service. 4. Jack Simpson of Applied Industrial Technologies is BSA’s new president for 2013-14. 5. Andy Nations, B&D Industrial, received BSA’s Lifetime Achievement Award. 6. Phil Schmidts and Dennis Tanrikulu, NTN Bearing. 7. Delores and Robert Marshall, RBC Bearings. 8. Joan and Mike Cook, Nook Industries. 9. Brian Negri, Jamaica Bearings and JP Bouchard, General Bearing Service. 10. Members at the BSA convention attended a special Canadian event.

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Online Reader Inquiry No. 136

Forged by decades of experience supplying metallurgical plants and steel mills throughout the world, Schaeffler - with our renowned INA & FAG brands - offers a complete line of some of the industry’s most innovative and highest-performance rolling bearings, along with unmatched product support & services, including: • Standard Spherical Roller Bearings • Split Spherical Roller Bearings • Single-, Double- and Multi-Row Cylindrical Roller Bearings • Multi-Row Sealed Tapered Roller Bearings • Spherical Plain Bearings with ELGOGLIDE® • Yoke Type Track Rollers/Cam Followers

• Full-Complement Cylindrical Roller Bearings

• High-Precision Angular Contact Ball Bearings • Needle Roller Bearings • Bearing Housings • Groundbreaking Condition Monitoring Products & Services • Cost-Effective Bearing Reconditioning Services

Our latest highlight: FAG’s remarkable “8-minute” cylindrical roller bearing for continuous caster operations. Developed to eliminate frequent turnarounds in steel mills’ strand guide rolls, its revolutionary design gives you the load-carrying capacity of a cylindrical roller bearing with the spherical roller bearing’s ability to compensate for up to 8 minutes of angular misalignment. Designed for quick & easy mounting, this is the ideal non-locating bearing solution for steel mills. When you’re in the business of making metal, you need bearings that have proven their mettle. You need Schaeffler.

Online Reader Inquiry No. 137