MACHINERY AND EQUIPMENT
Confined-space rescuers support maintenance teams at Nova Scotia brewery Special coating resolves unexpected bearing wear from vibration Why dry bearing lubricants can take the heat
Vol. 29, No. 5
NOVEMBER 2013
Troubleshooting motor bearings by measuring hidden electric currents Melding power tool innovations with safety Supervisors: Know your health and safety responsibilities, or else!
FOCUS ON
BEARINGS
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BEARINGS
MOTORS & DRIVES
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P R O D U C T
SP TLIGHT
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SKF System 24 LAGD series single-point automatic lubricators deliver the proper pre-set amount of lubricant needed for bearings in machinery across industries. These cost-effective, gas-driven feed versions are engineered to perform reliably on a 24-hour basis without manual intervention and can resolve issues typically associated with hard-to-access or potentially hazardous lubrication points. The lubricators feature flexible and user-adjustable dispense settings and transparent lubricant containers for visual inspection of dispense rate. They are supplied ready to use in 60-ml and 125-ml sizes and integrate tool-free activation.
Keep your machinery healthy, strong and efficiently rolling along with the widest choice of industrial bearings in the world…only from Baldor•Dodge. baldor.com
• Superior Reliability • Energy Efficient • American Made Since 1880
479-646-4711
©2013 Baldor Electric Company
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• Unmatched Quality
App supplies friction data for variety of materials/coatings
Based on General Magnaplate’s friction calculation tool, the company’s Friction Calculator iPhone app provides static and dynamic coefficients of friction for more than 200 pairings of commonly used materials and engineered coatings. The materials database is continually updated with new materials and coatings. Information is included on understanding COF, surface roughness, calculating corrosion rates, wear mechanisms and thread tolerances. In addition, the device can be used to contact General Magnaplate’s technical service department to ask for help with surface enhancement problems. The app can be downloaded at the iTunes store. An Android version is in the works, but in the meantime, a web app for all desktop and mobile devices is available. General Magnaplate Online Reader Inquiry No. 545
Stylish women’s heated jacket provides hours of active heat
Milwaukee Tool has expanded its line of M12 Heated Gear jackets with the introduction of the Special Edition women’s heated jacket. The jacket features a tailored fit and incorporates the iconic pink ribbon design on the sleeve to showcase the company’s partnership with the National Breast Cancer Foundation. Providing snug warmth and performance for all-day comfort in the cold, the jacket’s carbon fibre heating elements actively warm the body and stimulate blood circulation. Three heat settings, adjustable by zone, provide the right amount of heat to the hands, core and upper back with a simple touch of a button on the lapel. The jacket also features water- and wind-resistant polyester with an interior storm flap and thermal knit fleece inner lining to keep weather out and heat in. Powered by M12 RedLithium battery technology, the jacket offers up to six hours of active heat. A battery and charger are included. Milwaukee Tool Online Reader Inquiry No. 547
Automatic self-cleaning strainers enhance bag filter line
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Nothing is more frustrating than shutting down a machine, even an entire production line because of a bearing failure. Baldor•Dodge® bearings represent the best quality and reliability industry has to offer. From punishing mining applications to corrosive washdown environments, and everything in between, there’s a Baldor•Dodge bearing perfectly suited for the task at hand.
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Keeping Industry Up and Rolling
Various accessories, including connectors, brushes and no-return valves, and mounting and protecting devices, can be specified. SKF Canada
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The design of the Flexcut mill scale grinding wheel from Walter Surface Technologies improves mill scale removal. This flexible grinding wheel is formulated to prevent glazing or disc clogging and has a wide surface contact area for fast and easy mill scale removal. Offering a blend of highly refined, friable abrasives paired with its open diamond cut pattern, the long-life wheel is designed to grind off mill scale rapidly and will selfdress to avoid clogging. In addition to removing mill scale, it features a FE-free formulation that will not contaminate aluminum and is effective when used for rust removal on heavily rusted plates, aluminum or galvanized metal. Walter Surface Technologies
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Washdown shaft collars from Ruland help protect hygienic equipment from bacterial contamination. They feature a type 303 stainless steel shaft collar, a two-piece housing made from FDA-compliant materials and three O-rings with NSF H1 registered lubricant. Washdown collars function similarly to traditional shaft collars as guides, spacers, positioners and hard stops. They offer holding power comparable to clamp-style shaft collars and allow for simple adjustments without marring the shaft. The company’s design is pending an IP69K rating against the ingress of dust and water up to 80°C and 8 MPa to 10 MPa of pressure. The collars are supplied with a zinc-plated forged alloy screw and are available for shaft sizes ranging from 6 mm to 25 mm or 1/4 in. to 1 in. RotoPrecision Inc.
Single-point automatic lubricator built for accuracy
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Grinding wheel takes hassle out of mill scale removal
Washdown shaft collars help protect equipment from contamination
November 2013
To complement SAB Filter’s line of conventional bag filters, automatic self-cleaning strainers are also available. Of these, the BCM automatic backwashing filter is the most robust. These units are used for continuous flow applications where downtime is not an option, and come with 8 to 100 stainless steel wedge wire elements for flow rates from 300 gpm to 11,000 gpm. They are available in carbon steel or stainless steel and are designed to ASME standards. HMI controls allow for easy process parameter entry. SAB Filter Online Reader Inquiry No. 542
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C O N T E N T S
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November 2013
in this issue Rescue Ready / 11
Confined-space rescuers support maintenance teams at Labatt’s Oland brewery in Halifax.
columns
departments
Mr. O, the Practical
Editor’s Notebook / 6
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Problem Solver / 9
Replacement roller chain saves over $23,000 per year for this steel plant.
Bearing coating resolves vibration troubles / 12
A special thin dense chrome coating fixes the problem of unexpected bearing wear caused by vibration in magnetic clutches. Special solid lubricants have been developed for bearings that must operate at extremely high temperatures and at low speeds.
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Business Briefs / 9 The Safety File / 19 Maintenance 101 / 20
Knowing the dangers / 19
Dry lubricants take the heat / 16
Industry Newswatch / 7
Literature Guide / 25
The Safety File: Supervisors must know their health and safety responsibilities, or else!
MRO on the Road / 26 Product News
Troubleshooting conflict / 20
Product Spotlight / 2
Maintenance 101: Resolving the conflict between production and maintenance at a Toronto food plant is the first step to fix productivity issues.
Focus on Bearings / 21
MRO on the Road / 26
Report and photographs from the PTDA Industry Summit in Palm Desert, CA, highlight industry networking.
Focus on Motors & Drives / 22 Focus on Test & Measurement / 23 Focus on MRO Components / 24
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editor’s selections
Spark Patrol / 17
‘If rescue team members are called with an emergency, it will take precedence over everything else they are doing.’ Gail MacDonald / 11
Troubleshooting motors by measuring hidden electric currents and voltages in shafts and bearings. Melding power tool innovations with safety / 18
Vendor profile: How Walter sells safety through its tools, supplies and other solutions. trying to align pump and motor systems.
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p19 p23 Cover Cover photograph: Eric Achilles Cousineau. This production line photo was taken during a recent tour of Timken’s bearing manufacturing facilities. A full report from the tour will appear in our December 2013 issue.
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‘The test results were very successful and another, more economical, design was implemented, resulting in tremendous savings for the company.’ Richard Spore / 12 ‘In very high temperature applications, grease and oil lubricants deteriorate rapidly.’ Steve Gahbauer / 16 ‘Flashover currents can cause pitting and fluting of the motor bearing race, damage that can cause a motor to fail prematurely.’ Colin Plastow / 17 ‘The term competent person has a very specific meaning under the Act.’ Simon Fridlyand / 19
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E D I T O R’ S
N O T E B O O K
Machinery & Equipment MRO
November 2013
Nine really essential skills
W
hen industry complains about tion for learning all other skills, and skills shortages, it’s not just techwhich enable workers to evolve and adapt nical skills in welding, electrical to change. Without these nine ‘common knowledge or mechanical prowess that’s sense’ skills, one really can’t be expected missing from job applications. to effectively learn and perform the hard The fact is, there is a bunch of other technical skills that industry really needs. skills that potential hires need to be effecRecognizing this, Skills/Compétences tive at. These might surprise you. The list Canada (SCC), an organization that proincludes numeracy, oral communications, motes careers in skilled trades and techthe ability to work with others, continunologies, has launched a national awareous learning, reading text, writing, thinkness campaign to promote the importance ing, document use and digital skills. I esof basic, essential skills for young people pecially like the one about thinking! seeking careers in skilled trades sectors. These nine basic skills have been idenWorking in conjunction with ESDC, the new SCC campaign will focus on tified by a government agency, Employment and Social Development Canada young Canadians who are pursuing caMRO_Mag_Full-Page_Movie-Ad_April_2013.pdf 1 4/4/13 4:08 PM (ESDC), as ones that provide the foundareers in skilled trades and technology
sectors. It will highlight those nine essential skill profiles that are used in nearly every job and at different levels of complexity, and explain their foundational role in understanding and applying concepts introduced in technical training. It’s likely that your company already feels the pain of the skills shortage problem. From energy and natural resources to construction, manufacturing and services, employers in the sectors that are the growth engine of the economy are finding it increasingly difficult to find workers with the right skills to meet their business needs. Who doesn’t want a maintenance tech who can quickly figure out the problem with a machine, knows which parts to order (and how to get them super fast), understands when repairing or replacing is best, and can actually do the job properly so he can get your line up and running ASAP? SCC really is trying to help. It offers experiential learning opportunities
through events and skilled trades and technology competitions for youth, such as the National Skilled Trades and Technology Week and the Skills Canada National Competition. One example is the interactive Try-ATrade and Technology activities at skills competitions, providing an opportunity to learn more about skilled trade and technology careers in a direct, hands-on way. Essential Skills will be integrated into these activities, highlighting how basic skills are a prerequisite in all skilled trade occupations. That’s a good start, and one that all industries should support. Sure, it’s pretty late to get going on this, but it truly is the time for everyone in industry to get in gear and encourage the training of those nine basic skills. Without that, you’ll never get the qualified, technically skilled trades you really need. Bill Roebuck, Editor/Associate Publisher
MACHINERY AND EQUIPMENT
MAINTENANCE, REPAIR AND OPERATIONS
NOVEMBER 2013 Volume 29, No. 5 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 Jim Petsis, Publisher 416-510-6842 jpetsis@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
November 2013
Machinery & Equipment MRO
MANUFACTURING OUTPUT ACCELERATED IN SEPTEMBER Toronto – Canada’s manufacturing expansion accelerated to a 15-month high in September 2013, according to the RBC Canadian Manufacturing Purchasing Managers’ Index (RBC PMI). A monthly survey, conducted in association with Markit, a global financial information services company, and the Supply Chain Management Association (SCMA), the RBC PMI offers a comprehensive and early indicator of trends in the Canadian manufacturing sector. The seasonally adjusted RBC PMI – a composite indicator designed to provide a single-figure snapshot of the health of the manufacturing sector – rose to 54.2
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their manufacturing footprint will enable us to even better serve our customers and distributors in the industrial market worldwide,” he added. “In particular, this acquisition, combined with our other activities, investments and acquisitions in the last few years, shows our strong commitment to the North American market.”
IMPROVEMENTS IN GROWTH SEEN FOR OECD COUNTRIES The growing wind energy market will help bolster bearing sales.
in September, up from 52.1 in August. This indicated further improvement in manufacturing business conditions, with the rate of growth above the series average and the fastest since June 2012. The RBC PMI found that both output and new order growth accelerated in September. In particular, the latest rise in total new work intakes was strong and the fastest since June 2012. This partly reflected the greatest increase in new export orders for two-and-a-half years. Meanwhile, the rate of job creation also quickened to a 15-month high, as firms hired additional staff to handle increased business activity. “The global economy is gaining traction, and, with that, we are seeing increasing demand for Canadian exports – particularly from the manufacturing sector, which has contributed to the PMI reaching a 15-month high in September,” said Craig Wright, senior vice-president and chief economist, RBC. “While challenges in the sector remain, this rebound is encouraging. An anticipated strengthening in global economic growth, particularly in the US, which is Canada’s largest trading partner, bodes well for manufacturing activity late this year and early next.”
SKF TO ACQUIRE KAYDON Gothenburg, Sweden – The boards of directors of the SKF Group of Gothenburg, Sweden, and Kaydon Corporation of Ann Arbor, MI, have agreed that SKF will acquire Kaydon in an all-cash transaction valued at about US$1.25 billion, including US$95 million of net debt. The transaction will be paid through existing cash and credit lines and will be accretive to SKF earnings in year one. Kaydon is a diversified industrial manufacturer with three distinct business areas: friction control products (bearings), velocity control products, and specialty products – including environmental services. The SKF Group is a global supplier of products, solutions and services within rolling bearings, seals, mechatronics, services and lubrication systems markets. “We have followed the development of Kaydon for a long time. They have a strong product portfolio, strong management and a solid financial performance, and I am delighted that they will soon be part of the SKF Group,” said Tom Johnstone, SKF president and chief executive officer. “The complementary nature of their products and technologies, their geographical and customer presence and
Paris, France – Composite leading indicators (CLIs), designed to anticipate turning points in economic activity relative to trend, continue to signal improvements in growth in most major Organization for Economic Cooperation and Development (OECD) countries, with divergent patterns among large emerging economies. The CLIs point to economic growth above trend in the United States and Japan, and to growth firming in the United Kingdom. The CLI for Canada indicates a positive change in momentum. In the Euro Area as a whole, the CLI continues to indicate a gain in growth momentum. In Germany, the CLI points to growth firming. The CLI for Italy continues to signal a positive change in momentum. Also the CLI for France now more clearly points to a positive change in momentum. The CLIs point to growth returning to trend in China, and to a tentative positive change in momentum in Russia. In Brazil and in India, the CLIs continue to signal growth below trend rates
3D PRINTER TO BUILD SPARE PARTS IN SPACE Moffett Field, CA – NASA is preparing to launch a 3D printer into space in 2014, a toaster-sized game changer that greatly reduces the need for astronauts to load up with every tool, spare part or supply they might ever need. The printers would serve as a flying factory of infinite designs, creating objects by extruding layer upon layer of plastic from long strands coiled around large spools. In NASA labs, engineers are 3D-printing replacement parts and rocket pieces that can survive extreme temperatures. “Any time we realize we can 3D-print something in space, it’s like Christmas,” said inventor Andrew Filo, who is consulting with NASA on the project. “You can get rid of concepts like rationing, scarce or irreplaceable.” “If you want to be adaptable, you have to be able to design and manufacture on the fly, and that’s where 3D printing in space comes in,” said Dave Korsmeyer, director of engineering at NASA’s Ames Research Center at Moffett Field. “Imagine an astronaut needing to make a life-or-death repair on the International Space Station,” said Aaron Kemmer, CEO of Made in Space. “Rather than hoping that the necessary parts and tools are on the station already, what if the parts could be 3D printed when they needed them?” The Associated Press
SEARCH IS ON FOR THE TOUGHEST COLD WEATHER WORKERS Cincinnati, OH – The search is on for the toughest winter workers in the third annual Cintas & Carhartt Cold Crew Contest. Cintas first launched the campaign in 2011 to recognize individuals in the US and Canada who withstand the toughest winter working conditions. Contestants are encouraged to share their stories and explain why Carhartt is essential to their jobs at www.cintas. com/carharttcoldcrew. Entrants get a chance to win free merchandise and a grand prize trip for two. Entries are being accepted now through February
MOTOR MARKET DRIVEN BY DEMAND FOR HIGHER EFFICIENCY
©iStockphoto/Thinkstock
Cleveland, OH – Ball, roller and plain bearing demand in the United States is forecast to increase 4.4% per year to $12.9 billion in 2017. This will be a notable improvement from the growth registered during the 2007 to 2012 period. Market advances will be supported by improved conditions in motor vehicle manufacturing, the largest market for bearings. The trend toward ‘insourcing’ US durable goods manufacturing will create opportunities in a variety of markets. Major companies supplying bearings include Koyo, NSK, NTN, Schaeffler, SKF, STK, TEKT and Timken. The engine, turbine and power transmission equipment market will experience the fastest growth, bolstered by continued growth in the wind energy segment. The automotive market will not be far behind, outpacing overall bearing demand gains. Bearing manufacturers will benefit from particularly strong growth in heavy truck and bus production, as these vehicles use more bearings (both in unit and dollar terms) than passenger cars. Roller bearing demand is expected to continue to outpace other product types, supported by sales of higher value, technologically advanced bearings. Roller bearings will continue to be the largest product segment, comprising over 40% of demand in 2017. Demand for bearings in OEM applications will outpace the industry average, due to ongoing growth in US durable goods output. Many durable goods manufacturers are building or upgrading production facilities in the US, boosting demand for components such as bearings. Increased production of machinery will stimulate gains, since these industries are heavy users of more advanced, highvalue bearing products. Bearing shipments from US plants are forecast to increase 4.3% annually to $12 billion in 2017, approximating demand growth. Industry output will be stimulated by growth in several key domestic bearing-using industries (e.g., motor vehicles, machinery) and by rising demand in a number of export markets. However, intense competition from bearing suppliers in lower-cost countries is expected to hold back price increases. Both imports and exports will post steady gains through 2017, and the US will remain a net importer. The full report, Bearings to 2017, published by the Freedonia Group, is available for US$5,100 from the website at www.freedoniagroup.com.
©iStockphoto/Thinkstock
Demand for bearings to rise 4.4% annually
Working in winter conditions? Enter a contest for free swag.
28, 2014, at which time Cintas and Carhartt will select finalists and begin public voting at the contest website. Cintas designs, manufactures and implements corporate identity uniform programs, and provides entrance mats, restroom cleaning and supplies, tile and carpet cleaning, promotional products, first aid, safety, fire protection products and services, and document management services for about 900,000 businesses. Carhartt is a global work wear brand with a heritage of developing rugged apparel for workers on and off the job. The company is privately owned and managed by the descendants of the founder, Hamilton Carhartt.
Zurich, Switzerland – The market for low-voltage motors will grow to more than $23 billion by 2017, driven by regulatory requirements that stipulate higher motor efficiencies, according to a report from information and analytics provider IHS. In The World Market for Low Voltage Motors 2013 Edition, IHS reports that in 2012, the market size was $14.6 billion, with more than 48 million units shipped. Since the acquisition of Baldor in 2011, when it became a market leader, ABB has improved its market position by continuous investments in the development of high-efficiency motors and improvements in customer service. Over the past two years, ABB increased its sales of low-voltage motors by more than 26%. “The strengthening of our market position reflects the successful integration of Baldor in our total offering,” says Ulrich Spiesshofer, head of ABB’s Discrete Automation and Motion division. “We are now realizing the synergies that were created by this deal.” Recently, ABB introduced so-called synchronous reluctance motors that can achieve IE4 levels of efficiency without the use of permanent magnets. Compared with an IE2 motor, the energy losses are reduced by up to 40%. MRO
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Business Briefs
both the Dow Jones Sustainability World Index (DJSI) and the Dow Jones Sustainability Index for Europe. DJSI rated SKF as best in class for the company’s apNews and views about companies, people, product lines and more proach to environmental management. • The Timken Company, Canton, OH, • The following members have joined the named Tetsuya Sogo as CEO of has announced its board of direcSTLE (Society of Tribologiests & Lubricathe Americas Region, president tors has approved a plan to purtion Engineers) in its Toronto Section so of NTN USA and chairman of sue a separation of the company’s far in 2013: John Walsh, ALS Tribology; NTN Bearing Corporation of steel business from its bearings Paul Joseph Brear, Atlas Copco; Bram America. He is based in Mt. and power transmission business Muange, BASF; Guy Labrecque, Fluid Life Prospect, IL. Sogo has spent his through a spinoff, creating two Corp.; Ahmed Abou Gharam, Litens Autoentire career with NTN. He publicly traded companies. The motive; and John Cecchetti, Lubrication succeeds Toru Tomiyama, who bearings and power transmission Engineers of Canada. For membership inhas retired to an advisory posibusiness will continue to operate NTN has named formation, visit https://www.stle.org. tion with NTN in Osaka, Japan. as The Timken Company. The enTetsuya Sogo • ABB of Zurich, Switzerland, has signed • In preparation for its 100th angineered steel company will inas a CEO. an agreement to sell all assets of its Baldor niversary in 2016, NSK Ltd., clude about 3,000 associates, generator-set business to Generac HoldTokyo, Japan, is striving to exseven manufacturing plants, four ings Inc., a producer of generators and pand its global sales through improved cuswarehouses and five sales offices. The steel other engine-powered products headquartomer satisfaction, with the goal of attaining business is North America’s leading manufacturer of SBQ (special bar quality) large tered in Waukesha, WI. The sale is expectone trillion yen (C$10.5 billion) in corporate bars for industrial markets and its largest ed to close in the fourth quarter of 2013. global sales. To that end, NSK is strengthproducer of seamless mechanical tubing. ABB is divesting the business because of ening its corporate governance and com• W.W. Grainger Inc., Chicago, IL, has limited synergies with ABB’s core portfolio pliance in an effort to build a corporate modified its structure to provide greater and because Generac is in a better position structure and culture that is commensufocus and a more consistent integrated apto create additional value from it. The busirate with that of a one-trillion-yen corporaness was acquired as part of ABB’s acquisition. NSK is a manufacturer of bearings, proach to pursue growth opportunities. tion of Baldor Electric in 2011 automotive products and preciThe industrial distribution firm, which fo• Fahad Haq has joined Lafert sion machine components. Back cuses on maintenance, repair and operatNA, Mississauga, ON, as project in 1916, it produced the first ball ing products, has formed a new Americas manager. He has several years bearings made in Japan. The business that includes Canada, the US, of experience in industrial supcompany currently has manufacMexico, Panama, Puerto Rico, Dominican ply, motor distribution and projturing sites in 64 locations and Republic, Costa Rica, Colombia and Peru. ect management. Lafert NA ofsales offices in 120 locations This will be led by Court Carruthers, senior fers a complete range of metric throughout the world, with a vice-president and group president, Amerimotors, pumps and gearboxes total of over 28,000 employees. cas. Carruthers previously served as senior with extensive inventories • For the 14th year in a row, vice-president and president, Grainger US, Fahad Haq has throughout North America. For joined Lafert NA as SKF, Gothenburg, Sweden, has and before that, was president of Acklandsproject manager. details, visit www.lafertna.com. been listed as one of the world’s Grainger, the company’s Canadian opera• NTN Corporation has most sustainable companies by tion, based in Richmond Hill, ON. MRO
Mr.0 The Practical Problem Solver
Replacement chain saves over $23,000 Problem: A steel plant was using standard roller chain on the main drive of its steel polishing machine. The application is very demanding due to tiny metal shavings creating an abrasive environment. As a result, the chain needed to be replaced every four to five months. Solution: The plant replaced the chain with Renold Synergy, which lasted nearly two years before needing to be replaced – over four times longer than the previous chain. The estimated cost savings on downtime and maintenance for the plant was $23,500 per year. Mr. O thanks Rick Hamilton at Renold Canada for this tip. Do you have a solution for a maintenance problem? Send it in and if it’s published, we’ll send you $25 and a Mr. O Problem Solver T-shirt. Include your address, telephone number, complete details and, if possible, add a sketch to help explain your tip. Send your tips to Mr. O, Machinery & Equipment MRO, 80 Valleybrook Dr., Toronto, ON M3B 2S9.
TWICE THE OPERATING LIFE. HALF THE WORRIES.
1.877.994.6675 www.ca.nsk.com BALL BEARINGS
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M A I N T E N A N C E
C A S E
November 2013
RESCUE READY
Machinery & Equipment MRO
Fig 1: SSTL instructor Trevor Routledge and Oland environmental health and safety manager Gail MacDonald (reclining) demonstrate the use of a SKED stretcher. Fig 2: Gail MacDonald removes an access hatch from a 1,200-hectolitre Budweiser fermenter. The Rescue Plan includes how to remove a worker from it. Fig 3: Rescuers can safely hoist a confined space entrant
BY CARROLL MCCORMICK
An in-house rescue team will support maintenance crews working in confined spaces at Nova Scotia’s Oland Brewery.
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using the yellow rescue line being held by SSTL trainer Trevor Rutledge (left). Oland maintenance mechanic Shawn Paul wears the harness. Fig 4: SSTL’s Trevor Routledge explores an extraction concern. The safety plan must account for the limited space between a wall and the hatch of this filtration surge vessel.
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Photos: Carroll McCormick
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lmost every day, maintenance people or operators enter a confined space at Labatt Breweries of Canada’s Oland Brewery in Halifax, NS. To complement its safe work plans for working in these spaces, the company commissioned a rescue audit of all of its 145 confined spaces and will have a rescue team assembled, trained, equipped and ready for rapid response by year’s end. Oland Brewery, which occupies a full city block in Halifax’s North End, produces 800,000 hectolitres of beer, or 20 million dozen bottles, a year. Confined spaces entry generally is done on the day shift, Monday to Friday. Operators enter these spaces to perform tasks such as cleaning horizontal fermenting vessels. Maintenance people enter them for tasks such as changing and maintaining the cleaning equipment in horizontal fermenting vessels and servicing the agitators in vertical brewing vessels. Working in confined spaces requires special training, which the Oland Brewery has long provided. To this end, 90% of the maintenance team and designated operators have taken the Confined Space Entrant/Attendant course offered by Survival Systems Training Limited (SSTL) in nearby Dartmouth, NS. They take recurrent training from SSTL every two years. Entry procedures for entering and working in various types of confined spaces have long been in place. Each entry for maintenance crews is co-ordinated between the operations manager and the maintenance planner. In preparation for entering a confined space, the lockout procedure, SAFE (safe action for an event) form and permit are pulled and tasks on checklists are carried out. Equipment is set up; for example, the davit structure used to lower a worker down a vertical entry. The air is tested for the presence of gasses such as carbon monoxide, carbon dioxide, methane and hydrogen sulphide. The Oland Brewery’s environmental health and safety manager, Gail MacDonald, gives examples of procedures performed before an entry. “For vessels with agitators, we isolate the electrical power, double block and bleed the steam lines and blank off lines for the caustics. Doing a complete lockout of our bottle washer, for example, which has eight horizontal entry hatches, requires 28 locks.” Like most companies, Labatt and the Oland Brewery would have traditionally
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contacted external rescuers such as the Halifax Fire Department if there was an emergency in a confined space. Last year, however, Oland decided to assemble an in-house rescue team with rescue training and equipment, first aid skills and site-specific knowledge. To be on-call during every confined space entry, it would be ready to respond immediately to an emergency and follow a rescue plan for every confined space in the building. To this end, the Oland Brewery first hired SSTL to do a rescue audit of every confined space it had. It reviewed the hazards associated with each confined space; e.g., physical hazards such as moving equipment and steam, and atmospheric hazards such as carbon dioxide, which is a by-product of fermentation. “The reason for doing this is to identify and mitigate all of the hazards that a rescue team could encounter so they can perform a safe and timely rescue,” says Trevor Routledge, lead instructor - industrial safety and rescue, SSTL. “This could include lock out/tag out, atmospheric testing or ventilation. We also looked for potential problems unique to a certain space, such as openings too small for bulkier rescue equipment or spaces that required engineered points to hoist a victim out of a vertical entry. We discussed personal protective equipment such as helmets, harnesses, lifelines,
davit arms, gloves, boots, self-contained breathing apparatus and supplied air breathing apparatus,” Routledge explains. This summer, the Oland Brewery and SSTL began pulling together almost a year and a half of work to create the rescue team. This includes installing engineered points for davits beside vessels with two entry hatches and buying rescue equipment. The list includes coils of rescue rope, pulleys, carabiners, Prusik hitches, harnesses, a gas tester, climbing helmets (which are better suited for tight quarters than hard hats), a special stretcher and an Automated External Defibrillator (AED). Rescuers will also have an air cart that supplies air through a hose to a rescuer’s breathing mask. Rescuers using supplied air will carry a hip-mounted tank called an escape pack, which contains about five minutes of air. As part of the plan to keep the rescue team in constant communication with the workers who enter a confined space, MacDonald spent several hours making sure that two-way radio coverage extended to every corner of the brewery. “The attendant, security guard and rescue team members will all have their radios on during entries. The designated rescue team members will be made aware of the confined spaces entry task when it begins and when it ends. During this time they will be on call. If they are called with an emergency, that will take precedence over everything else they are doing,” MacDonald explains. The Oland Brewery wants to have about a dozen employees on the rescue team. “We are now canvassing people to get trained as part of the rescue team. Maintenance trades, operators whose jobs
require them to do confined spaces work and managers are stepping up to be members of the rescue team,” MacDonald says. Rescue team members will receive several kinds of training. Although SSTL offers a generic Confined Spaces Entry & Rescue (CSER) course, the company is working with the Oland Brewery to develop a site-specific CSER course. The team members will also take a one-day St. John’s Ambulance first aid course and receive training in the use of the AED. Which rescue team members are available on any given day will be built into the resource scheduling for the maintenance plan. How many of them must be on standby for any particular confined space entry is being worked out. “A lot of the co-ordination around confined spaces entry will be to be sure we have the rescue people available,” MacDonald says. Routledge elaborates: “The National Fire Protection Association [code] governs the size of the team [on standby for any particular confined space task]. For example, there could be four rescuers for a horizontal opening with all hazards mitigated, easy access and the victim in clear sight. There could be six or more rescuers when dealing with a dangerous atmosphere in the confined space or a difficult situation such as a vertical entry or a space in which it is hard to access the casualty.” The careful attention that Oland is paying to developing its rescue plan will add up to a process that will keep the rescuers safe and allow a rapid response in an emergency. Says MacDonald, “It is really important to roll this out right. Our goal is to get people home safely at the MRO end of each day.” Carroll McCormick, our senior contributing editor, is based in Montreal and has been writing award-winning articles for us for the past 15 years.
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November 2013
Bearing coating resolves vibration troubles BY RICHARD A. SPORE
Metal-to-metal contact issues between bearing components, resulting in magnetic clutch failures, are addressed by using a thin dense chrome coating on the bearings to create a sacrificial surface.
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VIDEO
Photos: C&U Americas
Initially, ceramic balls (left) made of silicon nitride were used because of their high strength, light weight and excellent performance. Then a more economical design using steel balls (right) was successfully tested and adapted.
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global refrigeration transport equipment manufacturer was experiencing excessive warranty costs for a product used in an over-the-road refrigeration application. The warranty issues were being caused by bearing failure in the magnetic clutch used in the system. To solve the problem, the bearing manufacturer partnered with a supplier that specialized in chromium coating technology to develop a cost-effective solution that resolved the problem and helped reduce warranty costs for the customer by 75%. Magnetic clutches are used in a variety of automotive applications, especially for over-the-road refrigeration trucks or reefer units. Typically, the bearings in the reefer unit’s magnetic clutch work well, as long as the unit is operating and providing refrigeration. When the truck is between deliveries and is not carrying a load that requires refrigeration, the unit is shut down. This is where the problem begins. As the truck is driven with the reefer unit shut down, a great deal of vibration is transferred to the various components of the unit. Since the magnetic clutch is idle at this time, the bearing components tend to vibrate or oscillate against one another. The bearing balls oscillate against the inner and outer bearing rings or raceways, and cause metal-tometal contact. In some cases, the presence of bearing grease in the raceway may help to offset the metal-to-metal contact. However, there is usually enough vibration and oscillation occurring during these long periods when the refrigeration unit is idle to cause the type of metal-to-metal contact between the balls and the raceways that can shorten bearing life. Because of this, typically, 50% of the clutches required premature service or repair, resulting in higher warranty costs. This is precisely the problem that the refrigeration transport equipment manufacturer was experiencing. Solution devised The initial design used by the refrigeration transport equipment manufacturer was based on a configuration of two 61908 bearings stacked together. The company learned that another division of its corporate parent had experienced similar metal-to-metal contact issues with other components and was able to successfully address the problem by continued on page 14
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using a thin dense chrome (TDC) coating to create a sacrificial surface. Believing that the use of this type of coating could work in a magnetic clutch application, the refrigeration manufacturer began looking for a bearing company with which to partner, and selected C&U Americas. The manufacturer was very concerned about the high warranty costs it was incurring, as well as the strain that this was placing on customer relationships. As a result, the initial design plan spared no expense in the development of a bearing that would solve the clutch problem. The new design incorporated the TDC coating, and used ceramic balls in lieu of steel. A standard bearing typically uses steel balls, but to maximize the reliability of the clutch bearings, balls made of silicon nitride (Si3N4) were used because of their high strength,
Photos: C&U Americas
continued from page 12
light weight and excellent performance. C & U s e nt t h e inner and outer base rings of the bearings to a coatings provider where a proprietary method was used to prepare the rings for coating. All of the surfaces that would receive the coating had to be honed beforehand to ensure proper adhesion of the thin dense chrome. The thickness of the coating was carefully monitored to maintain a tolerance of 1.0-2.5 microns on all critical functional surfaces. After the coating was applied, C&U completed the final assembly. The new bearings were then subjected to many hours of stringent testing to
Left: The thickness of the TDC coating was carefully monitored to maintain a tolerance of 1.0-2.5 microns on all critical functional surfaces. Below: After conducting a value analysis, C&U made a design change and recommended the use of a magnetic clutch bearing with the same envelope dimensions as two of the initially designed 61908 bearings.
validate the design, including the development of a special bearing test stand. Additional hours of real world field testing were also logged to further prove out the new design. The new bearings worked flawlessly and the new design was launched.
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Economical design improvement With the initial problem solved, C&U was consulted again to develop a more economical solution. Value analysis/ value engineering (VA/VE) was implemented to address this need. As a design change, C&U recommended the use of a magnetic clutch bearing (MCB) with the same envelope dimensions as two of the current 61908 bearings. C&U was already making this part as a regular MCB and just needed to overcome the hurdles of adding the TDC coating to the inner and outer rings, while still maintaining consistent quality and internal clearances. All of this had to be done to a bearing that was now twice as wide as the previous design. The coatings provider addressed the issue by developing new racks for coating the double-row bearing, and was able to maintain the required 1.0-2.5 micron coating thickness. C&U was able to make sure the coating, which was now being applied directly to the rings of a bearing with two raceways on each ring, maintained the correct internal clearance. The refrigeration equipment manufacturer then tested the use of steel balls in lieu of ceramic balls to help decrease the cost even further. The tests were very successful and another, more economical design was implemented, resulting in tremendous savings for the company. Application summary Applying a TDC coating to the bearing rings and balls provided the manufacturer with several design advantages and benefits. Overall, it helped to reduce maintenance and replacement costs. The coating only needed a thickness of 1.0-2.5 microns in the functional areas. This minimized the amount of coating required and helped maintain the bearing’s design tolerances. The coating also increased the surface hardness of the bearing’s components, which helped to reduce friction and wear. When the coating was applied to the surfaces, it resulted in absolute adhesion to the basis metal, so there was no chipMRO ping, cracking or flaking. Richard Spore, a bearing applications engineer with C&U Americas LLC, has over 11 years experience in the bearings industry and is responsible for bearing applications engineering at the company, which is the North American subsidiary of The C&U Group, China’s largest bearing producer. For more information, visit the website at www.cubearing.com.
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Dry lubricants take the heat Special lubricants have been developed for bearings that must operate at extremely high temperatures and at low speeds. BY STEVE GAHBAUER Photograph: SKF Group
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nderstanding what harsh environments demand of bearings has led the Swedish bearing maker SKF to develop bearings that incorporate dry lubrication for applications where ‘normal’ lubes don’t do an adequate job. This is of special benefit for operations such as metal processing, and for food and beverage industries, where a combination of extremely high temperatures and slow speeds present a formidable challenge. Dry, graphite-based lubricants can overcome many of the problems associated with conventional grease and oil lubrication in such demanding environments, where grease viscosity decreases rapidly at high temperatures, and liquid lubricants can evaporate. Dry lubrication contributes to reliable bearing performance, lower operating costs, reduced machine complexity, minimal maintenance requirements and longer bearing service life – even at temperatures as high as 350°C. Benefits, along with operating reliability and reduction of bearing system complexity, include longevity – bearings with dry lubrication can run for years as long as they are kept dry – and low startup torque at any temperature, as well as
Most SKF rolling bearings and bearing units can be supplied as dry lube bearings.
no need for a minimum speed. Dry lubricants also avoid leakage problems and have low disposal costs, compared to grease and oil lubes. There are, however, a couple of drawbacks. Dry lubricants offer limited corrosion protection and often exhibit a temporary increase in noise and vibra-
tion as small fragments of solid lubricant break free. The rationale behind dry-lubricated bearings is that in very high temperature applications – 200 to 350°C – grease and oil lubricants deteriorate rapidly, leading to poorly lubricated bearings that fail prematurely. Dry lubrication
does not deteriorate at these high temperatures, can work under heavy loads and low speeds, has high thermal stability, and can assure virtually maintenance-free operation. Dry lube bearings, especially suited for wheel bearings in kiln trucks, cooling beds in bar and sheet metal mills, and for continuous ovens, incorporate graphite and molybdenum disulphide as the dry lubricants. In these materials, the lubricating properties are the consequence of a lamella layer of plates structure that is created under load, when the lubricant adheres to the contact surfaces in the bearing, providing a presence of solid lubricant on the bearing surfaces, even at high shear stresses. This layered structure enables a sliding movement of the parallel plates. Weak bonding between the plates provides low shear strength in the direction of the sliding movement, but high compression strength in the direction perpendicular to the sliding movement. A solid lubricant with high compression strength can withstand heavy loads without creating metal-to-metal contact. In operation, the dry lubricant maintains a very thin film on the raceways and rolling elements that helps to avoid that dreaded metal-to-metal contact. MRO Steve Gahbauer is an engineer, a freelance writer, and a contributor of technical articles to Machinery & Equipment MRO. You can reach him at gahbauer@ rogers.com. For more information on dry lubricants, visit SKF Canada Limited’s website at www.skf.ca.
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BY COLIN PLASTOW
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oltage pulses from a variable speed drive can couple from a motor’s stator to its rotor, causing a voltage to appear on the rotor shaft. When this rotor shaft voltage exceeds the insulating capacity of the bearing grease, flashover currents (sparking) can occur, causing pitting and fluting of the motor bearing race, damage that can cause a motor to fail prematurely. This article explains how to use a scope meter and a shaft voltage probe to measure motor shaft voltage and bearing currents. Bearing currents Capacitive coupling between a motor’s stator and rotor can create a voltage on a motor shaft. For this reason, bearings in electric motors can suffer from wear and tear caused not only by the rotation of the shaft but also by electric currents flowing from the motor shaft to ground by way of the bearings. Motors powered by sine wave AC power may have a shaft/bearing-to-frame voltages of about 1 V to 2 V. Motors powered by the rapidly switching waveforms of variable frequency drives (VFDs), however, may have shaft/bearing-to-frame voltages as high as 8 V to 15 V. Voltages at these levels can overcome the insulating properties of bearing grease, and the resulting sparks can cause pitting, fluting, fusion craters, and eventually, premature failure of the bearings and motor. Shaft voltage probe Measuring the voltage of a rapidly spinning motor shaft can be difficult and dangerous. A shaft voltage probe helps to make shaft voltage measurements safer and more convenient by extending your reach, making the electrical connection to a motor shaft by means of a small conductive brush mounted on the voltage probe, such as that on the Fluke VPS420-R. The reference contact of the probe is connected to ground at the motor housing. For one study, an i400s Current Probe was clamped on one of the cables between the VFD and the motor. Measuring device Shaft voltages and current spikes caused by the pulse width-modulated
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output of motor drives can be exceedingly brief, often in the microsecond measurement range. The high bandwidth (up to 500 MHz) and fast sampling rate (up to 5 Gs/s) of the Fluke 190 Series II ScopeMeter make it an ideal tool for measuring rapidly changing voltages and currents – far superior to a digital multimeter. Connect-and-View triggering automatically displays stable waveforms with virtually any signal, while ScopeRecord enables users to store waveforms in memory for later viewing. And because 190 Series II ScopeMeters can record and display up to four signals, they can simultaneously display both current and voltage from more than one source. Measurement results The oscilloscope screen captures show three measurements that were made on a motor and drive using the scopemeter. All signals were measured on the T1, T2 and T3 of the motor drive. A typical measurement result can be explained as follows: • Channel A (red trace) shows the motor shaft voltage. Spikes can clearly be seen from the flashovers on the shaft through the bearing. • Channel B (blue trace) shows current spikes on top of the current signal measured by the current clamp. The spikes give a clear indication of when a peak occurs, confirming a flash or spark. It is assumed that these currents pass through the bearing. The presence of multiple inputs allows for a more detailed study of the common mode current as more than one current clamp can be connected. In principle, the total current through the T1, T2 and T3 line, referred to as Sigma current, should be equal to the current measured through the Protective Earth, referred to as PE current. In case there is a discrepancy, it is assumed that current is leaking through the bear-
ing, caused by parasitic capacitive coupling between the stator and rotor in combination with high-frequency circulating currents. Both Sigma current and PE current are made visible on the screen captures. The erratic behaviour of sparks can be seen on the captured screen of the Sigma current, which is related to the bearing current.
Left: Fluting of this bearing race was caused by bearing currents. Centre: The oscilloscope screen captures show three measurements that were made on a motor and drive using the ScopeMeter. Below: Measuring the voltage of a rapidly spinning motor shaft can be difficult and dangerous. A shaft voltage probe helps to make shaft voltage measurements safer and more convenient.
Photo courtesy of Fluke Electronics Canada.
Spark Patrol
Troubleshooting motor bearings by measuring motor shaft voltage and bearing currents.
Photo courtesy of Electro Static Technology.
November 2013
Photo courtesy of Electro Static Technology.
• Channel C (black trace) shows the output of the motor drive. The quality of this signal determines the efficiency of the motor. A fast rise time in conjunction with a high electrical capacity of the stator/rotor will contribute to the flashovers. The ScopeMeter is a useful tool for a wide range of additional tests on motors and drives, including analysis of harmonics present in the supply voltage, using the built-in fast Fourier transform (FFT) software. Because harmonics play
an important role in the efficiency of the motor, it is useful to know about their presence and amplitudes. MRO Colin Plastow is the industrial product manager with Fluke Electronics Canada. He may be contacted by e-mail at colin. plastow@fluke.com.
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Tool Talk
P R O F I L E November 2013
Walter sells safety through its tools, supplies and other solutions.
The grinder can be a very dangerous tool if not used properly.
I
BY CARROLL MCCORMICK
s a grinder a lethal weapon? The answer is not obvious, and many people will have never heard of grinders described this way. Yet when Walter Surface Technologies gives its safety
seminars, workers are keen to learn more about how to use them properly. Based in Point-Claire, QC, on the Island of Montreal, Walter, which manufactures products for the metalworking
Photo: Walter Surface Technologies
Machinery & Equipment MRO
industry, takes its commitment to safety directly to the shop floor. “We are focused on visiting our end users in their work environments to encourage safer and more efficient work practices. We do a lot of these seminars and it’s a free service,” says Claude Vandemeulebroocke, general manager, Walter Surface Technologies Canada.” “Several of our employees have taken the Walter safety seminar. They are very impressed with it,” says Marc Legault, a buyer for BP Canada. Workers in its Lasalle, QC, roofing shingle plant go through a lot of grinding discs cutting and preparing metal for welding. Walter sales professionals are trained to talk about how to work safely with power tools, bonded and coated abrasives, brushes, drill bits and other tooling. Although Walter manufactures all of these products, the information in the safety seminars is relevant to any brand of tools and supplies the host plant uses.
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Co-Owners
“We remain neutral with regards to the products we discuss. We talk about abrasives in general and best practices for grinding, for example. We never push our products directly in our safety seminars,” notes Vandemeulebroocke. The seminars are tailored to be relevant to each client’s employees and the day-to-day tools they use. So, for example, if they do not use wire brushes, then the Walter instructor will not talk about wire brushes. Topics include discussing the importance of a clean workplace, how to hold a grinder and the importance of respecting the maximum speeds of wheels. “We talk about the dangers, such as what can happen if a wheel shatters or if someone catches the drawstrings on their hoodie in the wheel. Respect your co-workers when you grind and be aware of who and what is around you. The grinder can be a very dangerous tool if not used properly,” says Vandemeulebroocke. Taking the safety seminar concept a step further, last year Walter created an iPhone app called Walter Safety. It contains valuable information such as speed charts for abrasives, drill bits and annular core cutters. Workers can also tap the app for grinding angles, metric/Imperial unit conversions and even a level that shows surface angles. Walter makes a practice of listening to plant personnel, in case they have an idea that its Point-Claire research and development team can use to make a better product. “We take these ideas and make them work. We do go to maintenance supervisors and listen; for example, if they say, ‘if you had a product like this, it might be better’,” explains Vandemeulebroocke. For instance, this is what led Walter to develop its Surfox weld cleaning systems as a substitute for pickling paste. “A lot of food plants weld stainless steel onsite. Pickling paste passivates TIG welds. It is a harsh product and highly dangerous in food plants. Surfox eliminates the use of pickling paste. It cleans and passivates, and is approved by the Canadian Food Inspection Agency and NSF International,” says Vandemeulebroocke. This focus on safer, more environmentally friendly products lies behind all of Walter’s Bio-Circle products, such as those developed for cleaning, degreasing and lubrication. Because they are biodegradable and non-toxic, they fit well with companies that have mandates to lower their impact on the environment. This attention to end-users also has guided Walter in developing safety features for its power tools. For example, Walter makes grinders with a safety clutch that disengages if the grinding wheel jams. Other worker-friendly features on its grinders include a dust guard to prevent grinding dust from getting into the motor, anti-vibration handles and a quick-connect nut that needs no wrench to tighten or untighten the wheel. Walter is ready to show prospective customers the potential advantages of buying its products, says Vandemeulebroocke. “We will prepare productivity reports for companies and compare Walter products with competing products. We will do productivity reports for using our abrasives, for instance. We show you what our abrasives can do. We can show companies how to reduce costs associated with abrasives, such as labour and time, and improve overall productivity MRO and worker safety.” Carroll McCormick, our senior contributing editor, is based in Montreal.
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WHAT SUPERVISORS MUST KNOW ABOUT THEIR DUTIES AND RESPONSIBILITIES.
Machinery & Equipment MRO
©Blend Images/Thinkstock
November 2013
take every precaution reasonable in the circumstances. This is a very high standard but not an absolute one. A supervisor does not have to take every precaution under the circumstances, but every precaution that is reasonable under the circumstances. What does ‘reasonable’ mean? It is a very common word used in the legal profession. You likely are familiar with some of the phrases using this word, such as, for example ‘beyond a reasonable doubt’, and so on. However, what one person thinks is reasonable is not what someone else may think is reasonable. Reasonableness is not subjective – it is objective. What is reasonable is not absolute perfection. It is a balanced, wise, prudent judgment that is understandable to others. One needs to imagine what a jury of your peer supervisors would think to do in circumstances similar to yours. Asking what your peers might do in the circumstances can lead to the
use of industry standards, codes of practice and so on. The due diligence standard is also very relative. What is reasonable varies with the circumstances and the risk. The greater the risk, the greater the amount of care that is considered reasonable. Risk is a combination of the probability that something will happen and the severity of the event if it happens. We tend to focus on high-probability events, but we should also be looking at high-severity accidents. As far as machine guarding is concerned, the industry standard is the CAN/CSA - Z432 Standard for Machine Guarding. The standard is performance-based and specifies the expected performance of the machine safety system based on the hazard analysis, and does not provide specific requirements for the machine’s control system. This complexity was recognized in Ontario when the requirements for the Pre-Start Health
and Safety Reviews (PSRs) were developed in 2000. They state that for new and modified machinery, where there is an electrical or electronic device that signals the machine to stop, a Professional Engineer shall review it and issue a report stating the compliance has been met. OHS regulations identify not only the responsibility of the major players involved (a supervisor is one of them), but also the rights of those players. You have the right to know. If you don’t know for sure whether a machine is safe for a worker to operate, you have the right to find out by obtaining the correct information from an engineer who specializes in this field. In fact, it is your duty. MRO Simon Fridlyand, P.Eng., of SAFE Engineering Inc., specializes in industrial health and safety concerns and PSR compliance. For more information, visit www.safeengineering.ca.
BY SIMON FRIDLYAND
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O
ccupational Health and Safety (OHS) legislation and regulations across Canada have similar requirements for superior staff in an organization. A supervisor is a person who is in charge of a workplace or has authority over a worker. There are very important duties and responsibilities under the law that supervisors must know and understand. The regulations stipulate that an employer shall appoint competent persons as supervisors. ‘Competent person’ has a very specific meaning under the Act. He or she must: • be qualified – through knowledge, training and experience – to organize the work and its performance • be familiar with the Act and the regulations that apply to the work being performed in the workplace • know about any actual or potential danger to health and safety in the workplace. To know about any actual or potential dangers to health and safety in the workplace is not an easy task. Some dangers are very obvious, while some are very difficult to spot. For example, a supervisor must be able to conduct a hazard analysis on a machine that employs an electrical or electronic device to signal the machine to stop (a light curtain, safety scanner or interlocked gate) in accordance with the CSA Z432 machine guarding standard, and verify the control reliability of the safety system based on the hazard analysis finding. As a supervisor, can you do that? Further, the OHS regulations set out specific duties for a supervisor. A supervisor must: • ensure that a worker complies with the Act and regulations • ensure that any equipment, protective device or clothing required by the employer is used or worn by the worker • advise a worker of any potential or actual health or safety dangers known by the supervisor • take every precaution reasonable in the circumstances for the protection of workers (this is known as a ‘due diligence’ clause). You might want to visit the website of the Ministry of Labour in your province to see how many convictions take place every month. It can be a real eye-opener regarding your responsibilities. Lawyers will tell you that due diligence is the only defence related to the contravention of an occupational health and safety act. So what does a supervisor need to do to demonstrate due diligence? Due diligence means that you have to
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Machinery & Equipment MRO
November 2013
TROUBLESHOOTING
CONFLICT
Resolving the conflict between production and maintenance at a Toronto food plant is the first step to fix productivity issues. BY PETER PHILLIPS
O
ver the course of my next few articles, I plan to write about one of our current projects at a large food plant in the Greater Toronto Area. We have been asked to revamp the food manufacturing facility’s maintenance and production systems. This is the first instalment covering the procedures involved in doing this. The company had recently gone through a major expansion and had installed a lot of new equipment. To meet customer orders, new maintenance and production people had been hired in order to staff a new shift schedule that is now 24 hours per day. We visited the site for two days to perform a preliminary assessment of maintenance and production activities. We met with managers, supervisors and others to gain their confidence and support for future meetings and discussions that we would be having to help them to be a more effective and productive team. Although the bulk of this assessment revolved around the maintenance department and its activities, we also observed and documented gaps and bottlenecks within the production department, many of which were linked with maintenance and equipment set-up activities. During our time on site, we met with several maintenance and production managers and supervisors, as well as hourly paid personnel. We attended several meetings, which included the morning planning meeting and a production lead hand meeting facilitated by the production supervisor. We also attended a production scheduling meeting, which set out the next week’s production schedule. To further understand some issues, I arrived at the plant at 6:00 a.m. to observe morning preparations for the 7:00 a.m. production start-up. As expected, the meetings and discussions we had with plant personnel contained both subjective and objective viewpoints, all of which were documented for use as reference material in future discussions with plant personnel. Overall, the feelings from plant personnel in regard to the maintenance and production relationship reflected that they were all good people with an interest in working together for the common good of the plant. That’s an important
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ingredient that would help us along the way to implementing change. However, it became obvious that the production department did not have confidence in the abilities of the maintenance crew to repair and maintain the equipment. There were several examples we observed that verified that problems did exist that were affecting the performance of the maintenance department. We found deficiencies in skills, knowledge and attitudes, as well as communication gaps. These, in turn, were causing line delays and stoppages. We broke down our assessment into three categories: • Communications and planning • Skills, knowledge and attitude • Next steps. The assessment covered our personal observations and the discussions we had with plant personnel, and included examples, followed by a summary. The Next Steps are what we plan to assess on our subsequent site visit. Communication and planning We found maintenance communications in regard to important equipment-related corrective maintenance and requests from the production department were verbal, sometimes passing through several people before reaching the maintenance shift and the people responsible to do the work. In one instance, the afternoon maintenance shift was verbally told that mobile conveyors were required for the following morning to run a trial product. Although there were two maintenance shifts available to prepare for the conveyors, the job did not get completed, causing a 45-minute delay in production start-up the following morning. We also documented a great many production changeovers and production schedule changes, often with short notice. Although the production schedule is normally set for the week ahead on the previous Thursday, changes do happen due to customer demands, etc. Because communications are limited between production and maintenance, changeover information does not always flow well and startup delays are commonplace due to set-up issues and equipment malfunctions. The communications process between
maintenance and production, and within their respective departments, needs a full review. Time must be given to identify the current communication processes in order to develop a sound communication structure, so production and maintenance personnel understand their roles, responsibilities and assignments. Skills, knowledge and attitude Although the maintenance staff consists of skilled tradesmen, we found that they lacked experience with and knowledge about the specialized production equipment used in this facility. It’s a common problem within most fast-growing companies. Training is just beginning to take place, using specialized equipment-repair representatives and contractors. There is a lot to learn in a short timeframe. Through our discussions with maintenance and production personnel, we quickly realized there are many reoccurring equipment failures. It was not uncommon to see production managers, supervisors and set-up people trying to figure out reoccurring problems that were keeping the line from starting up or from allowing it to keep running. Although some equipment will be replaced over the next several months, production staff feel that they are saddled with reoccurring failures because maintenance is unwilling or unable to fix the issues. Production staff expressed to us that maintenance people often tell them they don’t have time to investigate equipment problems because they have preventive maintenance tasks (PMs) to complete. The company also uses set-up people who are responsible for making sure equipment is configured to run specific products. However, these people were not fully available on each shift and were often overbooked for set-up – or were busy working as a relief operators as necessary. At these times, maintenance personnel are called to the line and expected to be able to perform set-up functions. It’s not something they like to do. There is a clear maintenance philosophy here at the plant that surfaced during our discussions: ‘If it’s not broken, do not call us’. Summary First of all, the ‘don’t call us’ attitude portrayed by the maintenance department
needs to change. There is a clear need to address the priorities of maintenance activities in regard to production needs. Attitudes need to change from ‘Don’t call if it’s not broken!’ to ‘What service can we give you?’ They also need to develop the philosophy of ‘fix it forever’. Second, the maintenance department does not have the skills to perform the set-up duties. It is not uncommon to see a production line not running because the maintenance staff was unable to properly set up the equipment. We feel that the skills and knowledge of the maintenance crew on specialized equipment and set-up procedures need to be addressed. A rigorous training plan needs to be established for the maintenance staff. With the new equipment on order, training will become a key ingredient for their success.
©iStockphoto/Thinkstock
In food production or any other such operation, communications between production and maintenance is critical for success.
Next steps As this was a brief, two-day assessment, we definitely will need to complete a more in-depth analysis of the key issues in order to begin the process of change. Meetings will be held with maintenance technicians to determine their needs in the skills and knowledge area. Although the facility uses a computerized maintenance management system (CMMS), a further assessment of maintenance activities and how the CMMS is being used will be done, in order to develop the program properly to help make the department more productive. The production department clearly has issues with the level of service that is currently being delivered to them. Further meetings with the production department will take place to determine its needs from the maintenance department and to identify the gaps in service. Daily issues occur that result in five to 10 minutes of lost time here and there, and overall cause line stoppages. These add up shift-to-shift, causing an overall loss of productivity that can not be afforded. We’ll report on our progress in the next issue. MRO Peter Phillips of Trailwalk Holdings, a Nova Scotia-based CMMS consulting and training company, can be reached at 902-798-3601 or by e-mail at peter@trailwalk.ca.
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What’s new in bearings ▼
Spherical roller bearing housed unit is built for long service life
Online Reader Inquiry No. 516
ER-style ball bearings find application in many industries
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Cylindrical roller bearing for large gearbox withstands hostile conditions
NSK has developed a high-load-capacity cylindrical roller bearing for large gearbox applications. It features an increase in the number of rollers and therefore the load capacity. This increase results in thinner cage walls, which in turn weakens the cage. To counter this side effect, the company has optimized the cage shape to sup-
Online Reader Inquiry No. 501
facilitate dismounting by hydraulic means, increased running accuracy to P5 for the inner ring and outer ring, and marking of the largest radial runout deviation on the inner ring and outer ring. Schaeffler Canada Online Reader Inquiry No. 510
The RD light-contact type sealed ball bearings from Koyo were developed to provide both low torque and tight sealing. They include several design features that help inhibit the ingress of contaminants and moisture. First, the inner seal lip prevents the leakage of grease by directing it towards the bearing interior, while clearances between the inner ring and lip seals form a labyrinth improving seal tightness. Second, the angled inner ring and seal outer lip help keep contamination out of the bearing, and the protuberance at the tip of the outer lip improves the seal’s tightness. Foreign materials are prevented from entering the bearing interior by centrifugal force resulting from rotation. Koyo Canada Online Reader Inquiry No. 507
Versatile spherical roller bearing keeps costs, inventory down
The Simatherm IH 025 Volcano portable induction heater from Simatec weighs just 3.5 kg, enabling efficient heating performance from an extremely light structure. It can heat roller bearings with an inner diameter as small as 20 mm (0.79 in.) up to an outer diameter of 160 mm (6.30 in.) and a weight of up to 10 kg (22 lb.). In addition to roller bearings, the device is also suited for heating other circular ferritic metal components such as gear wheels, pulleys, bushings, flanges, bearing rings, pinions and shrink rings. Each heater includes a temperature probe, protective gloves, instructions for use and a carrying case. Simatec
Longer life, larger capacities enhance split roller bearing line
Cooper Roller Bearings has increased the load capacities of many of its split roller bearings. The medium-duty 01E and heavy-duty 02E bearings are fully interchangeable with the company’s 01 and 02 series bearings, yet provide up to 29% more radial capacity and 16% to 90% more axial load capacity, and are completely split to the shaft. The L10 life is 23% to 135% longer (depending on size), which extends uptime and allows longer intervals between replacement. The increased life and capacities are due primarily to changes in internal geometry. The bearings are available with bore sizes from 160 mm to 300 mm (6.5 in. to 12 in.). Typical applications include power generation, industrial fans and conveyors, and mining equipment such as bucket wheel excavators, crushers and stacker reclaimers. Cooper Split Roller Bearings
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Online Reader Inquiry No. 512
Light-contact sealed bearings protect against contamination
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A line of Baldor Dodge ER-style ball bearings, available in two shaft attachment methods, has been introduced by Baldor Electric. The set screw version has a 65-degree set screw angle for maximum shaft grip, while the D-Lok product offers a clamp collar grip for maximum concentricity to minimize vibration. The bearings employ snap-ring retention to securely fit the cylindrical outer diameter into user equipment. In addition, they feature the Dodge ProGuard seal and flinger package to prevent contamination and maximize product life in dirty applications. They are suitable for a wide variety of industries and applications, including material and unit handling, conveying equipment, and agricultural, paper, packaging and printing machinery. The set screw offering ranges from 3/4 in. bore size (204 series) to 3-7/16 in. (218 series). The D-Lok style is offered in 3/4 in. bore size (204 series) to 2-7/16 in. bore size (212 series). Baldor Electric
Online Reader Inquiry No. 503
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Timken’s Blue Brute spherical roller bearing housed units come in two- or four-bolt pillow block, flanged or piloted flanged, or take-up models, all made of cast steel. The feet ends are machined to the true bore of the housing to help with proper alignment. Six types of primary seals provide protection from contamination, available in triple-lip self-purging or non-contact labyrinth styles. Steel or urethane covers offer secondary seal protection against dirt, dust and high-pressure washdown. In addition to set screw or eccentric lock collar, locking configurations include a premium double nut V-lock system, which is impossible to over-tighten yet easy to remove from the shaft. Timken Canada
press stress concentration in the cage bar members. The product is claimed to achieve an approximately 30% increase in life over that of the current product, improving the reliability of gearboxes, even in harsh environments. Its sale is being expanded for large gearbox applications such as wind power generators, which require high load capacity. The bearings are used in large industrial machinery, such as wind power generators and mining machinery. NSK Canada
Portable induction heater heats various circular ferritic metal components
Online Reader Inquiry No. 505
The FAG H140 universal design spherical roller bearing from Schaeffler, for the pulp and paper industry, combines the special requirements for such bearings with an O.D. of 320 mm or greater into a single design with multiple applications. This allows the user to lower inventory, control costs and reduce downtime. Features include a circumferential lubrication groove and three lubrication holes in the outer ring, a circumferential lubrication groove and six lubrication holes in the inner ring, aluminum plugs of various sizes for closing off the lubrication holes in order to
Test rig checks operating characteristics of rolling bearings
NKE Austria’s radial-axial test rig RAX380, for medium-sized rolling bearings with an outer diameter of up to 380 mm, can test the running characteristics of bearings under varying test conditions and loads, speeds, lubrication conditions and temperatures. Located at the company’s headquarters in Austria, the rig tests standard bearings as well as custom and application-specific bearings, and yields such data as their operating characteristics, wear and frictional behaviour and noise generation. In addition, the service life under set operating conditions can be tested. Capacities include speed up to
4,500 rpm, radial test load up to 250 kN, axial test load up to 75 kN and oil temperature up to 120°C. Possible test bearings include cylindrical roller bearings, deep groove ball bearings, taper roller bearings, angular contact ball bearings, spherical roller bearings, and more. Global Bear Online Reader Inquiry No. 506
Bearings for beverage industry now come in metric sizes
Emerson has added metric-sized Sealmaster PN Gold bearings to its CRES series of bearings. These bearings are engineered for the food/beverage industry using various materials and sealing systems to extend life and ensure performance in corrosive conditions, while meeting CIP and SIP sanitation requirements. The line includes metric bore sizes for mounted ball bearings (20 mm to 60 mm) and ER cylindrical O.D. ball bearings (20 mm to 60 mm). Designed with brewery chemical and cleaning solutions in mind, they are equipped with multiple-lip seals and specialty coatings, and are available with such features as bolt-on end caps
and backside shields. Solid base housings are machined from 316 stainless steel or high-strength composite with minimal gaps for fillings. Stainless steel bolt ferrules reinforce the bolt holes on composite bases for high load capacity and strength. Emerson Industrial Automation Online Reader Inquiry No. 508
MRO
Online Reader Inquiry No. 130
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November 2013
What’s new in motors and drives Regenerative three-phase digital DC drives expand motor control line
Sprint Electric’s regenerative three-phase digital PLX DC drives are able to regenerate energy back to the mains supply under
braking without the need for expensive and complex intermediate storage, resistive dumping or additional power bridges. Compact, powerful, flexible and easy to program, the drives are available in current ratings between 12 and 2,250 A at supply voltages up to 690 VAC. A fourquadrant DC drive uses two thyristor bridges to enable it to drive the motor and brake in both directions of rotation. This allows it to reverse the torque to slow the load very gently or almost instantaneously, regenerating energy at the same time. Applications include mixers, extruders and rollers that require high starting
Integrated motor/drive system a cost-effective option
Combination motor/drive packages from Siemens allow the option to select the optimum solution for a variety of heavy-duty industrial motion control applications from a single source. Choosing from a pre-determined list of motor/drive combinations, the customer makes the selection best suited to the application. The motor and drive are packaged on a single pallet, shipped and invoiced together. These combinations are power-matched for 480-V high-overload operation through a 20-hp range, with I2T protection from thermal damage provided as standard in both the motor and the drive components. The Intelligent Operator Panel is included with these packages, allowing easy step-by-step drive startup. Communications selections include RS485 with USS and Modbus protocols. Siemens Canada Online Reader Inquiry No. 523
torques and accurate control at low or zero speed, as well as for paper machines, wire drawing and machining. MDA Controls Online Reader Inquiry No. 524
Small drive offers big intelligence
Rexroth has introduced the Advanced performance level for the compac t d r ive ser ies I ndraDrive Cs. Integrated motion logic, according to IEC 61131-3, controls up to nine additional axes via a Sercos master interface. Multi-Ethernet or an additional field bus interface simplify integration into various automation concepts, while the drive-integrated safety functions achieve SIL 3. The series features both a Sercos master interface and increased processing power, making it possible to connect up to nine slave drives, as well as additional external I/O modules. Sercos allows users to use the high-efficiency Economy versions as slave drives on the Advanced device, even in hard real-time environments. The optional drive-integrated motion logic control system IndraMotion MLD allows IndraDrive Cs Advanced as a master to control independent drive packages and thus handle a wide range of drive tasks. Bosch Rexroth Canada Online Reader Inquiry No. 522
Modular motor protection system has something for everyone
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Online Reader Inquiry No. 131
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The DMPU series from Carlo Gavazzi is a modular electronic motor protection relay to control, monitor and protect the performance of three-phase constant or dual-speed AC induction motors. The device measures electrical motor variables (voltage, current, harmonic distortion, power, energy and earth leakage current), monitoring overloads through the thermal model, controlling them and measuring other variables, such as motor and bearing temperature. In addition, it includes a data logger function for storing trends of the electrical variables, alarms and fast data logging for storing start-up profiles. All monitored variables can be transmitted to a supervisory control system for data collection and process control. Features include an integral heat sink with robust metal DIN rail adapters, direct voltage measurement up to 690 VAC, direct current measurements up to 5 A, up to 23 temperature or digital inputs and up to 22 relay outputs. Operating temperature is minus 25°C to plus 5°C. Carlo Gavazzi (Canada) Online Reader Inquiry No. 525 MRO
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Machinery & Equipment MRO
What’s new in test and measurement ▼
Test and measurement series meets demands of industrial environments
Easy-to-use alignment system extends machine tool life
The Easy-Laser E940 from Benchmark PdM is a complete system for measuring and aligning machine tools. The HyperPSD technology of this lightweight and convenient system gives a displayed resolution of 0.0001 mm. The measurement data is transferred from the detector to the display unit wirelessly using Bluetooth, and the software guides the user step-by-step through
Full-featured inspection/ detection device fits in palm
the entire measurement process using clear graphics. It is also possible to use the measurement values directly, and measure and adjust as required. The system measures straightness, flatness, level, squareness, pointing direction of spindles, bearing condition and more. The versatile design makes it possible to measure most types of machines, such as lathes, milling machines, boring machines, presses and water cutting machines. Benchmark PdM Online Reader Inquiry No. 534
Hydraulic tester simulates operating conditions display panel. Instrument operations are supported by software that lets users plan and review routes, review historical record data and baseline sound spectra, generate reports, create alarm groups, produce trend charts and more. In addition to comprehensive condition monitoring and analysis of motors, gears and electric equipment, the system can also serve as an energy conservation tool to find compressed air and steam leaks, as well as help determine carbon footprint emissions and energy waste. UE Systems
Online Reader Inquiry No. 536
Online Reader Inquiry No. 541
Online Reader Inquiry No. 533
The Ultraprobe 15,000 Touch from UE Systems provides plant-inspection professionals the ability to use touch-screen technology to analyze plant equipment conditions. Features of this comprehensive inspection system include spectral analysis, camera, infrared thermometer, laser pointer and a large, easy-to-read
Emerson Process Management has introduced the Rosemount 3308 true wireless Guided Wave Radar (GWR) transmitter for continuous level and interface monitoring. The top-mounted transmitter is designed to meet the need for accurate level monitoring in remote or difficult-to-reach locations, where installing new cabling would be costly or impractical. The technology significantly reduces installation and configuration time. Also, since there is no need for cabling, trenching, conduit runs and cable trays, costs are typically reduced by 30% or more compared with a wired solution. Applications include process level measurement in vessels and storage tanks in refineries, oil fields, offshore platforms, and chemical and industrial plants. Emerson Process Management
The SDMKR reversible flow device developed by Stauff is for the rapid and accu-
rate monitoring of hydraulic components and systems. The design allows the simultaneous measurement of flow, pressure and temperature, allowing maintenance personnel to determine the performance of pumps, motors, valves or cylinders, as well as of complete systems. These portable flow devices are integrated in the hydraulic circuit only for the duration of the system test. They are equipped with BSP connection threads on the input and output, and can be installed in both pressure and return lines. The testers include a flowmeter with a visual display and a built-in thermometer, as well as a loading valve. The loading valve makes it possible to safely increase the working pressure gradually and continuously up to 420 bar (6 ksi or kips/sq. in.) to provide a realistic simulation of normal machine operation. Stauff
sues can be detected instantly, with no training required. Fluke Electronics Canada Online Reader Inquiry No. 532
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FLIR has introduced a new line of test and measurement devices, as well as several lines of thermal cameras. The lines includes the DM93, CM83 and CM78 electrical meters. All feature large, clear LCD displays, bright dual-LED worklights to illuminate dimly lit work areas, Bluetooth connectivity to Android and Apple mobile devices running the FLIR Tools Mobile app, and the ability to connect with METERLiNK-enabled FLIR thermal cameras. The three other products consist of the MR77 moisture meter, the VS70 HD videoscope and the VP50 compact, CAT IVrated NCV detector. The line of FLIR E-Series thermal cameras, which includes the E4, E5, E6 and E8 models, is aimed at professionals who need to track down electrical and mechanical overheating, moisture ingress, missing insulation, air leaks and other issues. FLIR Canada
spection of storm and sewer pipes. It offers better diffusion for viewing near targets, as well as extended life (up to 10,000 hours), instant start-up, variable intensity, good colour balance and reduced power consumption. The option is available for both standard and haloptic versions of the camera. Envirosight
Transmitter extends level monitoring to hard-to-reach locations
Leak detection flashlight easily spots all industrial fluid leaks
Suitable for all industrial fluid system applications, the Spectroline Opti-Lux 365 is a powerful yet compact and lightweight leak detection flashlight that provides UV light for optimal fluorescent dye response. It works with all Oil-Glo oil- and water-based fluorescent dyes and produces a brilliant glow that makes leaks easier to find, while reducing diagnostic time. Instant-on operation enables the device to reach full power immediately, and it provides up to four hours of continuous run-time. The rugged, anod-
Online Reader Inquiry No. 535
Visual IR thermometer’s sharp resolution detects issues instantly
Fluke’s VT04 visual IR thermometer, with a built-in digital camera and a thermal heat map overlay, bridges the gap between traditional IR thermometers and infrared cameras. Building on the Fluke VT02, the VT04 adds PyroBlend Plus with a four-times sharper resolution than the VT02 and advanced automatic alarm features. This frontline troubleshooting tool is designed for electrical, industrial maintenance, HVAC/R and automotive applications. The ultra-compact device is fully automatic, with built-in intelligence, so is-
ized aluminum lamp body reduces corrosion and stands up to years of heavy use. The flashlight comes with a lanyard, belt holster, two rechargeable batteries, smart charging cradle with AC power cord and UV-absorbing spectacles, all packaged in a padded carrying case. Spectroline Online Reader Inquiry No. 537 MRO
3,840 COFFEE BREAKS
WILL BE TAKEN BEFORE A DIAMOND CHAIN THINKS ABOUT ITS FIRST ONE.
Online Reader Inquiry No. 531
LED illumination enhances zoom on pipe inspection camera
Available as an option on new systems or as an upgrade to existing ones, the LED illumination option for Envirosight’s QuickView zoom pipe inspection camera enhances short- to mid-range zoom in-
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Scan the QR code for additional information about the Performance of Diamond Chain Products
©2012 The Diamond Chain Company. AD MRO32012 Calculations based on a Diamond series #80 roller chain. Test results are available at http://www.diamondchain.com/diamond-series.php.
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Online Reader Inquiry No. 132
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November 2013
What’s new…
Double C-face coupler rake reduces inventory and maintenance costs
Force Control Industries has developed a double C-face coupler brake that mounts on the drive end of a standard Cface motor, replacing motor brakes mounted on the back of a special motor designed with a mounting flange and extended shaft on the fan end of the motor. Mounting the brake between the reducer and motor allows a standard C-face motor to be used, simplifying inventory and reducing costs. These oil shear brakes also reduce maintenance costs. The Posistop air-actuated and the MagnaShear electrically actuated coupler brakes never need adjustment, and last longer without needing maintenance. An annual fluid change, without removing the motor, is all that is required. Applications include palletizers, packaging machinery, airline baggage handling systems, concrete block manufacturing, cranes and more. Force Control Industries
in products, systems, components and accessories for machinery and equipment MRO (maintenance, repair and operations).
Planetary gearbox product line is expanded to include five more ratios
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machines, steel rolling mills, test stands, cranes, mixers and oil/gas field equipment Siemens Canada
Online Reader Inquiry No. 527
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Cabinet module drive package complies with North American standards
JIS sizes expand linear bearing line
Thomson has announced that its Super Smart Ball Bushing linear bearings, already available in US inch and European metric models, are available in Japanese Industrial Standard (JIS) sizes. This technology provides up to six times the load capacity or 216 times the travel life of other linear bearings, according to the company. As a result, customers can minimize machine downtime and reduce machine costs through the use of smaller, more reliable and less expensive bearings and 60 Case LinearRace shafts. The bearings feature universal self-aligning bearing plates that are extremely forgiving of misaligned housing bores and shaft deflection, and promote uniform ball loading over the entire length of the bearing plate and optimized distribution of the load between ball tracks. Thomson Industries
Online Reader Inquiry No. 526
combination of slow swivel movements and high forces. The Elgotex WA material comprises two layers that are wound onto each other. The internal sliding layer, which is embedded in a resin matrix with fillers and solid lubricants, is made of continuous synthetic and PTFE fibres. The external layer also comprises continuous glass fibres in epoxy resin. A specific winding angle stabilizes the layers, thereby increasing the strength of the bush. Because the plain bearing is self-lubricating in water, there is no need to use oil or grease, and no seals are required. Schaeffler Technologies Online Reader Inquiry No. 515
Sumitomo has released a white paper, Reducer Shaft Mounting Systems. Direct shaft-mounted speed reducers feature a drive arrangement that saves space, reduces structural costs and increases safety. When the shaft-mounted reducer is a direct-connected right-angle bevel unit, significant gains in operating efficiencies, typically 5% to 10% or more, as well as reduced maintenance expenses, can be achieved. To help users in their product selections, the paper discusses the relative merits of five basic methods of mount-
Online Reader Inquiry No. 511
Plain bearings for marine applications require no seals
INA plain bearings with Elgotex WA for use in marine applications are maintenance-free and have a high loadcarrying capacity. Resistant to sea water, they have been developed for use as rudder and stabilizer bearings and have been optimized for a
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Online Reader Inquiry No. 133
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ing speed reducers directly onto a drive or head shaft. The five methods include keyed, splined, taper grip bushing, shrink disc and rigid coupling. Sumitomo Drive Technologies Online Reader Inquiry No. 519
Thermocouple logger streamlines temperature monitoring applications
Onset has announced the Hobo UX120 thermocouple logger, a four-channel LCD data logger for measuring and recording temperature in a broad range of monitoring applications. This compact and costeffective unit combines a full-featured, deployment-friendly LCD display and flexible support for a variety of plug-in thermocouple probes. It can record tem-
White paper discusses reducer shaft mounting systems
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Siemens has introduced a version of its Sinamics S120 Cabinet Module (CM) drive packages that is compliant with North American standards and offered with optional UL/cUL listing. Built to NEC (NFPA 70) standards, the product enables easy configuration of complex common DC bus lineups for multimotor coordinated drive systems, as well as high horsepower stand-alone drives for a wide variety of industrial applications. Pre-designed, fully type-tested modules, including line side components, line infeeds and motor inverters, all with a broad range of standard options, are selected and configured by the customer, reducing engineering and manufacturing lead times. Individual cabinet modules have a standardized power and control interface, which allows them to be freely positioned in a lineup that best suits the particular application and makes them easy to install and connect. Typical uses include paper
Online Reader Inquiry No. 529
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Groschopp has announced the release of an additional five ratios to its standard PL7300 planetary gearbox product line. The company states that it has nearly doubled its yield torque, creating longer life and use in a wider range of applications. Eighteen standard ratios range from 5:1 to 1000:1, with maximum output torque of 950 in.-lb. and 5,000-plus hours of continuous duty life. Two standard output mounting options are offered, and the product is available in right-angle options. Groschopp
peratures over a range of minus 260°C to plus 1,820°C and can accept up to four J, K, T, E, R, S, B or N type probes. In addition, it features an internal temperature sensor for logging ambient temperatures. Also featured is a large memory capacity capable of storing 1.9 million measurements. Recorded data can be easily viewed in graph form and analyzed using the company’s Hoboware Pro software. The broad range of applications ranges from process heating to concrete curing. Onset Online Reader Inquiry No. 538
Oil industry bearings deliver reliability in all conditions
Scheerer Bearing Corporation’s bearings for the oil industry meet stringent tolerances, ensuring equipment runs at maximum load for peak output. A supplier of bearings in operation in most environments and climates, both land and marine, the company provides rotary table thrust bearings, cylindrical radial roller pump bearings, swivel and crane hook bearings and custom machined bearings. Specifically designed with the needs of the oil industry in mind, rotary table thrust bearings can routinely handle the extremely high thrust loads of modern drilling rigs. Cylindrical roller bearings are available for most oil drilling, air, water or mud pump systems. Scheerer Bearing Online Reader Inquiry No. 509 MRO Obtain free additional information about any of these items by using our online reader reply card at www. mromagazine.com/rsc.
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L I T E R A T U R E
Advertising Feature
BALDOR’S NEW DODGE® TYPE EXL BEARING
MACHINERY AND EQUIPMENT
Baldor’s new Dodge® Type EXL tapered roller bearing offers enhanced features for increased reliability. The bearing provides both misalignment and expansion capability, while maintaining industry standard Type E mounting dimensions. This new design incorporates a cartridgestyle inner unit into a split ductile iron housing. The Dodge Type EXL will increase reliability and decrease downtime by offering better sealing, misalignment capability and load ratings versus the competition. Visit www.baldor.com or call 479.646.4711 for more information.
Free MRO Product
Literature Guide
BALDOR Circle Reply Card No. 270
NEW WEG E-CATALOG
ARC POWER® CATALOG “B217”
This application will allow WEG Electric Motor customers in NEMA markets to search an electronic catalog for motors and produce data sheets and technical drawings. The application will also allow the user to download or email PDF data sheets and drawings. The app is available for iOS, Blackberry, Android. Go to www.pamensky. com/downloads
BRECOflex CO., L.L.C. offers state of-the-art polyurethane timing belts with the patented “ARC” tooth design. ARC POWER® timing belts are available in open ended, welded and truly endless with steel cord tension members and is offered in AT10 and AT15 tooth profile. ARC POWER® is ideal for linear drives, conveying and power transmission applications. Download or order free catalogs online at www.brecoflex.com. Call for our free engineering support! Toll free at 888-463-1400 Phone: 732-460-9500 Email: info@brecoflex.com
VJ PAMENSKY Circle Reply Card No. 271
BRECOFLEX Circle Reply Card No. 272 YOU ROCK, WE ROLL: SCHAEFFLER ROLLING BEARINGS & SERVICES FOR MINING AND PROCESSING The acknowledged bearing specialists to the mining and processing industry, Schaeffler has spent decades developing products designed to optimize the performance of mine operations. Featuring our exclusive X-life™ series of bearings whose service life exceeds the conventional standard by as much as 70%, INA and FAG brand products from Schaeffler are specifically engineered to thrive in some of the harshest operating conditions on (or under) the earth. Rock on!
CHP hard chrome plated pins, with exceptional pin-surface wear resistance, help reduce chain elongation and can increase wear-life up to three times over conventional premium chain - with no reduction in working loads or operating speeds. CHP chain is ideal for applications that cannot be lubricated and operate in dry or abrasive environments - like timber, paper, gypsum and food – and is directly interchangeable with ANSI standard chain. TIMKEN DRIVES Circle Reply Card No. 273
2013 SMALLEY® CATALOGUE NOW AVAILABLE FROM ROTOPRECISION
The best way to increase productivity is to invest in training. If we put equal amounts of extra cash into more equipment, increasing hours worked, or into training – the biggest return is from training.
The 2013 Parts and Engineering Catalogue combines existing WAVE SPRING and RETAINING RING data with newly released product information, including Hoopster® rings, metric wave springs and small series wave springs. The updated content features 130 pages of part tables, engineering guides, design information and expanded part offerings for over 10,000 standard parts available from Smalley. It is an ideal resource for engineers including detailed product information for quick prototypes.
Equip yourself and your team with Knowledge! SKF Circle Reply Card No. 275
A TRADITION OF TRUST
PILLOW BLOCKS ARE TOUGH
When your business depends on productivity, when you need to meet a deadline, when the work is tough and the specs are demanding, you have to be able to trust your tools to help you get the job done. And you have to trust the company that makes those tools. The Snap-on Industrial Brands have earned your trust, each with a long tradition of quality workmanship, superior performance and constant innovation. The bottom line? Productivity.
NSK’s SAFD series pillow blocks are designed to provide robust performance in a wide range of applications and challenging operating conditions. Manufactured from heavy duty ductile iron, they possess a number of engineered advantages including strength to withstand substantial mechanical shock, resistance to corrosion and resilience in extreme temperatures. With standard features to accommodate high and low speeds, grease and oil lubrication, NSK SAFD pillow blocks also offer optional seal arrangements to ensure protection against environmental contamination and optimum bearing service life.
SNAP-ON TOOLS Circle Reply Card No. 277
TIMKEN-DRIVES – EXTENDED LIFE CHP® CHAIN:
SKF RELIABILITY MAINTENANCE INSTITUTE – GET THE 2013 TRAINING CATALOGUE
SKF RMI provides training courses designed to help increase equipment reliability and reduce wastes.
SCHAEFFLER Circle Reply Card No. 274
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ROTOPRECISION INC. Circle Reply Card No. 276 NEW EDITION OF KOYO’S NEEDLE ROLLER BEARING CATALOG NOW AVAILABLE Koyo is pleased to announce the release of a new Needle Roller Bearing Catalog (B2018E). The new catalog features Koyo’s full range of metric and inch size needle roller bearings and provides assistance in selecting the right bearing for the right application. For more information or to order a copy please contact your local authorized Koyo Distributor or Koyo Canada at 1-800-263-5163, www.koyo.ca KOYO Circle Reply Card No. 278
NSK Circle Reply Card No. 279
M R O
P R O D U C T
T E S T
We recently tested the Husqvarna 550xp chainsaw, which represents the company’s next generation of professional saws. It uses its X-torq technology, which reduces emissions by 75%, while lowering fuel consumption up to 20%. These benefits are created by using a two-stroke engine that allows pure air into the cylinder, minimizing unburned fuel from reaching the muffler. An Auto Tune feature fixes the problem of having to tinker with carburetor adjustments to make the chainsaw run flawlessly at different altitudes, temperatures or levels of humidity, while making it fully powerful and allowing it to run the chain at maximum speed. The ergonomics and weight balance of the chainsaw, combined with anti-vibration dampers, give the user a great range of motion and ease of handling. Husqvarna offers a wide range of saws for all pruning and cutting needs. By Eric Achilles Cousineau
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Machinery & Equipment MRO
November 2013
Networking abounds at PTDA Industry Summit BY BILL ROEBUCK
Michael Dolpp, Thomson Industries, Amherst, NY, concurred, stating “The opportunity that the Industry Summit provides by bringing together so many channel partners is unmatched. For someone like me, constantly on the road, seeing so many channel partners at once makes coming to the Industry Summit essential for my success.” The conference featured several speakers, including keynoter Jeffrey Gitomer, whose topic, Principles of Sales Greatness, emphasized that power in a sales relationship flows from proving your value to customers beyond their doubt. Jonathan Bein’s workshop, Marketing Strategy and Tactics for Uncertain Times, focussed on how segment leaders hold their share by implementing analytics to track sales and putting together plans to target their market’s sweet spots.
Photos by Eric Achilles Cousineau
More than 530 power transmission and motion control industry representatives from nearly 230 member companies attended the Power Transmission Distributors Association’s 2013 Industry Summit. Along with an additional 160 spouses, companions and guests, the top executives convened Oct. 3-5, 2013, at the J.W. Marriott Desert Springs in Palm Desert, CA. The conference theme was ‘Working Without a Net?’ “The PTDA Industry Summit offers a support net through its extensive networking opportunities,” said PTDA president Chris Bursack, ISC Companies Inc., Plymouth, MN. “In my own experience, this year’s Industry Summit helped me efficiently resolve vendor issues and most likely gain a new product line – all facilitated by the networks I built through PTDA.” PTDA Manufacturer Council chair 1
In The Market-Driven Sales Force, Steve Deist of Indian River Consulting Group mapped out the new realities for the power transmission and motion control (PT/MC) industry in a world on the verge of revolutionary changes, where technology has empowered customers to have greater control than ever before. As well, Mel Kleiman of Humetrics presented a workshop called Attract the Best, Repel the Rest: How to Create a Magnetic Culture. In it, he urged employers to look at the person’s qualifications for the job, rather than their appearance. In this year’s economic report, Alan Beaulieu of ITR Economics predicted moderate growth through the remainder of 2013, but noted that the second half of 2014 may see an additional, brief downturn. A charity walk organized by PTDA spouses and companions raised $1,900 for the Struthers Parkinson’s Center of
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Golden Valley, MN. Also, PTDA member companies pledged over $55,000 in contributions to the PTDA Foundation, supporting the work of the Industrial Careers Pathway. The Summit’s Manufacturer-Distributor Idea Exchange (MD-IDEX) brought together nearly 120 manufacturers, and the program featured well over 400 meetings through pre-scheduled appointments and open times. The Summit also included a Motion Control Showcase, featuring 15 motion control suppliers presenting their latest hardware. PTDA’s 2014 Industry Summit is scheduled for Oct. 23-25, 2014 at the Hilton Bonnet Creek in Orlando, FL. MRO Visit www.mromagazine.com/gallery to see more of MRO Magazine’s photos from this event.
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1. Pete and Jenn Haberbosch with Andrew Besancon, Fenner Drives. 2. Larry Anderson (president) and Larry Anderson (vice-president), A & A Resources, with Dave Ward and Tom Werking, Ringspann Corp. 3. Jon Lorello and Michael Cook, Nook Industries Inc. 4. Denys Bolanos, Dale Grosset and Rich Hanes, Lafert North America. 5. Chris Stanford, Henkel Corp.; Dennis Michaud, Walter Surface Technologies; David Gordon, Industrial Market Information; and Chester Collier, Walter Surface Technologies. 6. Keynote speaker Jeffrey Gitomer talked about the principles of sales greatness. 7. Rich Peterson, Daniel Dunn, Kevin Koziowski and David Zoesch, Schaeffler Group USA. 8. Frank Mascia and Barb Ross, Timken Drives LLC. 9. Ron Yob, Monarc Industries, won closest to the pin in the PTDA golf tournament. 10. Josh McGill, Barlett Bearing Co.; Steve DuComb, W.C. DuComb Co.; Tom Clawser, Delta Reliability Div.; with Elliot Wilson and Mike Power, Lovejoy Inc. 11. Cindie and Bob Casazza, Dave Humphry, Andrew Evans, Susan and Andy Alley, and Marlaine and Jerry Bartel, Koyo Bearings. 12. Chris Coughlin, Timken Company and Tim Breen, Motion Industries, with Pierre, Mitch and J.P. Bouchard from General Bearing Service.
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Whether you work on top of the world or deep in it‌
Whether your equipment is highly complex or fairly simple, you need your machines to work.
NTN has a solution that puts your mine at ease.
Online Reader Inquiry No. 134
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MRO Ad_June_2012_Mining_Focus_Schaeffler 10/7/2013 11:38 AM Page 1
From Extraction to Finish Processing — We Do It All As the acknowledged bearing specialists to the mining and processing industry, Schaeffler has spent decades developing products designed to optimize the performance of mine operations. From standard bearings to the most highly specialized application solutions, INA and FAG brand products from Schaeffler are specifically engineered to thrive in some of the harshest operating conditions on (or under) the earth. Some highlights of our expansive portfolio: • Large-bore spherical roller bearings for dragline & shovel applications • Special bearing designs for off-highway motorized wheel applications • Split spherical roller bearings for super-fast bearing replacement in hard-to-reach locations • SuperTac II taconite seals with multiple labyrinths to ensure contamination stays out • High-capacity cylindrical roller bearings for vibratory applications • The revolutionary WiProM with FisNet portable condition monitoring device (so advanced, it fits inside our signature yellow carrying case!) Schaeffler also offers its exclusive X-life series of products whose optimized roller geometries and raceway finishes are so precise, their service life far exceeds the conventional standard - as much as 70% in the case of our cylindrical and spherical roller bearings. Rock on. Superior-quality products. Comprehensive reliable solutions. www.schaeffler.ca Online Reader Inquiry No. 135
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