Machinery & Equipment MRO September 2014 by Annex Business Media

MACHINERY AND EQUIPMENT

Looking for trouble with non-destructive testing Balancing act cuts fan vibration Avoid pump problems with these startup tips

Vol. 30, No. 4

Event report: PDTA Canadian Conference

SEPTEMBER 2014

FOCUS ON HARSH ENVIRONMENTS Reducing vibration when chemicals attack Stop corrosion in electrical systems Dusty quarry reduces parts inventory Fastener lubrication solves severeservice woes

Cracking complications in

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ALIGNMENT

PUMPS

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P R O D U C T

SP TLIGHT

Machinery & Equipment MRO

App transfers measurement data from test tools to smart phones

Rugged handheld analyzer identifies scrap/ recycled metal

Oxford Instruments has added the mPulse handheld analyzer to its product line. Designed for the metal recycling market, the

instrument uses Laser Induced Breakdown Spectrometry (LIBS) and combines 1-sec. analysis speed with ease of use and rugged reliability. This scrap metal analyzer has been designed to allow quick, simple and reliable identification of scrap or recycled metal and determine its value, minimizing time and maximizing profits. It can be used to test large or small samples, including turnings and granules. The laser scans the surface of the sample and will bounce repeatedly across tiny samples to optimize the analysis. Samples can be held where convenient because the laser is microscopic, non-penetrating and cannot be felt. This is a surface analyzer so test pieces should be clean, but no specific sample preparation is normally needed. Anodized surfaces will usually be penetrated by the laser. NDT Products Online Reader Inquiry No. 448

Easy Call. Big Payoff.

Bearing assembly improves safety of oil rig maintenance personnel

A bearing that helps increase safety and improve uptime on oil rigs has been introduced by Timken. Designed to eliminate the need to re-grease the travelling block or crown block on oil rigs, the Sheave Pac bearing assembly is sealed for life, helping to increase safety for rig workers and reduce expensive downtime. The pre-greased, pre-set and unitized bearing can run an entire operating cycle between rebuilds without the need for re-lubrication or additional maintenance, and the assembly easily interchanges with current industry-standard bearing assemblies and seals. Timken Canada

Online Reader Inquiry No. 414

The Fluke Connect system allows maintenance technicians to wirelessly transmit measurement data from their test tools to their smart phones for secure storage on the cloud and universal team access from the field. More than 20 Fluke tools connect wirelessly with the app, including digital multimeters, infrared cameras, insulation testers, process meters and specific voltage, current and temperature models. Technicians can record measurements and infrared images to Fluke Cloud storage from wherever they are working, without writing anything down, and everyone on the

team with a smart phone and the app can see the data. Team collaboration is made easy with ShareLive video calls, where technicians can share measurements with other team members in real time, get approvals for repairs or get questions answered without leaving the field. Cloud storage security includes secure access, electronic surveillance, multi-factor access control systems, built-in firewalls, and encrypted data storage. The app can be downloaded for free from the Apple App Store and the Google Play Store. Fluke Electronics Canada

September 2014

Online Reader Inquiry No. 412

Laser vibrometer performs acoustic inspections of noise-critical equipment

The non-contact SKF laser vibrometer (MSL-7000 series) measures vibration and structure-borne noise from fans, electric motors and pumps for every measurement surface, regardless of environmental conditions. This digital, singleunit laser tool cannot wear and does not require servo-mechanisms or noise protection gear during use. It can cover acoustic measurements from 0.2 Hz up to 22 kHz and can integrate easily into a manufacturing line and existing control systems. This integration can create a real-time quality control system for products enabling pass/fail decisions on the basis of structure-borne vibration. The vibrometer further supports flexible re-setting of manufacturing batches and test set-ups. It can be combined in the field with SKF Microlog portable vibration monitoring and data collection instruments. A special package, the MSL-7000C, developed for laptop use with SKF FPM software and a mobile data acquisition card, also is available. SKF Canada Online Reader Inquiry No. 413

Save Energy. Save Money. targeting inefficient motors and mechanical drives as well as identifying systems where adjustable speed drives could be added to save even more energy. This report will provide recommendations for immediate action along with long term strategies… all positively affecting your bottom line.

The Baldor IBE Team uses advanced data collection equipment and software to work with your plant maintenance personnel to take an accurate account of your motors, drives and mechanical power transmission products, both in operation and from spares inventory. The IBE Team will produce a comprehensive report and plan,

If you’re ready to do something about your growing electricity consumption, email the Baldor IBE specialists at IBETeam@Baldor.com or call (864) 281-2100 to receive case studies with realworld savings. It’s an easy call with a big payoff. baldor.com

Baldor Electric has announced a new line of large AC–GPM induction motors, available up to 1,500 hp, is available in stock ratings of 250 hp to 1,000 hp, 2,300/4,000 V, TEFC, foot-mounted designs. Custom motors also are available in 250 hp to 1,500 hp, 460 V, 575 V, 2,300/4,000 V, TEFC, in foot-mounted designs. Features include all cast iron construction, drive end slinger, insulated opposite drive end bearing, winding RTDs, space heaters, provisions for bearing RTDs and a ground lug in the conduit box. This product line fits various industrial applications, including pumps, fan, conveyors and compressors requiring high torque, and is suitable for use on variable frequency drives. Baldor Electric

Motor-driven equipment accounts for 63% of your plant’s electricity consumption every minute of every day. Your choices are to let your electricity bills continue to grow or call in Baldor’s Installed Base Evaluation Team to identify improvements you can start making today.

New energy-efficient electric motor fits wide range of applications

Online Reader Inquiry No. 411

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MRO

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

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C O N T E N T S

Machinery & Equipment MRO

September 2014

in this issue

FOCUS ON CONDITION MONITORING

FOCUS ON ALIGNMENT

Testing for trouble / 12

Soft product, hard conditions / 17

Some equipment problems require the industrial version of a Crime Scene Investigation (CSI) scenario. That’s where non-destructive testing and evaluation (NDT/NDE) is useful, as it can see trouble coming and going. FOCUS ON FASTENERS Using fasteners effectively in harsh environments / 13

Precision-driven maintenance techniques eliminate vibration in a tissue plant’s pulp dryer, increasing production potential. Balancing Act / 18

Unbalance is the most common cause of increased levels of vibrations. In this case study, five fans are balanced using a vibration data collector and analyzer to reduce bearing failures.

departments Editor’s Notebook / 6 Industry Newswatch / 7 Business Briefs / 9 Mr. O, The Practical Problem Solver / 10 Maintenance 101 / 23 MRO on the Road / 30 Product News

Proper lubrication can help improve the performance of threaded connections

FOCUS ON DRIVES

Product Spotlight / 2

Tips for selecting the proper nut / 13

Chain Change / 19

Converting from roller chain to a belt drive at a bottling facility solved multiple problems.

Focus on Severe Service / 24

Vibration in the workplace can eventually loosen an incorrect threaded fastener. Demand for industrial fasteners to reach $14.8 billion / 13

Growth in fastener sales in MRO applications will improve from now to 2017.

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Focus on Pumping / 25 Focus on Alignment / 26 Focus on MRO Components / 27

FOCUS ON PUMPING The importance of electrical inspections for pump maintenance / 20

Comparing offline testing to newly developed online testing technologies and methods. Starting up pumps / 21

Is the way you’re handling pump startups wrong? Fluid sealing for potable water applications / 22

Gasketing that is certified is becoming the material of preference.

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columns Mr. O, the Practical Problem Solver / 10

Reducing contamination during oil changes in a dusty plant. The importance of training / 23

FOCUS ON HARSH ENVIRONMENTS Tracking Assets / 14

Here is how a quarry used a supplier’s Installed Base Evaluation service to improve performance by tracking its mechanical and motor products and spare parts. Preventing corrosion in electrical systems / 16

The worldwide cost of corrosion is estimated at $2.2 trillion, more than 3% of global GDP. Here are three methods to help control it.

Maintenance 101: Structured employee orientation and training processes are a way to give new employees a fair chance to show they are willing and able to work. MRO on the Road / 30

Education opportunities abundant at PTDA’s Canadian Conference in Quebec City.

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‘More than just a suite of techniques to be dusted off during teardowns or following equipment failures, NDT can be used for proactive equipment condition monitoring.’ Larry Cote / 12 ‘How can you put a preventive maintenance or inventory strategy in place when you don’t know what products you have running in your plant?’ Perry Finco / 14

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‘The majority of pump system problems happen when an operator is not present – the so-called ghost failures that occur in the late hours of the night.’ James Jette / 20

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editor’s selections

‘Since a high incidence of seal and bearing failures was a normal occurrence in that plant, we agreed that their traditional startup process should be changed.’ Ross Mackay / 21

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E D I T O R’ S

N O T E B O O K

Machinery & Equipment MRO

September 2014

Mechanics and hydraulics and electrics! Oh my!

few people have commented lately power topics as they relate to the conthat there’s a lot of content about cerns of industrial maintenance probearing products in our issues. fessionals. That’s true, since pretty much any movFor example, in this issue, we have ing or rotating piece of equipment intwo feature articles on electrical cludes them, and without proper mainthemes. Fluid power also gets coverage tenance and lubrication, they can be with three articles plus a Product News the cause of major downtime. Because section on pumping systems. of their importance in every industry Each month, we strive to balance our we cover, we’ll keep writing about bearcontent to meet the needs and interests ings regularly. of a big audience, which includes profesThey are just one component in the sionals with diverse interests from mepower transmission/motion control chanical power transmission to electripuzzle that’s a major area of our focus. cal power to fluid power to maintenance management to machinery and equipAlthough we have a strong bent to discussing things mechanical, we also ment operations. MRO_Mag_Full-Page_Movie-Ad_April_2013.pdf 1 4/4/13 4:08 PM offer content on electrical and fluid You might be interested to know

that this audience includes about 18,000 who receive personally addressed copies of the print magazine and another 36,000 or so of what we call ‘pass-along’ readers (those who read somebody else’s copy). Plus we have about 4,000 who receive our digital editions for viewing on computers or tablets, and around 12,000 that receive our weekly e-newsletter – MRO News. And then there are the 30,000-odd unique visitors we see each month on our website. That’s a potential audience of over 100,000 – although there’s likely some duplicate readers in that number. Keeping you all happy isn’t easy. Often, we are not able to fit everything we want in each issue due to the space constraints of our print format, so we’ll balance the topics by adding feature articles on specific themes to our website. Over the long term, we have something for everybody, so it balances out. Some of you may wonder how we’re

able to offer all this content to you for free (for those who are in our target audience in Canada). Well, we are a thriving business, and we’re able to do all this because of the support of our many advertisers. Importantly, we also ensure their messages about products and services are on-target for your needs. By the way, every time you read about a solution from one of these advertisers and follow up with them, we’d sure appreciate it if you let them know you got in touch because you read about them in MRO Magazine or our newsletters or website. That kind of feedback will go a long way to ensuring we can continue to provide more useful content in the future to keep you informed, knowledgeable and up-to-date. Thanks for doing that. MRO Bill Roebuck, Editor & Associate Publisher

MACHINERY AND EQUIPMENT

MAINTENANCE, REPAIR AND OPERATIONS

SEPTEMBER 2014 Volume 30, No. 4 Established 1985 www.mromagazine.com www.twitter.com/mromagazine EDITORIAL Bill Roebuck, Editor & Associate Publisher 416-510-6749 broebuck@mromagazine.com Hwee Kuan Choo, 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 Jay Armstrong, Sales Manager 416-510-6803 jarmstrong@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. ©2014. 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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We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund of the Department of Canadian Heritage.

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I N D U S T R Y

Machinery & Equipment MRO

ECONOMIC GROWTH IN ALBERTA EXPECTED TO LEAD CANADA

ditures with resource revenue helps to keep provincial tax rates low. But a large decline in royalties, such as what occurred in 2008-09, would make achieving and maintaining a balanced budget much harder.” Economic growth in Alberta is expected to be the strongest in the country in 2014 and 2015. Real GDP will rise by 3.5% in 2014 and by 3.1% in 2015. Strong economic growth will continue to fuel gains in employment and income, further increasing the government’s tax base. As a consequence, Alberta is one of the few provinces set to have balanced books in 2014-15, along with BC and Saskatchewan. In addition, Alberta is the only province with a net surplus of financial assets. This implies that interest payments on debt will be negligible over the forecast period – a feat that no other province will accomplish. While the Conference Board is projecting annual surpluses for three years starting in 2014-15, there are risks to the outlook: the potential constraints on economic growth if pipeline development stalls and the ability to limit growth in health care spending.

PTDA MEMBERS SAW GROWTH IN NEW ORDERS IN SECOND QUARTER Chicago, IL – The PTDA Business Index for the second quarter of the year (2Q2014) indicates strong growth in both business activity and new orders. From 1Q2014 to 2Q2014, business activity of distributor and manufacturer members of the Power Transmission Distributors

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Association increased 12.7% (from 67.7 to 76.3) and new orders improved 14.5% (from 67.7 to 77.5). This quarterly survey continues to point to growth, with the 2Q2014 Business Index at 68.7, up from the 1Q2014 reading of 63.6. However, when asked about their outlook for the entire year, survey participants’ expectations remained the same as the previous quarter at 6% growth. The index reading indicates the rate of change compared with the previous period. For example, a reading of 50 indicates no change from the prior period, while readings above 50 indicate growth and below 50 indicate contraction. The further the index is above or below 50 suggests a faster or slower rate of change. To purchase the full report, call 312516-2100 or visit ptda.org.

FOR HIGHEST SALARY INCREASES IN CANADA, LOOK TO THE OILPATCH Calgary – For the biggest pay hikes in Canada, look no further than the oilpatch. A new survey by Mercer, a global consulting firm, says the energy sector is leading the country in both actual and projected salary increases. The average base salary increase across the country is expected to be 3% next year, the same as in 2014. But in the energy sector, the pay bump is forecast to be 3.7% in 2015 after an actual 3.9% increase this year. When the energy sector is removed from the national sample, the average projected salary increase drops to 2.9%. On the other end of the spectrum, transportation, equipment, consumer goods and retail/wholesale industries are expected to see the smallest salary increases. The Canadian Press

CO-OP DIPLOMA APPRENTICESHIP PROGRAM TO PROVIDE NEW MECHANICAL TECHNICIANS Oakville, ON – Sheridan College is offering a three-year Co-op Diploma Apprenticeship program in Mechanical Technician-Tool Making to make it easier, cheaper and faster for individuals to pursue in-school and on-the-job training in a sector that is poised to grow, according to a 2014 Outlook Report by KPMG. The seamless program enables individuals to train as apprentices, completing all in-school learning outcomes and significant on-the-job training, while concurrently obtaining a post-secondary diploma. “Students complete a year-long, paid work experience in which they develop in-depth tool-making skills while accumulating up to 2,000 hours toward their apprenticeship,” said Alan Reid, associate dean of Sheridan’s Skills Training Centre in Oakville, where the program is based. “[Since] an employer consortium sponsors all participants, the program is available even to students who lack a

PTDA OPENS REGISTRATION FOR INDUSTRY SUMMIT IN ORLANDO

Photo: Monkey Business Images/Thinkstock

Photo: Katarzyna Bialasiewicz/Thinkstock

Ottawa – After six years in the red, Alberta is expected to balance its books in 2014-15, according to The Conference Board of Canada’s Alberta Fiscal Snapshot: Promising (But Potentially Risky) Prospects. “Overall, Alberta is in a very sound position and our forecast for Alberta is even more optimistic than the government’s own budget projections, thanks to an expectation of higher resource revenues,” said Matthew Stewart, associate director, Canadian Outlook. “Perhaps the greatest risk to Alberta’s future is its high reliance on royalty revenues to fund program spending. Funding so much of its operating expen-

employers in the West GTA that collectively offers about 40 placements. “Without tool making, there is no manufacturing,” noted Reid. “Every time you change the shape of any product that is mass produced, a new tool is required. This is the talent we’re cultivating at Sheridan. We’re building the foundational expertise that companies need to manufacture their products or make production happen, whether they operate in the pharmaceutical, automotive, electrical components, medical, food or aerospace industry. “Our biggest challenge at Sheridan is that we have five times the job offers as we do graduates to fill them.” For more information about the Mechanical Technician-Tool Making program, call 905-845-9430 ext. 8059, or visit the website at https://sheridancollege.ca/academics/programs-and-courses/ mechanical-technician-tool-making.aspx.

The Sheridan College program is available even to students who lack a sponsor, eliminating one of the biggest obstacles to apprenticeship training.

sponsor, eliminating one of the biggest obstacles to apprenticeship training,” said Reid. “Given that students complete three semesters of study prior to beginning their on-the-job training, the co-op diploma program also addresses employers’ growing demands for individuals with a stronger knowledge base at the start of their placement,” he added. Sheridan’s employer consortium group consists of 18

Chicago, IL – The Power Transmission Distributors Association (PTDA) will hold its Industry Summit Oct. 22-25, 2014, at the Hilton Orlando Bonnet Creek in Orlando, FL. Registration is now open. More than 550 delegates, representing 240 PTDA distributor and manufacturer companies, are expected to attend the event, which has the theme ‘Imagine’. The Summit opens with keynote speaker Mike Ditka, a former football player and coach, who will share the lessons he learned in a life of commitment and attention to the fundamentals, resulting in victory. Workshops will cover the latest information on B2B topics, including customer service, e-commerce, global expansion, leadership, maximizing technology budgets and social media. The closing keynote speaker, economist Alan Beaulieu, will return to the Summit with his latest economic forecast. For more information, visit ptda.org/ IndustrySummit.

BELTING GROUP AND PTDA TO HOLD JOINT MEETING IN 2017 Chicago, IL – The boards of directors of NIBA-The Belting Association and the Power Transmission Distributors Association (PTDA) are planning to hold a joint annual conference. The NIBA/ PTDA Joint Industry Summit is to take place in the fall of 2017. The leaderships of both associations have dedicated much effort in designing a program that will continue to provide the exceptional experience already

enjoyed at each organization’s current annual meeting, as well as bring enhanced benefits that are only possible through a joint conference. With the NIBA/PTDA Joint Industry Summit, members of both associations can expect enriched networking opportunities, enhanced educational content, and minimized conflicts and reduced multiple meeting attendance costs for shared members. PTDA president Ken Miko, director of category management and strategic accounts for BDI, Cleveland, OH, believes the NIBA/PTDA Joint Industry Summit will bring membership innovative new ideas. “We set out to create an event that is truly a joint event – that is, maximizing the opportunities for members of both associations to meet and discuss their businesses,” said Miko. NIBA president Tom Wujek, executive vice-president and chief operating officer of Flexco, Downers Grove, IL, agrees. “We took the best practices from each organization’s annual meeting and crafted a conference that elevates networking and education to a whole new level,” he said. For more information, call PTDA at 312-516-2100 or visit ptda.org, or call NIBA at 414-389-8606, visit niba.org or e-mail jennifer@niba.org.

BEARING FIRM PARTICIPATES IN US COUNTERFEITING RAID Mt. Prospect, IL – NTN has announced the results of a joint raid that it participated in with the US Naval Criminal Investigative Service (NCIS). The raid was conducted on a bearing storage location near Charleston, SC, on June 25, 2014, after NCIS agents concluded that the warehouse was illegally distributing lowquality, counterfeited bearings directly to end users. The search resulted in the seizure of hundreds of fake NTN products, as well as counterfeited merchandise of several other major Japanand US-based manufacturers. The investigation was coordinated by NCIS and included engineers from major bearing corporations that volunteered to aid in the identification of the counterfeit parts. NTN application engineers supported US Naval agents in detecting suspect products and packaging with fake NTN company logos. All of the suspicious products were confiscated and catalogued to assist in future prosecution and investigation of illegal bearing counterfeiting. For more information about stopping counterfeit bearing sales, visit the World Bearing Association’s website at stopfakebearings.com.

Photo: NTN

September 2014

High resource revenues will put Alberta in the black.

N E W S W A T C H

PEMAC’S REVIVED GTA CHAPTER TOURS WASTEWATER PLANT Toronto – The Plant Engineering and Maintenance Association of Canada (PEMAC) revived its GTA Chapter on Aug. 15, 2014, with a meeting and a tour of the GE Booth Wastewater Treatment Facility (also known as Lakeview) in Mississauga, ON, said chapter president Nigel D’Souza. For more information on the chapter, visit pemac.org or contact Melanie Mangion by e-mail at admin@pemac.org. continued on page 8

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I N D U S T R Y

N E W S W A T C H

Machinery & Equipment MRO

September 2014

APPRENTICESHIP TRAINING INCREASING ACROSS CANADA Ottawa – Apprenticeship training programs across Canada received 104,280 new registrations and reinstatements in 2012, up 6.8% from 2011, according to the latest survey of registered apprenticeship training programs from Statistics Canada. This marked the highest number of new registrations and reinstatements (individuals who were reinstated in 2012 after a year or more of absence) since the beginning of the economic downturn in 2008. Total registrations in apprenticeship training programs across Canada increased 4.3% from 2011 to 444,672 in 2012. New registrations in the Red Seal trades were up 6.8%, but the number remained below 2008 levels. New registrations in non-Red Seal trades

were up 11.5% from 2011. In 2012, 56,913 certificates were awarded to both apprentices and trade qualifiers/challengers, up 2.7% from 2011. Of the total certificates awarded,

much lower than the increases registered over the previous two years. In 2012, certificates awarded to trade qualifiers/challengers increased for the first time since 2008, up 8.2% from the previous year to 15,429. Less than half (19,701) of the apprentice certificates awarded were Red Seal certificates. For the first time since 2008, the number of apprentice certificates with Red Seal endorsements (-2.6%) declined while the number of certificates for trade qualifiers/challengers with Red Seal endorsement (+5.2%) increased. Among the top 10 Red Seal Total registrations in apprenticeship training trades, the construction elecprograms across Canada increased 4.3% in 2012 trician trade recorded the over the previous year. largest number of new regis41,481 were granted to apprentices trations, up 10.9% from 2011 to 9,714 in who completed their training, up 0.8% 2012, and surpassed the carpenter trade, which was down 13.2% to 7,881. from 2011. This annual growth was Photo: Thinkstock

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Online Reader Inquiry No. 119

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VIDEO DEMO

The number of new registrations in the construction electrician trade has increased every year since the end of the economic downturn. The steamfitter/ pipefitter trade (+45.7%) posted the largest annual increase in new registrations in 2012, followed by the welder trade (+41.7%), where the number of new registrations exceed those recorded in 2008. The proportion of females registered in trades has been constantly increasing over the years. In 2012, females accounted for 14.2% of all registrations. The highest number of new registrations for females was in the user support technicians major trade group (4,095), where for the first time, new registrations exceeded those in the hairstylists and estheticians group.

ELECTRICAL INDUSTRY COUNTERFEITING SURVEY REVEALS PARTS REPORTING ISSUE Arlington, VA – The Electrical Safety Foundation International (ESFI) has released the complete results of its 2014 Counterfeit Electrical Products Survey, which was developed to measure the awareness and response to the presence of counterfeit electrical products among several sectors of the electrical industry. The results reveal critical information about the observations, attitudes and perceptions of those who manufacture, distribute, install and inspect electrical products. Over the past decade, US seizures of counterfeit products have increased more than 325%. Consumer electronics were the top commodity seized in 2011, with a value of nearly $40 million. Counterfeit electrical products pose significant safety hazards if left undetected, and have been known to cause deaths, injuries and substantial property loss in the home and the workplace. “Counterfeit electrical products don’t just have serious implications for the electrical industry, but they also endanger everyone who uses electricity,” said ESFI president Brett Brenner. “We developed this survey to better understand this complex problem so we could mobilize the electrical industry to work toward a solution.” An overwhelming 96% of respondents believe that counterfeits are at least a moderate threat to public safety, yet only half reported a counterfeit electrical product upon discovery. Further, a strong majority of respondents reported that they do not have a process in place to report a counterfeit product. Other key findings included: • Almost 55% of respondents believe their company does not provide adequate training about the issues related to counterfeit products. • Those who have discovered a counterfeit electrical product reported finding five, on average, in the past 12 months. • Lighting, breakers and ‘other’ items such as appliances, signs and ground rods were the most frequently reported counterfeit products discovered. “Effectively combating the counterfeit electrical product problem will require a collaborative effort among stakeholders from all industry sectors as well as cooperation from consumers.” said Evan Gaddis, president and CEO of the National Electrical Manufacturers Association. The complete results can be viewed at esfi.org. MRO Are you contacting companies you read about in MRO Magazine? Please let them know you learned about them here.

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I N D U S T R Y

N E W S W A T C H

September 2014

Machinery & Equipment MRO

Business Briefs

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

Photo: NSK Americas

• NSK Americas, Ann Arbor, MI, has released its 2013 sustainability achievements, demonstrating the company’s ongoing commitment to environmental

Children of NSK employees designed a T-shirt to commemorate NSK’s environmental initiatives.

protection. The year’s accomplishments show that NSK saved 39,200 trees, equivalent to 485,688,000 sheets of newspaper; 3,891,400 litres of oil, enough to heat 6,456 homes for a year; 58,880,000 litres of water, enough to meet the daily needs of 207,413 residents in the US; 201,762 litres of gasoline, enough to drive a mid-size car 2,401,785 km; and 52,938,000 kWh of electricity, enough to power 6,456 homes

for a year. “NSK’s commitment to corporate social responsibility and our corporate environmental policy initiatives are producing meaningful results,” said Brian Lindsay, CEO. “The ongoing addition of new initiatives to complement our sustainability program continues to improve those results year over year. Ultimately, that benefits the global environment and the health of the local communities in which we operate.” Marcia Fournier, environmental and chemical manager, and the NSK’s frontline green ambassador, said the company has a master agreement with Safety-Kleen, which not only ensures responsible waste management and disposal, but enables NSK to track any issue that may arise, and quickly mitigate environmental risk. “In 2012, Safety-Kleen worked with us to help us better manage our mop water at our Bennington, VT, site, and now we are recycling that water in-house. The result is cleaner floors, which protect our customers’ products, and less waste, which reduces both environmental impact and cost,” Fournier added. NSK continues to advance its bearing production processes by reducing scrap waste, increasing energy efficiency and reducing the use of harmful chemicals. Steel and metal recycling is in place in all seven US sites, and a

number of sites began recycling cardboard and plastic in the past 12 months. NSK Canada is part of this program for its three facilities in Canada and its initiatives are included in the NSK Americas report. For more information, visit nskamericas.com. • Algood Caster Innovations, Brampton, ON, is marking its 45th anniversary this year with some big changes. On July 7, it moved into a 60,000 sq ft facility in Brampton, investing $1 million in the new location. The result is better integration of its in-house manufacturing operations. In all, over 2,000 rack spaces have been created; over 70 T5 light fixtures have been installed; and thousands of feet of wiring have been laid in this facility, which will allow Algood to double its manufacturing output. “This is an indication of our incredible commitment to North American caster manufacturing and meeting the needs of our customers,” said Algood president Craig Guttmann. Earlier this year, the company changed its name from Algood Casters Limited to Algood Caster Innovations. • Belterra Corporation of Delta, BC, Canada’s largest conveyor solutions company, has opened its first Quebec location. The new facility, located in Montreal, is responsible for the sales and marketing of the distributor’s primary product brands, which include Yokohama and Duraline conveyor belting, Bulk Pro Systems and Martin Engineered Products. Belterra also has branches in British Columbia, Alberta, Saskatchewan, Manitoba and Ontario. For more information, visit belterra.ca. • Motion Industries, Birmingham,

AL, a distributor of industrial maintenance, repair and operations (MRO) replacement parts, has launched a new knowledge website at mivendingsolutions.com. Through video, vending unit descriptions, applications and success stories, the new site offers visitors the opportunity to learn more about how MiVending can be a big money and time saver for any facility that uses industrial supplies. • Machinery & Equipment MRO magazine has received an award nomination in a prestigious competition for business and trade magazine journalism for a feature article published last year. The Kenneth R. Wilson Awards are presented annually by the Canadian Business Press and Magazines Canada. MRO Magazine’s senior contributing editor, Carroll McCormick, received the nomination in the Best Industrial/Manufacturing Article category for his feature story, ‘Climbing the Safety Ladder’. It appeared in the June 2013 issue. You can ready the story here: http://bit.ly/1ooSklu. Also, in July, we were awarded our seventh APEX Award for Publication Excellence in an international publishing competition. • Evan Boere has been appointed operations manager for Timken Canada LP, Mississauga, ON. He was previously the company’s business development manager. In his new role, he will have responsibility for corporate-level customer service functions, supply chain and warehousing. “This restructure is an opportunity for Timken Canada to be pro-active in supporting its business plan objectives,” said Frank Mascia, continued on page 10

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Machinery & Equipment MRO

September 2014

the Canadian subsidiary of global pump manufacturer KSB Group, is celebrating its 25th anniversary in Canada this year. To mark this milestone, the Mississaugabased pump specialist joined the ‘One Million Trees Mississauga’ initiative (onemilliontrees.ca) by planting 150 trees in Canada’s sixth-largest municipality. • Acklands-Grainger, Richmond Hill, ON, a distributor of industrial, safety and fastener products, plans to acquire WFS Enterprises Inc., a distributor of tools and supplies to industrial markets in southern Ontario and the US. WFS offers more than 100,000 products with a focus on safety, metalworking, plumbing, and hand and power tools. It employs about 275 people and has 12 locations, including 10 branches in southwest Ontario, and two locations in the US, in Michigan and South Carolina. The transaction is expected to close in the third quarter of 2014. • Standard Machine, Saksatoon, SK, part of the Timken Power Systems group, recently opened the first known dedicated high-speed gear test bay in Canada to further expand its expertise in gearbox services. The division also now offers Philadelphia Gear brand high-speed gearbox repair capabilities and Timken bearing remanufacturing services. “We recognize the importance of local access to repair services for complex equipment, particularly for end users in the energy sector, where the costs of down-

time are significant,” said Frank Mascia, managing director for the Timken’s business in Canada. “Customers count on us to help keep their mission-critical equipment running, and the expansion of our capabilities in Saskatoon fits with our commitment to deliver the value that demanding customers expect.” Bearing repair is another service addition at Standard Machine. The Saskatoon facility is now equipped to provide a full range of bearing services from reclaim to reconditioning and remanufacture. Bearings can often be returned to like-new specifications in as little as one-third of the time it takes to purchase a new bearing. • Des-Case Corporation, Goodlettsville, TN, a manufacturer of contamination control products that improve equipment reliability, has purchased the visual oil analysis product line of Houston, TX-based Esco, an oil sight glass and level monitor manufacturer, Copaltite distributor, and Dow Corning product distributor. Products acquired include Esco’s 3-D BullsEye Viewport, as well as its oil sight glasses, indicators, and oil level monitors. Esco will remain a distributor of Des-Case products and oil sight glasses and will continue to sell Dow Corning products. • Steve O’Brien is now the president and sole owner of Advantage Sales Network Corp. (ASN), Brampton, ON, a manufacturers’ sales agency. Ownership was previously shared with former president Dave Cummings, who has left the company. • Sheridan College and ABB Canada have announced a partnership that has led to the creation of a new Robotics Centre in the Centre for Advanced Manufacturing

ABB Canada helped create a new Robotics Centre at Sheridan College.

Mr.0 The Practical Problem Solver

Reducing contamination during oil changes in a dusty plant

Problem: In a dusty plant, what is the best thing to do with a gearbox plug while changing the oil? Solution: There is no good way to handle plugs, even in the cleanest of industrial environments. Plugs not only allow contaminants to enter through the opening, but also tend to attract dirt when removed. An additional consideration is that the threads themselves will have a tendency to produce metallic debris during both removal and installation from the shearing contact at the mating surfaces. I strongly recommend that these units be fitted with quick-connect couplings. This will protect the lubricant from becoming contaminated from the environment while it is being introduced, and will allow for the use of a filter cart more conveniently, either for periodic offline filtration or for new oil introduction. Mr. O’s thanks go to Adam Davis and Noria Corporation for this tip. Do you have a solution for a maintenance problem? Send it in and if it’s published, we’ll send you a Mr. O Problem Solver T-shirt. Include your name, company, address, and telephone number or e-mail address. Provide complete details and, if possible, include a sketch to help explain your tip. Send your tips to Mr. O, c/o broebuck@mromagazine.com, or by post to: Machinery & Equipment MRO, 80 Valleybrook Drive, Toronto, ON M3B 2S9.

and Design Technologies (CAMDT), located at Sheridan’s Davis Campus in Brampton, ON. The new ABB Robotics Centre will allow both students and industry partners to gain training in applications that include robotic welding, picking, packing and palletizing, machine tending, material handling and product assembly, and advanced vision-related programming. • Metso has agreed to a five-year lifecycle services contract with The Kami Mine Limited Partnership, an affiliate of Alderon, with respect to the development of its Kami iron ore project located in the Western Labrador region of Canada. The contract encompasses the ongoing maintenance services with respect to all the equipment in the processing area. Within this agreement, Metso will also be providing spare and wear parts. The mine’s estimated start-up is autumn 2016.

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• Baldor Electric Company, Fort Smith, AR, has promoted Greg Hewitt to mounted bearing engineering manager. Photo: Baldor

KSB’s birthday cake

Photo: Bill roebuck

managing director for the company’s business in Canada. “As our front-end continues to strengthen, there is the need for our internal/back-end support to perform at the same level. We will ultimately work closer with our CoLinx facilities to better support our sales performance and continuous plans for yearover-year growth. • KSB Pumps Inc., Mississauga, ON,

Photo: ABB Canada

continued from page 9

Greg Hewitt.

Galen Burdeshaw.

In this role, he will be responsible for all mounted bearing product-related engineering. Also promoted was Galen Burdeshaw to power transmission components engineering manager. In this role, he will be responsible for all Dodgeand Maska-branded power transmission product-related engineering. • Automatic greasing systems specialist FLO Components Ltd., Mississauga, ON, has announced the schedule for its 2014-2015 Lube Basics Seminars. Scheduled cities in Ontario will include Kitchener, Mississauga, Sudbury and Thunder Bay. Details can be found on the website at flocomponents.com. • The Timken Company’s board of directors has elected Ajita G. Rajendra as a director of the company for a term that expires at its May 2015 annual meeting. The election brings The Timken Company board to 10 directors. Rajendra serves as the chairman, president and chief executive officer of A. O. Smith Corp., a $2.2-billion global water technology company based in Milwaukee. Timken is based in North Canton, OH. • The Power Transmission Distributors Association (PTDA) has released its 2014 Membership Directory. It lists PTDA member companies that distribute and manufacture industrial products, including motors, bearings, gears, belts, drives, lubricants and dozens of others vital to keeping machinery moving. To purchase the directory or the contact database, order online at the PTDA Store at ptda.org/Directory or call 312516-2100. MRO Visit mromagazine.com for the latest news and longer, more detailed versions of the items here.

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Machinery & Equipment MRO

September 2014 Photo: Carroll McCormick

Testing for Trouble

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data from your equipment you can acquire manually or automatically.” Easing into NDT: NDT is a specialist occupation, but there is a place for non-experts, especially for condition monitoring. Installing a pressure gauge can be straightforward and inexpensive. Bi-metallic surface temperature thermometers can be had for under $30. Non-contact thermometers and vibration pens also are inexpensive. The task can be as straightforward as knowing what the normal operating values are and taking corrective action when they veer out of the normal operating range. “I envision sending people out into the plants and collecting straightforward readings,” Cote says. HowTop: Magnetic particle testing is a fast, generally inexpensive and very portable method for detecting fine, ever, he adds, “You shallow surface cracks in ferromagnetic materials. Left: Condition monitoring can be as simple as collecting have to interpret the data manually, or as elaborate as wiring an entire production line to automatically collect condition data. information from these Right: X-rays are a well-known way to spot hidden flaws. technologies knowledgeably. Taking straightforward readings are one thing, knowDetecting the dreaded commine shaft hoist brake assembly failure. ing what to do about them is something pressed air supply leak: It traced the failure to a quality issue else. That’s where an expert might have Some companies set themselves the goal with the spring steel from which the to be called in.” of eliminating air supply leaks – the cause brakes were made. Steel Image recomIntegrating NDT into inof unnecessary and costly compressor mended that all the springs from that service inspections: NDT/ cycling. Using airborne ultrasound – think material lot be replaced. NDE and CM techniques are well known headset, parabolic dish and some elecIn the case of the failure of a part for helping to satisfy regulatory requiretronic hardware – a technician can pick when there are other parts like it in use ments and mitigating risk in industries out the sound of escaping air against the or waiting in a spares bin, NDE can help that have severe safety or environmental racket of other plant machinery. a maintenance department make the consequences. They are useful for peri“It is fairly directional,” Cote explains. right decision – for example, whether or odic inspections of non-regulated equipThis lets the technician zero in on the not to make a warranty claim. ment too. “Look at your equipment and source of the offending sound. “With airNDT/NDE/CM and root cause ask yourself whether there are there borne ultrasonic kits, it is phenomenal failure analysis (RCFA): As enough of a type to justify an NDT or CM what you can detect,” Cote says. The well as being dandy reads, case studies program. If you have a large population same gear can be used to find other leaks offer insights into when you might want of [one kind of equipment], there is a way too, such as in fluid and steam systems. to bring in an NDT/NDE or CM specialto look at it with a comprehensive mainFailure assessment and opist. As a very rough rule of thumb, contenance management system that inerating error: Imagine an sider bringing in a specialist to help cludes the right amount of NDT/NDE equipment failure, such as a conveyor with a RCFA when, aside from the sheer and CM, and reduce the risk of failure. chain. Is it an operating problem or mystery of the failure, there are potenAnything to do with equipment life dodgy manufacturing? Flamborough, tial safety, environmental or expensive extension – increasing uptime while reON-based Steel Image, which does metdowntime issues. ducing maintenance costs – should drive allurgical analyses, presents a case “Companies will often call people in you to think of ways to monitor and test study on a failed chain link, the 15th because they don’t want a big failure to materials and equipment,” Cote says. such failure since the chain’s installahappen again. Some failures cannot jusNDT is not for amateur hour: tion. Steel Image determined that abtify the investment of time and money Although collecting trending normally high loading, not a material to do RCFA, but others easily result in data and doing basic inspections are flaw, was causing the failures. This is a hundreds of thousands or millions of within the reach of maintenance and nice example of how NDE after a failure dollars in costs,” Cote says. operations departments, the serious can diagnose a problem and provide However, he warns – and the Steel application of NDT/NDE and CM has guidance on preventing a recurrence. In Image case studies speak loudly to the become more and more of a specialist this case, the solution was to replace the complexity of the task – “It requires a occupation. compromised chain and reduce the really discerning individual. It requires “Many third-party personnel certifichain loading to within design levels. Crime Scene Investigation – the induscation programs for NDT and CM techFailure assessment and trial version.” MRO niques got started to help ensure consismaterial quality issues: On tent and competent application of techthe other hand, a failure may be due to a Montreal-based Carroll McCormick is niques and technology,” Cote says. “A spesubstandard batch of parts. Steel Image MRO Magazine’s award-winning senior cialist can help you assess your needs.” presents another case study about a contributing editor.

Photo: Carroll McCormick

Tip 3}

Photo: Fundy Gypsum

wo questions about manufacturing equipment frequently come to mind: “Are there any flaws in the materials or equipment that could cause them to fail?” and “What caused the defect or equipment failure?” Non-destructive testing (NDT) addresses the first question. As the name says, NDT causes no damage. It reveals material conditions and flaws, such as cracks, changes in material strength and other issues related to material quality, life-cycle use or changes in the operating environment. NDT includes visual examinations, non-contact surface measurements, subsurface inspections and ongoing condition monitoring (CM) that can reveal growing problems. As for the second question, non-destructive evaluation (NDE), a term often – if not entirely correctly – used interchangeably with NDT, can be thought of as more cause-oriented. NDE is used to study flaws and changes in equipment condition or material properties, among other things, with the goal of understanding of what caused a failure and how to prevent its recurrence. Here are some tips on what NDT/NDE and CM have to offer. Understand the possibilities: “If you are living in the land of ‘you don’t know what you don’t know’, the first thing you should do is acquaint yourself with the [NDT] techniques,” says Larry Cote, president & CEO, Canadian Institute for NDE. The five main categories of NDT are magnetic particle, liquid penetrant, ultrasonics, eddy current and radiography. However, Cote notes, “Other types of NDT and CM techniques include visual inspection, and other special technologies such as digital and computed radiography, phased array and time of flight diffraction UT (ultrasound technology), air-borne ultrasound, lubricant and vibration analysis and IRT (infrared thermography), to name just a few.” Choosing what to monitor: More than just a suite of techniques to be dusted off during teardowns or following equipment failures, NDT can be used for proactive equipment condition monitoring. “At Dofasco,” Cote recalls, “we had a methodology worked out where we would use subject matter experts to review manufacturing areas that could benefit from judicious application of NDT and CM.” In your own plant, he suggests, “Think of using a broad-based survey technique such as IRT or air-borne ultrasound. Start in one spot and ask yourself, what can you see or hear? What must you know to be sure equipment is operating reliably? “Try and understand what the normal operating condition of your equipment is. Then consider which [monitoring]

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September 2014

Machinery & Equipment MRO

Using fasteners effectively in

harsh environments

Proper bolt torque Proper bolt torque is required for accurate threaded-connection tension and elongation. In calculating the required torque specifications for torque tightening, a friction factor (k) is based on the fastener geometry and friction coefficients of the load-bearing surfaces (threads and bolt head). In assembly, the torque energy must first overcome friction and then create elongation to provide the clamping force. Effective lubrication can control the friction and k-factor to ensure proper tension and elongation for the specified tightening torque. Without lubrication, too much torque is used to overcome friction, which results in insufficient elongation (or clamping force). Lubricants are not created equal Greases, pastes and anti-friction coatings are different by design. In greases, the base oil provides the lubricating film. Once the base oil is gone, lubrication is gone. In pastes, the base oil is simply a carrier and surface-wetting agent for solid lubricants. Similarly, AFCs use a solvent carrier

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and a resin binder to carry and adhere solid lubricants to the friction surfaces. With pastes and coatings, effective lubrication stays in place long after the carrier fluids are gone. Anti-seize pastes: Anti-seize pastes create and maintain a strong lubricating film that withstands extreme loads and temperatures. Both metallic and nonmetallic lubricating solids are used with a mineral oil or PAO carrier fluid. These pastes provide wear protection, consistent coefficient of friction, water washout resistance and corrosion protection. Anti-friction coatings: Anti-friction

coatings are paint-like materials that cure to form a lubricating film that is unaffected by dust, dirt and moisture. Typical lubricating solids are molybdenum disulfide, graphite or PTFE. These AFCs provide dry lubrication bonded on material surfaces, resistance to extreme heat and cold, protection against rust and corrosion, and long-term lubrication for difficult-to-access parts. Regarding application, Dow Corning’s Molykote anti-seize pastes do not require surface preparation, so they are especially

useful for application on the jobsite, while its anti-friction coatings must be applied to clean, dry surfaces, so they are normally pre-applied to parts by a coating service. MRO This advice first appeared in Dow Corning’s Smart Lubrication Technology News.

Selecting the proper nut

hat do all the different nuts do, and which type or types do you need to purchase? Let’s take a glimpse at the world of nuts. The essential purpose of any nut is to mate with a bolt to discourage the bolt from loosening its grip against a surface. When you thread a nut on to a bolt until it sits tight against the opposite side of the surface from the bolt head, you create a kind of stress on the threads called preload, which holds both parts in position. What is preload? It is the tension created in a fastener when it is first tightened. The preload must be greater than the external forces applied to the assembly to prevent joint failure. Nuts come in a wide range of sizes and shapes, though the trusty six-sided hex nut is probably the most wellknown. Some nuts have shapes that

bolt, even if that bolt is secured by a nut. How can you forestall this problem if your structure will face constant vibration during its working life? Well, you can always place a second nut innermost to the surface. This nut receives about 50% of the torque of the outermost nut, which receives full torque. Another solution involves the use of a locking nut. Locking nuts have internal or external teeth that bite into the surface for extra grip. Finally, there are several kinds of thread-locking adhesives available that keep bolts and nuts together. They can convert any threaded fastener to a locking fastener. Manufacturers of such products include Henkel Loctite and Devcon Permatex. MRO ©iStockphoto/Thinkstock

Photo: Carroll McCormick

hreaded connections are the nuts and bolts for achieving strong equipment assemblies that can beat the stress of long-term service in harsh operating environments. However, microscopic differences in threads and metals can cause uneven coefficients of friction that make assembly with the proper tightening torque difficult and disassembly without damage nearly impossible. Proper lubrication can help improve the performance of threaded connections, allowing proper tensioning during assembly and helping to prevent stickslip, stress-corrosion cracking, fretting, galling and seizing. Anti-seize pastes and anti-friction coatings (AFCs), with high levels of solid lubricants, help ensure a consistent coefficient of friction and withstand harsh conditions such as scorching heat, freezing cold, crushing loads, vibration, blowing sand or salt spray, and airborne contaminants. Key functions of effective lubrication for threaded connections include: • Providing a consistent coefficient of friction to 1) help achieve proper connector preload forces and torque specifications; 2) limit effects of temperature and load variations, reducing fatigue failure rates. • Forming a barrier between substrates and air to prevent scale formation • P roviding protective layers between mating surfaces to a) minimize oxide layer depletion to reduce fretting, galling, seizing and shearing; b) reduce stress-corrosion cracking, and hydrogen and solder embrittlement.

©iStockphoto/Thinkstock

Proper lubrication can help improve the performance of threaded connections.

allow for protruding bolt heads, such as the acorn nut with its hollow cap-shaped head. Wing nuts have wing-shaped handles for easy tightening by hand. Sometimes the shape of the bolt determines the shape of a nut. If you’re using a square bolt, for instance, you’d want a square nut. Vibration can eventually loosen a

These tips are adapted from an online posting by Mountz Torque.

Demand for industrial fasteners to reach $14.8 billion in 2017

emand for industrial fasteners in the United States is expected to increase 4.3% per year to $14.8 billion in 2017. Gains will be supported by rebounding levels of motor vehicle manufacturing, a segment that makes up roughly one-quarter of all fastener demand. The fastest growth in fastener sales will be found in the construction market, as construction activity – both residential and non-residential – makes a strong recovery from the declines posted during the 2007-2012 period. These and other trends are presented in Industrial Fasteners, a recent study from The Freedonia Group, a Clevelandbased industry market research firm. The original equipment manufac-

turing (OEM) market for industrial fasteners will outpace growth in the maintenance, repair and operations (MRO) market, as US manufacturing output continues to recover from the 2007-2009 recession. Machinery and aerospace equipment shipments are forecast to expand at improved rates. US fabricated metal product output will rise, and the ongoing trend of ‘reshoring’ in a range of industries will support increases in fastener demand. Growth in fastener sales in MRO applications will improve from the performance registered during the 2007 to 2012 period, as fixed investment rises and fastener-containing equipment sees

more use with expanding production. Competition from alternative joining technologies, such as adhesives, clinching and welding, will prevent further gains in a number of applications. Moreover, fasteners are a mature product; while opportunities for value-added technological improvements certainly exist, they tend to be limited in many markets. Externally threaded standard fasteners will remain the largest single product category, posting the fastest gains, along with application-specific products. MRO Industrial Fasteners is available for US$5,100 from The Freedonia Group Inc. at www.freedoniagroup.com.

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Machinery & Equipment MRO

September 2014

Tracking

Assets

Here is how a quarry used an Installed Base

Evaluation service to improve performance

by tracking its mechanical and motor products.

1 Baldor’s Installed Base Evaluation team surveyed products at Premier Silica’s Brady operation quarry. The team provided an accurate count of electrical and power transmission equipment and captured detailed nameplate information, as well as the application and location. All equipment was properly locked and tagged out during the survey. 2 Bills of material and other relevant historical product records had been lost at the plant. Without knowing what products were installed at the facility, plant officials could not put a preventive maintenance or inventory strategy in place. 3 By getting the detailed information on all of the bearings running in the plant, the maintenance team was able to begin a preventive maintenance program using the correct grease and the correct lubrication schedule. 4 The survey of inventoried parts in the warehouse supplied critical information for plant management to determine its inventory strategy moving forward.

hen Perry Finco began work as the maintenance manager at Premier Silica’s Brady operation in the spring of 2012, he set a goal of bringing the 35-year-old facility up to 90% efficiency. However, because he and his team had to deal with constant unplanned downtime, they didn’t have the time to get organized. Their task was made even more difficult because they had no idea what products were installed at the quarry, which included two wet plants, three dry plants, two bagging facilities and two load-out facilities. Over the years, the Brady operation – located in Texas – had been purchased and sold many times, and bills of material and other relevant historical product records had been lost by the time Premier Silica acquired the operation in April 2012. “How can you put a preventive maintenance or inventory strategy in place when you don’t know what products you have running in your plant?” says Finco. “We didn’t even know what products were stocked in our warehouse. Not having this information meant we were operating by the seat of our pants, chasing down parts trying to keep the plant running.” While Finco knew where he wanted to end up, he understood that without knowing what products he had running in the plant and sitting on the shelf, he had no way to get there. But Finco did have experience with plant surveys at

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previous facilities, and when he found an Installed Base Evaluation (IBE) service offered by Baldor, he was very interested. What the motor manufacturer offered Finco was a team to survey the electrical and mechanical products installed and inventoried at the Brady operation, capturing detailed nameplate information, application information and location details in the facility. This was all the information Finco was missing. “Because of the fact that we are in such a remote area and a somewhat small project, I was worried about finding a firm to come in and conduct a survey,” explains Finco. “But Baldor was willing to come in and take on the job, and the IBE team fit our needs perfectly.” After the on-site survey was finished, the IBE team went to work analyzing the data and preparing a report. When the results of the IBE were presented, Finco immediately saw product standardiza-

tion opportunities, a critical step in his strategy to manage inventory better. “After we had reviewed all the details with our local Dodge field sales engineer, Chris Teague, we made the decision to standardize on Baldor’s Dodge TorqueArm II gearing,” says Finco. “By choosing to use the same size gearbox on multiple pieces of equipment, we can reduce the number of gearboxes we keep in stock in our warehouse. We also believe converting to the new Dodge product will help improve our plant uptime.” With the survey data uploaded to the Brady operation’s CMMS system, the maintenance team has created its own database, which Finco says is now the framework for a preventive maintenance strategy for both mechanical and motor products across the entire Premier Silica operation. “We’re using some of the information from the IBE report to write the scope for our new preventive maintenance program,” says Finco. “Now that we know what we have, we are outlining what’s needed for each product, setting up lubrication schedules, as well as other preventive procedures. And because we are now better organized, with all the correct parts on hand, we are prepared to support planned maintenance shutdowns.” Wrong grease caused constant bearing failures The effort has already had a tremendous impact on preventing the constant bearing failures that had been shutting down production. Finco says by knowing

exactly what kind of bearings were running in the plant, the team was able to upgrade products where necessary and also research the best way to maintain the bearings kept in service. “What we found out is that we were using the wrong grease,” says Finco. “By conducting the right preventive maintenance with the correct grease and the correct lubrication schedule, bearings are no longer causing shutdowns as they had in the past. And because we know what kind of bearings we have, we are also carrying the right quantity of bearings in the warehouse.” With strategic plans in place and work well underway, Finco is happy to report that plant performance has improved tremendously since the time the IBE was conducted. He says his team has changed from being reactive to proactive and is getting closer to the plant’s 90% efficiency goal. While there is still work to be done, Finco doesn’t hesitate to recognize that the Baldor IBE was the right tool to help his team move forward. “This tool helped us refocus our energies to work on all the strategies that will bring this plant back to the reliability levels we know are possible,” says Finco. “The IBE was just the beginning of our journey. Now we have to stay committed and follow through. However, we could not have begun this work without this survey to get us started.” MRO This article first appeared in Baldor’s Solutions Magazine, No. 10, and is republished here with permission.

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WINNER

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E N V I R O N M E N T S September 2014

Preventing

corrosion in electrical systems The worldwide cost of corrosion is estimated at $2.2 trillion, more than 3% of global GDP. Here are three methods to help control it. Above: There is a wide variety of corrosive elements that can damage electrical equipment. Right: Appleton’s Powertite Series of plugs, connectors and receptacles are made of triple coated, copper-free aluminum to withstand harsh weather, corrosive atmospheres and rough working conditions.

hen specifying electrical products for harsh environments, choosing the right materials to ensure adequate corrosion resistance is crucial. In offshore oil and gas operations, equipment is under constant exposure to seawater and salt spray, which are highly corrosive due to the autocatalytic action of sodium chloride and other dissolved chlorides. Corrosive substances such as hydrogen sulphide and carbon dioxide also occur naturally in oil and gas fields. Other corrosives that affect a wide range of industries include chlorine, bromine, hydrochloric acid and ammonia. Corrosion can take many forms, and

the correct selection of materials and finishes is the key to preventing each type. Common corrosion control methods include the following. Selecting materials according to their galvanic properties. Different metals and alloys have different electrode potentials. When two different metals are electrically connected in the presence of an electrolyte, such as seawater, the more active metal will become anodic – losing electrons and increasing its oxidation state in a process known as galvanic corrosion. The Galvanic Series ranks metals from noble to active, based on the strength of ion bonding at the surface. A relatively more noble metal, such as

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stainless steel, will resist corrosion better than a more active metal, such as cast iron. Galvanic corrosion can be minimized by selecting metals close together in the Galvanic Series. Alternatively, a more active metal can be used as a sacrificial anode that attracts corrosion in order to protect the more noble metal from attack. Using protective coatings. Various finishes can be applied to help isolate metallic surfaces from the surrounding corrosive environment. The most familiar example is ordinary paint applied to steel to prevent rust, but there are

©iStockphoto/Thinkstock

Machinery & Equipment MRO

many other methods, including baked enamel, epoxy powder coat and PVC coating. For effective protection, coatings must be applied properly and protected against damage during installation and use. The zinc surface on galvanized steel serves both as a protective coating and, if damaged, a sacrificial anode that will corrode in preference to the exposed steel. Taking advantage of passivation. Certain metals form a layer of metal oxide on the surface, a few molecules thick, in a process known as passivation. This occurs naturally, but the process can also be enhanced through chemical passivation treatments or anodization. Unlike ordinary rust, the passivated layer is tightly bound to the surface, preventing any further penetration of oxygen or corrosive chemicals. The most familiar examples are aluminum and stainless steel, which form passivated layers of aluminum oxide and chrominum oxide, respectively. If the surface is damaged, the passivated layer normally re-forms quickly. However, adverse conditions can defeat the process. For example, pitting corrosion can occur in aluminum exposed to seawater when chloride ions interfere with passivation. Welded stainless steel can corrode when the carbon content is sufficiently high to form chromium carbides, depleting the chromium available for passivation in the weld zone and enabling a galvanic reaction between areas with differing chromium content. When properly selected for the intended application, however, passivated materials can provide excellent protection, even in highly corrosive environments. Choosing non-metallic components. Manufacturers are increasingly offering non-metallic products that are completely impervious to the environments and substances that can corrode metals. Non-metallic materials may be attacked by specific chemicals, however, depending on the composition of the plastics used. The vast majority of applications will never be exposed to these substances. Prolonged exposure to UV radiation can also degrade plastics, and users in high-UV locations should account for this in their materials specifications. Not all industries have the same corrosion problems, but all industries do need to take the possibility of corrosion seriously and choose the right materials and products for their particular operations and environment. NACE International-The Corrosion Society estimates the worldwide annual cost of corrosion at US$2.2 trillion, more than 3% of global GDP. Any money that can be saved by preventing corrosion – including the cost of downtime, labour and new equipment to replace failed parts – directly improves profitability. MRO This article was prepared by the Appleton Group, a manufacturer of electrical products for virtually every type of environment. It is a division of Emerson Industrial Automation and is headquartered in Rosemont, IL.

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Machinery & Equipment MRO

Soft product,

hard conditions Precision-driven maintenance

techniques eliminate vibration in a tissue plant’s pulp dryer, increasing production potential. BY JOHN LAMBERT

Above: The heads were rotated after each measurement was taken and then the results were read on the display of the Easy Laser E710. Right: To align the flange faces, the shaft had to be removed.

n my business of providing alignment services, I get to see and work in a lot of harsh environments. In the past, I have written about doing this work in cement plants, which I think are some of the toughest because not only does the cement dust plug up the machines, it’s so abrasive that it wears them out quickly. Recently, I calibrated a laser system that had been used for a long time in a coke plant at a steel mill and I was reminded of just how harsh and very dirty these facilities are. Another example is a plant that makes a nice soft product – but the environment is anything but – it’s a tissue mill. Can you imagine how much nice, soft tissue is used in North America per day? Per hour? Tons! It’s a large industry. In one of the tissue plants I am working in currently, you could see some of the tissue or pulp floating in the air. It would get into every corner of the plant – including the machines. The motors would draw it in, adding a layer of insulation they did not need. Unseen components of this harsh environment are the chemicals used in the process. They attack the motors by adding a coating that degrades them – and all the machines over time. The main machine in the plant we are working on now is called a Yankee Dryer. Imagine a large drum as big as a living room that is heated by steam and is spinning. The wet pulp is sprayed onto the drum as it rotates and the steam heat dries the pulp and creates the tissue. The operators can control the density (the thickness) of the tissue by adjusting

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the speed of the dryer. This dryer had a higher than normal vibration at different speeds, so Steve Cameron of Advanced Balancing had made the call that the drive shafts needed to be aligned. My company went in to support the alignment work. This Yankee Dryer was driven by two separate motors that drive a single gearbox, which in turn drives the dryer. The connecting drive shafts are universal jointed shafts (also known as Cardan shafts). The shafts are designed to compensate for offset misalignment. With offset, the shaft will run in an angled position (it will be slanted), but the shaft will compensate for the offset (up and down or left to right). However, the two connecting flange faces, one on the motor and the other on the gearbox, have to be parallel with each other in both the vertical and horizontal plane. Yes, they can be offset with each other, but if there is any angle involved, they will move in the axial plane and vibrate if running at speed. In essence, the shaft is opening and closing along its length as it rotates. These shafts have a splined slip assembly to compensate for this movement. It works at very low rpm (even so, it will still wear out), but at higher speeds it will vibrate and eventually damage the motor, shaft and gearbox. The solution is easy: align the flange faces. Most good laser systems provide Cardan (universal joint) shaft alignment programs. In this case, we used an Easy

Laser E710 with specially ground, flat, anodized aluminum mounting brackets. These brackets were attached to the flange faces because that’s what we were aligning – not the outer edge. This meant that we had to remove the shaft, which was worth doing if we wanted to get it right. The dimensions and distances were input into the system. The heads were rotated after each measurement was taken and then we read the results live on the device’s display. We made the vertical correction by shimming the moveable machine (in this case, the motor) at either the front or back feet. Then we adjusted horizontally at the front or back feet while watching the movement results live on the device’s screen. We only had to adjust the machines at one foot pairing because we were only correcting angular misalignment – not offset. The next day, after the shutdown was over and the Yankee Dryer had been restarted, there were some happy faces in the plant. Why? Because we had removed the high vibration level. This vibration had been restricting the speed of the dryer, so now that it was gone, the big bonus was that production could now speed up the process. This meant it has increased capacity and production output. In other words, the plant has more opportunity for more throughput, if it wants. This is a win-win scenario. The maintenance department increased the

reliability of a machine unit and production added potential capacity. One note of caution is to be observed when aligning universal jointed shafts. They are not designed to be perfectly in line. In fact, if they are aligned, they will damage the bearings in the joint. This is because they need a certain amount of misalignment to draw the lubricant through the bearing – the same way a gear coupling does. This happens more so in shafts that have needle rollers as opposed to the ball bearings used in many industrial applications — but don’t worry, as a small amount of offset will look after this. (If you have the need to have a shaft inline, you should be using a jack shaft.) There is also another winner – us. By doing the work correctly and working to the correct tolerances, we have achieved very good results that should prove to management that precision driven maintenance techniques should always be used. MRO John Lambert is the principal of Benchmark Maintenance Services Inc., Pickering, ON. He can be reached at 905-5096522, by e-mail at info@benchmarkpdm. com, or visit www.benchmarkpdm.com. Online Reader Inquiry No. 462

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September 2014

Balancing Act

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Unbalance is the most common cause of increased levels of vibrations. In this example, five fans were balanced using a vibration data collector and analyzer. BY FLORIAN BUDER

or several years the vibration behaviour of the fans in a major industrial facility had been neglected. No predictive maintenance (PdM) program was in place, but eventually a new reliability engineer decided to reduce the vibrations of this equipment by getting the fans analyzed. After performing several diagnostic tasks, the sources of vibration could easily be detected. Accumulation of dust and dirt on all rotor blades lead to a 1X vibration peak in the velocity spectrum. The sine waveform and phase analysis confirmed the results. A static unbalance was the reason for the increased vibration. The balancing procedure was successfully performed on-site during the next shutdown phase of the plant. Pruftechnik’s VIBXpert II and Omnitrend devices were used for the balancing runs. The static unbalance requires only a one-plane balancing procedure, which was ideal for these fans.

The accelerometers were attached to the non-drive end (NDE) and drive end (DE) bearing in horizontal direction. VIBXpert offers a ‘second plane control feature’, where the second accelerometer controls any negative influence on the NDE bearing during the trim runs. This ensures that the vibration on both bearings will be equally reduced and balanced. The target quality grade of 6.3 according DIN ISO 1940 was easily reached. The plant went back online a few days later and the customer was extremely satisfied with the result of the service. “In the past six years, I have never seen those fans run so smoothly,” the plant’s operator said. MRO Florian Buder is the managing director of Prüftechnik Canada in Montreal.

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LIGHTWEIGHT CONVEYOR BELTING FROM

Figure 1. The VibXpert II instrument sits on a chair while its accelerometers are mounted on the fan’s bearings. Figure 2. A Prüftechnik engineer checks the readings on one of the fans. Figure 3. Results after the balancing procedure are displayed using Omnitrend vibration software. Figure 4. The display on the instrument shows the balancing status visually. Figure 5. Results are shown as the equipment is operating. Figure 6. A happy face symbol on the display confirms a good balance.

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A MEGADYNE GROUP CO. 9135 COTE DE LIESSE EDMONTON, ALBERTA DORVAL, QUEBEC H9P 2N9 780.461.4400 514.631.6781 l FAX: 514.631.7408 Online Reader Inquiry No. 125

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Online Reader Inquiry No. 126

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F O C U S September 2014

bottling facility was troubled by glass bottles breaking at the end of a series of conveyor lines driven by #60 roller chain, which fed bottles into a labelling unit. Differing rates of chain wear, stretch and elongation on the multi-stage drives caused variations in speed so that one end of the conveying line would begin running faster than the other. As a result, bottles were slammed against each other, breaking them and halting production. When this happened, the entire operation had to be shut down to retension the chain drives, which took two hours of maintenance time and stopped all production downstream. The broken bottles had to be cleaned up and dumpsters full of them were sent to a recycling facility. Additionally, each shift was spending two hours of preventive maintenance time in an attempt to keep the roller chain drives running properly. Regardless, the roller chain had to be entirely replaced every three months. The facility’s managers solved the problem by converting to synchronous belts. After investigation, they chose Gates Poly Chain GT Carbon belt drive systems. The high power rating of these carbon fibre-reinforced synchronous belts allowed width-for-width replacement with the roller chain drives. Because a synchronous belt doesn’t stretch over time as does roller chain, the conveying speed remained consistent across all the lines, preventing the bottles from piling up and breaking. As a result, throughput increased by

O N

D R I V E S

Chain Change Converting from roller chain to a belt drive at a bottling facility solved multiple problems.

Synchronous belts avoided the problem of chain stretch that had resulted in conveyor line problems.

20%. Fewer bottles breaking reduced the need for and cost of recycling. Synchronous belts don’t need lubrication, which eliminated the two hours per

shift of preventive maintenance time, freeing maintenance personnel to handle other tasks and eliminating the risk of contamination from the lubricant.

Machinery & Equipment MRO

Also, without metal-to-metal contact, the synchronous belts are less subject to wear. Life expectancy for the synchronous belts is two years, compared with three months for the roller chain. The annual cost savings resulting from this chain-to-belt conversion was calculated at $330,000 per year, not including the recovery of lost production time and reduced recycling costs. Payback on this one conversion was less than one year. In sum, the benefits of switching from a chain drive to a belt drive can include the following: • W hen considering investment costs, belts last three times longer than chain, and the sprockets 10 times longer. Total cost of ownership for a belt drive is significantly less than a chain drive. • No stretch, no lubrication and no metal-to-metal part wear result in a lowmaintenance drive. Hours spent lubricating and retensioning can be refocused on more critical tasks. • Production is lost every time the drive is shut down. Less maintenance means less downtime. • The stronger-than-steel carbon fibre tensile cord construction of the belt gives the drive high horsepower-carrying capacity and compactness. • The belt drive is impervious to washdown, resisting moisture, chemicals, and abrasion. MRO This article was prepared by Gates Corp. For additional information, send an email to ptpasupport@gates.com.

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Online Reader Inquiry No. 128 TSU-SL-007 IndustryAd CI 4.5WX7.5H[291013]v1.indd 1

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September 2014

The importance of electrical

inspections for pump maintenance

Comparing offline testing to newly developed online testing technologies and methods.

tween coils, the insulation of the windings becomes carbonized, basically turning the material into a semiconductor. A semiconductor acts like an insulator until a barrier potential voltage is reached. Then it shorts and behaves like a conductor. In the case of carbonized winding insulation, a multimeter cannot detect the ground fault because the test voltage of the meter (9-10 V DC) is too low to reach the barrier potential of the carbonized insulation. In the past we used a hi-pot (high potential) test to find ground shorts: a high voltage potential (2,000 V) is placed across the windings and leakage through the insulation is measured to determine the condition of the insulation. Unfortunately, these testers can cause damage to the windings over time. If there is moisture or dirt present on the winding, then the hi-pot may cause an arc to flash, instantly ruining the windings. Hi-pot tests are used at the factory to determine the dielectric breakdown

Photos: KSB Pumps Inc.

BY JAMES JETTE

Above: Hi-pot testing is being done on a submersible pump stator. Left: KSB’s SES multi-channel test equipment is capable of monitoring complete pumping systems. Right: A maintenance technician performs a Megger test.

hy should electrical inspections be an integral part of your pump maintenance routine? The answer is simple: performing electrical inspections on pumps and their systems helps to locate faults before they become failures. This allows the maintenance technician to plan ahead by ordering parts or replacement pumps and by scheduling system maintenance well in advance, so that you can avoid costly downtime and emergency repairs. Moreover, electrical inspections can tell you much about the overall condition of the pumping system. This is especially true for submersible pumps in which the motor and the pump are packaged as a single unit. Most of these pumps are equipped with internal sensors for winding temperature, bearing temperature and the presence of moisture. Over the past five years, vibration sensors have become standard equipment in larger pumps. The information these sensors provide can make the difference between

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a simple rebuild or a more expensive stator rewind and rotor replacement. In short, regular electrical inspections can help reduce each pump’s total cost of ownership and make significant contributions to system reliability and uptime. Offline testing During a motor inspection there are several tests that are performed on the stator windings. Using a multimeter, we can test the resistance of the coils and compare them to each other. For single-phase motors, the resistance readings can be compared to an ohms chart provided by the manufacturer. In three-phase motors, the resistance (ohms) on each phase should be within 2%. Shorts to ground can only be found with a multimeter if there is a direct short. Other conditions, like moisture, dirt or carbonization, may not be detectable. When there is electrical arcing between the windings and ground, or be-

voltage of new windings. A hi-pot test is also required for explosion-proof certification. Today, we use a ‘Megger’ (a registered trademark of the Megger Corporation) to test for shorts to ground. Megger tests work by sending a low amperage (0.001 A) pulse of DC voltage between the coil leads and the stator ground at two times the motor’s operating voltage (250-1,000 V). The Megger displays the results in megaohms. The readings from the Megger can determine whether there is a direct short to ground or an insulation fault in the windings – such as from moisture or dirt. In the case of moisture or dirt, the stator can be washed, dried and re-dipped in varnish, saving the owner an expensive rewind. For coil-to-coil and turn-to-turn shorts, multimeters and Meggers can only detect a major short. For minor shorts, you need a coil and winding tester. When there is a small turn-to-turn fault, there will typically be only a tiny change to the DC resistance. With larger motors

this change can be too small to detect with an ordinary multimeter. To find the short we must look at the difference between the AC resistance (inductance) and the DC resistance. While the DC resistance may change only slightly due to a minor short, the AC resistance will vary greatly with frequency. By comparing the three windings while testing over a range of frequencies, minor shorts can be easily detected. There are two types of coil and winding testers. Both types input a low-voltage AC signal and read the output. A surge tester, the most common style of coil tester, has a screen that displays the waveform as the tester steps through the frequencies. Other types calculate the differential internally and display the results on a screen. Online testing The most exciting new development in the world of pump electrical maintenance is the development of online testing. This new breed of instruments can be attached to a pumping system to monitor the pump and motor while they are running. Using online testing, we can analyze the temperature, vibration, flow, pressure, power and electrical waveforms. On the motor side, we can detect problems with the incoming power and bearings, as well as stator shorts and dirty or wet windings. On the pump side, we can measure the intake pressure, discharge pressure, fluid temperature, flow rate, bearing condition and vibration. Another feature of online testing is the ability to collect measurements over a period of time. We call this data logging. The majority of pump system problems happen when an operator is not present, the so-called ‘ghost’ failures that occur in the late hours of the night. Data logging can monitor multiple channels of information for long periods of time to capture these events as they happen. Examining data logger records collected over extended periods can also reveal trends that point to a gradual deterioration of pump or motor conditions before they become critical. With a data logger, we can also see the operating parameters of the pump system and evaluate the exact duty point and duty cycles of the system. By comparing this information with the manufacturer’s pump curves, we can determine with high accuracy where the pump is operating on the curve, measure the system curve and also determine where the motor is running on the power curve. This information allows you to see the effects of pump wear, pipe restrictions and suction issues. You can also accurately calculate the pump system efficiency, which allows the engineer to offer solutions that can improve efficiency, reduce wear and decrease downtime. A great example of this is the KSB SES system, an advanced data collection tool capable of monitoring complete pumping systems. By using electrical inspections during pump maintenance, you can diagnose pump system issues, offer pump owners accurate data on their pump system and find failures before they happen. The result? Better pump performance, better system availability and lower total cost of ownership. MRO James Jette, an industrial millwright for service sales – rotating equipment, is with KSB Pumps Inc., Mississauga. ON. For more information, visit www.ksbcanada.com.

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Is the way you’re doing pump startups wrong?

BY ROSS MACKAY

uring a recent in-house training program with a company in Trinidad, our discussions were directed to the problems of starting up a pump, and I was reminded of an experience I had with a plant engineer in an old chemical process facility some years ago in Europe. For reasons that will become obvious, I will not identify the plant or even a more specific location. We were walking through his facility to inspect one of his ‘bad actors’ (a pump that was giving him frequent and regular difficulties). As we passed another pumping unit, he paused briefly and pressed the green button to start up the driving motor, and immediately resumed walking. Knowing that automated controls were unlikely to be connected to this particular installation, I stopped and asked him if he was going to open a valve or two. His response stunned me. He said, “Oh, we’ll just let it run for a little while to let it warm up, then we’ll put it online.” It turned out his “little while” could be anything up to five or even 10 minutes. When I asked if this was a regular practice, he assured me that it was standard with all pump startups, and had been practiced for all the years he had been employed in that facility (over 10 years). We then reviewed some of the major problems of running a pump in the shutoff condition – challenges such as high temperature build-up and excessive radial loading, both of which result in reduced pump reliability. Since a high incidence of seal and bearing failures was a normal occurrence in that plant, we then agreed that their traditional startup process should be changed. In general terms, there are only three things we need to do to start a pump. First, we prime the pump. To do this with a flooded suction, the suction valves are opened and the liquid is allowed to flow into the pump. It may also be necessary to open an air-release valve at the highest point in the pump casing to ensure that all the air/vapour is bled from the pump as it fills with the pumpage. When operating on a suction lift, the same effects must be achieved manually, while, if a self-priming pump is used, this step is unnecessary. The next step is to start the pump and open the discharge valve. Which comes first, the pump or the valve? This decision is based on two factors; the pressure in the system and the driver horsepower. With most process pumps, the driver is usually sized to accommodate the run-out condition, which allows the pump to be started against an open valve. However, if the pressure in the system beyond the discharge valve needs to be maintained at an operating pressure, then the pump needs to be started

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©iStockphoto/Thinkstock

September 2014

STARTING UP PUMPS

P U M P I N G

against a closed valve, with the valve being slowly opened as the pump comes up to speed. The major exception to this is with pumps with a high specific speed impeller, such as the axial flow design found in vertical propeller pumps. With

Running a pump in the shutoff condition can lead to high temperature build-up and excessive radial loading, both of which result in reduced pump reliability.

this type of impeller, the highest power draw is at the shutoff condition and the driving motor horsepower does not usually cover the demand at that point. In view of this, the pump must be started up with an open discharge valve, thus allowing the pressure resistance in the

system to build gradually up to the required operating head. MRO Ross Mackay of Ross Mackay Associates Ltd., Aurora, ON, runs a Pump School. Details can be found on the website at practicalpumping.com.

Online Reader Inquiry No. 129

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G A S K E T S

Machinery & Equipment MRO

Fluid sealing for potable

water applications

Certified gasket materials are preferred for many drinking water and sanitary service applications as more certification-compliant products become available. BY BILL SEARLE

pecial considerations need to be applied with equipment used for drinking water applications. These applications are influenced by the NSF/ANSI Standard 61: Drinking Water System Components – Health Effects, which was first published in 1988 to establish minimum requirements for the control of potential adverse human health effects from products that contact drinking water (potable water).

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NSF/ANSI 61 includes criteria for testing and evaluating products to ensure they do not leach contaminants into water, thus creating a health concern or hazard. Developed by a team of scientists, industry experts and key industry stakeholders, NSF/ANSI 61 sets health effects criteria for many drinking water system components, including sealing materials such as rubber sheet. Increasingly, in North America,

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September 2014

Continuous Service: 500°F (260°C) Maximum Service: 752°F (400°C)

Source: Teadit North America

Continuous Service: 1160 psi (80 bar) Maximum Service: 1595 psi (110 bar) Blue F712120E12M5

Teadit NA1002SAN Sheet Physical Properties.

products are required to comply with NSF/ANSI 61 by most governmental agencies that regulate drinking water supplies. As a result, NSF/ANSI 61-certified gasket materials are the preferred materials for drinking water and sanitary service applications.

NSF/ANSI 61 is quite comprehensive. The standard establishes minimum criteria for impurities and contaminants that may be released indirectly into drinking water from products, components and materials, including the following: • Protective barrier materials (cements, paints, coatings) • Joining and sealing materials (gaskets, adhesives, lubricants) • Mechanical devices (water meters, valves, filters) • Pipes and related products (pipe, hose, fittings) • Plumbing devices (faucets, drinking fountains) • Process media (filter media, ion exchange resins) • Non-metallic potable water materials. While the fluid sealing industry is affected by the requirements of NSF/ANSI 61, the industry has been somewhat slow to react to the standard. However, this is now changing, with wider adoption of the standard serving to drive an increased availability of gaskets and sealing materials that are NSF/ANSI 61 compliant. NSF/ANSI 61 requires that only gaskets and seals approved by NSF certification can be used in facilities and in applications where the standard has been adopted as a requirement. Certification of gaskets and seals provides an assurance that the products have passed all the required physical property tests and that they are approved for use in situations where compliance to NSF/ANSI 61 is a requirement. At the time of writing, there are now about six North American manufacturers of gasket and sealing materials offering a product that is certified to the requirements of NSF/ANSI 61. The latest gasket material certified to NSF/ANSI 61 to come onto the market is the NA1002SAN sheet manufactured by Teadit North America, a manufacturer of gasket sheet material. NA1002SAN sheet is especially designed for sanitary service applications and it combines excellent physical properties and performance characteristics (see table) at a lower cost than many competitive offerings. The advent and adoption of NSF/ ANSI 61 means that traditional materials used in water sealing applications, such as gaskets and seals fashioned from red rubber, will give way to newer-generation materials that are NSF/ANSI 61 compliant. It is therefore highly recommended that when purchasing gaskets for potable water applications that you source product from distributors and gasket cutters who can supply product that complies with NSF/ANSI 61. MRO Bill Searle is a technical sales specialist with Canada Rubber Group Inc. (CRGI), Bowmanville, ON, a provider of fluid sealing products and services. For more information on NSF/ANSI 61 compliant gaskets and seals, contact him at bsearle@ canadarubbergroup.com.

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Machinery & Equipment MRO

Source: Teadit North America

September 2014

The importance of

training

Structured employee orientation and training processes are a way to give new employees a fair chance to show they are willing and able to work. BY PETER PHILLIPS

This issue’s column continues a look at an ongoing project aimed at improving maintenance operations at an Ontario food plant. his plant needs to develop support systems for every position and activity that its personnel are responsible to perform. We have implemented some intermediate corrective actions to improve communications between maintenance and production, and at the shift handover meetings to improve communication with the day shift management. The plant realizes that there are many areas that need attention. The plant is experiencing tremendous growth, with new products being developed and millions of dollars being invested in new equipment. There are days when five to 10 new employees are being hired. We identified in our last visit to the plant that the new employee training process has little structure and employees do not receive quality instruction or and training. We will now address this issue and focus on new employee orientation and training. A process to monitor the progress will be implemented and

ongoing support will be provided as the new hires progress through on-the-job training. Properly trained people result in fewer production errors, a higher retention of employees, and a faster transition into them being productive and happy employees. We have noticed a common theme in industry across Canada. It is getting increasingly difficult to find and hire people with good work ethics. In another example, we recently were working at a food processing plant in Newfoundland. For those of you who are not familiar with the current Newfoundland economy, you may be surprised to learn that the province is booming. The oil, mining and electricalgeneration projects – along with various support companies – are driving a full economic expansion. Housing costs in many cases have doubled and anyone who wants to work can find employment. A few months ago, I was staying in a town about two hours from St. John’s and it had a brand-new coffee shop sitting closed because, I was told, there were not enough unemployed people in the local area to hire and open it.

The management team at the St. John’s food plant explained to me they were having problems finding quality people to fill vacant positions in production and maintenance. They, like those in every other industry, want employees who want to come to work every day, want to work when they arrive, and who want to have an interest in doing a job in an efficient and effective way. Unfortunately in Canada, many of our younger generation feel they are entitled to a job that pays well and requires little effort from them, regardless of their education or experience. Every person – young, middle-aged and older – must understand that companies need reliable, hard-working, dedicated employees so the company can make money and therefore pay them a salary. Companies across North America are struggling with this issue, especially in areas of high economic growth and low unemployment rates. There are no easy answers or quick fixes to correct this issue. However, we believe that structured employee orientation and training processes are a way to give new employees a fair chance to show they are willing and

able to work. It also gives the employer a way to measure the new employee’s skills, knowledge and attitude. It will also help the employer to determine if the employees will be offered permanent employment after their probation period. Back at the Ontario plant, we will indeed start with new employee processes and support systems. As one experienced employee explained, poorly trained production employees cause problems all the way down the production line. We have seen this since our first visit, as the company struggles daily with production mistakes that cause startup delays, waste and rework. It’s not because the people are incompetent, but because they do not know their roles and responsibilities. They have not been given meaningful and effective training from the beginning. As I look back at the employee questionnaire we did back in January with the plant’s production crew leaders, improvement in the training of new people scored very high in importance. We will visit this plant again next month and will thoroughly examine its orientation and training programs. I plan to spend at least a full day acting as a new employee and experiencing the process first hand. I will be able to communicate with other new employees about how they feel on the first day at work. Then I’ll be able to do a full analysis and determine what changes and improvements need to be developed to properly introduce people to the company and the training process. This done, we can help them to develop an effective company orientation and a structured on-the-job training package for every production position and work activity. We also will recommend that all recent new employees go through the new training process. We realize this development may take several months but we also know the company is committed to these improvements. The goal here is to stop the daily reoccurrence of line problems caused by poorly trained people and to effectively address these problems at the source. Once again, we will stick to our fundamental belief that we need to set up people to succeed every day. Doing so, we will have happier and more productive employees. When we started this project, the plant manager estimated it would take two years with us on-site for one week a month to turn the plant around. We agreed to this and we are soon to have our seventh visit. Improvements are being noticed and people are totally on board with us, so we know success will be the result. MRO Peter Phillips of Trailwalk Holdings, a Nova Scotia-based CMMS consulting and training company, can be reached at 902798-3601 or by e-mail at peter@trailwalk.

Online Reader Inquiry No. 131

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What’s new for harsh and severe-service environments

Online Reader Inquiry No. 428

NEMA premium and high-efficiency explosionproof motors. These motors are available as TEFC single-phase motors in 2-pole from 1/3 hp to 2 hp and 4-pole from 1/3 hp to 1.5 hp. Three-phase motors are available as TENV for 1/3 hp, 2 and 4-pole, TEFC in 2-pole from 1/2 hp to 3 hp and 4-pole from 1/2 hp to 2 hp. Features include Class F insulation, 50°C ambient temperature rating, service factor of 1.0, long leads for remote wiring, thermal protection, IP 55 rating, Class I – Group C & D and Class II – Groups E, F & G – T3C, foot mount with and without C flange, unassembled aluminum conduit box, aluminum endshields, and three-phase motors also rated for 50 Hz. These motors are suitable for applications requiring UL and/or CSA certification for hazardous locations. VJ Pamensky Online Reader Inquiry No. 430

Modular temperature transmitter helps raise efficiency areas, even at long measuring distances. Features include a backlit display, dual laser sighting, K-type probe connection and a bright LED illuminator for visibility even in poorly lit environments. A data logging function can be engaged to track temperature changes over time. SKF Canada

A range of SmartLine industrial temperature transmitters has been introduced by Honeywell’s Process Solutions. Designed to improve overall plant and employee efficiency, even in harsh and noisy process environments, this product helps reduce project costs and start-

Online Reader Inquiry No. 429

Housed spherical roller bearings can be customized

Online Reader Inquiry No. 461

Explosion-proof motor comes in wide range of models

WEG Electric has added a line of fractional hp motors in both single-phase and three-phase models to its line of

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up time, avoid unplanned downtime, improve product quality, and shorten time to repair. Features include dual-compartment housing, a built-in dual-input and digital output option, and an advanced graphic display capable of showing process data in graphical formats and communicating messages from the control room. Field operators can configure the device in the field, solve problems and avoid errors with no need for a handheld device. Also, the modular design enables employees to use similar parts between both pressure and temperature models, making it faster and easier to change a part or upgrade the devices. Honeywell Process Solutions Online Reader Inquiry No. 435

NPT stainless steel ball valve has many safety features

W.E. Anderson, a division of Dwyer Instruments, has released its series WE31 automated full port 3-way NPT stainless steel ball valve. The valve features a blowout proof stem, reinforced PTFE seats and seals for long life, and a 316SS (ASTM CF8M) ball, while direct-mounted actuators create a compact assembly

cranes, paper machinery, wind turbines, and hydroelectric plants. It only takes minutes for a single operator to buckle the flexible magnetic belt around the shaft using only two included screws. As a result, the flex encoders can be installed in existing machinery without removing any parts. Available for shaft diameters from 300 mm (11.8 in.) to more than 3 m (9.8 ft), the encoders are available either as incremental with HTL, TTL/RS422, or 1 Vpp SinCos outputs and up to 131,072 lines per revolution, or as quasi-absolute with SSI data and additional incremental output signals. With IP 67 protection class, 30 g vibration, and 300 g shock ratings, these encoders are suitable for the harshest

Online Reader Inquiry No. 434

Submersible pressure sensor resists corrosion in harsh liquids

The model AST 4530 liquid level transmitter from American Sensor Technologies is a submersible pressure sensor designed to measure the level of harsh liquids such as slurries, salt water and oil in vented tanks or containers. Constructed with PVDF material and a PTFE diaphragm, the sensor features a submersible PVDF cable, cord grip and housing, as well as a conduit connection for turbulent installations such as process plants, salt water holding tanks, onboard ships, turbulent tanks and rail cars. Sensors are certified to Class I Div 1, Groups C and D, for use in intrinsically safe areas with an approved barrier. The device is not affected from lid angle or proximity to tank wells, and will not have an offset in output due to foaming or reflectivity. In addition, it is

applications from minus 40°F to plus 185°F. The operational speed rating is up to 1,850 rpm, making the series suitable for any large shaft application. Baumer Online Reader Inquiry No. 438

Corrosion-resistant floodlights suit saltwater applications

Appleton, a brand of Emerson Industrial Automation, has introduced a line of powerful, energy-efficient, weatherproof floodlights designed for industrial and marine areas. Ruggedly constructed of high-grade 316 stainless steel, the corrosion-resistant Areamaster floodlights are impervious to saltwater or harsh chemicals. They comply with NEMA 4X requirements and also are UL Listed for Class I, Division 2 hazardous industrial locations, such as oil rigs, chemical plants and sewage treatment centres. Compact and easy to install, these floodlights come in a variety of efficient, high-power ballast and voltage configurations for both domestic and export uses. All models feature thermal-shock and tempered impact resistant glass, along with a built-in double segment reflector. Firmly-seated silicone rubber gaskets prevent ingress of damaging moisture, chemicals or saltwater. Luminaires can be mounted in any position ranging from lens-down to horizontal lens-up. Appleton

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Timken’s Blue Brute Spherical Roller Bearing Housed Units offer both durability and customization. They are available as 2- and 4-bolt pillow block, flanged, piloted flanged or take-up units. Housings are made of cast steel for performance in virtually any application and the feet ends are machined to the true bore of the housing to help with proper alignment. The housed units are available with a choice of six types of primary seals to keep out contamination. They also are offered with standard locking configurations – Set Screw or Eccentric Lock Collar – or the Double Nut V-Lock for fast and easy installation and removal. Timken Canada

for tight spaces. Limit switches are able to be mounted directly to the valves, allowing for remote position indication. The series can be configured with either an electric or pneumatic actuator. Electric actuators are available in weatherproof or explosion-proof, a variety of supply voltages and two-position modulating control. The pneumatic double acting actuator uses an air supply to drive the valve open and closed. It has two supply ports, with one driving the valve open and the other driving the valve closed. Dwyer Instruments

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The SKF TKTL 40 portable infrared thermometer enables safe and efficient measurement of machine temperatures at a distance. The device has the capability to take photos and videos showing the temperatures measured, allowing maintenance technicians and other operators to ascertain surface temperatures of equipment with greater ease and safety, and enabling readings to be reviewed and shared. The thermometer is easy to use by simply aiming and pulling the trigger. It performs with a distance-tospot ratio of 50:1 for accurate surface temperature readings of very small

Schaeffler develops bearing supports for water power applications that can be directly installed in water, using a special steel that is resistant to corrosion for the rolling bearing rings. The rolling elements are made of ceramic, while the cages are manufactured from water-resistant plastics. There is no need to use oil and grease because the rolling bearings are lubricated by water. Reliability and low maintenance are important requirements since, once the plants are installed under the surface of the water, access to them is limited. Water power will make a significant contribution to supplying renewable energy in the future, including tidal stream and wave power sources, in which turbines are installed under water to use the energy from currents and tides. The company is involved in numerous projects of this type as a development partner. Schaeffler Canada

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Portable infrared thermometer measures temperatures at a safe distance

Rolling bearings are lubricated with water

vented through the cable to the outside of the tank or container. Voltage and 4-20 mA output signals allow users to interface for low current consumption or long-distance transmission applications. American Sensor Technologies Online Reader Inquiry No. 437

Encoders have flexible magnetic belt for mounting around shafts

HDMag flex magnetic encoders from Baumer allow flexibility in mounting and accurate measuring under harsh conditions on large shafts such as those in torque motors, generators, large drive units, azipod drive units, hoists and

Online Reader Inquiry No. 433

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Whatâ&#x20AC;&#x2122;s new in pumping Variable frequency drive/motor combo provides energy savings

KSB Pumps has introduced the PumpDrive series of variable frequency drives for mid-sized pumps. These units enable

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Ultra-high-pressure waterjet pump allows for easy maintenance

â&#x2013;ź

be ordered with impellers with built-in cutters to reduce long pieces of fibrous material in the waste stream, vortex impellers, which are good for dealing with solids and dissolved gases, and screw-type impellers that feature contours specially designed to avoid catching fibrous material. A onepiece motor housing design ensures accurate bearing alignment for reduced vibration and long seal and bearing lives. Completely leak-proof cable entries help lower maintenance costs by reducing the

Flow International has introduced the HyPlex Prime direct drive ultra-high-pressure waterjet pump. Combining HyperJet intensifier pump technology with direct drive pump efficiency, the pump is designed to minimize downtime. Maintenance intervals are increased over prior models, while the highly modular design allows for customized performance at a production-level price. The compact pump has a maximum developed pressure of 60,000 psi and comes standard with the companyâ&#x20AC;&#x2122;s Pac-V control valve, which reduces maintenance and enables cutting at any pressure. Customers can tailor the pump performance for their needs. Flow International Online Reader Inquiry No. 445

possibility of water in the motor chamber. Meanwhile, optimization of the hydraulic elements improves pumping efficiency and reduces energy costs. The pumps are available with capacities of up to 135 cm/hour and heads as high as 47 m. Ex-

plosion-proof ATEX-certified versions are available for use in situations where there are high concentrations of flammable gases. KSB Pumps Online Reader Inquiry No. 446

MRO

pump operators to adjust the operating speed of their pumps so that output characteristics precisely match system requirements. Reducing operating speed reduces energy requirements so that pumps will run efficiently while delivering reduced flows. These speed controls are compact, modular units that are easy to integrate into any plant environment. They would normally be combined with flow, pressure or temperature sensors as part of a control system that automatically fine-tunes pump output according to overall system requirements. Also available is the SuPremE series of high-efficiency synchronous reluctance motors, featuring a carefully optimized rotor design that provides higher energy efficiency, especially when the motors run at partial loads. The PumpDrive speed controllers and SuPremE motors can especially improve energy efficiency when they are used together. KSB Pumps Online Reader Inquiry No. 441

Rugged custom overhung load adaptors handle challenging demands

Zero-Max overhung load adaptors offer creative solutions for increasing radial and axial load support for hydraulic motors and pumps. Custom designed to meet the needs of specific applications, the device can handle up to 50% greater loads than normal. Features include custom inverted bearing designs and multiple lubrication ports that increase load capacity, bearing life and smooth system performance. Designed for either face or foot mounting, standard OHLAs are available in over 50 models with input bore sizes that range from 5/8 in. to 3-1/2 in. SAE mounts available include A, B, C, D, E and F mounts with two- or four-bolt mounting flanges. The ruggedly built systems are manufactured to ISO 9001:2008 quality standards, and the shafts are precision machined from 130,000 psi stress-proofed steel. Applications include oil drilling systems, forestry shredders, recycling systems and industrial conveyor drives. Zero-Max Online Reader Inquiry No. 444

Energy-saving submersible pump improves efficiency, cuts costs

Widely used in wastewater processing, the Amarex N series of submersible pumps from KSB is designed to minimize clogging or blockage. The pump can

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Sensor enhances mid-range laser shaft alignment systems

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Pruftechnik’s RS5 sensor for its Optalign Smart RS measurement system is smart, fast and easy to use. The XL HD PSD detector size, combined with the powerful ExtendRange functionality, makes the measurement range virtually unlimit-

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What’s new in levelling and alignment

WITHOUT AN ACCIDENT WITH OVER 1,000 PRODUCTS, THE INDUSTRY’S MOST COMPREHENSIVE DROP PREVENTION SYSTEM

J.W. Winco Canada has announced that it offers GN 340.5 stainless steel levelling mounts with tapped socket and rubber pad in inch and metric sizes. These RoHS-compliant levelling mounts feature a tapped socket of stainless steel with a shot-blast finish and are available with a black pad inlay of nitrile butadiene rubber or white pad inlay of Santoprene (TPE) rubber. The black pad offers high resistance to swelling when in contact with oils and fuels, while the white pad has good resistance to solvents and acids. The units have long dynamic fatigue life and are resistant to ozone and atmospheric influences. Inch and metric base diameters run from 1.97 in. to 4.72 in. and 50 mm to 120 mm. Thread options for the tapped sockets range from 5/16-18 to 3/4-10 and from M8 to M20. Load ratings are 8 kN to 20 kN (1,800 lbf to 4,500 lbf). J.W. Winco Canada Online Reader Inquiry No. 423

ed. In real terms, this means that large misalignments can be measured over long distances. The sensor’s five-axis technology enables live monitoring of horizontal and vertical machine corrections at the same time, with the sensor at any rotational shaft position. The powerful synergy between

OUR GOAL: PREVENTING DROPPED TOOLS

Stainless steel levelling mounts come with black or white rubber pads

the faster CPU and the MEMS inclinometer ensures a finer and faster screening of measurement points during a sweep, and more measurement readings can be taken during shaft rotation. Energy consumption is reduced, which means longer laser and sensor battery run-time. Pruftechnik Canada Online Reader Inquiry No. 422

Keep up to date weeKly! Machinery & Equipment MRO’s weekly e-newsletter lets you keep up to date on the latest news, trends, feature articles, technical tips and events you want to know about. It’s quick and easy to subscribe – and it’s free too! simply go to this link: http://www.mromagazine.com/ subscribe/update.aspx. Now, every Tuesday morning, you’ll be the one who is in-the-know.

For more information call - (800)446-7404 Email - industrialbrands@snapon.com snapon.com/industrialbrands

Online Reader Inquiry No. 132

iPad geometric measurement system offers ease-of-use

Alignment Supplies’ AliSensor levelling system is designed for super-accurate geometric measurements in applications of all levels of complexity. The technology of the system’s platform, which is known as Industrial MFi (Made for iPad), is the integration of the iPad and other iOS devices into industrial-grade tools and equipment. In addition to offering users the ability to work with their iPads, iPhones and iPods, this platform opens up a sphere of industrial uses that can be performed with the full range of Apple’s best-selling iOS devices. The system, consisting of a sensor unit and an iOS unit, is a complex and rugged data collector that contains MEMS gyros, accelerometers and a microprocessor. The level is supported with a dedicated App, downloadable for free from the App Store, which guides the user throughout the measurement. Features include the ability to select from a wide range of measurement units, self-calibration for measurement with new or special fixtures, and reports that are instantly created with all data from the measurement, including the resulting graph. Reports can include a photo of the measurement object (taken with the built-in camera of the iOS device). The hardware will be supported by several free Apps that can use the functionality of the hardware to implement different types of measurements. Alignment Supplies Online Reader Inquiry No. 426

Tired of being kicked in the bearings? Quit Hammering. Install Bearings Right. Try the Super Lightweight, ConeMount™ Bearing Heater. With ConeMount™ you can: fix an elevator, repair a Porsche®, get the AC going, upgrade a tractor tranny, restore a hydraulic pump, assemble a mixer - the list goes on and on.

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Online Reader Inquiry No. 133

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Geometric alignment system is built for flexibility

Seifert Industrial’s FixturLaser XA geometric alignment system uses such technologies as touch screen navigation, Bluetooth wireless communication, and live position data while making alignment adjustments. Preconfigured templates are available or the user can freely design the measurement task. Either way, a distinct overall view of the measurement is provided. The user can instantly see the display of the measurement object’s position, along with colourcoded measured points related to alignment tolerances. Measurements can be taken in any order. The built-in inclinometer guides the user to the same angular position for remeasure, or ensures proper positioning for the next point. Live values during the adjustment phase allow the user to watch the adjustment being made. With a one-person operation, setup and measuring are fast, easy and accurate, and the variety of brackets and bases allows easy setup on almost any application. The system is used for straightness, flatness and bore position. FixturLaser Online Reader Inquiry No. 427

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What’s new ...

Smaller size enhances modular industrial connector line

in products, systems, components and accessories for machinery and equipment MRO (maintenance, repair and operations). Spherical washers optimize bolt mounting of machinery

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SKF Spherical Washers optimize bolt mounting of machinery and bolted equipment by integrating unique design features, promoting ideal performance in industrial, marine, and all other heavy-duty bolted joint applications. The all-spherical two-piece washer automatically adjusts under compression to compensate for up to four degrees of angular deviations. This creates an exact parallel plane between the inner face of the bolt head and inner face of the nut to distribute the load evenly over the entire inner contact surface areas. Any need for on-site machining (spot facing) to achieve parallelism is eliminated. The washers ultimately serve to reduce the likelihood of bolt relaxation by distributing bolt tension evenly, retaining proper bolt tension by preventing bolt bending, and keeping bolts straight as intended. The extended length of the spherical washer allows for the use of longer bolts, resulting in additional bolt clamping length and elongation in the bolt. SKF Canada Online Reader Inquiry No. 460

Finishing/polishing products work well individually or together in a sequence

Walter Surface Technologies has added the Quick-Step Finisher, Quick-Step Blendex and Quick-Step Flex tools to its Quick-Step line of surface finishing and polishing products. Featuring Velcro support, with a central pin to ensure proper placement and safety, the timesaving products are designed for finishing ultra-clean stainless steel surfaces in industries such as food prep, nuclear,

pharmaceutical, construction and others. The compact, lightweight and variablespeed Quick-Step Finisher tool is suitable for sanding, finishing and polishing tasks, particularly in small, confined spaces. The updated Quick-Step Blendex surface conditioning disc features more consistent performance, double the disc life, and non-woven construction. It prepares surfaces for the final finishing treatment, such as painting on steel, aluminum and stainless steel. Designed as the first stage in a multi-step finishing

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process, the flexible, long-lasting QuickStep Flex finishing disc is built to fit all sanding applications and offers surface finishing and a high removal rate of grinding and finishing welds. Walter Surface Technologies Online Reader Inquiry No. 452

Heavy-duty dual-wheel solid pneumatic caster gives soft ride in harsh conditions

A line of dual-wheel solid pneumatic casters, designed to cushion loads while providing a carrying capacity up to 8,400 lb. per caster, has been introduced by Hamilton. Providing a soft ride and stable base, the 7700 series represents the company’s highest-rated caster series built for heavy-duty ground support and heavy manufacturing applications over rough surfaces. All models have drop forged steel mounting plates and CNC machined raceways. Available in six diameters from 10 in. by 4 in. to 21 in. by 6 in., the wheels are equipped with 1-in. or 1-1/4-in. precision tapered roller bearings, making them well suited for power-towed applications. The 16in., 18-in., and 21-in. wheels comprise three tread sections: a firm, stable rubber base compound for strong rim adhesion, a very resilient middle section, and a tough low-rolling-resistance tread. The 12-in. and 14-in. wheels comprise two tread sections. The series can be optioned with permanently welded fourposition swivel lock and a heavy-duty contact brake. Hamilton Caster & Mfg. Co. Online Reader Inquiry No. 451

Online asset management tool tracks data for critical drivetrain couplings

Emerson’s Power Transmission Solutions has introduced an online tool for tracking the location, life history and latest revision drawings and installation in-

Harting has expanded its Han-Yellock line of modular industrial connectors with the introduction of a smaller size. The space-saving, zinc die-cast Han-Yellock 10 can fit both rectangular and circular panel cut-outs, allowing direct replacement of circular connectors with a panel cut-out diameter between 28 mm and 30 mm. An addition to sizes 30 and 60, this compact unit comes with cable glands M20 or M25, top or angled entry. It can be used for power only, or for combinations of power, signal and/or data. Any Han 3A insert will fit in it, and it can carry up to 40 A/690 V of power, data for Ethernet applications, and optical data transmission. In addition, multi-pole inserts with up to 21 contacts are available. Termination options include crimp, screw and Harting Han-Quick Lock. Harting Canada Online Reader Inquiry No. 456

structions for all critical drivetrain couplings owned by customers, whether installed or in spares inventory. Developed by the company’s Kop-Flex business unit, the web-based tool, known as the Asset Management Program (AMP) for couplings, accurately identifies couplings, graphically displays the location in a specific drive, identifies parts/couplings at the site that are interchangeable, makes assembly drawings a click away, and gives a detailed service history and action to be taken during service intervals. Applications include petrochemical equipment, turbine generators and mill drives. Coupling AMP is a subscription service maintained by Emerson. Emerson Power Transmission Solutions

PC. The instruments allow the user to determine the condition of the insulation of the twisted copper cable pair, which could cause problems for services such as voice, video and data or VOIP. The MIT410-TC2 offers insulation testing up to 500 V and 100 G-ohms, the MIT430TC2 up to 1,000 V and 200 G-ohms. Fea-

Online Reader Inquiry No. 450

Feature-rich insulation tester is for twisted coppercables

The Megger MIT410-TC2 and MIT430TC2 insulation resistance and continuity testers have been designed for use within the telecommunications industry. The model MIT430-TC2 offers extensive results-storage capability for later recall and Bluetooth download capability for wireless transfer of stored results to a

tures include analogue arc and dual digital display, CAT IV 600-V rating, TRMS and DC voltage measurement, continuity testing at 200 mA or 20 mA down to 0.01, Pass/Fail limit alarms, and PI/DAR and timer function. A soft canvas carrying bag with shoulder strap and rugged snap hook to attach to a tool belt, and a test lead set are included. Megger Online Reader Inquiry No. 453

continued on page 28

C & U hybrid ceramic ball bearings are engineered to maximize the benefits of precision steel ring construction and light weight silicon nitride balls. They have excellent electric insulation properties, high-speed capability and provide longer service life than all steel bearings in most applications. Global Bear is a stocking distribution specialist of precision bearings and power transmission products. We have built our reputation on: Superior quality products

Outstanding service and delivery

Competitive pricing

Available from Global Bear Inc., 2064 Chartier Ave., Dorval, QC H9P 1H2 Ph. 866 631-1110 1601 Matheson Blvd. Unit 10,Mississauga, ON L4W 1H9 Ph. 877-820-4865

www.globalbear.ca

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Severe service bearing line is available fully split

Rugged cast steel chain moves heavy loads with ease in hostile conditions

Iwis Drive Systems has introduced the Flexon brand’s cast steel C600 chain. Robustly built yet simple in design, the chain is especially suitable for applications that involve pulling or conveying heavy loads in rugged conditions and over long distances, such as in the tim-

Online Reader Inquiry No. 431

Explosion-proof light cart can lay flat to roll under parts

An upright aluminum wheeled light cart designed for use in hazardous locations has been introduced by Larson Electronics’ Magnalight.com. The explosionproof EPLUC-48-432 light cart provides

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operators with the high output of fixed lighting with the easy manoeuvrability of portable lighting. UL listed Class 1 Division 1, and UL 1598 Marine Type approved and certified for paint spray booth use, the cart is constructed of heavy-gauge aluminum and is fitted with a folding aluminum handle, a pair of solid rubber wheels at the bottom and two uni-directional caster wheels at the top. This design allows the user to lay the unit flat and roll it underneath vehicles or into hard-to-reach areas. It incorporates a pair of Magnalight’s EPL-48-216 explosion-proof light fixtures fitted with eight T5-HO fluorescent lamps to produce a total of 40,000 lumens of illumination. Also included is a 50-ft chemical- and abrasion-resistant cord fitted with an explosion-proof plug and inline switch. Larson Electronics

Designed to fit precisely into the grooves of Parker Hannifin’s Code 61 and Code 62 flanges, the Engineered Flange Seal (EFS) provides consistently strong seal retention, helping eliminate the problems that plague standard O-rings, which are prone to pop out of the flange groove. The purpose-designed shape reduces the possibility of pop-out and the need to replace or reinstall the O-ring, eliminating costly leakage and time-consuming pre-assembly handling. Product features include secure seal retention before, during and after installation, quick assembly with no tooling or lubrication needed, reduced risk of seal damage and leakage, ability to withstand working temperature of up to 257°F, and 90 Durometer nitrile. The seal is suited for high-pressure applications in construction, agriculture, forestry, industrial, mining and many other markets. Parker Hannifin Hose Products Division Online Reader Inquiry No. 454

Servomotor’s hygienic design meets food-safety guidelines

A line of robust stainless steel AKMH servomotors has been introduced by Kollmorgen. Designed for food-safety compliance, these IP69K-rated synchronous servomotors feature a hygienic housing designed to meet EHEDG, NSF, BISSC and 3A machinery guidelines. The servomotor is constructed with ma-

terials to provide long-life and trouble-free operation, even with daily exposure to chemicals and highpressure washdowns. The unit requires no additional protection and can be sanitized without covering it or removing it from the machine. Kollmorgen Online Reader Inquiry No. 305

Gasket e-training course can be delivered anywhere and anytime

New Standard Institute’s interactive eLearning programs, available as CD, download or web-based, use text, narration and animations to present information in a way that is both interesting and effective. The Gaskets and Bolted Flange Connections training course shows how to achieve a good flanged connection, as well as the essentials of studs, bolts and nuts. The course includes Gasket Terminology and Selection Criteria, Minimum Operating Bolt Load, The Stress vs. Strain Relationship, Bolt and Stud Size and Thread Standards, Determining Bolt Torque Values, Flange Faces and Connections, Flange Leakage and Maintenance, and more. New Standard Institute Online Reader Inquiry No. 463

Large-diameter seals for rotating equipment suit severe conditions

SKF sealing solutions for industrial rotating equipment retain lubricant and block harsh contaminants from adversely impacting asset performance and reliability. Large-diameter seals can be delivered in a wide range of styles, configurations and materials to accommodate the most demanding speeds, temperatures, pressures and environmental conditions. They especially can withstand the severe operating challenges typically encountered in the steel, pulp and paper, and mining industries, among many others. Standard designs include metal-cased outside diameters, rubbercased outside diameters, and all-rubber types both in split and solid styles. They can be manufactured in virtually any size shaft diameter greater than 102 mm (4 in.). Custom solutions can be developed to meet particular application requirements. SKF Canada

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Waiting Is Costly. Call Now! 800-553-2112

Online Reader Inquiry No. 135

Online Reader Inquiry No. 302

Flange seal cuts down on rework and replacement, provides quick assembly

FLUORESCENT REPLACEMENT

• Simply snap it in...It’s EZ! • Requires no ballast bypass or rewiring. • Drastically lowers air conditioning costs (up to 17% in additional savings). • Payback: typically less than one year (before rebates). • Available in tube lengths: 2’, 3’, 4’, 8’, U and T5 sizes. • No Mercury. No Radiation. No UV. RoHs Compliant. • Rebate Eligible. • 5 Year Warranty. 50,000+ hour life.

A linear speed control option for Model RG rolling ring linear drives has been introduced by Amacoil/Uhing. Normally, the drive moves on a driven shaft with linear speed being adjustable via a pitch control lever located on the drive unit. The option lets users fix a specific linear travel speed in one or both directions of travel. The fixed travel speed is achieved using set screws that Amacoil inserts into the drive housing. No adjustments to motor speed or controls are necessary. Based on application needs, the company will work with customers to determine custom settings for the set screw speed control option. The option is inexpensive and is easily retrofitted to existing Uhing linear drive set-ups. Amacoil

Online Reader Inquiry No. 440

FLUORESCENT REPLACEMENT

“Plug and Play” Direct-Replacements

“EZ LED”

Linear speed control option can fix different speed in each travel direction

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Online Reader Inquiry No. 457

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ber or construction material industries, in pallet conveyor systems, or for moving barrels, bulk containers, gas bottles and cage pallets. An increase of measured breaking loads by about 25% can be achieved by the use of cast steel rather than cast iron chains. Features of this durable chain include threaded pins in the connecting link, which make the chain easy to close and unclose. A plastic version can be supplied on request, while a galvanized, zinc-plated version provides additional corrosion protection. Chains are available with a pitch of 63.5 mm and with or without TAB. Iwis Drive Systems

EDT has added Type E bearings to its Solution line of severe-service bearings. These durable, cost-saving bearings have high load capacity and the same dimensional footprint as industry-standard Type E tapered roller bearings. Non-corrosive and completely greaseless, they are constructed with a 304 stainless housing, a Poly-Sphere plane bearing that is made from a high performance polymer, plus a 316 stainless locking sleeve. Plane bearings work without rolling elements, so grease is unnecessary and seals are eliminated, reducing maintenance. Plane bearing design also makes it possible to offer completely split inserts in addition to split housings. The bearings are available in one-piece or split styles of pillow blocks, four bolts and piloted housings for shaft sizes from 1-3/16 in. to 5 in. Split units are drop-in replacements for RPB, RFB and RFP spherical roller bearings with the added options of split bearings and split sleeves. EDT Corp.

Online Reader Inquiry No. 465

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P R O D U C T

N E W S

September 2014

Machinery & Equipment MRO

Ultrasonic sensor is built with rugged stainless steel housing

Carlo Gavazzi has introduced the stainless steel UA18EAD and UA30EAD series ultrasonic sensors with digital and analogue output configurations. These sensors feature maximum sensing ranges of 250 mm to 3,500 mm and offer two different flexible output configurations to fit most applications. The first configuration has two digital NPN or PNP outputs, while the second has an analogue output in either 4-20mA or

0-10VDC, as well as one digital NPN or PNP output. The two digital outputs can be set as standard switching outputs with two set points or as a window function. The analogue output can be set with a positive or negative slope for both filling and emptying applications. Available with a 2-m cable or M12 quickdisconnect plug, the sensors are designed for use in a wide variety of applications, including material handling, food and beverage, HVAC, packaging, plastics, agriculture and automotive. Carlo Gavazzi Online Reader Inquiry No. 439

Controller stands up to extremely hostile conditions

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The HEC-P5000 harsh environment controller from Divelbiss is RoHS compliant, has a temperature range of minus 40°C to plus 80°C and allows for programmable intelligence under less than ideal conditions. It features a sealed, water-tight enclosure, analogue and digital I/O, high speed counting, TCP/IP, communications ports, CAN network communications and Structured Text programming. Built for the most adverse of environments, the controller can be directly machine-mounted and is suitable for use in mobile, marine, agriculture, mining, oil, gas and most electro-hydraulic applications. It is easy to apply and program using the EZ Ladder Toolkit PC-based software. EZ Ladder software parallels the IEC-61131 standard and provides an easy-to-use interface. EZ Ladder Toolkit’s Structured Text allows for the creation of custom functions and function blocks. After a ladder diagram program is developed, it can be downloaded to the HEC controller via the serial port or Ethernet port.

The controller is also available without the real time clock, Ethernet and serial communication ports. Divelbiss Online Reader Inquiry No. 436

Anti-seize products receive naval qualification status

MIL-PRF-907F qualification status has been granted to two anti-seize products from Henkel by the Naval Sea Systems Command. Formulated to prevent seizing, galling and corrosion on metals, Loctite C5-A copper-based anti-seize and Loctite Silver Grade anti-seize resist high temperatures, heavy loads, chemicals, fluids and vibration, and are available in general-purpose, metal-free, foodgrade, marine-grade and high-purity formulas. The C5-A product can be used on copper, brass, cast iron, steel, all alloys including stainless steel, all plastics

and all non-metallic gasketing materials to protect metal parts from rust, corrosion, seizing and galling at temperatures up to 982°C (1,800°F). The Silver Grade anti-seize is a heavy-duty, petroleumbased lubricant that resists temperatures up to 871°C (1,600°F). Both products are designed for either maintenance or equipment manufacturing applications, and can be used on bolts, bushings, pipes, fittings, flanges, manifolds, nuts, studs, heat exchangers, valves, steam lines, union retainers and clamps. Henkel Online Reader Inquiry No. 455

Sensor transmits pressure/temperature over Bluetooth

The TDWLB pressure/temperature sensor designed by Transducers Direct is powered with a coin-cell battery, controlled with a smartphone

app and certified as Bluetooth Smart. Developed for industrial, marine and

Stainless steel gear drive withstands caustic washdown

A line of Boston Gear stainless steel, right-angle helical bevel gear drives is available with output torque up to 7.700 lb.-in. (870 Nm) and input power to 10 hp (7.5 kW). Designed to meet the demands of washdown applications, SS2000R models feature a 316 series stainless steel housing with domed crown and rounded corners for superior washdown runoff in harsh environments where high-pressure caustic solvents and cleaners are used. The drives are designed for use in high-torque applications with continuous- or high-duty cycle operations, high-ratio reduction, and limited access installations where long life is a necessity. Applications include cheese slicers, dairy and bakery mixers, spiral heating and cooling racks, produce drying bins (tumblers), meat forming and carcass processing equipment, bottling lines, conveyors and palletizers. Boston Gear Online Reader Inquiry No. 304

commercial applications, the sensor provides an 18- to 24-month battery life and redundant sensing. Its smartphone app lets the user name each sensor one time securely, then program setpoints/ alarms for multiple sensors, monitor readings and graph activity over time, all from a smartphone, tablet or computer. It is available in two compensated accuracies of 1% and 0.25%, with temperature sensing as an option, and is designed for intermittent, rather than dynamic, machine-control applications. The sensor is all digital, eliminating mechanical components, wear parts, analogue circuitry and setpoint drift. A one-piece, precision-machined stainless steel diaphragm and header eliminates springs, pushrods, micro switches and O-rings. The sensor is EMI/RFI protected and sealed to IP-67 rating. Transducers Direct

moulding process equipment. Freudenberg-NOK Sealing Technologies Online Reader Inquiry No. 469

Expanded anti-vibration mount line includes wide range of sizes

J.W. Winco Canada has expanded its line of anti-vibration mounts to include a full range of inch and metric sizes. Also known as shock absorbing mounts, vibration mounts, vibration/shock absorption mounts, vibration bobbins or rubber bumpers, these RoHS-compliant components are frequently used as endstop bumpers, for example for conveyor trolleys. Vibration absorption mounts, made of natural rubber with steel or stainless steel components, absorb most of the accumulated kinetic energy on impact. They act as dampers and pre-

Online Reader Inquiry No. 432

Gearbox radial shaft seal material is for use with synthetic oils

Simrit’s 75 FKM 260466 fluoroelastomer material, a wear-resistant FKM, was developed for use in radial shaft seals that interact with aggressive oils in various industrial gearbox sealing applications. FKM material blends are commonly used in applications containing synthetic oils because of their high-temperature and chemical resistance. However, when blends encounter synthetic oils, they can demonstrate wear and material degradation, which reduces the service life of the entire application. Simrit’s material, in contrast, provides a high level of wear resistance when in contact with synthetic oils and good resistance properties over the service life of radial shaft seals across many temperature and load ranges. It has the potential to significantly extend the service life and decrease the downtime of industrial gear applications. In addition, the material can be processed in existing injection-

vent damaging shock and rebound. They also act as sound dampers, and can be used as levelling feet. The parabolic shape generates progressive resilience characteristics, and impact and shock effects are absorbed more gently. The product line includes inch and metric sizes, tapped and stud types, and cylindrical and conical styles to accommodate a wide range of applications. J.W. Winco Canada Online Reader Inquiry No. 459

MRO

ONE PLATFORM FOR ANY APPLICATION • Laser Shaft Alignment • Vibration Measurement • Geometric Laser Measurement • Bearing Condition • Digital Belt Alignment CANADIAN DISTRIBUTOR

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PRECISION DRIVEN MAINTENANCE

SALES | SERVICE | TRAINING | CALIBRATION

Online Reader Inquiry No. 136

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M R O

O N

T H E

R O A D September 2014

Education opportunities abundant at PTDA Canadian Conference Quebec City – More than 200 people gathered June 5-7, 2014, at the historic Fairmont Le Château Frontenac, in Québec City, QC, for PTDA’s 13th annual Canadian Conference. Networking between channel partners and peers was a top priority at the event. The Canadian Conference kicked off with an Industry Showcase and Welcome Reception, which featured tabletop displays by 28 manufacturer members. A highlight of the event was a reception and dinner at the Parliament Building, home of the Assemblée nationale du Québec. Canadian Conference co-chairs Gerry Prezeau, Rotator Products Ltd., and Bruno Mylchreest, Timken Canada LP, alternated as the conference’s emcees. PTDA president Ken Miko, BDI, spoke on PTDA’s strategic plan and PTDA Foundation president Barb Ross, Garlock Sealing Technologies, addressed recent successes of the Industrial Careers Pathway program. The conference program also included several other speakers: • A ndrew Bell, reporter and news anchor on Business News Network, interspersed his rather bleak outlook for manufacturing in Canada with clips of bloopers from various news media outlets. • Nigel Southway, president of Nexus Consulting and chair of the Toronto chapter of the Society of Manufacturing Engineers (SME), informed

attendees about the need for and the goals of SME’s ‘Take Back Manufacturing’ initiative. • A briefing on the aerospace market was presented by Dale Gordon, director of supplier quality assurance for Aerojet Rocketdyne. Speaking on behalf of the International Aerospace Quality Group, Gordon discussed the organization’s efforts in product and supply chain improvements. • In response to recommendations for industry-relevant content, the Canadian Conference called up a panel made up of a quartet of industry executives to discuss how technology is affecting distributor/manufacturer relationships. • Attendees were entertained, motivated and engaged by Stephan Maighan’s closing keynote. Interspersing his six lessons for achieving excellence with activities involving combination locks and dancing, Maighan used his own experience to demonstrate how a positive attitude can produce a positive result. The PTDA is the global association for the industrial power transmission/ motion control (PT/MC) distribution channel. Headquartered in Chicago, it represents distribution firms that generate more than $16 billion in sales and span over 3,400 locations. PTDA members also include manufacturers that supply the PT/MC industry MRO

Photos: Bill Roebuck

Machinery & Equipment MRO

1. A panel of industry executives discussed how technology is affecting distributor/ manufacturer relationships. Distributors Ali Moghadam (left), Canadian Bearings, and Mitch Bouchard, General Bearing Service (3rd from left), joined manufacturers Jean-Sebastien Lavigne, Baldor Electric (2nd from left), and Dave Strutt, C&U Bearings (right), to share their perceptions. 2. Canadian Conference co-chairs Bruno Mylchreest, Timken Canada, and Gerry Prezeau, Rotator Products. 3. Bev and Don Latham, Belterra Corp. 4. Kevin Kozlowski and Otto Gerum, Shaeffler Canada. 5. Rick Hamilton and Darrell Tetreault, Renold Canada. 6. Sean Hickey, Lafert North America, Kevin Powers, US Tsubaki Power Transmission, and Mel Langford, Diamond Chain. 7. Normand Paradis, Anthony Peluso and Lyall Watson, SEW-Eurodrive Co. of Canada. 8. PTDA staffers Kelly Butler, Dave Strutt and Ann Arnott. 9. Pierre Bouchard, General Bearing Service, with Marlee Willis, Kim Foore and Lee Willis, Transmission Supplies Ltd.

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Whether you work on top of the world or deep in itâ&#x20AC;Ś

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. 137

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From Extraction to Finish Processing — We’ve Got You Covered Schaeffler has spent decades developing products designed to optimize the performance of equipment used in mine operations: DRAGLINES • SHOVELS • HAUL TRUCKS • VIBRATORY SCREENS CRUSHERS • BALL / SAG MILLS • CONVEYING EQUIPMENT

With an expansive portfolio that ranges from a complete line of standard bearings to the most highly specialized application solutions, Schaeffler products are specifically engineered to thrive in some of the harshest operating conditions on (or under) the earth. Looking to improve bearing life and reduce downtime? Consider: • 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 • All-new SNS ductile iron housings for extended bearing life Schaeffler also offers its exclusive X-lifeTM 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. Need more details? Please contact us at ads.ind@schaeffler.com www.schaeffler.ca ©2014

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Superior-quality products. Comprehensive reliable solutions. Online Reader Inquiry No. 138

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