ENERGY SAVING
WATER ENERGY SAVING SAVING
ENVIRONMENTAL WATER SAVING
ENVIRONMENTAL
Sustainability Solutions for Australian Industry SOLUTIONS
SOLUTIONS SOLUTIONS
www.bsc.com.au
SOLUTIONS SOLUTIONS
SOLUTIONS
Australian owned since 1921
F
ormerly known as Bearing Service Pty Ltd and established in 1921, BSC is the premier and most experienced Bearing and PT product distributor in Australasia. Proud of its Australian
owned heritage, we are primarily engaged in the supply of Bearings and Power Transmission products. Today, BSC employs around 300 permanent staff and operates over 40 branches in all states around Australia. The BSC product range is the largest of its type and is supported by a large distribution network of more than 100 computer-linked branches and authorized distributors to ensure that our broad stock range is available in all areas throughout Australasia
including PNG, New Caledonia, Fiji, Solomon Islands, etc. Comprehensive bulk stock and accounts are managed using an IBM AS400 server platform. Over the years BSC has built a reputation as a respected supplier of quality products and services. Since 1995 BSC has been licensed as a Quality Endorsed Company (QEC4475) and regularly audited and certified by SAI Global Limited to comply with the requirements of AS/NZ ISO 9001:2000 for the procurement, warehousing, distribution and sale of a wide range of bearings, power transmission and associated products.
www.bsc.com.au 2
INDEX
Sustainability Solutions for Australian Industry
Sustainability Solutions for Australian Industry
INDEX Energy Management
BSC understands our responsibility to the environment and our customers, and sustainability has been an important part of our company policy for many years. Our commitment to sourcing technically advanced products across our product range from world class manufacturers has been our response.
Motors 4 Variable Speed Drives 8 Engineering Services 11 Gear Boxes 17 Belts 19 Water Management TS Flat Chain AESSEAL Water Management
25 26
Environment Management
In today’s environment with soaring energy
Bearings 27
prices it is essential for companies to reduce costs in order to remain competitive. This has prompted BSC to put together a range of products with potential energy saving initiatives and ideas. BSC’s new Sustainability Catalogue will not only save you money with smart product choices and energy saving initiatives and ideas but will also be helping our planet. Selecting products from this range will significantly reduce your energy consumption or water usage or simply using environmentally friendly products.
“
We won’t have a society if we destroy the environment. Margaret Mead
www.bsc.com.au
3
Industry Information
MOTORS
Energy Wise Electric Motors Published - ecoBiz Queensland
H
alf of the world’s electrical energy goes toward
Improve performance with a VSD
powering electric motors.
A Variable Speed Drive (VSD) is an electrical device that
To improve energy-efficiency in your workplace, ensure
controls power to the motor, and is suitable for inconsistent
electric motors are suitable for the tasks they perform. The best
loads. Rather than continuously running at full speed, the VSD
way to identify potential energy savings is to work backwards
varies the motor speed to meet the energy needs of the load.
from the task the motor performs to its power input.
While a VSD can cost more than the motor, it can achieve
A smaller motor may provide sufficient power for a specific task
energy savings of up to 50 percent a year. VSDs provide best
and cost less to run. If feasible, install a time switch to control
energy savings when applied to a motor-driven centrifugal
the length of time the motor operates. Alternatively, install a
pump.
calendar time switch to prevent motors running on days when
There are cheaper alternatives to VSDs. Multi-speed motors
not in use, such as when your workplace is closed.
can be used with two or more pumps running parallel systems.
Does your motor match your needs?
One motor is used for the base load, and the second is used
Consider three basic factors when assessing motor suitability: 1. Consider total life costs when buying an electric motor, including purchase price, installation and operating costs. If you invest in an energy-efficient motor your business will save more over time. 2. High Efficiency Motors (HEM) are about two to four percent more efficient than standard electric motors, and offer lower operating costs and reduced energy consumption. The initial investment will be greater, but it only takes about two years to recoup the additional costs in energy savings. HEMs produce less heat, reducing air-conditioning costs and providing a cooler work place. They maintain high efficiency over a wider range of loads and have a greater thermal tolerance. It is important to match the HEM to its application as these motors operate at a slightly higher full-load speed than standard motors. This means that centrifugal loads, including pumps, fans, and compressors, can be affected by higher speeds and negate energy savings. This may involve replacing an existing motor with a smaller one, trimming impellers on pumps or changing gear or pulley ratios. 3. Consider the size of the motor. Companies often buy an oversized motor to cope with unexpected peak loads or to allow for process expansion in the future. As a result, hundreds of motors used in industrial applications are grossly oversized. Motors are most efficient when operating at full load, and installing a smaller motor, which operates at full load, will greatly improve the operating efficiency.
4
only during peak load times, offering improved reliability and providing a back-up if one motor or component fails. Maintaining your motors • Check that drive belts, chains and couplings are in good condition and are adjusted in accordance with the supplier’s recommendations. • Check for motors that are running hot, as this is a sign of energy loss. Use an infrared non-contact thermometer to measure the temperature of the motor casing (investigate if it is 60 degrees or higher). • Check alignment, as parts in a misaligned motor will be susceptible to wear more quickly, reducing both the motor’s service life and efficiency. • Record data for each motor to assess if it is running unnecessarily. Record the motor’s application, the nominal power (in kW) from the motor identification plate and how the motor is controlled. • Replace a motor rather than rewinding it. Although rewinding is popular, efficiency is reduced by up to three percent each time a motor is rewound, leading to lower operating efficiency than the nameplate efficiency. If a motor burns out, the best solution is to review your load needs and purchase a highefficiency motor to match that load.
MOTORS
Sustainability Solutions for Australian Industry
ENERGY SAVING
ENERGY SAVING
SOLUTIONS
SOLUTIONS
W22 E3 Motor Reduce energy loss and save money.
Completely interchangeable with lower level
noise level. The fan provides greater amounts
Based on state-of-the-art technologies which
efficiency motors (eg MEPS2) and designed
of air to cool the motor and the fan cover with
reduce carbon foot print from manufacturing,
to comply with standard EN 50347 for ‘kW to
its aerodynamic outline is designed to avoid
to installation and on-going use, the W22 range
frame’ ratios. The W22 E3 has a flat efficiency
recirculation of air (loss of performance) and to
of E3 High Efficiency motors will reduce your
curve: from 75% up to 100% of load the high
better direct the airflow over the motor fins.
operating, inventory and maintenance costs,
efficiency is kept constant for maximum
The ageing of the insulating material is directly
whilst helping you achieve carbon emission
energy saving in applications where the motor
proportional to its operating temperature –
targets.
has been oversized.
the optimised cooling system of the W22 E3
The new generation W22 E3 super long life performance advantages including reliability, life, energy efficiency, reduced noise and vibration levels, extended lubrication intervals, standardisation and flexibility. The W22 motor
provides outstanding heat dissipation and
TYPICAL EFFICIENCY CURVE OF W22 LINE EFFICIENCY (%)
High Efficiency Motor encompasses many
100
eliminates hotspots by providing a uniform temperature distribution throughout the frame. OH&S regulations call for reduced noise levels.
90
It is possible to meet the lowest noise levels
80
60 70 80 90 100 110 120 130 PERCENT OF RATED OUTPUT
comes in two design variants either meeting the requirements of AS1359.5 High Efficiency
Constant efficiency area
E3 levels or exceeding them with a Super High
on the market simply and economically as the W22 limits noise to 80Db(A) at 1 metre from the motor without compromising flexibility. An electric machine’s lifespan is governed by its
Efficient model.
insulating material operational hours. H Class
W22 E3 super long life High Efficiency motor
The optimised cooling system of the W22 E3
insulation is standard in W22 E3; providing a
designed to exceed the requirements of MEPS3
composed of fan, fan cover and motor frame is
design life of up to 3.35 times that of standard
high efficiency levels are among the most
designed for optimum balance of airflow and
F Class insulated motors. This super long life
efficient motors in the world. In fact the W22
COST BREAKDOWN OF MOTOR
E3 can reduce energy losses by between 10%
maximizes product serviceability and results in a significant reduction in materials spend – from reduced replacement to providing a
For the life of the motor, the purchase cost can
$220
solution enabling plants to halt the practice
be as low as 2% of the total cost of ownership. The payback period for a W22 over a standard efficiency motor can be less than 7 months depending on the operating hours. www.bsc.com.au
COST
and 40% compared with other typical motors.
$225
of rewinding – universally identified as a
$215
significant contributor to lowering motor
$210 IE1 Energy Cost
Purchase Cost
IE3
efficiency levels.
Maintenance Cost
5
MOTORS
W22 E3 Motor (Continued)
COMPARISON BETWEEN W22 AND MEPS EFFICIENCY LEVELS 98
EFFICIENCY (%)
97 96 95 94 93 92 91 ENERGY SAVING
SOLUTIONS
37
ENERGY SAVING
SOLUTIONS
45
75
90
110 132 160 200 250 315 355 KW
W22 Top Premium Efficiency
Minimum High Efficiency Level
W22 Premium Efficiency
Minimum Efficiency Level
motors are fitted with WISE insulation which
information on Optimal Flux® please refer to
recognized to be one of the major driving
permits them to be operated by VSD – the
the section in this catalogue on the CFW11.
forces for energy efficiency because it can
WISE system is composed of Class H wire
Insulated bearings are expensive and, like any
adjust motor output to best suit load needs.
(200C), enhanced insulation materials and a
load carrying rotating or sliding product, are
However, voltage spikes from the PWM
solvent-free resin. When used with a VSD, our
subject to wear which eventually requires
waveform can have harmful effects on the
innovative WISE® insulation will deliver years
replacement. W22 E3 motors can be fitted with
motor winding, leading to premature failure
of reliable operation. Operating the W22 with
a non-drive end shield where the bearing hub
of the insulation system. This worsens as
WEG’s CFW11 VSD, the patented Optimal
is insulated. This component doesn’t wear and
switching frequency is increased. All W22 E3
Flux® will provide further savings. For further
guarantees longer operating hours.
CASE STUDY
The use of Variable Speed Drives (VSD) is
Quarrying Application
REDUCTION
Total Design Life Materials & Energy Saving
The outcome for the customer:
of over $451,170
• Reduction in energy consumption of
A major BSC quarrying customer in Victoria recently worked
321 T pa
223,778kwh per annum
with BSC’s Engineering Services to identify site improvement
• Reduction in CO2 emissions of 321 tonnes per annum
opportunities that would enhance reliability, reduce ongoing
• Nett reduction in energy costs of $31,329 per annum
materials spend associated with replacements and rewinding and deliver significant energy consumption reduction. Quarry environments are tough and require mining class rated motors. Following the survey and analysis, Engineering Services identified a number of areas throughout the quarry where a progressive change-out to the Super Long-Life High Efficiency mining specification motor range would provide significant benefits to our customer.
6
55
• Increased motor life of 335%.
MOTORS
Sustainability Solutions for Australian Industry
The DE end shield has a patented design with
are achieved through patented end shield
most operating environments, as there is no
fins and reinforced structure that increases heat
design and reduced bearing temperature rise.
longer any need to carry motors of varying IP
dissipation, ensuring low bearing operating
W22 E3 motors are IP66 rated – the highest
ratings in inventory.
temperatures. This results in extended
Ingress Protection rating against solid objects
lubrication intervals and subsequently lower
such as dust and the highest Ingress Protection
maintenance costs and reduced TCO as
against water (powerful jetting) other than
lubrication intervention relies upon personnel
totally immersible motors. This IP rating allows
and equipment. In the W22 E3 design,
for standardisation of motors throughout, in
CASE STUDY
extended lubrication intervals of up to 126%
Premium Efficiency Motor Audit – Food & Beverage Industry
REDUCTION
6600 T pa
Energy consumption reduction equivalent to over
At a glance:
$400,000 per annum
• Reduction in energy consumption of 4.6 million kwh per
BSC’s Engineering Services was asked by one of our major
annum
national customers, a multi faceted manufacturer with
• Reduction in CO2 emissions of 6,600 tonnes per annum
production plants in most States throughout Australia,
• Increased motor life of 335%
to conduct a detailed audit of electric motor applications with a view to identifying opportunities to reduce energy consumption and increase reliability.
• No more rewinding costs • IP66 standardisation opportunity
Utilising our Super Long Life High Efficiency motor range BSC was able to provide an attractive solution which would provide very significant savings.
www.bsc.com.au
7
VSD - Variable Speed Drives
ENERGY SAVING
ENERGY SAVING
SOLUTIONS
SOLUTIONS
CFW-11 VSD WEG CFW-11 variable speed drive for
Improve Efficiency and Save Energy
Optimal Flux®
all industries.
The CFW-11 VSD provides the ability to directly
When working on Heavy Duty loads with
Using state of the art technology, the CFW-11
control motor speed and motor torque
constant, or high, torque requirements
variable speed drive is designed for control of
to meet the process requirements. More
throughout a wide speed range, the patented
three-phase induction motors. CFW-11 utilises
importantly the CFW-11 improves efficiency by
Optimal Flux® provides the most cost effective
precise sensorless vector control or closed
saving energy when controlling motor speed.
and energy efficient solution. Optimal Flux®
loop vector contol and since it is designed
Operating a centrifugal pump or fan with a VSD
automatically minimizes losses within the W22
for operating on either Normal or Heavy
will provide high energy savings negating the
motor negating the need to oversize the motor
Duty loads, it can be used in a wide range of
need for throttling control. Power consumed
to meet the torque requirements, and negating
applications such as:
by a pump is proportional to the cube of the
the need for a separate forced cooling system
• pumps
speed. Comparing the two operating points
on the motor (further reducing the size of the
• fans
shown in the graph below, VSD control shows
installation).
• air compressors
remarkably lower power consumption for the
Optimal Flux® can reduce motor temperature
• refrigeration compressors
same flow. A flow-on benefit of VSD control on
rise by up to 11% which can increase motor
• converyors
centrifugal pumps is reduced pressure within
winding life by over 200%.
• ball mills
the system. (See below)
• mixers • crushers • palletizers Normal duty provides 110% overload for 60 secs every 10 minutes and 150% overload for 3 secs every 10 minutes. Heavy duty provides 150% overload for 60 secs every 10 minutes and 200% overload for 3 secs every 10 minutes.
Head (m)
H1
TYPICAL Q-H CURVES FOR A CENTRIFUGAL PUMP C
H2
Flow reduced by throttling
A
ENERGY SAVED
• hoists
Flow reduced by speed control
B
With rated ambient temperatures of 50°C and maximum ambient temperature of 60°C (up to frame size D), the CFW-11 is robust enough for the most arduous conditions.
8
FLOW Q1 CHANGE
Q2
Flow (m3/h)
Sustainability Solutions for Australian Industry
VSD - Variable Speed Drives
Reduce the cost of the installation
Oriented Startup reduces time to configure
An often overlooked aspect of a VSD is the
the drive by providing the minimum required
installation where costs can be incurred. The
parameters necessary to control a motor. The
CFW-11 has features that can reduce the cost
default configuration of the CFW-11 is suitable
of the installation.
for most applications out of the box. The
The design of CFW-11 allows the heatsink to be mounted external from a panel, reducing the temperature rise within the electrical cabinet and reducing the cost of ventilation and
intuitive keypad and menu structure makes a programming manual almost redundant. Navigating the keypad is as simple as navigating a mobile phone. (See right)
cooling. The internal components of the CFW-11 are protected by an IP54 seal ensuring reliable operation. Automatic control of the speed of the heatsink fan reduces the power consumed by the VSD providing lower energy usage in favourable ambient conditions. With application functions such as Multipump for multiplie pumps systems, crane, winder, and a SoftPLC for customising, additional time and equipment is not required for specific applications. (See right)
www.bsc.com.au
9
VSD - Variable Speed Drives
CFW-11 VSD (Continued)
TYPICAL BRAKING TORQUE x SPEED GRAPH (FOR 10HP / 7.5 kW MOTOR DRIVEN BY A CFW-11)
Braking Torque (%)
100%
TB1 ENERGY SAVING
ENERGY SAVING
0 0
SOLUTIONS
20%
100%
200%
SOLUTIONS
Dynamic Braking Torque Curve Optimal Braking Torque Curve DC Braking Torque Curve
In applications where braking is required,
ambient temperature rating, and has high start
typically braking resistors are needed. These
torque/overload torque.
resistors are an additional cost and take up
BSC can also provide other WEG Automation
additional installation space. With Optimal
products such models covering single phase
Braking the need for these additional resistors is
input, three phase input in low voltage and
reduced. (See above)
medium voltage, IP ratings from IP20 to IP56,
The CFW-11 is C-Tick compliant, comes in IP21,
and softstarters.
IP54 variants for flexible installation, has DC link
CASE STUDY
reactors to improve power factor, has a high
A Major Food Processing Facility Energy savings of $6300
to reduce conveyor speed in lightly loaded
A major food processing facility had a problem with two screw
conditions to save energy.
75 T pa
conveyors in their grain handling plant. The conveyors, driven
The CFW-11 can provide 200% starting torque for 3 seconds
by 2 x 22kW motors were started with star-delta starters. The
followed by 150% overload for one minute – enough in this
star-delta starters were installed to replace previously used DOL
instance to start the loaded conveyors, saving 2 hours of lost
starters, in an effort to reduce the high starting currents. The
production each time the loaded conveyor was stopped.
customer mentioned that during certain conditions when a
With the ability to control the speed of the screw conveyors to
loaded conveyor was stopped due to bottlenecks within the
match the loading, the CFW-11 variable speed drives were able
plant, the star-delta starters did not always get the conveyors
to provide energy savings of approximately $6300 based on
started due to the low starting torque. Operators would have
the loading of the conveyors during various production cycles.
to manually unload the grain, which would take on average 2 hours, adding unnecessary down time and lost production. The BSC solution was to offer two 22kW, heavy duty rated CFW-11 WEG variable speed drives which could provide the necessary starting torque and the added benefit of being able
10
REDUCTION
Energy consumption was reduced by 52.,560kWh per annum and CO2 emissions were reduced by 75 tonnes.
Engineering Services
Sustainability Solutions for Australian Industry
BSC’S Engineering Services
H
elp your business enhance its
BSC’s major priority in supporting our
Reducing lubricant usage and waste are also
sustainability and improve profitability
customers in this area is electricity
important areas that contribute to an overall
and competitiveness.
consumption reduction. Electricity is the largest
level of sustainability and BSC’s expertise and
Corporate sustainability encompasses
resource consumed in the industrial process
niche products again support these goals.
strategies and practices that aim to meet the
and, with significant price/kwh increases in
The products and services featured have been
needs of stakeholders today whilst seeking
recent years and forecast in coming years, the
carefully selected and designed to provide
to protect, support and enhance the human
critical priority for industry is the management
BSC’s customers with the benefit of the latest
and natural resources that will be needed in
of electricity usage.
technologies that can support you build a
the future.
Our proven strategies are guaranteed to deliver
sustainable and competitive business by
From a macro perspective, the challenge for
immediate reductions in energy consumption,
reducing consumption & increasing reliability.
business is to lower greenhouse gas emissions
increasing reliability and reducing the total cost
whilst remaining globally competitive.
of ownership for our customers.
At plant level the opportunities to achieve
Water consumption is generally a much
lower operating costs through reduced energy
smaller input to industry costs than electricity
and resource consumption, reduced materials
or gas; however business recognizes a social
spend and increased reliability....and in doing
obligation to the broader community to lower
so improve profitability and competitiveness...
water usage. BSC’s water management systems
by adopting environmentally sustainable
and new technologies contribute notably to
practices, are significant.
achieving these goals.
As one of Australia’s largest suppliers of bearings, sealing and power transmission products, BSC recognises the positive impact that our specialised products and services can, and do, have in helping our customers become more sustainable across economic and environmental objectives. BSC has been actively working with our customers to achieve these outcomes for several years and we have achieved a level of experience and market leadership demonstrated with significant success across all market segments.
“
If we are going to carry on growing, and we will, because no country is going to forfeit its right to economic growth, we have to find a way of doing it sustainably. Tony Blair
www.bsc.com.au
11
Engineering Services
ENERGY SAVING
ENERGY SAVING
SOLUTIONS
SOLUTIONS
Engineering Services To partner our customers to achieve
BSC Engineering Services include:
optimum plant reliability through
• Energy Reduction Program –
the application of knowledge and technologies which deliver the highest level of service and results. BSC Engineering Services provide a range of services designed to assist you to achieve optimum plant reliability. This can be through a complete reliability program using a variety
• Predictive Maintenance PdM using Condition Monitoring • Stop Leak – Air Leak Detection • Oil Analysis • Infra Red Thermography
of technologies and services. By utilizing
• In-situ Balancing
our complete program, BSC Engineering
• Laser Alignment
Services will work in conjunction with clients
• Failure Investigation
engineering and maintenance teams to
• Installation & Training
achieve agreed results that deliver improved
• Product Redesign
plant reliability and productivity whilst reducing maintenance and capital costs.
12
Energy Audit Service (EAS)
Engineering Services
Sustainability Solutions for Australian Industry
ENERGY SAVING
ENERGY SAVING
SOLUTIONS
SOLUTIONS
Energy Reduction Program – Energy Audit Service understanding how much energy you
reduction of energy consumption via power
up to 40% by analysing inefficient and
currently use and how you can reduce that
transmission and covers AC motor survey,
poorly designed drives and adopting
consumption. BSC is very active in the
analysis and upgrade recommendations to
good drive design practices.
reduction of our customers’ carbon footprint
premium high efficiency super long life motors,
The path to becoming an environmentally
via the BSC Energy Audit Service (EAS). The
gearbox analysis and upgrade, belt and chain
sustainable manufacturer begins with
program focuses upon the meaningful
drives analysis and upgrades.
CASE STUDY
Energy consumption can be reduced
Food Manufacturing Energy Audits for energy savings. BSC Engineering Services conducted an Energy Audit at a manufacturer in
BSC Engineering Sevices conducted a REDUCTION
304 T pa
detailed Energy Audit and Analysis of AC motors at two sites of a large dairy
REDUCTION
1032 T pa
Smithtown. A total of 213 motors were
products manufacturer in Western Victoria
identified for improvement as a result of the audit. Utilising the
who are committed to manufacturing efficiency, quality and
BSC super long life High Efficiency motor range
sustainability. Utilising the super long life High Efficiency motor
• Energy consumption reduction $21,216pa. • Annual CO2 reduction >304 tonnes. • Creation of an up-to-date Asset (motors) Register detailing application, type and size.
range BSC provided an excellent outcome for both sites. • Site 1 • Energy saving $44,748 pa • Annual CO2 reduction 642 tonnes
• >300% increase in motor design life.
• Design life materials and energy savings $1.3m
• Design life materials and energy savings of $887,581
• Project Payback – 10 months
• Project Payback – 16.6 months
• Site 2 • Energy saving $27,198 pa • Annual CO2 reduction 390 tonnes • Design life materials and energy saving $1.1m • Project Payback – 14 months
www.bsc.com.au
13
Engineering Services
ENERGY SAVING
ENERGY SAVING
SOLUTIONS
SOLUTIONS
Predictive Maintenance PdM Program For Asset Optimization.
analysts are called into action immediately
Predictive maintenance PdM aims to find
reviewing detailed machine data to assess
measures of machinery condition and use
condition and recommend the most cost
them to prevent breakdowns. Establishing
effective actions available. Remote program
trends allow accurate pinpointing of
benefits include reduced failure risk and allows
machinery problems and their severity.
for just-in-time maintenance of equipment.
Increasing up time on machines is the primary
Our expertise spans all areas of condition based
aim, while reduced likelihood of secondary
maintenance, including:
failures and less unnecessary maintenance are
• Vibration analysis
additional benefits. Condition Monitoring is most frequently used as a Predictive or Condition-Based Maintenance technique. Condition Monitoring uses advanced technologies in
• Lubrication analysis • Infrared thermography • Laser alignment
order to determine equipment condition, and
• Failure analysis
potentially predict failure.
• In situ balancing
BSC’s Predictive Maintenance Program
• Installation
utilises Azima DLI technology. AzimaDLI is a world leader in condition monitoring services to industry delivering a wide range of technologies and services reducing maintenance costs whilst ensuring maximum equipment reliability. The BSC – Azima Watchman Remote is a robust, automated monitoring and diagnostic service that links industries critical equipment with our best systems engineers and analysts via automated alarms and advanced internet technologies 24/7. When an alert occurs our
14
• Onsite data collection
Engineering Services
Industry Information
Sustainability Solutions for Australian Industry
Predictive Maintenance Published - U.S. Department of Energy - Energy Efficiency & Renewable Energy
Basically, predictive maintenance differs from
Disadvantages
preventive maintenance by basing maintenance needs
• Increases investment in diagnostic equipment
on the actual condition of the equipment, rather than on some predetermined schedule. A predictive maintenance approach strives to detect the onset of equipment degradation and to address the problems as they are identified. This allows causal stressors to be eliminated or controlled, prior to any significant deterioration in the physical state of the component or equipment. This leads to both current and future functional capabilities.
• Increases investment in staff training • Savings potential is readily seen by management There are many advantages of using a predictive maintenance program. A well-orchestrated predictive maintenance program will all but eliminate catastrophic equipment failures. Staff will then be able to schedule maintenance activities to minimize or eliminate overtime costs. And, inventory can be minimized, as parts or equipment will not need to be ordered ahead of time
Recall that preventive maintenance is time-based. Activities
to support anticipated maintenance needs. Equipment will be
such as changing lubricant are based on time, like calendar time
operated at an optimal level, which will also save energy costs
or equipment run time. For example, most people change the
and increase plant reliability.
oil in their vehicles every 3,000 to 5,000 miles traveled. This is effectively basing the oil change needs on equipment run time. No concern is given to the actual condition and performance capability of the oil. It is changed because it is time.
Past studies have estimated that a properly functioning predictive maintenance program can provide a savings of 8% to 12% over a program utilizing preventive maintenance strategies alone. Depending on a facility’s reliance on a reactive
This methodology would be analogous to a preventive
maintenance approach and material condition, savings
maintenance task. If, on the other hand, the operator of the
opportunities of 30% to 40% could easily be realized.
car discounted the vehicle run time and had the oil analyzed at some periodicity to determine its actual condition and lubrication properties, he or she may be able to extend the oil change until the vehicle had traveled 10,000 miles. This is the fundamental difference between predictive maintenance and
In fact, independent surveys indicate the following industrial average savings resulted from initiation of a functional predictive maintenance program: • Return on investment: 10 times
preventive maintenance, whereby predictive maintenance is
• Reduction in maintenance costs: 25% to 30%
used to define needed maintenance tasks based on quantified
• Elimination of breakdowns: 70% to 75%
material and equipment condition.
• Reduction in downtime: 35% to 45%
Advantages & Disadvantages
• Increase in production: 20% to 25%
Advantages
The down side of using a predictive maintenance approach are
• Provides increased component operational life & availability
its initial costs. The up-front costs of starting this type of program
• Allows for preemptive corrective actions • Results in decrease in equipment and/or process downtime • Lowers costs for parts and labor
can be expensive. Much of the equipment requires expenditures in excess of $50,000. And, training of in-plant personnel to effectively utilize predictive maintenance technologies and practices will require substantial additional funding. And,
• Provides better product quality
beginning a predictive maintenance program requires an
• Improves worker and environmental safety
understanding of the facility’s predictive maintenance needs and
• Raises worker morale
the approaches which need to be undertaken. It is also essential
• Increases energy savings
to have a firm commitment, by management and all facility staff
• Results in an estimated 8% to 12% cost savings over which might result from a predictive maintenance program
www.bsc.com.au
and organizations, to make it work.
15
Engineering Services
ENERGY SAVING
ENERGY SAVING
SOLUTIONS
SOLUTIONS
Operation Stop Leak Air leaks are one of the biggest
its location, severity and cost. From this, total
• Reduce fluid loss
contributors to needless costs in any
estimated savings are generated within a
• Identify Cost Savings
industrial plant/facility.
corresponding report. The report provides a detailed format for a targeted approach and
• Energy savings translate into cost savings
A leak is a costly drain on overall operating costs. State-of-the-art ultrasonic equipment is
allows monitoring of progress by cfm and
used to identify air leaks.
dollars saved.
The “Operation Stop Leak” Process is the first
Objectives of Operation Stop Leak
step in continuous improvement. Every
• Identify Air and Fluid Leaks
identifiable leak, including fittings, valves,
• Reduce energy usage
CASE STUDY
• Increase Safety & Reliability • Identifying air and fluid leaks enable corrective action to be implemented • Training in use of Loctite solutions reduces rework and improves equipment reliability
flanges and hoses are tagged with a number,
Printing Works
REDUCTION
945 T pa
BSC Engineering Services utilising Ultrasonic Leak
all the leaks rectified the company was able to
Detection has produced annual savings of $80,000
shut down one of their compressors as the third compressor
for a large Sydney based printing works.
was just servicing their air leaks.
Producing high volume magazine and brochure print requires
This was a cost saving of $80,000 in energy costs alone and
volumes of compressed air to be transported to machinery
a substantial reduction in green house emissions! The third
throughout the plant as do many packaging processing
compressor is used today as a back up and in time will be
plants. This particular printer uses three large Atlas Copco
decommissioned further reducing maintenance and
Compressors to service their plant and was concerned about
operating costs.
their inability to identify problem leaks. Using the Ultrasonic Leak Detection service BSC Engineering Services were able to tag and locate the costly leaks providing a comprehensive report on the actions and products required to repair the compressed air system. Three months later with
16
• Reduce cleanup costs
Sustainability Solutions for Australian Industry
GEAR BOXES
Nord Helical-bevel geared motor
ENERGY SAVING
ENERGY SAVING
SOLUTIONS
SOLUTIONS
Nord Helical, Parallel shaft & Helical-bevel gear units Highly efficient power transmission.
A worm gear unit can have efficiencies
Operating at 16 hours per day with a cost of
Gearboxes are used throughout industry to
ranging from as low as 40% to as high as 93%
15cents/kWh, it costs $1603 per annum in
achieve a speed reduction from the motor
depending on the worm size, ratio and input
electrical energy. A 15% reduction compared to
shaft to the output shaft. Conversely, gearboxes
speed. A 2 stage helical-bevel box has an
the worm gear unit. This saving does not even
multiply torque as they reduce speed. There are
efficiency of up to 98% and a 3 stage helical-
include the use of a W22, super high efficient
various forms of gearboxes and consideration
bevel of up to 95%. A large amount of energy
motor compared to a standard efficient motor
should be given to the efficiency of the
saving can be achieved by using helical-bevel
– which at 2.2kW can provide approximately 6
gearbox during the selection process.
gear units instead of worm gear units.
to 7% additional savings.
NORD gear units are the right solution for your
Taking an example of a 3 inch worm box with
Multiplied by the number of gearboxes that
application if the highest levels of efficiency are
an output speed of 72 RPM and providing
can installed on one production line, not to
required. Due to optimised gear design relative
239 Nm. This equates to 1.8kW of mechanical
mention the whole plant, installing helical-
to rolling motion, especially in NORD helical
power however, due to the low efficiency of
bevel gearboxes can provide significant
and bevel gear units, mechanical losses caused
the worm box, it requires a 2.2kW motor to
savings, especially as the above comparison
by friction are reduced to a minimum – the
operate. This worm gear unit has an efficiency
was with a relatively high efficient worm gear
drive is practically without losses!
of 82%. Operating this unit 16 hours per day
unit. In certain instances it is even possible
with a cost of 15 cents/kWh, it costs $1880 per
to reduce the motor size as the helical-bevel
annum in electrical energy.
boxes have higher torque ratings.
An equivalent helical-bevel gear unit to provide
All NORD drives are built in the UNICASE™
the same mechanical power would only
housing design first developed by NORD in
consume 1.83kW of electrical power.
1981. In addition to the high levels of efficiency of the NORD gear drives helical and bevel gears there are other key advantages for the user. Greater operational reliability, high output torques, high axial and radial loading capacity, quiet running, high efficiency as well as
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17
GEAR BOXES
Nord Helical, Parallel shaft & Helical-bevel gear units (Continued)
Nord Unicase housing - cutaway
ENERGY SAVING
ENERGY SAVING
SOLUTIONS
SOLUTIONS
and therefore no sealing surfaces are subjected
longer service life of the product are the key
to torque loads. Additional advantages of
features of this series.
this system are the high rate of production
The main feature of the UNICASE™ housing
accuracy, lowest tolerances and smooth,
design is that all boreholes are integrated into
quiet running.
one housing block. All boreholes and sealing
Nord are a leading German drive manufacturer
surfaces are incorporated into a single-line. The
for the global market with a range of gearboxes
advantage: no screwed-on bearing surfaces
from 0.12kW to 1MW, 19Nm to 200,000Nm.
CASE STUDY
reduced maintenance requirements and a
Mixing Application
138 T pa
Total Increase in Gearbox Efficiency of 88%
The outcome for the customer:
Major BSC confectionery customer in Tasmania recently
• Reduction in energy consumption of 96, 910 kwh
worked with the local BSC branch for 5 replacement specialty
per annum
inline gearboxes on mixers. The existing gearboxes that had to
• Reduction in CO2 emissions of 138 tonnes per annum
be replaced had an efficiency of 51%.
• Nett reduction in energy costs of $9,691 per annum
After consultation with the customer and Nord, BSC offered helical-bevel boxes which were ex-stock and had an efficiency of 96%. Being a Nord standard gearbox configuration, the purchase cost and lead time was lower compared to a direct replacement from the original vendor.
18
REDUCTION
BELTS
Sustainability Solutions for Australian Industry
Belt Drives & Energy Efficiency
A
bout one-third of the electric motors
strides to improve efficiency and productivity
Timing Belts are toothed and operate by
in the industrial and commercial
of motors and driven equipment. However,
mating the tooth profile of the belt with that of
industry sectors use belt drives. Belt
little attention has been given to the power
a sprocket. Timing belts are also called positive
drives provide flexibility in the positioning
transmission component connecting the
or synchronous and offer efficiency levels of
of the motor to the driven equipment.
equipment. Ordinary wrapped belts waste
about 98% and maintain this efficiency over
Pulleys of varying diameters allow the speed
energy - an average typical operating
a wide load range. In contrast timing belts
of the driven equipment to be increased
efficiency for wrapped V-belts is 90% to 94%.
do not have the sharp reduction in efficiency
or decreased. A properly designed belt
There are two belt constructions that can
at high torque due to increase in slippage as
transmission system provides high efficiency,
improve efficiency levels.
v-belts do.
low noise, does not require any lubrication,
Raw Edge Cog Belts have cogs that run
Energy savings of up to 20% can be realised
and presents low maintenance requirements.
perpendicular to the belts length and are
immediately by simply upgrading the belt
However, certain types of belts are more
manufactured in raw edge construction.
transmission used on the drive. Timing belts
efficient than others, offering potential energy
The cogs improve the belts flexibility
are the most efficient choice, however cog
cost savings.
reducing bend resistance and the raw-edge
belts may be a better choice when vibration
The majority of belt drives use V-belts. V-belts
premium rubber sidewalls allow better grip
damping is needed or shock loads are present
use a trapezoidal cross section to create a
characteristics reducing belt slip.
causing abrupt torque changes in the drive.
wedging action on the pulleys to increase
On average the raw edge cog belts will
Cog belts also do not require any pulley
friction and the belts power transfer capability.
run 4.5% more efficient than ordinary
modifications as cog belts can be installed on
Joined or multiple belts are specified for
wrapped belts.
existing pulleys.
heavy loaded drives. V-belts can have a peak efficiency of 95% to 98% at the time of installation. Efficiency is also dependant on pulley sizes, driven torque, under or over belting, belt tension and V-belt design and construction. Efficiency can deteriorate by as much as 5% to 15% (to nominal efficiency of 93%) because of the belts tension. If tension is not applied correctly at installation or is not periodically checked over time slippage occurs thus dramatically reducing efficiency levels. In all drive systems the efficiency of a drive system is at the mercy of its weakest link. The maintenance industry has taken great
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“
We must all work together in order to save the environment and the world that we live in from further change. Dave Foreman
19
BELTS
ENERGY SAVING
ENERGY SAVING
SOLUTIONS
SOLUTIONS
Gold Label Raw Edge Cog Belts pulleys better and precision molded cogs for
immediate energy savings without changing
energy waste by 50% or more.
improved flexibility and cooler running. Saving
pulleys or modifying your drive! Conventional
Ordinary v-belts waste energy and money.
energy on air moving systems is as easy as
V-Belts deteriorate to a nominal efficiency of 93
Tests prove the Gold Ribbon Cog-Belt by
taking old v-belts off the drive and installing
percent. Carlisle Gold Label Cog-Belts maintain
Carlisle is more energy efficient than ordinary
a factory matched set of the Carlisle Gold
higher efficiency ratings, resulting in significant
v-belts. The secret to the energy saving
Ribbon Cog-Belts. Gold Ribbon can be installed
savings.
power of the Gold Ribbon Cog-Belt is in its
on your existing drives without any special
unique design. The Gold Ribbon Cog-Belt has
drive modifications. Install Carlisle Gold Label
raw-edge premium rubber sidewalls to grip
Cog-Belts on your existing V-Belt drive to realize
CASE STUDY
Gold Label Cog-Belts can reduce
Fine Sediment Crusher An Improved Crusher Drive Saving $1700 Annually
The drive was installed and run, with the New Carlisle
Standard wrapped V-Belts were lasting up to 6 weeks on a Fine
SPBX3000 running for nearly 9 months, more than 6 times
Sediment Crusher. The cost of the continual maintenance and
longer than the original set up. The plant noticed that the
shut down of the machine was a large factor in the annual
drive no longer required maintenance due to belt problems.
maintenance budget for the plant. The abrasive environment
The improved up-time and reduced maintenance meant time
was considered the main root cause for the failures.
could be invested in other problem areas. Altogether a saving
With the drive information supplied by the site, we were able
for the plant of more than $1700 annually.
to use the Carlisle Drive Engineer 3.1 program to analyze the
ANNUAL BELT LIFE COMPARISON
drive. The change from the original “B� section to the high power SPBX3000 Cogged Raw Edge belts ensured that the
300
drive had sufficient capacity for all situations. With the new
200
drive tensioning was also pointed out as the probable culprit of some of the failures.
262
100
42
0
DAYS Original Life
20
New Life
BELTS
Sustainability Solutions for Australian Industry
ENERGY SAVING
ENERGY SAVING
SOLUTIONS
SOLUTIONS
RPP Panther® of 98% efficiency. RPP Panther is the power
these components are likely to be worn out
effectively transfer power at
transmission system of choice on many
and wasting energy due to drive slippage and
98-99% efficiency.
new installations. Because of the positive
tension loss. It’s probably time to replace these
For maximum drive system efficiency, the
engagement power transfer of Panther,
worn out components. It is also an opportune
Carlisle RPP Panther high torque synchronous
operating speeds can be controlled much
time to upgrade your existing power
belt can put some real teeth into your plant
more closely than with ordinary v-belts. The
transmission system from outdated chain or
maintenance energy conservation program.
RPP Panther is ideally suited for modern
v-belt drives to the modern and efficient RPP
The RPP Panther synchronous drive system
systems where inverter devices and / or
Panther drive system. The payback in energy
operates on a “teeth in mesh” principle for
modern systems where inverter devices are
savings is often recovered in just a few short
positive engagement between belt and
used because of its inherent high operating
months.
sprocket. As a result, power is transferred
efficiency. Also, if your belt drive pulleys or
from the motor to the driven unit at a rate
chain sprockets are more than five years old,
CASE STUDY
Tests show that RPP Panther can
Stock Feed Plant Total Cost Savings $5,500 per individual auger Premature failure of the roller chain drive on the auger was causing ongoing downtime losses every 4 months. Time was also being lost in having to lubricate the chain drive. This was not a regular program and the inevitable failure of the drive caused loss of production and unplanned downtime to replace the chain. The augers were difficult to access and operated in a hot, dry and dusty environment. BSC’s objective was to design a drive that would extend life from the existing 4 months to a minimum 12 months. BSC recommended the new Panther Ultra Cord and completed a drive design for this application, the Dayware software selection offered a drive that would meet all space requirements and provided an adequate service factor for the application. In most harsh environments Panther Ultra Cord belts last many
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times longer than conventional chain. The new drive was installed and has been a success. The customer has already ordered some more belts for the other 8 augers as the trial is running so well. Extended Life = 20 months… AND STILL GOING!
EXTENDED LIFE = 20 MONTHS + 600
600 400 200
120
0
DAYS Original Life
New Life
21
BELTS
ENERGY SAVING
ENERGY SAVING
SOLUTIONS
SOLUTIONS
Power Wedge Raw Edge Cog Belts Wedge Cog-Belt is heat and oil resistant and
Raw Edge sidewalls provide greater contact
belts improve system performance.
static dissipating. It’s available in SPZX, SPAX,
with the pulley surface and produces a
Transmit more torque with less slippage.
SPBX, SPCX & SPPX cross sections lengths up
smoother running belt.
Higher horsepower ratings translate into
to 5000mm.
greater design flexibility, reducing space,
The Hi-Modulus cord carries high horsepower
weight and drive costs. Carlisle’s raw edge
loads with minimum stretch and improved belt
construction creates outstanding operating
stability, requiring fewer take-up adjustments.
efficiency. More torque with less slippage
Fabric Laminates are located in the “Power
reduces energy costs. The Power-
Zone” to maximize response to shock loads.
CASE STUDY
Efficient raw edge and synchronous
Fan Drive Refurbishment
120 T pa
$10,000 energy saving per annum
the top performing V belt available and the
A major industrial site had advised a need to refurbish the
Megadyne Silver Series High Performance Timing Belts were
existing fan drives as they were over 14 years old. The fans
also an option.
we visually inspected and condition of the pulleys all had
The proposal for the total refurbishment included both belt
shown signs of extreme wear. The site was also heavily into
types. The extra cost for changing the drives to the Megadyne
conservation of resources so they expressed an interest in the
Silver RPP profile timing belt was a $2,000 premium over the V
energy conservation options available
belt version.
Using the Carlisle Design program each drive was checked
The lower bearing loads by up to 30% that the timing belt
to ensure the latest belt types would be used to offer the
offered, plus the $10,000 energy saving over the V belt per
best drives for the purpose. As the pulleys would also be
annum resulted in a payback period measured in only months..
looking at getting replaced there was an opportunity to explore the timing belt option as a way to improve efficiency and also lower the bearing usage from the site. The Carlisle Power Wedge Cogged Raw Edge design was favoured as
22
REDUCTION
BELTS
Sustainability Solutions for Australian Industry
ENERGY SAVING
ENERGY SAVING
SOLUTIONS
SOLUTIONS
Super II Energy savings of up to 20% can
mill debarkers, pipe descalers, and any other
eliminates backside idler problems. Superior
be realised immediately by simply
application known for being tough on v-belts.
grade 100% neoprene rubber compound
upgrading the belt transmission used
The secret to the Super II v-belt’s durability is
resists cracking from heat and flex fatigue
its unique construction. Several innovative
better than ordinary wrapped v-belts that use
Many heavy-duty, industrial drive system
Super II design features allow you to avoid
cheaper, less effective rubber. Neoprene also
applications demand more than conventional
many problems common to ordinary wrapped
provides the best resistance available against
v-belts can stand. Punishing drives make
v-belts. Rugged multiple fabric plies on both
dirt, dust, ozone, oil, and grease. Unique fabric
ordinary wrapped v-belts crack under pressure,
the top and bottom of the v-belt help relieve
loaded raw edge sidewalls grip pulleys better
resulting in costly downtime. End the hassle
stress on the centre cord, assist in minimizing
than wrapped v-belts but still allow controlled
and expense of constant v-belt breakdowns
belt stretch, and help to control slippage under
slippage during extreme shock loads for
with Super II from Dayco. This rugged v-belt
heavy loads. The high modulus polyester
increased productivity. The raw edge Super II
is specifically designed to provide superior
cord located in the mid-section of the v-belt
also dissipates heat quicker for cooler running,
performance on the most brutal v-belt drives
resists extreme shock loads without stretching,
longer lasting v-belts.
including rock quarry shaker screens, lumber
increases v-belt flexibility for longer life, and
CASE STUDY
on the drive.
Aggregate Plant Carlisle Super II V-belts outlast wrapped belts up to
II having the characteristics of wrapped construction but the
6 times longer.
performance of raw edge would make them ideally suited for
A large Aggregate Plant using wrapped construction v-belts
the off & on load cycles generated by the shaker screen drive.
was constantly having to change out the V-belt drives on
After 8 weeks no belts had failed and the Super II was proving
their shaker screens. Belts would only last 2-4 weeks on
to be a great success. The original set of Super II was eventually
average depending on the volumes being processed. The
replaced after 18 weeks in operation. Performing over 4 times
constant changing of belts was a huge problem in belt costs,
longer than the wrapped construction belt.
maintenance time and down-time. The maintenance supervisor was introduced to Carlisle Super II V-belts. It was explained that the unique construction of Super
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23
BELTS
ENERGY SAVING
ENERGY SAVING
SOLUTIONS
SOLUTIONS
Powermiser Software Use the Powermiser program to calculate the energy savings you can enjoy with efficient Carlisle Raw Edge V-belts and timing belts. An area not often considered when looking at a cost of a belt is energy efficiency. The efficiency of a v-belt drive is a measure of the utilization of total energy input to the belt pulley system. A major source of energy loss in a v-belt is internal friction of the rubber, cover and cords when they are cyclically deformed while traversing a pulley. The magnitude of energy loss depends upon material properties and the amplitude of deformation.
CASE STUDY
Many original equipment manufacturers tend to standardise on traditional wrapped V-belts. These belts are generally designed
for long life, high load, power capability and smooth running. One of the design criteria of a wrapped belt is also its ability to slip somewhat on start-up, which tends to compensate for high starting torque or load, which can sometimes vary from 1-1/2 to 3 times the normal running torque of the motor. While these belts will provide exceptional performance on a drive, they generally have an overall efficiency rating of between 88% - 94%, which equates to a performance and energy loss between 6 to 12 percent. This unfortunately is a potential savings that is overlooked when doing system design or system maintenance.
Features • Will allow you to calculate the energy savings you can enjoy. • Input fields hours of operation per year, Motor Power rating. Motor efficiency level, Utility rate, belt efficiency % increase. • User friendly and Windows® based • Calculates the annual dollar savings based on your utility costs. • Include V-belts and timing belts
This energy loss can be difficult to measure, however Carlisle Power Transmission has
Paper Mill Savings of $156,000 per annum In today’s economic environment it is important that each industry operates efficiently and economically. BSC was asked to evaluate 132 belt driven machines in a Pulp and Paper mill to ascertain any problems and offer advice on improving belt performance and efficiencies With the drive information supplied by the site, we were able to use the Carlisle Drive Engineer 3.1 program to analyze each drive. We checked for conformance to ISO design standards, noticeable drive warnings such as excessive shaft loadings and under designed drives. We advised remedial action for the
24
developed a software program called POWERMISER that will enable end users to calculate the energy cost when changing to more efficient belt construction such as Raw Edge Cog or Timing Belts.
REDUCTION
under designed and over designed drives and tensioning information for all drives to ensure best maintenance practices were followed.
286 T pa
The 9 drives evaluated as under designed could be the cause of at least 9 plant stoppages a year. With the cost of downtime at the plant at approx $16,500 per hour, the possible savings from a belt drive re-design was estimated in excess of $121,000 a year. Combined with an energy saving of up to $30,000 per year by using the most efficient belt drive types and tensioning drives correctly, the customer can enjoy the benefit of a $156,000 saving per annum.
Sustainability Solutions for Australian Industry
WATER SAVING
WATER SAVING
SOLUTIONS
SOLUTIONS
WATER MANAGEMENT SYSTEMS
Habasit TS EXTRA Low Friction Flat Top Chain The environmental choice, save money
Habasit’s TS option for Flat Top chain, uses
than standard low friction models, which also
save the environment.
extra low friction resin technology, resulting in
contributes to smooth, effortless and quiet
•
the lowest coefficient of friction, with special
operation.
self-lubricating agents built into its molecular
Habasit TS, is dimensionally interchangeable
structure.
with most LF products on the market, so there
Ideal for critical bottling applications, this chain
is no need to change out sprockets and wear
Reduce water usage Reduced power consumption
•
Reduce noise
•
Smooth operation
is well suited to dry running applications. The
•
Long life
strips unnecessarily. However, Habasit can also
benefits include, reduced water consumption
provide a special low noise sprocket option
•
Improved reliability
associated with top chain lubrication. The
complete with a patented split sprocket / split
extra low friction Habasit “TS” uses less energy
bush and suitably compatible wear strips.
CASE STUDY
•
Major Bottling Plant TS Series Habasit / KVP chain has been recently
In straight water saving this saves the site over $15,000 per
installed as the exclusive specification within a
annum in water consumption costs alone. An additional
major bottling plant in Queensland.
benefit of moving from the ‘LF’ chains to the TS Series is the
In the past the plant had used standard low friction ‘LF’ acetal
240% - 270% extra life that will be achieved thanks to the
table top conveying chains throughout the site. The ‘LF’ series
harder-wearing nature of the special TS material.
chains did the job, however this busy plant was consuming
The TS Series table top conveying chain has proved to be a
over 11 Million litres per annum in potable water in order to
significant weapon in the battle to reduce ongoing operational
constantly lubricate the acetal conveying chains.
costs in the areas of resource consumption and maintenance
The significantly increasing cost of water plus the social
expenditure.
imperative to preserve what is the most precious and often taken for granted resource on our planet, were driving factors in the site’s decision-making process. The self-lubricating properties of the TS Series chain have resulted in the plant ‘turning off the taps’ as the need to water lubricate no longer exists. www.bsc.com.au
25
WATER MANAGEMENT SYSTEMS
WATER SAVING
WATER SAVING
SOLUTIONS
SOLUTIONS
AESSEAL Water Management “The Problem” Mechanical Seal water wastage and seal unreliability.
one pump of 6.3 million litres per year (1.7 million gallons per year).
The most common methods of supporting mechanical seals with water are either flush/ quench to drain or into the process fluid.
Bearing in mind there is an initial cost attached to this water which multiplies upwards when we consider the cost of steam generation required to drive this flush water out of the process via the evaporator. This figure further escalates with the number of pumps associated in any given production line.
The two key impacting negatives here are the high water consumption and high cost of removing injected water by evaporation further along in the manufacturing process. These methods typically waste huge amounts of water, and in some cases produce vast amounts of water effluent which subsequently needs to be treated, adding even more cost and consuming even more environmental resources.
CASE STUDY
Typical water consumption of a single mechanical seal in this arrangement is in the region of 12 litres per minute (3.17 gallons per minute), which gives a total consumption for
26
AES Water Management Seal Support Systems – “The Solution” Rather than running water straight through the seal to drain, the AES standard water management system removes heat and lubricates the mechanical seal faces by use of the ‘thermosiphon effect’. Colder water is supplied to the mechanical seal, which is in turn heated
up by the seal faces. This ‘warmer’ water then rises back into the vessel, raising the bulk temperature of the vessel. The vessel then loses heat to the atmosphere which results in an ‘equilibrium temperature’ being reached. Should the vessel be required to lose more heat to the atmosphere, the increased surface area of the system ensures that this can occur. In order to prevent contamination of the system, a positive pressure is applied to the clean water in the system. This is achieved by connecting the system to the plant mains water supply and adjusting the integral water pressure regulator to the required pressure. This also ensures that if a small trace of water is lost into the process across the seal faces, this will be immediately replaced by water from the mains supply.
Mechanical Sealing & Water Management Payback: the total cost of the redesign was $30,813.50, bringing the full payback period below 12 months and ensuring significant nett savings each following year of nearly $35,000pa. BSC Engineering Services, working in conjunction with one of BSC’s national contract customers, analysed mechanical sealing and water management systems around 12 individual pump applications. The site had 10 pumps that were flushing to drain and 2 that were flushing to process. Measuring the flow from the pumps that were flushing to drain revealed an annual usage of 24.2 million litres of water at a cost of $35,562 per annum.
BSC Engineering Services redesigned the mechanical seals to reliable double seal assemblies with AES SW02 water management systems fitted with flow and purge fuses. The reduction in water usage was dramatic – reducing to only 450 litres per annum across all 10 pumps ...a saving of over 24 million litres per year. In addition to the huge savings, the application of the flow and purge fuses had the benefit of removing the opportunity for bacterial growth within the system vessel. The flow fuse also provided a further benefit of protecting the final product from mass contamination in the situation of eventual momentary upset or failure of the mechanical seal.
BEARINGS
Sustainability Solutions for Australian Industry
In recent years, demand for hybrid vehicles has been rising rapidly due to their low fuel consumption and low emissions, realised through a more efficient integration of the engine and electric motor. NSK has developed low-torque ball bearings for hybrid vehicles designed to improve fuel efficiency. In order to further improve fuel efficiency, there is a growing need to reduce torque loss in the bearings used in the transmissions (drivetrains) of new generation hybrid cars. ENVIRONMENTAL
ENVIRONMENTAL
SOLUTIONS
SOLUTIONS
NSK has met this need with its lowtorque bearings, which reduce frictional loss. The new product will be featured in Toyota’s latest Prius model. NSK has claimed to have found a way to cut torque by 50-65 per cent compared to existing bearings.
Molded-Oil™ Bearings Environmentally friendly lubricant. Anti-friction bearings by their very nature are designed to be energy efficient. One particular area of modern bearing technology that does make a noticeable contribution to sustainability is the NSK Molded-Oil Bearing. Molded-Oil Bearings are lubricated with NSK’s own oil-impregnated material, consisting of lubricating oil and polyolefin resin that has an affinity for oil. Oil slowly seeping from this material provides ample lubrication to the bearing for the life of the bearing.
CASE STUDY
The solid lubricant is resistant to both water
and dust and acts as a barrier to protect the bearing from penetration of contaminants. Bearing life in water or dust contaminated environments is consequently increased significantly. A significant benefit of the Molded-Oil Bearing is that once fitted there is no subsequent need to worry about relubricating. Environmentally friendly as oil seeping from the Molded-Oil inside the bearing provides sufficient lubrication, troublesome oil refilling or grease repacking is not required and, as well as consumption of lubricant being negated, contamination of the environment is negligible.
The number of balls has been reduced, and ball diameters, race dimensions and clearances have been optimised utilising analysis technology, which has allowed rolling friction losses to be minimised. NSK’s new manufacturing processes overcame conventional hurdles to decrease the number of balls. Losses have been reduced by agitating lubrication oils during operation via the introduction of specially shaped cages made of resin. NSK has achieved compactness, lightness and low torque for automobiles via its four core technologies: tribology, materials, analysis and mechatronics.
Cane Train Locomotives Total maintenance & materials savings > $270,000 PA A Sugar Mill was experiencing ongoing life problems with the performance of crank bearings on its fleet of cane train locomotives resulting in frequent maintenance and re-greasing. Normally the cranks are totally covered in grease which, apart from being environmentally unfriendly, results in contaminants sticking to the lubricant and eventually working their way into the bearing set-up and shortening bearing life. The bearings would need to be changed every year. The cranks in each of the 16 locomotives would require 182 hours of re-greasing per season, using 26 barrels of grease each year.
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Engineering asked BSC Cairns to assist by identifying a ‘better way’. The solution was to replace the bearings with NSK Molded Oil bearings which contain an integral solid lubricant with oil life designed to last approximately 8 years and are therefore maintenance-free. The Molded Oil bearings have now completed two years and will remain in service for a third year with the likelihood of that extending out an additional year or two as the Mill is intending to run them until failure – no additional lubrication is required. The maintenance and materials (grease) savings have been significant and will continue to be enjoyed in subsequent years.
27
VICTORIA
QUEENSLAND
WESTERN AUSTRALIA
SYDNEY STATE OFFICE
MELBOURNE STATE OFFICE
BRISBANE STATE OFFICE
PERTH STATE OFFICE
MOOREBANK Phone: (02) 9824 2100
CLAYTON Phone: (03) 9560 3222
NORTHGATE Phone: (07) 3866 8333
Welshpool Phone: (08) 9251 4444
BRANCHES
BRANCHES
BRANCHES
BRANCHES
ARNDELL PARK (Bearing Traders) Phone: (02) 9622 9322
BALLARAT Phone: (03) 5337 6001
ARCHERFIELD Phone: (07) 3277 4488
O’CONNOR Phone: (08) 9337 3000
DANDENONG Phone: (03) 9794 5624
BUNDABERG Phone: (07) 4153 3220
OSBORNE PARK Phone: (08) 9445 1811
GEELONG Phone: (03) 5272 2951
CABOOLTURE Phone: (07) 5495 6266
MORWELL Phone: (03) 5134 3633
CAIRNS Phone: (07) 4225 3100
SHEPPARTON Phone: (03) 5821 4911
MACKAY Phone: (07) 4952 1399
SOMERTON Phone: (03) 9308 7000
ROCKHAMPTON Phone: (07) 4927 2033
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ACT Canberra Phone: (02) 6280 7517
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