Canada’s trusted journal for plant operations, engineers and maintainers
PM # 40063602
PAP Registration # 10778
RELIABILITY n FACILITIES n PRODUCTION n MACHINERY
PEM_Apr07-front.indd 1
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PEM_Apr07-front.indd 2 1
Henkel_PEM_Apr_07.indd
4/19/07
4:01:49 PM
4/4/07 2:28:17
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Table of Contents
VOLUME 30, ISSUE 2
APRIL 2007
FEATURES
Your Bearings
24 Get
Prevent bearing failures with proper lubrication
Lubrication plays a critical role in extending the life of bearings and
improving equipment uptime.
By Ken Bannister
and Bruises
30 Bumps
Handle bearings properly to improve operating life
Companies spend lots of money on new bearings. Handle your bearings with care or pay a big price for neglect.
24
Uptime
32 Belt
Repair conveyor-belt cleats faster on the shop floor
These helpful and back-to-basic tips will make your next conveyor-belt
cleat repair go a little easier.
By Beth Miller
Belle Province
38 La
PTDA Canadian conference set for Québec City
The Power Transmission Distributors Association (PTDA) will hold its
Canadian conference in Québec City.
By Robert Robertson
In the next issue of PEM:
FUTURE LOOK
n
As PEM highlights the past 30 years, we'll also chart
the future of maintenance.
YOUNG GUNS
n
Spot
40 Hot
BSA set to hold annual
convention in Florida
New breed of savvy maintenance professionals set to
make shop-floor change happen.
Also see our preview of the upcoming
Bearing Specialists Association annual
convention in Florida.
By Robert Robertson
FOR HIRE
n
Industry strives to find critical answers to Canada's
looming skilled trades shortage.
P
PLANT ENGINEERING
AND MAINTENANCE
A CLB MEDIA INC. PUBLICATION
EDITOR
Robert Robertson
rrobertson@clbmedia.ca
(905) 726-4655
SENIOR ART DIRECTOR
Nicole Diemert
ndiemert@clbmedia.ca
PROD./OPERATIONS EDITOR
ASSOCIATE PUBLISHER
SUBSCRIBER SERVICES
David Berger, P.Eng. (Alta.)
Mike Rightmyer
mrightmyer@clbmedia.ca
(905) 726-4665
Kristen Schulz
kschulz@clbmedia.ca
CONTRIBUTORS
Wilfred List
Ken Bannister
Terry Wireman, CPMM
John Gross, P.Eng.,
CPE, CQE
Joel Levitt
Galen Burdeshaw
John Lambert
4
Lisa Drummond
ldrummond@clbmedia.ca
ACCOUNT MANAGER
CREATIVE DIRECTOR
PRODUCTION CO-ORDINATOR
GROUP PUBLISHER
Kathryn Nyenhuis
knyenhuis@clbmedia.ca
(905) 713-4334
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fshoniker@clbmedia.ca
(905) 713-4379
Return undeliverable addresses to:
CLB Media Inc., 240 Edward St.,
Aurora, ON L4G 3S9
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VICE-PRESIDENT, IT AND OPERATIONS
David Overall
DIRECTOR, SALES & MARKETING
Frank Shoniker
DIRECTOR, EDITORIAL & PRODUCTION
Jackie Roth
DIRECTOR, CIRCULATION
James Zammit
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-front.indd 4
MANAGER, PRODUCTION
Peter Helston
peterhelston@yahoo.com
(416) 236-7852
PRESIDENT
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VICE-PRESIDENT MEDIA, PUBLISHING
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VICE-PRESIDENT FINANCE/
CORPORATE DEVELOPMENT
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38
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erice@clbmedia.ca
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DIRECTOR, HUMAN RESOURCES
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MEMBER, CLB MEDIA INC.
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PEM Plant Engineering and Maintenance is published six
times yearly by CLB Media Inc., 240 Edward St., Aurora,
ON L4G 3S9. All rights reserved. The contents of PEM are
copyright by ©2007 CLB Media Inc. and may not be
reproduced in whole or part without written consent.
CLB Media Inc. disclaims any warranty as to the accuracy,
completeness or currency of the contents of this publication
and disclaims all liability in respect of the results of any
action taken or not taken in reliance upon information in this
publication. Issue dates are February, April, June, September,
November and December. Yearly subscription rates: Canada
$84 plus GST*; U.S. $96; Others $240. Single copy prices:
Canada $15; U.S. $20.
Canada Post – Canadian Publications Mail Product Sales
Agreement 40063602. International Standard Serial Number
(ISSN) 0710-362X. PAP Registration No. 10778. We acknowledge the financial support of the Government of Canada
through the publications Assistance Program toward our
mailing costs.
*Goods & Services Tax Registration No. R101006989.
Printed in Canada.
For information on reprints of any article that appear
in this publication, contact The Reprint Outsource at
1-877-394-7350.
c a
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4/16/07 11:53:30 AM
EDITOR’S NOTE
COLUMNS
16
Plant Safety
16
Sell this to
your boss
and CEO
Put a stop to workplace injuries
Safety is everyone's business.
by Fred Matthews
18
A
Power Transmission
Get the most out of your V-belts
Install V-belts the right way.
by Ryan LaFevre
22
Maintenance Software
Work hard to achieve CMMS success
6
It all starts with simple steps.
by David Berger, P.Eng. (Alta.)
6
DEPARTMENTS
Hands On
Industry Update
Ask Ken
n Back to Basics
n
n
43
Marketplace
46
MRO Express
49
FYI
50
People and Productivity
43
Industrial products and services.
PEM’s bonus showcase of the
latest product innovations.
Advertiser contact information.
Cup runneth over.
by Wilfred List
Celebrating 30 years in publishing!
50
Please join PEM as we celebrate
30 years in publishing. Our mandate
remains to provide you with mustread editorial, while contibuting and
giving back to the industry. Watch
ccording to a recent report
published by the U.S.-based
Aberdeen Group, nearly 87
percent of asset owner/operators in asset-intensive industries agree that proper maintenance of their production
assets is crucial to their organizations.
The report titled: “Collaborate Asset Maintenance
Strategies” (www.aberdeen.com) further reveals that
leading companies have achieved success with key performance metrics, including a larger return on invested
capital, greater asset productivity, improved asset uptime
and lower maintenance costs.
Report findings were based on the results of a study,
which examined how 300 companies (i.e. Coors Brewing,
DuPont and Nova Chemicals) in asset-intensive industries are excelling with process definition, organizational
alignment, data management, technology integration
and performance management.
“We found proactive maintenance processes that
augment regularly scheduled preventive maintenance
routines tend to boost companies into the best-in-class
category,” says Michael Israel, research director, service
chain research at Aberdeen and author of the report.
“Corollary data strongly suggests that best-in-class organizations operate in a ‘break-fix’ mode far less often than
do their laggard counterparts.”
Israel offers the following recommendations, which he
says will lead to maintenance improvement:
· Implement aggressive proactive maintenance strategies;
· Use analytics software to measure actual asset performance against established goals;
· Centralize management and control of asset maintenance;
· Build a case for the CFO that focuses on the importance
of investing to support proper service and maintenance
practices; and
· Consider spare parts/MRO inventory planning and
strategies.
More than ever, maintenance managers require
the financial support from management to get the
job done. Check out the useful online report and
push it up the corporate ladder.
for the June 2007 issue, as it will
Robert Robertson, Editor
PEMAC Allied Member
rrobertson@clbmedia.ca
be PEM's official 30th anniversary
issue. The issue will include a new
graphic design and more!
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AP R I L 2 0 0 7
5
4/16/07 11:31:10 AM
Hands On
0n
NEWS AND NOTES FOR THE PLANT PROFESSIONAL
INDUSTRY UPDATE
SKF celebrates its 100th anniversary
around the world
GÖTEBORG, SWEDEN—When SKF was estab-
6
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-front.indd 6
PHOTOS: PEM
in the second half of 2007. SKF also
lished on February 16, 1907, it was with an
says the European Commission’s LIFEoffer not only of a revolutionary new bearing,
Environment program 2006 supports
but also of the technical support and service
its efforts to lower machinery energy
to get the most value out of it. One hundred
consumption.
years later, providing service is as essential to
“Innovation isn’t new to SKF and
SKF as the product itself.
bearings have been the core of the comBut when Swedish engineer and founder
pany in the past—today and tomorrow,”
of SKF, Sven Wingquist, invented the selfsays Johnstone. “With this announcealigning ball bearing in 1907, service was far
ment, you could say that SKF started its
from a matter of course. At that time, most
first 100 years with an innovation—and
If you have the chance to visit SKF in Sweden, make
of the suppliers of mechanical components
we have started our second 100 years
sure that you check out the informative display that’s
just sold their products. Then it was up to
with another innovation. Energy is a
available to visitors. You won’t be disappointed.
the customer to learn—often through trial
top issue for industry. At SKF, energy
and error—how to put it to use.
will be a big focus in the future.
(i.e. railway, ships, wind energy, conveyors and
Wingquist, on the other hand, knew that
“This new family of bearings is the reextruders). The initial size range will be 200being in the forefront of
sult of a focused effort
600 mm outside diameter and SKF is expected
technology, having a keen
from the SKF organizato first apply the bearings in wind turbines.
knowledge of customer
tions to develop a bearTechnical improvements of the bearneeds, as well as offering
ing family, that while
ings that deliver the energy savings include:
technical support and sermaintaining the service
surface topography; raceway profiles and
vice, would pay off in the
life and load-carrying
geometry, together with a special polymer
long run. This strategy has
capacity of standard
cage; and an optimized set of rollers. The
worked for SKF.
ISO bearings, will suboptimized roller set means a lighter bearing,
“As in 1907, SKF is From left: Tom Johnstone, SKF presi- stantially reduce energy
which itself is more energy efficient because
dedicated today to help dent and CEO and PEM editor Robert consumption. Our goal
it takes less power to move the rolling elecustomers get optimal Robertson at the SKF press conference is to reduce world enments, says SKF. It also lowers inertia of the
value out of their invest- in Göteborg, Sweden.
ergy consumption and
moving parts, reducing the chance of skidments,” says Tom Johncustomer energy costs.”
ding and smearing that would otherwise
stone, president and CEO of SKF. “So over
affect performance and service life.
a hundred years, there’s a straight line that
TAPERED-ROLLER BEARINGS
combines cutting-edge technology with an
The bearings will deliver energy savings on
DEEP-GROOVE BALL BEARINGS
exact knowledge of customer-service needs.
average of at least 30 percent. SKF says it will
The bearings will deliver energy savings on
This leads to knowledge-engineering soluinitially target industrial segments where apaverage of at least 30 percent. SKF says it
tions.”
plications exceed 1 MW of power consumpwill initially target light-loaded applications,
While SKF celebrated its 100th annivertion. Such applications include heavy industry
with the first including industrial-electrical
sary in the many countries it serves, Sweden
motors that drive machinery in many
was the place to be to discover what the
sectors. Production will initially cover the
company has planned for the future. At
smaller diameter-sized series.
the forefront was the announcement that
“Two years ago at the SKF annual genSKF will soon bring to market a new family
eral meeting, we launched the BeyondZeof “green” bearings, which reduce energy
ro initiative. This means that the energy
consumption by at least 30 percent comsavings from the products and solutions
pared to standard ISO products, says the
that SKF supplies to its customers will be
company.
greater than the SKF Group’s own energy
This new bearing family comprises the
consumption,” says Johnstone. “For SKF,
From left: Gord Duncan, Kinecor LP; Pierre Bouchard,
two bearing types that are most widely used
it means more than being energy neuGeneral Bearing Service; Jan Lindhe, SKF Canada;
in the world: deep-groove ball bearings and
tral—it means being energy positive. We
and Farrokh Khalili, Canadian Bearings, attended
tapered-roller bearings. According to SKF,
will achieve our BeyondZero target.”
the SKF gala dinner.
manufacturing of the new bearings will start
www.skf.ca
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Lafe
To contact this advertiser turn to page 49
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1
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1/30/0711:31:37
2:14:37AM
PM
Hands On
NEWS AND NOTES FOR THE PLANT PROFESSIONAL
ENERGY
Less is more at SKF facilities in Sweden
GÖTEBORG, SWEDEN—For a number of years,
SKF has worked together with the Massachusetts Institute of Technology (MIT) to define
new models to evaluate and measure the energy
use of systems. This includes the development of
bearings where SKF determines the energy im-
pact of any change in design along the lifecycle—
during manufacturing, in use and in the recycle
stages. SKF also works closely with the School of
Business, Economics and Law at Göteborg University and Chalmers University of Technology
to further support its BeyondZero program.
faster. safer. easier.
Victaulic Mechanical
Pipe Joining Solutions
• up to 30% faster than welding
• no flame for enhanced safety
• ease of installation and maintenance
• proven reliability for over 80 years
tel: 905-884-7444
www.victaulic.com
To contact this advertiser turn to page 49
8
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-front.indd 8
“Climate change is real and a lot of Co2 emissions are going into the air—and will be there
for 200 years,” says David H. Marks, co-director,
MIT Labs for Energy and the Environment. “The
battle [energy] is going on now and can’t be
ignored. SKF isn’t waiting 50 years to reduce Co2
emissions—since 50 years will be too late.”
As part of the BeyondZero program, SKF
implemented a number of actions to reduce
Co2 emissions and save energy in its production
facilities. Already in 13 Swedish factories, energy
savings of 24 GWh have been achieved through
the installation of more energy efficient pumps
and motors; new heating and energy recovery
systems; new exhaust systems, recovering what
would be “waste heat”; reducing compressed air
usage; and installing energy efficient lighting.
Most savings will come from improvements
in the production lines where reducing the use
of compressed air offers the biggest opportunity.
There are also large savings to be made in machining and assembly. Here factory audits have
shown that savings of five percent of the total
energy consumption can be achieved in each
factory. A series of actions are in place to garner
these savings (i.e. replacing pneumatic cylinders
on positioning machines with SKF electromechanical actuators where the energy saving per
machine is 35 percent).
The expected total savings will be made systematically with a transition to more energy efficient processes and an increased focus placed on
energy conversion efficiency across SKF’s plants.
Due to the need to make changes, while continuing manufacturing, improvements have to be
made sequentially and are expected to deliver
a 15 percent saving, in terms of SKF’s current
energy consumption within three years.
In 2005, SKF launched a target to reduce
its Co2 emissions by five percent per annum.
At that time, a reduction of seven percent was
achieved; in 2006 the reduction was more than
five percent.
“The United Nations recent report on world
climate shows that we have a problem and there
are many views and discussions on the subject,”
says Tom Johnstone, SKF president and CEO.
“Each of us, however, has to make a contribution and this is the start of ours. We have
developed and offer technical solutions that
can significantly reduce energy consumption.
In addition, we’re addressing our own energy
consumption to reduce Co2 emissions.”
www.skf.ca
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4/16/07 11:31:49 AM
Unti
Tired of the same routine?
Buy a Vac that lasts!
Stop throwing your money away on electric vacuum cleaners that are sure to fail. EXAIR
vacuums have been engineered to withstand the dust, dirt, chips and liquids common to
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Coolant sumps can be easily
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Chip Vac is powered by
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chips directly into your
ordinary 55 gallon drum. It
is easy to move from drum
to drum to keep materials
separate for recycling. Clean
chips from floors, fixtures,
work surfaces and machines.
The Vac-u-Gun uses
compressed air to provide
solutions to a wide variety
of industrial housekeeping
problems. This versatile tool
is a vacuum gun, blow gun
and a transfer tool all in one.
Three Vac-u-Gun systems are
available.
The Line Vac air powered
conveyors convert ordinary
hose or pipe into a complete
conveying system for bulk
materials, plastic granules,
scrap, trim and other complex
shapes. Generate a vacuum
on one end and high output
flows on the other.
• Durable stainless steel
• Recover coolant, sludge, spills
• No motors to clog or wear out
• Dust free operation
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• Aluminum and stainless steel
• Attaches to hose, tube or pipe
www.exair.com/39/462.htm
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To contact this advertiser turn to page 49
PEM_Apr07-front.indd
Untitled-4 1
9
www.exair.com/39/463.htm
www.exair.com/39/464.htm
11510 Goldcoast Drive, Cincinnati, OH 45249-1621
(800) 903-9247/Fax (513) 671-3363
4/16/07
9/11/0611:33:14
9:11:59AM
AM
Hands on
NEWS AND NOTES FOR THE PLANT PROFESSIONAL
P O W E R TR A N S MISSION
PTDA announces year-end industry results
CHICAGO—The Power Transmission Distribu-
tors Association (PTDA) released 2006 year-end
trend data for distributors and manufacturers of
power transmission/motion control (PT/MC)
products in the U.S. and Canada.
Following the previous year’s annual increase
of 10.7 percent, U.S. distributors saw a 10.2 percent increase in PT/MC product sales in 2006.
The annualized sales-to-inventory ratio for 2006
dropped to 7.3 compared to 7.7 in 2005.
Canadian distributors also continued the
trend of growth in PT/MC sales with a 2006 in-
Advanced Science.
Advanced Grease Lubrication.
At Petro-Canada we designed our line of PRECISION Greases to deliver longer life,
*
less water wash-out and better surface protection. Petro-Canada grease crafters
combine our ultra-pure base oils together with other selected oils and specific
performance additives. Then we process them using the advanced science of our
distinctive two stage manufacturing process. The results speak for themselves: less
wear on equipment and improved productivity for your operation.
Put the Advanced Science of PRECISION to work in your plant.
Contact 1-866-335-3369 or www.petro-canada.com
crease of 8.9 percent. As with the U.S. market, the
annualized sales-to-inventory ratio for Canadian
distributors also showed a slight decline from 7.5
in 2005 to 7.1 in 2006.
U.S. manufacturers experienced sales growth
in 2006 although at a slower rate than in 2005.
Year-to-date sales of PT/MC products were up
6.9 percent in 2006 versus a more robust growth
rate of 9.6 percent in 2005. The same trend holds
true for year-to-date orders of PT/MC products
for U.S. manufacturers, gaining 3.9 percent in
2006 compared to 11.3 percent in 2005. The annualized sales-to-inventory ratio dropped to 9.0
at year-end 2006 from 9.6 in 2005.
Canadian manufacturers continued to show
positive sales growth although also at a slower
rate. Year-to-date sales of PT/MC products in
2006 increased 1.0 percent versus a 3.4 percent
increase in 2005. The annualized sales-to-inventory ratio jumped to 7.9 for Canadian manufacturers compared to 6.6 at the end of 2005.
Considering sales growth on a product-byproduct basis in 2006, all product categories
for U.S. manufacturers showed positive growth.
For Canadian manufacturers, only three categories—clutches and brakes, mechanical-drive
systems and other PT products and positioning
systems/linear motion products—showed a
reduction in sales.
www.ptda.org
AWARDS
PEM 2007 Maintenance Awards
We're calling for PEM 2007 Maintenance Award
submissions. Here are general guidelines for the
awards:
•How big is your maintenance department? Tell
us about your operating structure.
•Why is your maintenance team better than the
rest (i.e. quality, innovation and performance)?
• Tell us about a maintenance success story.
•What kind of maintenance best-practice strategies and tools are you using and why?
• How have you reduced asset management costs
and improved equipment uptime?
• What kind of return on investment (ROI),
equipment reliability and production capacity
improvements have been achieved?
Email your submissions to PEM editor Robert
Robertson: rrobertson@clbmedia.ca.
*Marque de commerce de Petro-Canada - Trademark
To contact this adver tiser turn to page 49
10
PEM PLANT ENGINEERING AND MAINTENANCE
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4/16/07 11:33:37 AM
M A TE R I A LS H ANDL ING
Toyota introduces new 8-series lift trucks
TORONTO—Toyota Industrial Equipment, a
division of Toyota Canada Inc., in conjunction with Toyota Material Handling USA, Inc.
(TMHU), recently introduced its line of 8-series
lift trucks, which includes 3,000-6,500-pound,
internal-combustion cushion and pneumatictire models.
The 8-series also features a programmable
planned-maintenance hour meter that notifies
operators of the need for routine maintenance
and service via the digital display monitor.
“We’re very excited about providing the new
8-series to the Canadian market. The reliabil-
ity, ergonomic and serviceability enhancements
make the truck suited for any type of application,
including the harshest of environments,” says
Rob Reinders, director, Industrial Equipment
Division, Toyota Canada, Inc.
www.forklift.toyota.ca p
Toyota Canada Inc. is offering its new 8-series
lift trucks, which have been designed to meet
stringent U.S. environmental standards.
PHOTO: TOYOTA
Toyota says that its 4Y engine features an
exclusive closed-loop fuel system design that
automatically adjusts and optimizes the air-fuel
mixture ratio. This system works in conjunction with a three-way catalytic muffler, together
minimizing emissions, such as hydrocarbons
(HC), oxides of nitrogen (NOx) and carbon
monoxide (CO).
As a result, the 8-series gasoline, LPG and
CNG-configured models will produce 70 percent
less smog-forming emissions than the 2007 U.S.
federal EPA standards. This emission system also
meets the more stringent 2010 California Air
Resource Board (CARB) emission standards,
says the company.
“In the 8-series, we’ve delivered an environmentally friendly lift truck that reduces operation costs, enhances operator safety and also
meets California 2010 emission standards three
years early,” says Shankar Basu, president and
CEO of TMHU.
With the optional multi-function digital display, the 8-series lift truck performs self-diagnostics through a built-in analyzer, which eliminates
the need for a hand-held unit, says the company.
When the truck is in Analyzer Mode, it displays
the status of the electrical system and allows
instantaneous access to information detected by
the controller, which reduces downtime, says the
company.
To contact this advertiser turn to page 49
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PEM_Apr07-front.indd 11
APRIL 2007
11
4/16/07 11:33:45 AM
Hands on
NEWS AND NOTES FOR THE PLANT PROFESSIONAL
By Ken Bannister
ASK KEN
How can managers become better?
Do you want to know how to improve
equipment uptime and reduce costs? Or maybe
you have a question about predictive maintenance (PdM) tools or how to enhance MRO performance. In each PEM issue, respected industry
practitioner Ken Bannister will provide the answers. If your question is picked, PEM will send
you a maintenance textbook for your library.
Email your questions to Ken Bannister today!
Work with staff and peer groups
to recognize and develop
areas in which cooperation
is required by either group.
of equipment reliability and availability, it
must establish healthy working relationships
on two levels: inter-departmentally between
clerical staff, trades, planners, schedulers and
managers; and intra-departmentally between
management, production, purchasing, accounting and human resources.
Building these vital relationships commences with understanding and mapping
the difference between what you must manage versus what you can actually control.
For example, maintenance managers are responsible for managing all equipment repairs, but aren’t always able to control access
to equipment (production), access to parts
RELATIONSHIPS ARE KEY
In the 2006 edition of the ground-breaking
book, “Leadership and the New Science: Discovering Order in a Chaotic World,” management guru Margaret Wheatley writes: “In
organizations, real power and energy is generated through relationships. The pattern of
relationships and the capacities to form them
are more important than tasks, functions,
roles and positions.”
If a maintenance department is to succeed in its mission to provide adequate levels
(purchasing) or access to funds (management/accounting). They also must rely on
a mutual working relationship with other
stakeholders to deliver on the maintenance
mandate.
As a result, the single best piece of advice
I can offer is to manage your maintenance
department with full open disclosure. Work
with staff and peer groups to recognize and
develop areas in which cooperation is required by either group. This involves performing duties (input/output model) and
establishing mutual agreements that benefit
everyone, including the company. Measure
and track what you can control, while providing regular updates and reports to your
partners. p
Ken Bannister of Innerkip, ON-based Engtech
Industries Inc. is a production and maintenance
management specialist. You can email your questions to him at kbannister@engtechindustries.com.
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To contact this advertiser turn to page 49
12
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-front.indd 12
w w w . p em - m ag . com
4/16/07 11:34:27 AM
Gru
To contact this advertiser turn to page 49
PEM_Apr07-front.indd
Grundfos_PEM_Apr_07.indd
13
1
4/16/07
3/22/0711:34:40
4:13:17AM
PM
Hands On
NEWS AND NOTES FOR THE PLANT PROFESSIONAL
By John Lambert
BACK TO BASICS
Shaft alignment can cause problems
In each PEM issue, top industry practitioner
John Lambert will provide you with useful tips
on maintenance fundamentals. His many
years of experience will help you get back
to the basics, which is the first step to advancing to world-class maintenance. In this
column, John Lambert talks about machine
shaft alignment.
GET THE BOLTS RIGHT
Do you need to loosen the bolts of a coupling when performing shaft alignment on a
machine unit? It depends on the coupling—
not the style, but the amount of stiffness it
has. Many couplings are very stiff and when
you clamp them together, they force the two
shafts into alignment. Gear couplings that
have shoulder bolts in the flanged sleeves are
a stiff coupling.
If you work with these couplings, this
won’t surprise you as they are well-machined
couplings that are very popular because of
Do you need to loosen
the bolts of a coupling
when performing shaft
alignment on a machine unit?
the high torque they can withstand. Other
couplings have the look of being flexible, but
they’re not. One that comes to mind is an
elastomeric-style coupling.
When you assemble them on the shafts,
they go together very easily. The rubber
insert is bolted into place. As you tighten
all the bolts, you draw the two shafts into
alignment. When all the bolts are tight, the
coupling is now like a solid block. When you
measure across this coupling with a laser,
you can get a result that’s within your tolerance guide.
If you release the bolts and re-measure
with the laser, however, you can get a different result. This isn’t a big issue as long as
you’re aware of it. All you need to do is make
sure that the insert bolts are backed off. This
allows for a lot of play (flexibility). Be careful,
however, as some laser systems are sensitive
to backlash in couplings.
For gear couplings, I would suggest that
you do an open-coupling alignment (the
best method of alignment). Better still—my
suggestion is to try it yourself and learn
how stiff the couplings are. Start with the
coupling together (coupled) and measure
the shaft alignment, then open it up and
re-measure. p
John Lambert is president of Pickering, ONbased Benchmark Maintenance Services Inc. You
can reach him by email: info@withinspec.com.
For a more detailed abstract of this column, visit:
www.withinspec.com/articles.
To contact this advertiser turn to page 49
Kinecor_PEM_June_06.indd 1
PEM PLANT ENGINEERING AND MAINTENANCE
14
PEM_Apr07-front.indd 14
w w w . p em - m ag . com
5/17/06 3:53:18 PM
4/16/07 11:34:56 AM
Lov
To contact this advertiser turn to page 49
PEM_Apr07-front.indd
Lovejoy_PEM_Apr_07.indd
15
1
4/16/07
4/16/07 11:35:09
10:31:17AM
AM
Plant Safety
BY FRED MATTHEWS
Put a stop to
workplace injuries
As a health and safety practitioner over the
years, I have encountered many attitudes and beliefs
about who is responsible for health and safety in the
workplace. In some organizations, the opinion is that
safety is the responsibility of management. In others,
however, it’s perceived as the responsibility of workers.
There are also those who think it’s the sole responsibility of the safety officer or safety committee. Are
these beliefs about responsibility and accountability for
health and safety correct? If not, then what’s the answer?
At the end of the day, who is responsible for health and
safety? To help us find the answer, we need to look at the
past and the origins of modern safety legislation.
When compared to most Canadian law, health and
safety legislation is relatively new.
In fact, it wasn’t until the mid 1970s
Most of the injuries suffered that we observed the creation of
occupational health and safety law in
by mature workers involve
Canada. The emergence of such legislation occurred after the release of
muscoskeletal disorders.
the “Report of the Royal Commission
on the Health and Safety of Workers
in Mines,” which is affectionately
known by Canadian safety professionals as the “Ham
Report.” What the report gave us was a concept that
we’ve come to refer as the internal responsibility system
(IRS). This concept is the foundation for much of our
existing health and safety legislation.
To put it simply, the IRS is a system in which
every individual is responsible for health and
safety. The term “internal” in the IRS refers to the
primary responsibility for health and safety being
internal to the workplace. It means that health and
safety is integrated into each and every aspect of
the workplace. The term “responsibility” in the IRS
refers to the personal health and safety responsibility that everyone must own. Finally, the term “system” refers to a system of internal feedback loops,
which are required to ensure the health and safety
of company stakeholders. An example of these
feedback loops include many of the elements of our
TH E C OL UM NIS T :
health and safety management system, such as health
Fred Matthews is the prairie and
and safety committees, hazard identification, inspecnorthern regional health and safetions, incident investigations and system audits, etc.
Under the IRS, responsibility for health and safety
ty coordinator for Edmonton-based
increases as you go up the corporate ladder. Senior
Golder Associates Ltd. For more
managers and executives are responsible for setting
information call (780) 930-8647
policy, ensuring the development of the occupational
or visit www.golder-ehs.com.
health and safety (OHS) management system, allocat-
16
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-front.indd 16
ing sufficient resources and holding middle managers
accountable for health and safety performance. Middle
managers are responsible for the implementation and
monitoring of the OHS management system, responding to safety reports, evaluating safety performance and
managing the resources allocated for health and safety.
Supervisors are responsible for identifying and controlling hazards, enforcing company safety standards,
communicating with workers about health and safety
issues, discipline, training, resolving health and safety
problems (as they arise) and investigating incidents/
taking corrective action when they occur. Finally, workers are responsible for reporting unsafe conditions and
incidents, following safe-work procedures and participating in hazard identification. Clearly, “doing health
and safety” isn’t the responsibility of the safety coordinator or the safety committee—it’s the responsibility of
all concerned in the plant.
The concept of “safety is everyone’s responsibility”
is reflected in provincial safety legislation across the
country. The responsibility for health and safety is also
reflected in changes to the Criminal Code of Canada.
Section 217.1 of the Criminal Code holds anyone who
directs the work activities of another worker criminally
responsible should a serious injury or death occur that
could have been prevented. Front-line workers can also
be held accountable under the Criminal Code as parties
to the offence.
"Doing health and
safety" isn't the
responsibility of the
safety coordinator or the
safety committee—it's
the responsibility of all
concerned in the plant.
To improve health and safety performance, it’s
important to ask the following questions: What can I
do to prevent incidents? What do I need to do to ensure
that I am fulfilling my health and safety responsibilities? What do I need to do to enable my co-workers and
I go home in one piece at the end of the shift? After
reflecting on these questions, the next step is to take
responsible action and always keep your health and
safety goals in sight. p
w w w . p em - m ag . com
4/16/07 11:35:20 AM
Imagine a company that will send you a
consultant at no charge to show you how
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Sounds incredible. But that’s what we do.
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We will review the natural gas use of your facility
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email: energyser vices@enbridge.com
To contact this adver tiser turn to page 49
PEM_Apr07-front.indd
Enbridge_PEM_Apr_07.indd
17
1
2007-02-00011
4/16/07
3/30/07 11:35:32
12:35:38AM
PM
Power Transmission
BY RYAN LAFEVRE
Get the most
out of your V-belts
Excessive
can result
V-drives are a common means of transmitting
power between two shafts. When properly designed,
they should achieve a life of 20,000 to 25,000 hours.
If the drive isn’t installed properly, however, that life
can be drastically shortened. In addition, improperly
installed belts can place excess loads on other components of a machine, including shafting and bearings.
This is why proper V-belt installation procedures are
crucial to machine performance and longevity.
When replacing belts on existing sheaves, the first
step of V-drive installation is to inspect the grooves of
the sheaves for wear. Excessive wear in the grooves can
result in belt slippage. Slippage reduces the power the
belts are able to carry in addition to
wear in the grooves accelerating wear on the belts. Most
drive manufacturers sell inexpenin belt slippage.
sive gauges, which can be placed in
the grooves to check for wear.
If a gauge is unavailable, check
for wear by running a ballpoint pen across the groove
sidewall. Any inconsistency felt should be noted as
wear and the sheave should be replaced. The grooves
on both new and used sheaves should be checked for
dirt, corrosion, grease or oil. Dirt and corrosion will
accelerate belt wear, whereas grease or oil will reduce
the friction between the belt and sheave. This reduces
the power rating of the belt.
The next step in properly installing a V-belt drive is
alignment. Excess misalignment places extra loads on
the belt and sheaves, while reducing the power-carrying
capacity of the belts. Misalignment can also cause the
belts to roll in the grooves. Excess misalignment also
results in extra thrust load on the bearings of both the
driver and driven shafts.
V-drives tolerate a maximum of 1/2° misalignment. It’s best to align the sheaves as close to 0° as
possible, however, for maximum belt life. To check the
misalignment on drives with shorter centre distances,
TABLE 1: Take-up allowances for 3V, 5V and 8V belts
Belt Length
Designation
Over
Up to &
including
3V
3V
Joined
5V
5V
Joined
8V
8V
Joined
Minimum
Allowance
Above
Centre
Distance
--475
710
1000
1250
1700
2000
2360
2650
3000
3550
3750
475
710
1060
1250
1700
2000
2360
2650
3000
3550
3750
5000
.05
.8
.8
.8
.8
---------------
1.2
1.4
1.4
1.4
1.4
---------------
--1.0
1.0
1.0
1.0
1.0
1.2
1.2
1.2
1.2
-----
--2.1
2.1
2.1
2.1
2.1
2.4
2.4
2.4
2.4
-----
----1.5
1.5
1.5
1.8
1.8
1.8
1.8
2.0
2.0
2.0
----3.4
3.4
3.4
3.6
3.6
3.6
3.6
4.0
4.0
4.0
1.0
1.2
1.5
1.8
2.2
2.5
3.0
3.2
3.5
4.0
4.5
5.5
Take-up Allowance Below Centre (in)
TABLE 2: Take-up allowances for classical belts
Belt Length
Designation
THE C OL UM NIS T :
Ryan LaFevre is an application
engineer with Baldor-Dodge-Reliance). For more information, call
(905) 792-1739 or visit www.
dodge-pt.com
18
Over
Up to &
including
--35
55
85
112
144
180
210
240
300
390
35
55
85
112
144
180
210
240
300
390
---
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-front.indd 18
Take-up Allowance Below Centre (in)
A
0.75
0.75
0.75
1.00
1.00
-------------
A
Joined
B
B
Joined
C
C
Joined
D
1.20
1.20
1.30
1.30
1.50
-------------
1.00
1.00
1.25
1.25
1.25
1.25
1.50
1.50
1.50
-----
1.50
1.50
1.60
1.60
1.80
1.80
1.90
2.00
2.20
-----
--1.50
1.50
1.50
1.50
2.00
2.00
2.00
2.00
2.00
2.50
--2.00
2.00
2.00
2.10
2.20
2.30
2.50
2.50
2.70
2.90
--------2.00
2.00
2.00
2.50
2.50
2.60
3.00
Minimum
Allowance
Above
D
Centre
Joined Distance
--------2.90
3.00
3.20
3.20
3.50
3.60
4.10
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
6.00
1.5% of belt
length
w w w . p em - m ag . com
4/19/07 2:54:05 PM
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To contact this advertiser turn to page 49
PEM_Apr07-front.indd 19
4/16/07 11:35:54 AM
Power Transmission
Key Focus
Key Factor
Reliable
Predictable
Profitable
Machines
performing
at optimum
Partner in Plant Maintenance
+EEPINGäAäPLANTäRUNNINGäATäOPTIMUMäEFFICIENCYä
ISäAäKEYäFACTORäTOäREMAINäCOMPETITIVEä4AKEä
ADVANTAGEäOFä2EXROTH@SäCOMPREHENSIVEäRANGEäOFä
SERVICESäTOäSUPPORTäAUTOMATIONäSYSTEMSäINäTHEä
FIELDä7EäADAPTäOURäSERVICESäTOäSUITäYOURä
INDIVIDUALäREQUIREMENTSäENSURINGäOPTIMUMä
RESOURCEäDEPLOYMENTä/URäSERVICEäOFFERINGäISä
AVAILABLEäFROMäSTRATEGICALLYäLOCATEDäSERVICEä
CENTERSäACROSSä#ANADAä"OSCHä2EXROTHä
The Drive & Control Company
Bosch Rexroth Canada
boschrexroth.ca
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To contact this adver tiser turn to page 49
For more information,
go to boschrexroth.ca and
enter webcode CA0013
PEM_Apr07-front.indd 20
a straight edge can be placed flat
against the face of both sheaves. If
not, adjust one of the sheaves until
the straight edge is flat against
both faces.
If the centre distance is too large
to use a straight edge, string can
be applied in a similar fashion. For
extremely long centre distances,
laser-alignment tools may be necessary. Generally, this involves a
laser transmitter and a reflector
mounted on a machined surface
on both the driver and driven
sheave. Usually the rims of the
sheaves act as a mounting point
for the laser-alignment devices.
Once the sheaves are aligned,
the next step is to actually place the
belts in the sheave grooves. Always
replace all of the belts in the drive
at the same time. V-belts stretch
during use and used belts will
require a longer centre distance to
achieve the same tension as new
belts. It’s also not recommended
to mix belts from different manufacturers.
The belts should be installed,
while the sheaves are close enough
that the belts don’t need to be
stretched. To do this, first find the
calculated centre distance from the
drive design and then subtract the
amount shown in Table 1 and
Table 2. The last column in each
table shows how much extra takeup beyond the calculated centre
distance should be available.
This allows the belts to be adjusted, as they break in to maintain
their proper tension. The sheaves
will then need to be moved away
from each other until the correct
tension is reached. There are many
ways to check the tension in the
belts. The most accurate method, however, is the force-deflection method. The force-deflection
method involves measuring the
amount of force required to deflect
each belt by a given distance.
The first step is measuring the
span length of the drive. The span
is the distance between the points
where the belt is tangent or touches the sheaves. It can be measured
using a yardstick or tape measure
from the point where the belt is
just touching the driver sheave
to the point where the belt is just
touching the driven sheave. The
belt should be deflected 1/64th of
the span.
New belts will seat themselves in the grooves and
stretch during operation,
which results in reduced
tension in the belt. If not
corrected—then belt
slippage is probable.
For example, if a 32-inch span
is measured, the force required to
deflect the belt 1/2-inch should
be measured. The second step is
to determine how much force it
should take to deflect the belt. This
can be done by looking at charts
published by different belt manufacturers. Generally, the amount of
force varies by the size of the driver sheave, the RPM of the driver
sheave and the type of belt being
used. It’s also important to not
use any belt dressing. These can
degrade the rubber compound in
the belts and reduce their life.
It’s best to re-check the initial
tension within the break-in period or after the first 24 hours of
loaded operation. New belts will
seat themselves in the grooves and
stretch during operation, which
results in reduced tension in the
belt. If not corrected—then belt
slippage is probable. This is why
there needs to be an allowance for
take-up over the nominal centre
distance, as shown in the right
hand columns in Table 1 and
Table 2.
V-drives can be a trouble-free
method of transmitting power.
Installing them correctly is the
optimum way to ensure that they
will last for their intended life without the need for costly and timeconsuming maintenance. p
4/20/07 10:10:21 AM
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To contact this adver tiser turn to page 49
PEM805HYD
PEM_Apr07-front.indd 21
4/16/07 11:36:15 AM
Maintenance Software
BY DAVID BERGER, P.ENG. (ALTA.)
Work hard to
achieve CMMS success
Regardless of how many computerized maintordination of the CMMS system implementation, inenance management software (CMMS) systems your comcluding liaison with management and workers from all
pany has implemented over the years, the probability
departments and software vendor(s). The most difficult
of failure is surprisingly high for these new projects.
task of the system champion is to constantly motivate
Many studies have shown that the failure rate ranges
senior management and users by removing barriers to
from about 50 to 65 percent, despite ever-improving
success.
NEED ANALYSIS: Before the CMMS system
software functionality, decades of experience and even
design is finalized, it’s imperative to conduct a
knowledge of these dreadful statistics.
thorough investigation as to the perceived needs of all
It's critical to improve your odds for a successful
parties—from maintainers to management across all
CMMS implementation. Although most senior mandepartments. This is a long and arduous process, as
agement teams will nod their heads in agreement when
the more people you solicit, the more data you must
they hear what needs to be done, the industry track
sift through to build consensus. The work is well worth
record speaks louder than words. Sadly, there are so
the effort, however, because of the ownership factor
few organizations with a solid track record for CMMS
discussed earlier.
project implementations. I’m talkA proper needs analysis should be process-driven,
ing about being on time, on budIt's critical to improve your
in light of a qualitative and quantitative definition of
get and delivering a quality product
success for the project that clearly defines goals, objecthat meets all performance targets.
odds for a successful CMMS The following are eight key CMMS
tives, performance measures and targets. There are two
key deliverables that are driven out of a needs-analysis
implementation action items:
INVOLVEMENT: Without top
implementation.
exercise, including new and improved processes (i.e.
management support, CMMS
process maps, detailed procedures or simple notations
systems are doomed to failure. All of
that pertain to process improvements) and technology
the other seven key success factors depend on managespecification in support of the process changes.
ment support, in terms of resource allocation
and/or using the information coming from
the new CMMS system. Almost as important
is the backing by maintenance. If maintainers want to sabotage the system—they can by
distorting the entered source data.
Cooperation of production management
and other plant workers is also vital for proper requesting, scheduling and reporting of
maintenance-related work. Use of a steering
committee, project team, frequent departTH E C OL UM NIS T :
mental meetings and written communications
Use of a steering committee, project team, frequent
David Berger, P.Eng. (Alta.) is
will help ensure company-wide commitment.
departmental meetings and written communications will
PEM’s production/operations ediMaximizing involvement in the decision-makhelp ensure company-wide commitment.
ing process—right from the start—increases
tor and a principal with Western
the feeling of ownership of the CMMS system
Management Consultants. He’s
Many successful CMMS implementations began
and the likelihood of success.
also the founding president of
SYSTEM CHAMPION: A highly motivated senior
as inexpensive, manual trial-and-error periods prior
the Plant Engineering and Mainperson, with excellent people skills and a positive
to implementing costly hardware and software. Once
tenance Association of Canada
attitude towards computers, ideally fills this position.
proper maintenance management practices have been
Best results are achieved when the person comes from
mastered, computerization is less onerous or intimidat(PEMAC). For more information
operations as opposed to maintenance, since this will
ing. As well, system selection is facilitated as needs are
call (416) 362-6863 ext. 237;
deepen the partnership with production and the level of
clearly identified during the manual pilot.
email: david@wmc.on.ca or visit
ownership felt by everyone on the shop floor.
A needs analysis should include hardware/software
www.wmc.on.ca.
The system champion is responsible for overall cospecification, system-performance expectations, se-
3
1
2
22
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-front.indd 22
w w w . p em - m ag . com
4/16/07 11:36:22 AM
We keep them running,
curity requirements and vendor
criteria, etc. Before the selection is
finalized, you should go on-site for
short-listed vendors, conduct telephone reference checks, participate
in extensive vendor demos using
your test data and possibly bring
the software on-site to test drive in
your environment.
EDUCATION: Training and
implementation costs are
typically more expensive than
hardware and software combined.
Without such a heavy expenditure
on education, however, computerization will do more harm than
good. It’s imperative that all users
be adequately trained in overall
CMMS system operation to appreciate the “big picture.” Each user
must then have plenty of personalized “just-in-time” hands-on training to maximize retention.
Note that the better software
packages can minimize required
training through proper system
design, good documentation and
user-customization capability.
There are also numerous online
tools, such as computer-based
training (CBT), wizards, videos
and Web-based help.
4
5
RESOURCE ALLOCATION:
The level of management support can, in part, be determined
by the quality and quantity of resources thrown at the CMMS project. This includes people, capital
and facilities required to successfully implement process and system changes. Every manager in an
organization is fighting for management attention and the best
resources, since the success of the
project depends on it. It’s far better
to wait until the right resources
are available—instead of proceeding down a path of failure with a
poorly resourced project.
IMPLEMENTATION: “Change
management” is a buzz-term
that still hasn’t lost its relevance.
People tend to resist change. It also
takes time to prepare for and provide a level of comfort with new
CMMS processes. Be prepared for
a long haul of up to two years—
6
from needs analysis through system selection and installation—to
meeting performance targets expected by all key project stakeholders.
Proper change management involves regular communication with
major stakeholders in the project.
This includes using a variety of
techniques, such as “town-hall”
meetings, workshops, newsletters
and other correspondence with
employees. Above all, regular
meetings with first-line supervisors will have the highest impact,
according to years of change-management research. This is because
the level of trust is highest between
employees and immediate supervisors. During the entire CMMS
process—it’s imperative to keep
first-line supervisors informed and
motivated.
VENDOR SUPPORT: Over
the long haul, choose a CMMS
vendor(s) that will provide the appropriate level of hardware and
software support for installation
and maintenance. Some companies require more assistance from
vendors because they have minimal in-house resources. Additionally, software vendors can play a
key role in training users.
FOLLOW-UP: Listen to the
users and respond with at
least a reason why a suggestion
can’t be implemented. The process
and CMMS system should be flexible enough to meet the changing needs of individual users and
the organization as a whole. There
should be a formal mechanism
for dealing with idea generation
and implementing continuous improvement.
Maintainers always seem to have
enough time and money to deal
with “fires” and emergencies when
a project goes off the rails—no
matter how long things drag on.
Many never seem to have enough
time or resources, however, to plan
out a CMMS system properly in
the first place. Always remember
that you get out of a CMMS system
what you put in. p
7
8
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To contact this advertiser turn to page 49
w w w . p em - m ag . com
PEM_Apr07-front.indd 23
APRIL 2007
23
4/16/07 11:36:30 AM
Get Your
Bearings
Prevent
bearing failures
with proper
lubrication
24
The majority of bearings are manufactured
with a design life target, which is designated
by its L10 rating. Under ideal conditions when
bearing loads are moderate—ambient temperatures are moderate, bearing-material quality is excellent, the bearing is installed the right
way and lubrication is correctly chosen and
applied—a bearing can be expected to outlive
the machinery in which it resides. Reality often
provides a different scenario, however, in which
the maintenance department must compensate
for what's gone wrong. Since maintainers are
rarely able to influence bearing-manufacturing
quality, engineering-design choice and productivity abuse, they must focus on what can be
controlled—bearing lubrication.
PHOTOS: SKF
A
s it supports a sliding or rotating part,
a bearing can take on many forms. It
can be flat where mating surfaces
slide over one another (i.e. as in a
machine gib or way). It can also
be cylindrical where a mating surface either
rotationally slides over another (i.e. as in a plain
journal-style bearing or where one surface rolls
over the other as in a rolling-element bearing).
Regardless of bearing design or function, the
common denominator for achieving acceptable
life span is the need for effective lubrication—be
it in solid, liquid or gaseous form.
by Ken Bannister
Four major causes of bearing failure
Many years ago, Dr. Ernest Rabinowicz of MIT
performed a landmark study on the effect of
lubrication on the U.S. gross national product (GNP). At the time, the study concluded
that American manufacturing companies spent
more than US$600 billion annually to repair
damage caused by mechanical wear. The study
further determined that more than 70 percent
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-features.indd 24
4/16/07 11:40:33 AM
A Case for NTN Tapered Roller Bearings
Special Features
Crowned rollers provide
lower friction and smooth
operation through even
load distribution.
Case carburized steel enhances
long life operation and improves
shock loading capabilities.
Preferred by leading manufacturers, NTN tapered roller
bearings are renowned for their ability to operate reliably
in some of the world’s harshest environments. NTN
Soft Core
tapered roller bearings are ideally suited for heavy duty
applications ranging from rail to aggregate and mining
equipment, where marginal lubrication, vibration and
impact loads are considered the norm. NTN tapered roller
Hardened
Surface Layer
bearings are made to meet or exceed industry standards
and feature case carburized steel. Carburizing hardens
Optimized roller/rib interface
promotes lubrication and lowers
bearing running torque
Honed raceways ensure low
friction for miles of trouble
free operation.
the steel from the surface to the proper depth, leaving a
relatively soft core, improved durability and longer life.
These results make the material ideal for shock loading
and extreme conditions. Like all NTN products, our
tapered roller bearings are backed by knowledgeable
technical support from our engineering and technical
service team, competitive pricing, 24/7 service and
Creative Solutions... Delivering Value
unmatched inventory capability.
Better Support Makes a Better Bearing
• In depth bearing failure and machine troubleshooting
As an integral part of after-sales service and support, NTN provides
• Bearing (re)selection and machine redesign to prolong bearing life and up time
an engineering and service staff across Canada to assist customers
• Liaison with original equipment manufacturers and third party suppliers
in gaining maximum service from the life of their bearings
• Preparation or review of maintenance schedules and procedures
• End user in-house training seminars
www.ntn.ca
PEM_Apr07-features.indd
NTN_PEM_Apr_07.indd 1
25
To contact this advertiser turn to page 49
• Accurate part number crossover to one of NTN’s complete range of products
4/16/07
4/11/0711:40:48
3:43:41AM
PM
lubricant in a timely manner when additives are
depleted from the oil, will prevent corrosion;
Mechanical wear by adhesion: Adhesive
wear occurs when a lubricant film, which
separates two sliding surfaces fails to completely
separate the two surfaces. This allows metal-tometal contact to occur, causing metal fragment
transfer from one surface to the other. This is
commonly referred to as seizing, galling, scuffing or scoring of surfaces. Correct lubricant
viscosity and application frequency will significantly reduce or eliminate adhesive wear;
Mechanical wear by abrasion: Abrasive
wear, sometimes referred to as “cutting
wear,” is the result of hard particles (wear particles or introduced contaminant particles)
bridging two moving surfaces—scraping and
cutting either one surface (two-body abrasion)
or both bearing surfaces (three-body abrasion).
Reducing adhesive wear, along with contamination control of the lubricant transfer, application and filtration processes, is needed to stem
abrasive wear; and
Mechanical wear by fatigue: Fatigue
wear results when bridged wear particles
cause small surface-stress risers (surface rippling), which will eventually expand and break
away from the parent metal as a spall (flake
or splinter) due to repeated cyclic stress of
the damaged area. Correct lubricant viscosity
choice and contamination control is essential to
retard fatigue wear.
2
3
Maintainers should use lubrication strategies to improve and extend bearing
life. For example, the correct choice of lubricant viscosity and contamination control is essential to retard fatigue wear.
of bearing loss of usefulness (failure) is directly
attributable to surface degradation—a totally
preventable condition. In his study, Rabinowicz
determined there are four major contributors
to surface degradation:
Corrosive wear: All metallic-bearing surfaces will corrode if left unprotected from
contact with water and corrosive acids. Water
is introduced into lubricated environments
1
from outside sources that penetrate the sealed
reservoir or bearing (washout, product contamination) or through condensation, which
causes ferrous metals to rust. Corrosive acids
are caused when the lubricant becomes oxidized and suffers loss or breakdown of its corrosion-inhibitor additive packages. Specifying and
using a lubricant with rust-inhibitor and corrosion-inhibitor additives, as well as replacing the
4
Make the right lubricant choice
▲
In the above four cases of wear, the primary
strategy to retarding wear lies in the correct
choice of lubricant. Industrial bearings can
be lubricated with oil or grease. According to
SKF, approximately 90 percent of all bearings
are currently grease-lubricated. Grease enjoys
an advantage over oil thanks to its ability to
“stay put” in the bearing and a requirement for
a simpler and less expensive delivery system.
Grease obtains its lubricating properties from
an 80-95 percent oil base, which is mixed with
fatty acids and alkaline soap to provide a semisolid lubricating gel.
Oil becomes the preferred lubricating medium when operating speeds and temperatures
make it difficult to retain grease in the bearing,
when the lubricant must transfer heat from
the bearings and when oil can be physically
contained or protected (gearbox). A lubricant’s
(oil or grease) primary function is to reduce
friction and wear by forming a separating film
between the two sliding surfaces. When viewed
under a microscope, machined-metal surfaces
will appear “jagged” with peaks and valleys that
can easily collide with another bearing surface.
This results in mechanical wear if not separated
by a lubricant film.
To contact this advertiser turn to page 49
26
PEM PLANT ENGINEERING AND MAINTENANCE
Shat-R-Shield_PEM_Feb_07.indd 1
PEM_Apr07-features.indd 26
1/30/07 12:28:54 PM
4/16/07 11:45:00 AM
The Good Vibrations
of Increased Operational Reliability
With a comprehensive range of products and
services from F'IS - FAG Industrial Services –
Schaeffler Group offers increased competence to
help customers save maintenance costs, optimize
machine availability and avoid unexpected
machine downtime.
From tools and equipment available from stock to
the most highly tailored solutions, Schaeffler is an
invaluable maintenance partner for:
• Bearing installation and repair
• Lubrication
• Alignment
• Condition monitoring and balancing
• Maintenance management
Conceived and designed to promote efficiency
around bearing applications, Schaeffler
maintenance solutions and services support
reliable, longer service life.
SCHAEFFLER GROUP
To contact this advertiser turn to page 49
INDUSTRIAL
Schaeffler Canada Inc. • 2871 Plymouth Drive • Oakville ON L6H 5S5 • 905/829-2750
PEM_Apr07-features.indd
Untitled-6 1
27
4/16/07
4/10/07 11:41:12
12:12:34AM
PM
To contact this advertiser turn to page 49
28
By the shearing action of the fluid along its
viscous planes, the lubricant film adheres to
both bearing surfaces and effortlessly allows
one part to move over the other. The resistance
to flow along these shear planes is named
“fluid friction” and measured as a lubricant’s
viscosity—the most important attribute of a
lubricant. If the viscosity is too low (thin oil)
for the operating speed, temperature and load
conditions—the lubricant film will easily rupture and fail to separate the moving surfaces. If
the viscosity of the lubricant is too high (thick
oil)—it will create a viscous “drag” that results
in overheating and heavy energy consumption.
When lubricating journal-style, sliding-bearing surfaces—full lubricant film separation as
described above is required. It’s also known as
hydrodynamic lubrication (HDL). The least
desirable lubrication state (boundary layer
lubrication) occurs when not enough lubricant
is available or when the lubricant viscosity
is too low and unable to adequately separate
the moving surfaces. A third example occurs
in low rpm/slow-moving applications, when
movement is too slow to generate an adequate
separation film.
In all instances, metal-to-metal contact
between high points will occur and result in
wear. HDL lubrication state is only achieved
once the moving elements are up to speed,
relying on the pumping action of centrifugal
force to generate the lubrication-film supply.
Consequently, when these parts are at rest, and
more importantly in start-up mode, they're in
a boundary lubrication state. It’s why a high
percentage of wear occurs at this point.
A third type of lubricating film (elastohydrodynamic film) is a desirable state and
unique to the operation of rolling-element
bearings. When a rolling element, such as a ball
or roller is placed under load, a momentary
high pressure point is created at the contact
face. This causes the rolling element to elastically deform or “flatten out.” As the surface
deforms, it “traps” the lubricant under extreme
pressure, which forces the lubricant viscosity to
dramatically rise and act as a solid. This allows
the ball or roller to move over the area in an
almost frictionless state (a tire at this stage is
said to be aquaplaning). As the rolling element moves through the load zone—the ball
or roller elastically returns to its former state
of round—just as the contact patch of a tire
returns to round as it leaves the pavement.
signature or recipe and is an engineered liquid
custom-built to perform a specific job in a specific environment. All additives are sacrificial.
As a result, careful attention to additive-package
levels through the use of oil analysis will tell
users exactly when to change the oil without
detriment to the bearing. Oil additives will typically include the following:
• Viscosity improvers: Sometimes a base oil of
inferior quality will require “thickeners” to assist
in achieving the specified viscosity levels over a
varied temperature range. Viscosity improvers
are also used to prevent the oil from “thinning”
at higher temperatures. This allows the manufacturer to build multi-grade lubricants that
operate over wider temperature ranges;
• Antioxidants: Oxygen attacks the base oil,
especially at higher temperatures. Lubricants
designed for higher operating temperatures will
contain higher levels of antioxidants;
• Anti-wear agents: Solids, such as molybdenum disulphide (moly), graphite and polytetrafluoroethylene (PTFE), are employed to assist
as additional sliding agents when metal-tometal contact occurs under heavy loads;
• Extreme-pressure (EP) additives: These
additives, such as sulphur, phosphorous and
chlorine, are used to “soften” bearing surfaces.
This allows them to break away as small asperities without adhesive “tearing” when metal-tometal contact is unavoidable. Please note these
additives can be detrimental to yellow metalbearing material;
• Anti-foaming agents: When oil is moved quickly,
these agents act to retard the formation of air bubbles (air bubbles contain oxygen that will attack
the base oil and cause cavitation in pumps);
• Anti-rust agents: These are used to form a
protective shield against water;
• Detergents: When it comes to cleaning bearing surfaces, detergents are the chemical cleaners to use;
• Dispersants: These work in conjunction with
detergents to chemically suspend dirt particles
in the oil, allowing them to be extracted by
lubrication-system filters; and
• Pour-point depressants: They prevent the
formation of wax crystals in mineral oil at low
temperatures, allowing it to be more fluid at
colder temperatures.
Choosing a suitable lubricant is an essential first
step to achieving full bearing design life and equipment reliability. It’s a choice, however, that most
maintainers can’t make by themselves. p
The lubricant’s additive package
KenBannister is a principal consultant with
Engtech Industries Inc., a production and maintenance operations consulting firm based in Innerkip,
ON. He’s also the author of “Lubrication for
Industry” (second edition). You can reach him by
email:kbannister@engtechindustries.com.
When friction does occur between two bearing surfaces, the lubricant is designed to mitigate the circumstances through the addition
of engineered additives to the base oil. Every
manufactured lubricant retains its own unique
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-features.indd 28
4/16/07 11:45:28 AM
To contact this advertiser turn to page 49
PEM_Apr07-features.indd
Roto_PEM_Apr_07.indd 29
1
4/16/07
4/4/0711:41:36
3:45:52AM
PM
Bumps
&
Bruises
Handle bearings properly to improve operating life
Common handling mistakes
Incorrect bearing handling often occurs during installation. To avoid such mistakes, it’s
important to closely follow the instructions
and recommendations provided by the bearing
manufacturer.
The most common mistakes at installation
are improper bearing setting and adjustment.
Set or adjusted incorrectly, the bearing is at risk
for conditions, such as misalignment, nicking
or spalling—all of which may lead to premature
failure.
Aside from the initial installation, it’s advised
to consult manuals provided by the manufacturer for proper technique and procedure when
re-building equipment. During a re-build, it’s
critical that the entire system is properly cleaned
30
and re-lubricated to ensure the system is free of
any damaging debris or particles.
If not cleaned properly, replacement bearings
and components still may be at risk for damage
because the contamination might remain in the
system. When the system is properly cleaned, it’s
equally important to be sure to handle replacement bearings and components in a clean environment. This prevents dirt or contamination
being transferred into the system during the
re-building process.
Other common mistakes that can diminish
bearing life include denting the cup during
installation and not pressing the cup correctly.
In addition to carefully handling the bearing
itself, it’s important to remember that the bearing is affected by its surrounding components,
such as lubricants and seals. That’s why careful
inspection of these elements will also help with
the overall performance of a bearing system.
Handling strategies
To alleviate these problematic situations, manufacturers offer a variety of proper bearing handling tips to assist users in maximizing bearing
life. First, ensure that the work area is clean and
free of debris. Clean out the machine or equipment with a clean rag and gloves. Remember,
sometimes solvents can help to loosen up any
hardened grease and air hoses can clean out air
holes or castings.
Although an excellent method to clean out
a bearing, if using an air hose, be sure to use
proper safety equipment and take care to not
blow any debris into or onto the clean work
area. Lastly, before final installation, check the
seals and use an appropriate lubricant to provide additional security and ensure better system performance.
PHOTOS: TIMKEN
R
egardless of the industry or application, the proper handling of bearings is required to maximize bearing life and performance. From
shipping and receiving to unpacking, installing,
disassembling and re-building—a bearing is
exposed to a variety of handling techniques.
Done incorrectly at any stage, handling may
reduce the life of the bearing.
Understanding and following proper techniques reduces bearing damage and equipment
downtime. This offers significant productivity gains for maintenance departments. The
Timken Company provides the following tips
to help users get the most out of their bearings:
Bearing-handling tools
Beyond these general handling tips and guidelines, the next step is selecting the right tools for
the job. Remember, with any tools, it’s important to exercise proper safety techniques and use
the recommended safety equipment.
■ Induction heaters: Induction heating is
a superior, fast, clean and controlled heating
method for bearings, gears and other products
requiring a press fit. It’s a safer and more environmentally friendly alternative to traditional
heating methods, such as oil baths or blowtorches. Heating the bearing with an induction
heater increases the diameter of the bearing
slightly to allow easy placement over a shaft.
This tool will eliminate any damage to or
debris from the bearing when moving over the
shaft. If the user attempts to place an unheated
bearing over the shaft, microscopic particles
may break off and get into the machine. This
causes premature damage to the bearing and
other components. Once the bearing cools
down, it grabs the outside diameter (OD) of
the shaft and enables it to have a proper fit, so it
doesn’t move or spin in place.
When using an induction heater, make sure
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-features.indd 30
4/16/07 11:41:45 AM
Warning: Handle with care!
Proper bearing maintenance and handling practices are critical. Failure to observe the following
warnings could lead to a risk of serious bodily
harm:
• Never spin a bearing with compressed air.
The rollers may be forcefully expelled with great
velocity;
• If a hammer and bar are used for bearing
removal, fragments from the hammer, bar or the
bearing can be released with high velocity. Note:
a mild steel bar is preferred, since it’s less susceptible to fragmenting;
• When installing or removing bearings, always wear safety glasses or goggles;
• Cleaning solvents may be toxic or flammable. Ensure adequate ventilation and wear protective
clothing; and
• Remove oil or rust inhibitor from parts before heating to avoid fire or fumes.
the heater has an automatic demagnetizing
and the fits. Feeler gauges or dial indicators
feature. An extremely magnetic bearing may
should be used to check critical applications.
collect unwanted debris. Also use a feeler gauge
It’s important to follow the design engineers’
to ensure the back-face of the bearing doesn’t
requirements when installing all bearing types.
move away from the shoulder on the shaft.
It’s recommended to seek classroom and handsFinally, take care not to overheat the bearing.
on training.
This may damage, soften or misshape the
bearing. Temperatures of 200 to 250 degrees
Fahrenheit will generally allow the bearing to
overcome most fitting conditions.
■ Feeler gauges: Because it’s difficult for
the naked eye to see if the bearing is sitting
against the shoulder, feeler gauges can be
used to measure thousandths of an inch
between the two surfaces to ensure proper
seating.
■ Dial indicators: These are used to check
the end play (amount of movement of It pays to look after your bearings. Use
of simple checks and proper cleaning
the shaft axially, relative to the housing) in
will create big dividends.
tapered-roller bearings only. To make sure
there’s proper clearance (end play), the folBearing or gear pullers
lowing procedure should be used:
If planning to re-use a bearing or gear, pull• After mounting a dial indicator on the housers can be used to safely and properly remove
ing with the indicator point on the end of the
them. Compare the “reach” and “spread” of
shaft, move the shaft in one direction axially,
the puller with the product to be removed and
while rotating or oscillating;
select a puller with dimensions larger than
• Set the indicator to read ‘0’;
those of the job. Make sure the jaws don’t inter• Move the shaft in the opposite direction,
fere with the free movement of the cage. One of
while once again rotating or oscillating. The
the most common mistakes is to attach the jaws
indicator will read the amount of end play in
to the cage and begin the pulling operation. For
the system; and
proper removal, the jaws must engage the back• Consult your manufacturer for the proper
face of the bearing.
amount of end play for your application,
When properly handled, bearing damage
since each application is unique, resulting in
can be greatly minimized, ultimately saving
an end play tolerance that’s unique for that
your company time and money. For more
particular application.
information on how to handle bearings, trainFor spherical, cylindrical and ball bearing—
ing programs or tools to help maximize bearing
clearance is measured in a radial direction
life, visit www.timken.com. p
and is affected by the class of bearing ordered
A new way to
look at funnels.
Introducing the
Industrial Fast Funnel®
Simple
Convenient
Clean
THE NEW Industrial
Fast Funnel® from
Trico is easy to carry,
easy to use, and
easy to store.
Because you use a
fresh funnel every time,
you can be sure you’re pouring
clean oil into your machinery
each time.
www.tricocorp.com
800-558-7008
To contact this advertiser turn to page 49
APRIL 2007
PEM_Apr07-features.indd 31
31
4/19/07 2:56:47 PM
Belt Uptime
Repair conveyor-belt cleats faster on shop floor
By Beth Miller
Most maintenance managers, along with plant and material handling engineers, know that belt conveyors enhanced with cleats can
boost conveyor efficiency, permit faster speeds and allow steeper
inclines that use less belt and save floor space. The following are
maintenance and repair tips to help users get the most out of their
conveyor belt cleats:
PHOTO: FLEXCO
D
amaged and broken cleats result from a variety of circumstances.
Sometimes cleats suffer abuse on the conveyor’s return side,
banging into the framework and return idlers. In the case of
vulcanized or bonded cleats, bonds can simply deteriorate over time.
Severe operating environments—such as extreme or wildly fluctuating
Too hot to handle?
Infrared
thermometers
Thermal imagers
Lab-accuracy
contact thermometers
Find it. Fix it. Fast.
The new Fluke 561 HVACPro combines the
temperature measurement functions you need
in one tool. Non-contact and contact temperature
measurements. Single-point laser sighting. MIN,
MAX and DIF temperature readings to quickly
identify problems. Fast, efficient and easy to use.
Save time and effort.
• Measure hot, moving, electrically energized
and hard-to-reach objects instantly
• Check motors, insulation, breakers, radiant
heating, pipes, corroded connections and wires
• Pipe probe included for superheat and
sub-cooling contact measurements
• Compatible with industry-standard K-type
thermocouple probes
For more information call 800-36-FLUKE
or visit www.flukecanada.ca/hot
Rugged and reliable
temperature test tools.
All in the Fluke familiy.
Temperature
multimeters
Fluke. Keeping your world
up and running.™
To contact this advertiser turn to page 49
32
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-features.indd 32
4/16/07 11:42:09 AM
temperatures, or added drag forces brought on
In addition to potentially harming conveyed
by the conveyor passing through water, etc.—
products, a makeshift cleat may also damage
can cause cleats to weaken at the base or lead
the conveyor system. A piece of angle-iron, for
to vertical cracking. The conveyed products
instance, will not yield if it catches on framing
themselves—especially those made of abrasive,
or return idlers; more likely it will rip out the
jagged and heavy materials, or dropped from
belt. Angle-iron or wood will not flex going
hoppers—also can lead to cleat failure.
around a pulley, but instead will stress the belt
Maintaining cleated belting is important
and eventually shear the belt fabric.
because a nearly direct ratio can be drawn
Likewise, improper fasteners, such as nails,
between the number of broken
wire, standard bolts or screws,
cleats and the loss of conveyor Often when cleats
can tear and weaken the belt’s
efficiency. A 10-cleat conveyor break, conveyor users carcass. This contributes to early
loses 10 percent of its potential
belt failure and perhaps damagproductivity for each broken improvise with a piece ing pulleys or lagging. Though
cleat. Furthermore, one misssome belt productivity may be
of wood, angle-iron or
ing cleat overloads the one
temporarily saved, this type
immediately behind it, creating whatever else is handy, of improvisation can easily do
a domino effect. Damaged cleats
more harm than good.
crudely attached to
usually become more costly and
Hot vulcanization, cold
disruptive the longer they go the belt where the
bonding and heat welding usuunrepaired.
ally are not viable on-site methJust be careful which action broken cleat sat.
ods for replacing broken or
you take. Often when cleats
missing cleats because their cost
break, conveyor users improvise with a piece
and downtime aren’t easily justified. Sometimes
of wood, angle-iron or whatever else is handy,
the belting is too old or worn to even consider
crudely attached to the belt where the broken
them. In contrast, mechanically attached concleat sat. Although such improvised cleats might
veyor-belt cleats provide a fast, easy, economical
move product with varying degrees of success,
and dependable method of replacing individual
their inflexibility can initiate new problems.
cleats—even on belts initially cleated by mould-
Tips to help you select a sealant
With so many products to choose from, making
sure you select the proper sealant is especially
important. Selecting the wrong industrial sealant, or applying the correct sealant in the wrong
manner, can have serious consequences. The
following useful tips will come in handy when
selecting an industrial sealant:
1. Stability over a wide temperature range:
Once fully cured, high-quality sealants perform
across a wide range of temperatures. The best
sealants can withstand temperatures ranging
from -85 degrees Fahrenheit to 599 degrees
Fahrenheit (-65 degrees Celsius to 315 degrees
Celsius). Select a sealant that functions reliably at
temperatures outside the performance range to
accommodate unexpected temperature changes;
2. Weather resistance and chemical stability:
V rays, radiation and weather can cause lowquality sealants to crack, crumble and become
brittle, compromising the seal over time. Look
for sealants with good resistance to these and
other erosive factors. Also, some organic sealants react to atmospheric pollutants or chemicals much like iron reacts with water to produce
rust. Use a sealant that doesn’t readily degrade
after prolonged contact with common elements
and industrial chemicals;
3. Good bond strength: Good industrial assembly sealants provide durable adhesion to a wide
Setting a
higher standard.
up to
10,000
SUS
Introducing the Trico HighViscosity Gear and Lube Oil
Portable Filter Cart System –
specifically designed for highviscosity fluids associated mainly
with gear oils and can filter oils
up to 10,000 SUS @72ºF.
By Russ Noel
variety of industrial materials, including glass,
ceramics, wood masonry and many metals and
plastics. A variety of factors contribute to the
bond strength of individual sealants, including
chemical composition, cure type and substrate
penetration;
4. Electrical properties: If electrical properties
are a concern, be aware that some organic
sealants are less well-suited to applications
where they may be exposed to electricity. In
such instances, a high-quality silicone sealant
may be a better option; and
5. Low flammability: In fire conditions, some
sealants are more burn-resistant than others.
Silicone sealants, in particular, are especially
reluctant to burn and many comply with UL
flammability standards.
Most importantly, make sure you select a
sealant that can perform at the highest temperature you require, but also offers a secure
and flexible hold at lower temperatures. Good
luck with your sealants.
Ross Noel is a senior applications engineer
at Dow Corning supporting IAM (Industrial
Assembly and Maintenance) and automotive
sealants applications. For specific product information, visit: www.dowcorning.com.
Our system ensures that your
equipment receives the cleanest oil
possible – enhancing its life span.
• Bypass Valve - Allows transfer
of oil without filtering.
• Oil Sampling Ports - Two
sampling ports available to
monitor condition of oil.
• Dual Filters - Two-stage
filtrations for long element life
and pump protection.
• Differential Pressure Gauges Indicates when elements need to
be changed.
www.tricocorp.com
800-558-7008
To contact this advertiser turn to page 49
APRIL 2007
PEM_Apr07-features.indd 33
33
4/16/07 11:42:18 AM
To contact this advertiser turn to page 49
Goodyear_PEM_Apr_07.indd
PEM_Apr07-features.indd 341
4/11/07
4/16/07 11:04:57
11:42:27AM
AM
57 AM
ing or fabrication. Repair downtime is minimal
because spare cleats can be stocked in-house for
immediate replacement, or delivered off the shelf
from distributors that maintain an inventory of
attachable cleats.
Replacement time depends largely on the
installation method. Bolt and screw-type attachments ensure better stability, and can be completed quickly with common hand tools, such as
a carpenter’s square, punch or drill, hammer and
screwdriver or wrench.
Cleat material is simply cut to the desired
length. Holes are punched or drilled through
the belt at intervals, corresponding to the holes
in the bottom of the cleat or the distance desired
between lugs or pegs. Holes can be conveniently
made with a hammer-driven belt punch. For
easier, faster or higher-volume installation, however, power punches are available for use with
square-drive air or electric-impact tools. Most
screw-attached cleats have threaded anchors
securely moulded into the cleat body at engineered intervals, while some cleats attach with
traditional through-bolts and nuts. This allows
bolt placement wherever the installer chooses.
With minimal training, in-house maintenance personnel usually can replace a broken or
missing cleat within half an hour. p
We don’t just
have the most
complete lubrication
product line.
Beth Miller is market manager with Downers Grove,
IL-based Flexible Steel Lacing Co. You can reach her
by email: bmiller@flexco.com.
Industrial Belt Showcase
V-belt is checked for electrical conductivity as
standard before dispatch and then supplied
with a certificate, says the company.
www.optibelt.ca
Goodyear industrial belts
Full speed with Optibelt
To step on the gas has a special meaning in
some South American countries. The reason
for this lies not in speeding motorists with a
lead foot on the accelerator, but in the naturalgas driven cars, which have long since become
an everyday sight on the roads, especially in
Argentina and Brazil. They’re also the reason
why the network of natural-gas filling stations
is denser than anywhere else in the world.
The core component of each system is a compressor. It ensures that the gas is compressed
and made usable. Aspro, a natural-gas market
leader, not only equips its own filling stations with its compressors, but also has Shell,
Esso and Texaco among its customers. Aspro
chose its drive belts with care: Optibelt’s Red
Power II with an operational life of more than
8,000 hours. When it comes to the mining sector, Optibelt says that Optibelt V-belts recently
were inspected by DMT-Dortmund (Deutsche
Montan Technologie) in accordance with the
standard DIN 22100-7. For safety reasons, every
Goodyear says its Falcon Pd belts and sprockets
are available in 8mm and 14mm belt sizes
and provide a complete system alternative to
polyurethane systems in the market. Flexible
rubber construction and overall system design
provides decreased operating noise, says the
company. Goodyear further says its Eagle Pd
delivers real bottom-line savings by reducing energy consumption, and by design, can
provide significant lowering of noise levels in
most applications. Eagle Pd is an alternative to
chain, V-belt and straight-tooth synchronous
belt drives, says the company.
www.synchronousbelts.goodyear.ca
We have exactly
WHAT YOU NEED.
Don’t just think of Trico as the
company with the most diverse
lubrication management product line. Instead, contact Trico
because we have the products
you need to take care of your
problems today.
Rely on Trico as your single
source for all of your lubrication product needs.
TRICO. Answers today,
for today’s problems.
www.tricocorp.com
800-558-7008
To contact this advertiser turn to page 49
APRIL 2007
PEM_Apr07-features.indd 35
35
4/16/07 11:42:35 AM
Take charge of your
CAREER at MainTrain!
Attend Canada's premier physical asset management
and maintenance event — MainTrain 2007:
Building a Foundation for Excellence —
and return with the tools to excel at your job.
EXPERT PRESENTATIONS • HANDS-ON WORKSHOPS • NETWORKING & SOCIAL EVENTS • EXHIBITS FROM LEADING VENDORS
Novotel Toronto Centre
Main Conference: Nov. 27-28, 2007
PdM and NDT workshops: Nov. 26, 2007
MMP certification: Nov. 26 and 29, 2007
Experts will share the secrets of maintenance success!
MainTrain 2007 is
produced by the
Plant Engineering and
Maintenance Association
of Canada (PEMAC).
www.pemac.org
(905) 823-7255
This invaluable information can save your company
time and money — and boost your career!
Visit MainTrain.ca for event
and registration information
Platinum Sponsors:
Gold Sponsor:
Training Sponsor:
Media Sponsor:
CLB Media Inc.
Publishers of:
Plant Engineering
and Maintenance
PEM_Apr07-features.indd 36
4/16/07 11:42:46 AM
MainTrain 2007
Get on board:
The MainTrain is roaring back to Toronto! MainTrain is Canada’s premier
annual learning event and conference for maintenance and reliability
professionals from across Canada.
On top of our regular sessions featuring world-class speakers and industry
experts, MainTrain 2007 will open with a full day of hands-on training sessions
designed to help delegates learn more about the latest condition-based
monitoring and non-destructive testing tools and technologies on the market.
The second day of main conference will break after lunch and delegates can
choose to attend one of two excellent workshops designed to send them home
ready to implement all their new ideas.
Register
today!
Conference Highlights:
• Maintenance Planning and
Scheduling
• Predictive Maintenance &
NDT training
• Maximize CMMS Projects
& Investments
• Maintenance Fundamentals
• Effective Plant Shutdowns
& Turnarounds
• Mission-Critical Maintenance
• PEMAC MMP Certification Module 1
• Reduce Energy Costs
& Go “Green”
• Maintenance Masters:
PEM Maintenance Award Winners
• Hydraulics & Drive Controls
• Maintenance Best Practices
• Achieving World-Class Reliability
Who should attend MainTrain?
Plant managers, plant engineers, maintenance managers, director of engineering,
director of operations, production/operations, reliability engineers, facility
managers, purchasers, supply chain managers and anyone involved in physical
asset management.
Reasons to attend MainTrain:
• Reduce equipment downtime, improve production capacity and lower costs.
• Discover how to sell world-class maintenance to management and operations.
• Better manage maintenance to generate a greater ROI and bottom line.
• Learn how to maximize equipment reliability and lifecycle management.
• Become a successful manager and take your maintenance career to new levels.
• Network and connect with industry peers and Canada's maintenance leaders.
MainTrain 2007
Conference information:
MainTrain 2007
Sponsorship information:
Plant Engineering
and Maintenance
Plant Engineering and Maintenance
Association of Canada
Norman Clegg, executive director
(905) 823-7255
maintrain@pemac.org
PEM_Apr07-features.indd 37
Official Media Sponsor:
CLB Media Inc.
Mike Rightmyer, associate publisher
(905) 726-4665
mrightmyer@clbmedia.ca
Learn new
skills
Increase
reliability
Reduce
costs
and
MORE!
www.maintrain.ca
4/16/07 11:43:02 AM
La
Belle Province
PTDA Canadian conference set for Québec City
By Robert Robertson
Schedule of Events
Thursday, May 31
n 10:45 a.m.
Golf outing
n 7:00 p.m. - 9:00 p.m.
Welcome reception
Friday, June 1
n 8:00 a.m. - 9:00 a.m.
Canadian economic forecast
n 11:00 a.m. - 12:30 p.m.
Customer presentations
n 12:45 p.m. - 1:45 p.m.
Lunch
n 2:00 p.m. - 3:30 p.m.
Customer presentations
n 6:30 p.m. - 9:00 p.m.
Reception and dinner
Saturday, June 2
n 8:00 a.m. - 9:00 a.m.
Breakfast
Highlights of this year’s PTDA Canadian conference include:
• Keynote presentation by Peter R. Andersen, Ph.D.,
president, Andersen Economic Research Ltd. He will
analyze domestic and global-leading indicators that
affect Canadian markets;
• Customer presentations, including: Christian
Van Houtte, president, Aluminum Association
of Canada; Catherine Swift, president and CEO,
Canadian Federation of Independent Business; Buzz
Hargrove, president, Canadian Auto Workers; and
Sean Whittaker, director policy and technical affairs,
Canadian Wind Energy Association.
These industry presentations will offer an overview of both key economic drivers and other industry trends affecting their markets. Each speaker will
provide a summary of their industry’s growth
prospects and the impact on their supplier base;
• The conference closer will feature a motivational
presentation titled: “Put Your Heart into It,” with
Jean-Marc Chaput. Be prepared to have your energy lifted and enthusiasm rejuvenated. Chaput has
Past PTDA Canadian conferences have
enabled members and their spouses to
socialize and connect with industry peers.
n 9:00 a.m. - 9:45 a.m.
PTDA update
n 10:00 a.m. - 11:00 a.m.
Motivational session
n 11:00 a.m. - 11:15 a.m.
Conference wrap up
* Free afternoon to enjoy Québec
City on your own
n 8:00 p.m. - 10:00 p.m.
Reception and dinner
38
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-features.indd 38
“The PTDA Canadian conference program
continues to be a success every year."
— PTDA executive vice-president
Mary Sue Lyon
instilled a passionate philosophy on life into thousands of entrepreneurs;
• Formal and informal networking with important
Canadian power transmission/motion control market decision-makers; and
• Social events, including an optional golf outing,
dinner at the Musée de la Civilisation and closing
dinner at the world famous Château Frontenac.
“The PTDA Canadian conference program continues to be a success every year. We expect the conference in Québec City to be the best yet,” says PTDA
executive vice-president Mary Sue Lyon. “The PTDA
Canadian conference is a tremendous opportunity
for both learning and networking. We’ll have the
leaders of the Canadian power transmission industry
in one place at one time.”
The conference is open to all PTDA members
selling product in Canada (distributors and manufacturers), as well as non-members who qualify for
membership. For more information on the conference, contact the PTDA at tel: (312) 876-9461; email:
ptda@ptda.org; Web site: www.ptda.org. p
PHOTOS: PETER HELSTON
Welcome breakfast
n 9:00 a.m. - 10:30 a.m.
T
he Chicago, IL-based Power Transmission
Distributors Association (PTDA) will
hold its sixth annual Canadian conference on May 31 to June 2, 2007 at the
Fairmont Le Château Frontenac Hotel in Québec
City. The conference will provide an opportunity
for attendees to explore nationally focused industry
issues and trends, hear how their peers are tackling
industry challenges and connect with potential business partners.
Robert Robertson is PEM editor. You can reach him by
email: rrobertson@clbmedia.ca.
w w w . p em - m ag . com
4/16/07 11:46:00 AM
When it comes to industry-specific education and exceptional
networking events, no other conference comes close!
PTDA 2007 Canadian Conference
May 31 - June 2, 2007
Join PTDA at the breathtaking Fairmont Le Château Frontenac in Québec City, Québec and discover:
Register
online:
www.ptda.org/
ccregistration
PTDA has negotiated a
room rate of C$199.00
single/double per night
at the Fairmont Le
Château Frontenac. To
book accommodations,
contact the hotel directly
at +1.800.441.1414 and
reference the PTDA
Canadian Conference or
•
•
•
Canadian economic trends that will impact your business.
Where your customers see their businesses going.
The toughest challenges facing power transmission/motion control industry professionals.
Featuring three programs focused on the Canadian PT/MC markets:
Customer Presentations
Canadian Economic Forecast
Representatives from the Aluminum Association of
Canada, the Canadian Auto Workers - Canada,
the Canadian Wind Energy Association, and the
Canadian Federation of Independent Business will
discuss supplier expectations, vendor selection and
evaluation, and threats and opportunities for PT/MC
suppliers. Each presentation will be followed by a
Q&A session.
Peter R. Andersen, Ph.D., President, Andersen
Economic Research Ltd.
Gain insight into the likely twists and turns facing the
Canadian PT/MC industry.
Put Your Heart into It
Jean-Marc Chaput
The simplicity and heartfelt nature of Jean-Marc
Chaput's presentation is sure to reignite your
passion for life.
Complimented by networking at a Welcome Reception and reception/dinner at Québec's own Musée de la Civilisation.
Optional events include a golf outing on May 31 and evening reception and dinner on June 2.
Group Code PTD-97.
For more
information
on the PTDA
Canadian Conference,
please visit
www.ptda.org/
Canadianconference
or e-mail
ptda@ptda.org
or contact us at
+1.312.516.2100
The Canadian Conference is open to all PTDA members selling product in Canada
as well as non-members who qualify for membership.
To contact this advertiser turn to page 49
PEM_Apr07-features.indd
PTDA_PEM_Apr_07.indd 39
1
4/16/07
4/11/0711:43:39
4:07:30AM
PM
By Robert Robertson
Hot Spot
BSA set to hold annual convention in Florida
A
ttendees at the Bearing Specialists Association (BSA) 2007
annual convention, which will be held on May 4-7 at the
Marriott Marco Island Resort, Golf Club and Spa, Marco
Island, Florida, will get a knowledgeable and potentially profitable introduction to the next generation of employees from speaker and
author Eric Chester.
Chester will present: “Meet Generation Why: Understanding,
Managing and Motivating Your New Workforce.” Chester has identified
the 68 million Americans born between 1980 and 1994 as “Generation
Why.” For more than a decade, Chester has worked extensively with this
generation and helped more than two million youth through his motivational programs.
BALL BEARINGS • LINEAR MOTION PRODUCTS
• RO L L E R B E A R I N G S • B A L L B E A R I N G S • L I N E A R M OT I O N P RO D U C T S • RO L L E R B
HARSH WORKING
CONDITIONS?
BRING ’EM ON!
• RO L L E R B E A R I N G S • B A L L B E A R I N G S • L I N E A R M OT I O N P RO D U C T S • RO L L E R B
PEM_Apr07-features.indd 40
4/16/07 11:43:51 AM
Schedule of Events
Friday, May 4
Sunday, May 6
n 3:30 p.m. - 4:00 p.m.
n 7:00 a.m. - 11:30 a.m.
Committee chairman
briefing
n 4:00 p.m. - 6:30 p.m.
Committee meetings
Registration
n 7:30 a.m. - 8:00 a.m.
Breakfast
n 8:00 a.m. - 8:45 a.m.
Annual general meeting
For many years, representatives from Canadian bearing
companies have attended the BSA annual convention.
They will wave the Canadian flag again in Florida.
Saturday, May 5
n 8:45 a.m. - 11:30 a.m.
n 7:00 a.m. - 5:00 p.m.
Business sessions
* Afternoon open to social activities
n 6:00 p.m. - 9:00 p.m.
Reception and dinner
Registration
n 8:00 a.m. - 10:00 a.m.
Committee meeting
n 8:00 a.m. - 10:00 a.m.
Past presidents council
n 10:00 a.m. - 12:00 p.m.
Board of directors meeting
Monday, May 7
PHOTO: PETER HELSTON
* Highlights include business
sessions and golf tournament
Chester says that members of this generation don’t see things like their
predecessors. They also can’t be recruited, trained, managed or motivated
using the same strategies and methods by companies.
Offering further motivation will be former NBA player
USA Today listed Mayland as one of America’s top
BSA 2007 annual
Walter Bond. He’s the author of: “All Buts Stink! How to Live
10 forecasters for 2005.
convention will be held at
Your Life and Eliminate Excuses.” Bond encourages people
These are just a few of the speakers scheduled to
the Marriott Marco Island
to rise above mediocrity, position themselves to reach their
address attendees over two days at the convention.
Resort, Golf Club and Spa, The schedule also includes BSA’s Conference Tables
potential and be free from all excuses.
At the convention, attendees will also hear economic
and the opportunity to network with industry
Marco Island, Florida.
forecaster Ken Mayland, president of ClearView Economics,
peers. For more information on the convention,
LLC, provide an update on the state of the U.S. economy. Mayland has won
contact the BSA at tel: (630) 858-3838; email info@bsahome.org;
several awards for his economic forecasting and is a leader in his field.
Web site: www.bsahome.org. p
B E A R I N G S • B A L L B E A R I N G S • L I N E A R M OT I O N P RO D U C T S • RO L L E R B E A R I N G S •
www.getNSKtough.ca
NO
COMPROMISE
CALL 1-877-994-6675 TODAY
BALL BEARINGS • LINEAR MOTION PRODUCTS
GO TO:
B E A R I N G S • B A L L B E A R I N G S • L I N E A R M OT I O N P RO D U C T S • RO L L E R B E A R I N G S •
To contact this advertiser turn to page 49
PEM_Apr07-features.indd 41
4/16/07 11:44:23 AM
PEM’s 30th ANNIVERSARY ISSUE
Plan now to advertise in the June 2007 issue –
PEM’s official 30th anniversary issue!
This special issue will include:
•
•
•
•
New graphic design look
PEM reader survey results
30 years of industry change
Future trends and predictions
BONUS DISTRIBUTION: Canadian Manufacturing Technology Show (Toronto)
CONTACT YOUR PEM SALES REPRESENTATIVE TODAY!
Associate Publisher
Mike Rightmyer
905-726-4665
mrightmyer@clbmedia.ca
Account Manager
Peter Helston
416-236-7852
peterhelston@yahoo.com
C A N A DA’ S T R U S T E D J O U R N A L F O R P L A N T O P E R AT I O N S , E N G I N E E R S A N D M A I N TA I N E R S
To contact this advertiser turn to page 49
Untitled-1.indd
PEM_Apr07-back.indd
1
42
2/5/07
4/16/07 11:48:57
11:25:17AM
AM
57 AM
Marketplace
INDUSTRIAL PRODUCTS AND SERVICES
Safety controller
housing and stainless-steel eye nut for reliable operation and long life (minimum of one million
The Allen-Bradley SmartGuard
actuations) in the most demanding industrial environments, says the company.
600 safety controller, measuring
Contact: Omron Scientific Technologies, Inc.
a compact four inches by three-
(Omron STI Inquiry Management)
and-half inches by five inches, is
P.O. Box 343, Elk River, MN 55330
designed for those applications
Toll free (800) 479-3658 www.omron.com
that have traditionally fallen
between safety relays and safety
Classic line of screwdrivers
PLCs. This new safety control-
Adding to its extensive line of high-end, professional-grade screwdrivers, Wera Tools
ler helps reduce the wiring and
introduced Kraftform Classic screwdrivers. This new line of hand tools is suited for both
installation costs commonly
“do-it-yourselfers” and professionals, and
associated with relay-based systems, and tightly interlocks with programmable controllers
includes the basic design concepts of its pro-
to help manufacturers integrate their standard and safety systems for increased productivity,
fessional-grade screwdrivers. The screwdriv-
says the company. The SmartGuard 600 safety controller integrates 16 safety-rated inputs,
ers feature the ergonomic Kraftform Classic
eight safety-rated outputs, four pulse-test sources, a USB port for configuration and a
handle, which is shaped to perfectly fit into
DeviceNet port that supports both standard and CIP Safety communication into a single
the hand and allows for fast and efficient
and highly compact package, says the company. The built-in DeviceNet port will allow users
fastening, says the company. The ergonomic
to expand the number of safety inputs and outputs by controlling up to 32 Allen-Bradley
shape ensures high torque transfer and
Guard I/O safety modules, the same safety distributed I/O used in GuardLogix systems.
quick repositioning, and the hex-shaped end of the handle provides anti-roll protection,
Contact: Rockwell Automation
preventing the tool from rolling away, says the company. Kraftform Classic screwdriver
(Rockwell Automation Response Center),
blades are made from high-grade tool steel. A special hardening process makes the screw-
10701 Hampshire Ave., S., Bloomington, MN. 55438
drivers highly wear resistant, says the company.
Toll free (800) 223-5354
Contact: Wera Tools
www.rockwellautomation.com
7-710 South Service Rd., Stoney Creek, ON L8E 5S7
Toll free (800) 267-5541
Deep-groove ball bearings
www.weratools.com
SKF Canada Ltd. will soon bring to market new “green”
deep-groove ball bearings, which reduce energy
Power Application
Engineering
consumption by at least 30 percent compared to
standard ISO products, says the company. SKF
says to consider that the energy consumption of
If you can’t measure it,
you can’t manage it.
industrial motor-driven systems in the U.S. and
European Union is 1.36 million kWh per year.
If these motors used SKF energy efficient deepgroove ball bearings, the company says the estimated
savings would be 2,460 million kWh per year. This
is equivalent to the total energy consumption of
more than three million Swedish households for one month.
40 Executive Court, Scarborough, ON M1S 4N4
Schneider Canada
Services’ highly
Toll free (866) 832-6753
experienced Power
www.skf.ca
Application Engineering
Contact: SKF Canada Ltd.
team is here to develop
Rope-pull emergency stop switches
turnkey solutions
Omron Scientific Technologies, Inc. says its new ER series rope-pull emergency stop switches
providing advanced
cover spans from 40m to 200m for emergency stopping capability along the entire rope
technologies and
length, while reducing the number of required switches
services to monitor
per application. All models are available with an integral
and manage power.
top-mounted, metal emergency stop (E-stop) button that
provides emergency stopping capability at the switch end
of the installation, says the company. In addition to the EStop button, ER series rope-pull switches are available with
a dual-indicator LED beacon that may be wired to flash
www.schneider-electric.ca/services
red, or glow a constant green, indicating the status of the
switch. The ER1022 with 125-metre span and ER1032 with
a 200-metre span are supplied with this indicator beacon in
Schneider Canada Services
the lid. The ER6022 with an 80-metre span is available with
the indicator beacon as an option. The ER series features a heavy-duty IP67 (NEMA 6) die-cast
To contact this advertiser turn to page 49
w w w . p em - m ag . com
PEM_Apr07-back.indd 43
APRIL 2007
43
4/16/07 11:25:30 AM
Marketplace
INDUSTRIAL PRODUCTS AND SERVICES
Clean up hazardous spills
Oil Eater introduced a line of all-in-one, professionalgrade emergency spill kits, which are designed to contain
and clean up hazardous spills in factories. An added
dimension to each kit is the inclusion of a five-gallon pail of Oil Eater
Cleaner/Degreaser
clean
surfaces
to
after
absorption of a spill.
Each kit contains a
generous
supply
of
absorbent pads; pillows;
universal snakes; booms;
Motor/generator monitors
MSE of Canada Ltd. says MotoSafe monitors essentially
automate the meggering requirement of critical motors
and generators. The devices continuously monitor the
insulation resistance of idle machines, and will provide
an alarm once the insulation resistance decays to a preset
level. This reduces downtime, frees up manpower, eliminates periodic meggering requirements, increases machine
readiness and reduces operating and capital costs, while
increasing personnel safety, says the company. This pre-
protective gloves; oil-resistant,
high-temperature disposal bags; an emergency response
instruction guide; and a five-gallon pail of Oil Eater
Cleaner/Degreaser, says the company. Kits are available in
95-gallon and 65-gallon over packs, which can handle the
corresponding volume of liquid, says the company.
Contact: Kafko International Ltd.
3555 West Howard St., Skokie, IL 60076
Toll free (800) 528-0334
www.oileater.com
ventive maintenance device may be used with an existing
SCADA/PLC system or as a standalone monitor. Monitors
for motors up to 13.8 kV.
Contact: MSE of Canada Ltd.,
261 Millway Ave., #12, Concord, ON L4K 4K9
Tel: (905) 738-3744
www.msegroup.net
Open-ended adjustable wrench
LoggerHead Tools LLC introduced six- and 10-inch sizes
of the Bionic Grip, an open-ended version of its Bionic
Wrench. Last year, the eight-inch Bionic Grip was introduced as the first open-ended wrench to distribute forces
240 degrees over a work surface, says the company. It
automatically fits multiple sizes of fasteners, pipes and
tubes with the squeeze of a hand, says the company.
With four serrated jaw surfaces
and an Interlock mechanism that
stays locked while under torque
load, the Bionic Grip is suited to a
wide range of applications
that require turning nuts
and bolts or pipes and tubes,
such as renovations, repairs,
machinery and vehicle maintenance, equipment assembly and plumbing. When the
Bionic Grip’s handles are squeezed,
four gripping jaws converge and grab the
curved surface of a pipe or the flats of a fastener-distributing force over 240 degrees, says the company.
Contact: Loggerhead Tools
Toll free (888) 564-4374
www.loggerheadtools.com
Work-performance gloves
Radians announced that Remington has developed a
new line of work-performance gloves. The new 2007
Remington Work-Performance Gloves are suited for handling materials, gears, equipment and machinery. The
RG-10 slip-on glove has an elastic flair cuff, terry cloth
thumb, reinforced fingertips and leather palms, providing
users with durability and comfort, says the company.
The RG-11 is a general-purpose utility glove that
comes with a breathable spandex back, reinforced thumb crotch, fingertips, leather palm
and a streamlined wrist to ensure a comfortable
secure fit, says the company. While the gel-padded
RG-12 glove comes with the basic terry cloth thumb,
reinforced fingertips and thumb crotch, it also has a
gel-padded palm and neoprene knuckle band for additional dexterity and comfort, says the company. The RG-13
impact gel-padded glove comes with terry cloth thumb,
reinforced fingertips and thumb crotch.
Contact: Radians
7580 Bartlett Corp. Dr., Bartlett, TN 38133
Toll free (877) 723-4267
www.radians.com
To contact this advertiser turn to page 49
44
PEM PLANT ENGINEERING AND MAINTENANCE
Tero_PEM_Apr_07.indd 1
PEM_Apr07-back.indd 44
w w w . p em - m ag . com
3/23/07 12:32:17 PM
4/19/07 2:49:22 PM
ELIMINATE DUST AND
FUMES AT THE SOURCE!
With Source Capture Tools and an
Affordable Eurovac Vacuum System.
Adjustable-height
workstation
Lista International Corp. introduced the
AlignAdjustable Height Workstation, which
ING
GRIND
can be adjusted to accommodate the worker
with the appropriate work-surface height.
ING
WELD
Industrial wet/dry vacuums
ING
SAND
Ridge Tool Co. introduced its new line
of RIDGID industrial two-stage wet/dry
INING
MACH
vacuums, which are designed specifically
for clean up of heavy debris and liquids.
Two models are available: offering a 14-gal-
ING
CLEAN
lon (Model No. RV2400A) and 16-gallon
(Model No. RV2600B) drum. The stronger,
Designed with the operator in mind, the
quieter RV two-stage proprietary motor
work surface of the Align Adjustable Height
series and its blower wheel are designed to
Workstation aligns with the worker’s opti-
handle heavy debris and liquid more quickly
mal reach zone to reduce fatigue, stress
and efficiently, says the company. A three-
and potential injury, says the company. The
layer pleated filter has a large surface area
height of the work surface can be adjusted
for increased motor efficiency and long life,
from 25-1/2 inches to 41 1/2 inches through
says the company. The two models convert
use of a motorized, hand crank or slide-leg
to a blower, with 150-mph blowing velocity.
base. The motorized base can be pre-set
Both models feature a rugged polypropyl-
with three height positions.
ene drum, which is impact and corrosion
Contact: Lista International Corp.
resistant, as well as a durable two-layer
106 Lowland St., Holliston, MA 01746
ProHose that’s 10 feet long.
Toll free (800) 722-3020
Contact: Ridge Tool Co.,
www.listaintl.com
There’s a Eurovac product for every need and budget, from 2-man
Portables to 65-man Continuous Systems. Our services include system
design, tool conversions, integrated airlines and complete installation.
1-800-265-3878
www.eurovac.com
Specialists in Dust & Fume Extraction Systems
To contact this advertiser turn to page 49
PowerLogic
and ION
400 Clark St., Elyria, Ohio 44035
Toll free (800) 769-7743
www.rigid.com
Smooth-controlled grinding
Rex-Cut Products Inc. says it offers a full
line of cotton fibre-mounted points, which
expose fresh abrasives as they work to
Weld-alignment clamp
deburr and finish in
Esco Tool says its new compact, high-
one step, with chat-
strength, weld-alignment clamp is easy to
ter-free performance.
use for rigidly holding in place two sections
Rex-Cut
Mounted
of tube, pipe, flanges or plate. The Esco
Points
constantly
HOG-TIE Weld Alignment Clamp delivers
reveal fresh abra-
up to 15,000 pounds of force for rapidly
sives as they work
positioning two pipes, boiler tubes, flanges
Maximize energy
efficiency and
reliability across
your entire network
t Multi-port, web-enabled
data sharing
t Wide-area power
quality analysis
t Real-time and
historical diagnostics
to deburr and finish
or plates, says the company. It consists of two
precision-machined cast and extruded parts
clamping jaws and a steel strap that inserts
in one step, says the company. Providing
between the two sections being aligned,
smooth, controlled grinding with virtu-
engages the two clamping jaws, positioned
ally no vibration, they come in a variety of
on either side and pulls them together using
shapes, sizes, grits and bonds for use on all
a wrench. Machined from heat-treated
www.pwrm.com
hard and soft metals and will not change
steel, the clamp sets up quickly and releases
their geometry, says the company.
www.powerlogic.com
instantly, while allowing users to set the weld
Contact: Rex-Cut Products, Inc.
t Revenue-class
metering
t Power management
services
www.schneider-electric.ca
gap in the same step, says the company.
960 Airport Rd., P.O. Box 2109
Contact: Esco Tool
Fall River, MA 02722
P.O. Box 530, Medfield, MA 02052
Toll free (800) 225-8182
Toll free (800) 343-6926
www.rexcut.com
www.escotool.com
Schneider Canada Services
p
To contact this advertiser turn to page 49
w w w . p em - m ag . com
PEM_Apr07-back.indd 45
APRIL 2007
45
4/19/07 2:49:44 PM
MRO ress
p
Exp
Your guide to all the latest innovations
in plant engineering and maintenance
products and services.
High-speed pumps
P I P I N G , P U M P S & VA LV E S
Versatile ball valves
COMPANY NAME
FULL PAGE AD
4/C
GF Piping Systems introduced the Type 546 ball valve in sizes two-andhalf inches, three inches and four inches. Complete modularity and
versatility is achieved through its multi-functional module, pneumatic or
electric actuation and a wide range of accessories, from simple to complex, says the company. The new valve is suitable for use across a broad
spectrum of applications, including industrial water treatment, swimming
pools, aquariums, water parks, wastewater technology, potable-water
treatment, chemical distribution, electroplating and power plants.
Available in five materials—Polypropylene, PVC, CPVC, ABS and PVDF
(polyvinylidene fluoride)—the Type 546 valve’s multi-function module
expands the number of uses by allowing the user to easily add different
accessories, actuators and switches, says the company. The module’s
electric position feedback switch, available for both manual and actuated
versions, signals a controller to indicate valve position and also transmits
the information remotely. Designed for maximum efficiency and spacesaving economies, the Type 546 valve requires minimum torque for
operation, allowing for smaller, less-expensive actuators—and resulting
in less wear, easier movement and longer valve life, says the company.
www.gfpiping.com
Pump-control unit
KSB Pumps Inc. says its new Control
Plus pump-control unit is a functional, but easy-to-use controller that’s
suited for submersible pumps used
in municipal or industrial water-treatment facilities. With a large LCD
display, the Control Plus panel uses
simple graphical symbols to keep
the operator fully informed of pump
status and water levels. The system
monitors conditions (overload, temperature and leakage) and operating
history, so that it can provide warnings to the operator when repairs or
routine maintenance are required, says the company.
www.ksb.ca
46
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-back.indd Sec1:46
Viking Pump released a new addition to its high-speed rotary transport
pumps, the RTP20. Offering configuration flexibility and ease of maintenance, the RTP20 (1.0 litre/rev) is built with all
the features of the proven RTP30 (1.28
litre/rev) design, says the company.
The series’ tri-lobe design, customizable per customer specifications, is
compact and lightweight and features
removable feet and multiple mountings for easy vertical or horizontal
adaptation, says the company. Flexible
for a variety of operational needs, the
RTP20 series is also available with
ACME-threaded or tri-clamp ports, as
well as many other port-connection types. Both
the RTP20 and RTP30 series efficiently fill rotor voids, allowing for
faster and quieter operation on viscous liquids, says the company.
The RTP20 offers a capacity to 264 GPM (1,000 L/M / 60 M3/Hr.),
pressure to 145 PSI (10 Bar), viscosity to 250,000 SSU (55,000 cSt)
and operates in temperatures to +230 degrees Fahrenheit (+110
degrees Celsius). The RTP30 offers a capacity to 340 GPM (1,283
L/M / 77 M3/Hr.), pressure to 175 PSI (12 Bar), viscosity to 250,000
SSU (55,000 cSt) and operates in temperatures to +300 degrees
Fahrenheit (+150 degrees Celsius).
www.vikingpump.com
Plumbing-parts catalogue
Grainger released a new specialty 316-page catalogue
for plumbing products and
supplies. The catalogue is a
one-stop shop for users seeking maintenance, repair and
operating (MRO) supplies,
says the company. The catalogue features the following
products: water heaters and
coolers, pipes, valves, fittings,
fixtures, faucets and water-filtration systems. The catalogue
includes more than 16,000
plumbing, valves and fittings
items (of which 12,000 are
new to the Grainger offering).
An additional 1,500 products
related to plumbing (from various categories) are featured in the catalogue. The catalogue includes other products, such as fasteners, materials handling and security items for MRO and facility operations.
www.acklandsgrainger.com
w w w . p em - m ag . com
4/16/07 11:26:43 AM
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To contact this advertiser turn to page 49
PEM_Apr07-back.indd Sec1:47
4/19/07 3:11:07 PM
ADVERTORIAL
Pickering fab shop
turns to online service to find
new customers and grow its business
Want to grow the business? Here’s a tool that does just
that. You’ve got a great fab shop. All the latest technology. A very
good local reputation. But how do you get out of the “local box”?
How do you reach a broader audience, make it aware of your presence and capabilities — in short, grow your customer base?
CREDIT: A.P.S METAL INDUSTRIES
Step one: Start with the computer on your desk!
PICKERING, ONTARIO — Andy Pavletich, founder and owner, A.P.S. Metal
Industries Inc, says his company specializes in stainless steel fabricating and
forming of a variety of products (food processing equipment, hoppers,
chutes, mixers, conveyor system parts, environmental products, packaging
machinery parts, electronic enclosures and cabinets, display units, lighting
fixtures, product holding fixtures, medical equipment, furniture and appliOne of three Trumpf L-3030 4,000 watt laser cutters with flying optics,
ances and so on). The company employs 60-70 people and operates out
dual 60” X 120” material beds and state-of-the-art nesting software
of a 30,000 sq. ft. facility.
inside the A.P.S. facilities in Pickering, Ontario.
“We opened in 1986,” Pavletich says, “and we’ve built our business
on a reputation for quality, quick turnaround on delivery —sometimes
in a matter of a few days to a few hours — and a fair and competitive
where we were in the bidding THE COMPANY: A.P.S. Metal Industries,
price. But we knew we had to tap new customers and markets if we
hierarchy. It was like taking a a Pickering, Ontario fabrication shop
were to grow.”
risk, which is true of most
found an innovative way to market its
The company’s Purchasing and Materials Manager, Rob Zakojc says
things in business. But soon I
production capabilities. A.P.S joined an
he’d used the Internet to try to find new customers, and came across
became very familiar with the
online marketplace to find new business
MFG.com, an online production-level solution for OEMs and suppliers
site.”
in Canada and the United States.
of engineered-to-order components, which instantly and intelligently
matches buyer requirements with potential suppliers possessing the right
Extend your reach
expertise, credentials, and capacity for the job being sourced.
Zakojc says that clearly one of the reasons A.P.S. Metal Industries joined
“When I came across the site,” Zakojc says, “and took it for a test drive,
MFG.com was to spread its reach and broaden its exposure to potential
I thought this might be the tool I’ve been looking for.”
new customers. And apparently it’s done just that. “The fact that we’re
Zakojc says that for his purposes the site is a helpful new tool. “I’m able
Canadian,” Zakojc says, “a lot of these customers would not have even
to check at any time of the day what RFQs are out there,”
thought to look here. At the same time, I
he says. “And the real plus is that when I see an RFQ for
wouldn’t have thought to look at some of the
fabrication or forming, I know that company has the
smaller areas in the U.S. or even assume that
work, wants it done, and wants it done now. If they
I could work for these companies. But today
match our capabilities and capacity, I’ll bid. And it’s so
freight is not really an issue whether your
easy. I can’t even begin to tell you how much time I’ve
shipping from Toronto to Tennessee or
saved over traditional means of finding prospects and
Chicago, and NAFTA has opened the trade
new customers. I can easily pull down and process 50
doors. What companies have to deal with
RFQs a day. When I get here in the morning, I turn my
now is really nothing more than some minor
machine on and the site comes up. It stays on until I turn
paper work issues.”
my machine off at night.”
Before joining, for example, Zakojc says he
Suppliers can sign up for a FREE TEST
had a handful of U.S. customers. Today, he
DRIVE at http://pem.mfg.com
Using the site
has 15 US companies and that number is
Zakojc says that using MFG.com is in at least one way
growing. “What the site really does,” he says,
like using any other new tool: The more you use it, the easier it is to use.
“is make everybody my neighbor, regardless where they are. Everybody is
“The first couple of times we used it,” he says, “we really didn’t understand
a company right down the street, and how great is that?”
http://pem.mfg.com
Try it! Free Supplier Test Drive!
To contact this advertiser turn to page 49
PEM_Apr07-back.indd Sec1:48
4/16/07 11:27:17 AM
APRIL 2007
Plant Engineering
and Maintenance
Do you want to know more about any product advertised in this
issue of PEM Plant Engineering and Maintenance? Here, you’ll
find all the information you need to make the right connections!
Every advertiser is listed, along with several ways that you can get
FOR YOUR INFORMATION
HOW TO CONNECT WITH ADVERTISERS IN THIS ISSUE
ADVERTISER
PG #
Advanced Gas Technologies Inc.
50
Bosch Rexroth Canada Corporation 20
CompreVac Inc.
23
Enbridge Gas Distribution
17
Eurovac Inc.
45
Exair Corporation
9
Flir Systems Ltd.
52
Fluke Electronics Canada Inc.
12, 32
Gates Canada Inc.
3
Goodyear Industrial Products
34
Grundfos Canada Inc.
13
Henkel Corporation
2
J.W. Winco
50
Kinecor Corporation
14
Lafert North America
7
Lovejoy Canada
15
Main Train
36-37
MFG.Com
48
NSK Canada
40, 41
NTN Canada
25
Nilfisk-Advance America Inc.
28
PTDA
39
Petro-Canada
10, 21
RotoPrecision Inc.
29
SKF Canada
51
Schaeffler Group
27
Schneider
43, 45
Shat-R-Shield
26
Tero Consulting Ltd.
44
Timken Canada
19
Trico Corporation
31,33,35
Victaulic Company of Canada
8
Wainbee
11
WEG - V.J. Pamensky Canada Inc.
49
Western Manufacturing Show
47
in touch. Whether you phone or fax, visit a Web site or send an
e-mail, getting the information you need has never been easier.
PHONE #
FAX #
905-305-0094
905-335-5511
905 624-4096
866 844-9994
800 265-3878
800 903-9247
905-637-5696
905 890-7600
519 759-4141
416 201-7895
905 829-9533
1-800-263-5043
1-800-877-8351
866 546-3267
800 661-6413
905 670-9421
905 823-7255
877-866-5353
877 994-6675
905 564-2700
877 215-6974
312 876-9461
866 335-3369
888 712-3400
866-832-6753
905 829-2750
905-678-5848
800 248-4911
604 458-1401
905 826-9520
800 558-7008
905 884-7444
888 WAINBEE
416-781-4617 or 877-Pamensky
888 322-7333
905-305-0092
905-335-4184
905 624-4099
416 495-6047
905 738-4603
513 671-3363
905-639-5488
905 890-6866
519 759-0944
416 253-3000
905 829-9512
905-814-6511
1-800-472-0670
514 636-7777
905-629-2852
sales@adgastech.com
karen.park@BoschRexroth.ca
sales@comprevac.com
energyservices@enbridge.com
info@eurovac.com
garygunkel@exair.com
IRCanada@flir.com
canada@fluke.com
staylor@gates.com
brad_baber@goodyear.com
tellul@grundfos.com
todd.hassard@ca.henkel.com
905 823-8001
mail@pemac.org
tcraig@mfgquote.com
babcocg@ca.nsk.com
rpayne@ntn.ca
905 564-7749
E-MAIL ADDRESS
msavaino@kinecor.com
sales@lafertna.com
312 876-9490
--905-712-3301
888-753-6584
905 829-2563
905-678-9814
704-633-3420
604 468-1408
905 826-0482
ptda@ptda.org
lubecsr@petro-canada.ca
gregg@rotoprecision.ca
marketing@skf.ca
pmckenzie@ca.fag.com
skye.ball@ca.schneider.com
info@shatrshield.com
905 568-0083
416-781-4352
jbachmann@wainbee.ca
anthonyz@pamensky.com
boerre@timken.com
lkiepert@tricocorp.com
WEB ADDRESS
www.adgastech.com
www.BoschRexroth.ca
www.comprevac.com
www.enbridge.com/gas
www.eurovac.com
www.exair.com
www.flir.ca
www.flukecanada.ca
www.gates.com/driven
www.goodyearindustrial.ca
www.grundfosalldos.com
www.loctite.com
www.jwwinco.com
www.kinecor.com
www.lafertna.com
www.lovejoy-inc.com
www.maintrain.com
pem.mfgquote.com
www.getNSKtough.ca
www.ntn.ca
www.n-aa.com/info15
www.ptda.org
www.petro-canada.com
www.rotoprecision.ca
www.skf.ca
www.schneider-electric.ca
www.shat-r-shield.com
www.tero.ca
www.timken.com
www.tricocorp.com
www.victaulic.com
www.wainbee.com
www.pamensky.com
www.wmts.ca
Severe Duty Motors at
Standard Pricing
Built Tough To Last
Massive Inventory
Friendly Service with
Competent Technical
Know-How
3rd Largest Full-Line
Motor Manufacturer in
the World
From
PAMENSKY
1-877-PAMENSKY (726-3675)
w w w . p em - m ag . com
PEM_Apr07-back.indd Sec1:49
INVERTER
DUTY
CORROSION
RESISTANT
LOW NOISE
www.pamensky.com
APRIL 2007
49
4/20/07 9:02:36 AM
People and Productivity
BY WILFRED LIST
Max Watkins, who had been drinking hot chocolate,
placed a half empty paper cup on top of a desk, which Jamie Brown was
using for paperwork. Unfortunately, the desktop was uneven and the cup
tipped on its side—spilling hot chocolate on the paperwork.
Jamie picked up the cup and threw it at Watkins;
leaving a few drops of hot chocolate on a new Tshirt Watkins was wearing in preparation for an
interview for a company promotion.
In retaliation, Watkins picked up the cup
and began flicking the hot chocolate at Brown,
with droplets landing on Brown’s shirt and face.
Brown picked up a magic marker and warned
Watkins to stop or else. Other employees, who
stopped work to watch, laughed at what they
saw as horseplay.
The laughter stopped, however, when Brown
lunged at Watkins and marked up his shirt. At
this point, an infuriated Watkins grappled with
Brown. As they shouted at each other, Brown’s
shirt was almost torn off. Brown then punched
Watkins in the eye. In turn, Watkins said he
was reporting the fight to the human resources
(HR) director.
When they appeared before the HR director, both men displayed visible signs of their
encounter: minor cuts and scrapes and red welts. They were sent home,
pending further investigation. Although Watkins or Brown didn’t have
any previous record of violating company rules, management decided
that retaining them would send a message to other employees that workplace violence would be tolerated.
The arbitrator, who heard the grievance against dismissal, agreed on one
count with the employer. When it
comes to cases of violence or threats
of violence, he said that employees are
now being held to higher standards
today than in the past. At the same
time, however, he found that the fight
wasn’t malicious or premeditated.
According to the arbitrator, it was
a case of horseplay that quickly spun
out of control. For this reason and
because Watkins and Brown had
exemplary work records during
their six years of employment, the
arbitrator ordered their reinstatement. This included full credit for
service and seniority, but with no
compensation for lost wages and
benefits. p
ILLUSTRATION BY KATHY BOAKE W.
Cup runneth over
CUT COSTS!!!
PRODUCE YOUR OWN NITROGEN OR OXYGEN
• Turnkey gas generating systems available
for purchase or rent
• Produce nitrogen or
oxygen on site from
compressed air
• Nitrogen purities to
99.999%
• Oxygen purities to
99%
• Flow capacities from
10 SCFH to 20,000
SCFH
• PSA, VSA and membrane type systems
…using tomorrows technology to
cut industrial gas costs today!!!
Advanced Gas Technologies Inc.
230 Don Park Road, Unit 15, Markham, ON L3R 2P7
Tel: (905) 305-0094 Fax: (905) 305-0092
www.adgastech.com sales@adgastech.com
To contact this advertiser turn to page 49
50
PEM PLANT ENGINEERING AND MAINTENANCE
PEM_Apr07-back.indd Sec1:50
To contact this advertiser turn to page 49
w w w . p em - m ag . com
4/16/07 11:27:41 AM
SKF
To contact this advertiser turn to page 49
PEM_Apr07-back.indd
SKF_PEM_Apr_07.indd
Sec1:51
1
4/16/07
4/5/07 11:27:59
12:36:15AM
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To contact this advertiser turn to page 49
TM
The Global Leader in Infrared Cameras
1-800-613-0507 Ext. 25
IRCanada@flir.com
Untitled-4
PEM_Apr07-back.indd
1
Sec1:52
www.flir.ca
1/30/07
4/16/07 12:04:47
11:28:09PM
AM