bsc sustainability solutions catalogue

Sustainability Solutions for AuStrAliAn induStry

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS

WATER SAVING

SOLUTIONS

WATER SAVING

SOLUTIONS

ENVIRONMENTAL

SOLUTIONS

ENVIRONMENTAL

SOLUTIONS

www.bsc.com.au

AuStrAliAn owned Since 1921

2

Formerly known as Bearing Service Pty Ltd and established in

1921, BSC is the premier and most experienced Bearing and

PT product distributor in Australasia. Proud of its Australian

owned heritage, we are primarily engaged in the supply of

Bearings and Power Transmission products. Today, BSC employs

around 300 permanent staff and operates over 40 branches in all

states around Australia.

The BSC product range is the largest of its type and is supported

by a large distribution network of more than 100 computer-linked

branches and authorized distributors to ensure that our broad

stock range is available in all areas throughout Australasia

including PNG, New Caledonia, Fiji, Solomon Islands, etc.

Comprehensive bulk stock and accounts are managed using

an IBM AS400 server platform.

Over the years BSC has built a reputation as a respected supplier

of quality products and services. Since 1995 BSC has been

licensed as a Quality Endorsed Company (QEC4475) and regularly

audited and certified by SAI Global Limited to comply with the

requirements of AS/NZ ISO 9001:2000 for the procurement,

warehousing, distribution and sale of a wide range of bearings,

power transmission and associated products.

www.bsc.com.au

Margaret Mead

“ We won’t have a society if we destroy the environment.

Sustainability Solutions for Australian Industry

3www.bsc.com.au

INDEX

Sustainability Solutions for Australian Industry INDEX

BSC understands our responsibility to the environment and our customers, and sustainability has been an important part of our company policy for many years. Our commitment to sourcing technically advanced products across our product range from world class manufacturers has been our response.

In today’s environment with soaring energy

prices it is essential for companies to reduce

costs in order to remain competitive. This

has prompted BSC to put together a range

of products with potential energy saving

initiatives and ideas.

BSC’s new Sustainability Catalogue will not

only save you money with smart product

choices and energy saving initiatives

and ideas but will also be helping our

planet. Selecting products from this range

will significantly reduce your energy

consumption or water usage or simply

using environmentally friendly products.

Energy Management

Motors 4Variable Speed Drives 8Engineering Services 11Gear Boxes 17Belts 19

Water Management

TS Flat Chain 25AESSEAL Water Management 26

Environment Management

Bearings 27

Energy Wise Electric MotorsPublished - ecoBiz Queensland

IND

uS

tr

y IN

fo

rm

AtIo

N

Half of the world’s electrical energy goes toward

powering electric motors.

To improve energy-efficiency in your workplace, ensure

electric motors are suitable for the tasks they perform. The best

way to identify potential energy savings is to work backwards

from the task the motor performs to its power input.

A smaller motor may provide sufficient power for a specific task

and cost less to run. If feasible, install a time switch to control

the length of time the motor operates. Alternatively, install a

calendar time switch to prevent motors running on days when

not in use, such as when your workplace is closed.

Does your motor match your needs?

Consider three basic factors when assessing motor suitability:

1. Consider total life costs when buying an electric motor,

including purchase price, installation and operating costs.

If you invest in an energy-efficient motor your business will

save more over time.

2. High Efficiency Motors (HEM) are about two to four percent

more efficient than standard electric motors, and offer

lower operating costs and reduced energy consumption.

The initial investment will be greater, but it only takes about

two years to recoup the additional costs in energy savings.

HEMs produce less heat, reducing air-conditioning costs

and providing a cooler work place. They maintain high

efficiency over a wider range of loads and have a greater

thermal tolerance.

It is important to match the HEM to its application as

these motors operate at a slightly higher full-load speed

than standard motors. This means that centrifugal loads,

including pumps, fans, and compressors, can be affected by

higher speeds and negate energy savings. This may involve

replacing an existing motor with a smaller one, trimming

impellers on pumps or changing gear or pulley ratios.

3. Consider the size of the motor. Companies often buy an

oversized motor to cope with unexpected peak loads or

to allow for process expansion in the future. As a result,

hundreds of motors used in industrial applications are

grossly oversized. Motors are most efficient when operating

at full load, and installing a smaller motor, which operates at

full load, will greatly improve the operating efficiency.

Improve performance with a VSD

A Variable Speed Drive (VSD) is an electrical device that

controls power to the motor, and is suitable for inconsistent

loads. Rather than continuously running at full speed, the VSD

varies the motor speed to meet the energy needs of the load.

While a VSD can cost more than the motor, it can achieve

energy savings of up to 50 percent a year. VSDs provide best

energy savings when applied to a motor-driven centrifugal

pump.

There are cheaper alternatives to VSDs. Multi-speed motors

can be used with two or more pumps running parallel systems.

One motor is used for the base load, and the second is used

only during peak load times, offering improved reliability and

providing a back-up if one motor or component fails.

Maintaining your motors

• Check that drive belts, chains and couplings are in good

condition and are adjusted in accordance with the supplier’s

recommendations.

• Check for motors that are running hot, as this is a sign of energy

loss. Use an infrared non-contact thermometer to measure the

temperature of the motor casing (investigate if it is 60 degrees

or higher).

• Check alignment, as parts in a misaligned motor will be

susceptible to wear more quickly, reducing both the motor’s

service life and efficiency.

• Record data for each motor to assess if it is running

unnecessarily. Record the motor’s application, the nominal

power (in kW) from the motor identification plate and how the

motor is controlled.

• Replace a motor rather than rewinding it. Although rewinding

is popular, efficiency is reduced by up to three percent each

time a motor is rewound, leading to lower operating efficiency

than the nameplate efficiency. If a motor burns out, the best

solution is to review your load needs and purchase a high-

efficiency motor to match that load.

4

motorS

Reduce energy loss and save money. Based on state-of-the-art technologies which

reduce carbon foot print from manufacturing,

to installation and on-going use, the W22 range

of E3 High Efficiency motors will reduce your

operating, inventory and maintenance costs,

whilst helping you achieve carbon emission

targets.

The new generation W22 E3 super long life

High Efficiency Motor encompasses many

performance advantages including reliability,

life, energy efficiency, reduced noise and

vibration levels, extended lubrication intervals,

standardisation and flexibility. The W22 motor

comes in two design variants either meeting

the requirements of AS1359.5 High Efficiency

E3 levels or exceeding them with a Super High

Efficient model.

W22 E3 super long life High Efficiency motor

designed to exceed the requirements of MEPS3

high efficiency levels are among the most

efficient motors in the world. In fact the W22

E3 can reduce energy losses by between 10%

and 40% compared with other typical motors.

For the life of the motor, the purchase cost can

be as low as 2% of the total cost of ownership.

The payback period for a W22 over a standard

efficiency motor can be less than 7 months

depending on the operating hours.

Completely interchangeable with lower level

efficiency motors (eg MEPS2) and designed

to comply with standard EN 50347 for ‘kW to

frame’ ratios. The W22 E3 has a flat efficiency

curve: from 75% up to 100% of load the high

efficiency is kept constant for maximum

energy saving in applications where the motor

has been oversized.

The optimised cooling system of the W22 E3

composed of fan, fan cover and motor frame is

designed for optimum balance of airflow and

noise level. The fan provides greater amounts

of air to cool the motor and the fan cover with

its aerodynamic outline is designed to avoid

recirculation of air (loss of performance) and to

better direct the airflow over the motor fins.

The ageing of the insulating material is directly

proportional to its operating temperature –

the optimised cooling system of the W22 E3

provides outstanding heat dissipation and

eliminates hotspots by providing a uniform

temperature distribution throughout the frame.

OH&S regulations call for reduced noise levels.

It is possible to meet the lowest noise levels

on the market simply and economically as the

W22 limits noise to 80Db(A) at 1 metre from

the motor without compromising flexibility.

An electric machine’s lifespan is governed by its

insulating material operational hours. H Class

insulation is standard in W22 E3; providing a

design life of up to 3.35 times that of standard

F Class insulated motors. This super long life

maximizes product serviceability and results

in a significant reduction in materials spend

– from reduced replacement to providing a

solution enabling plants to halt the practice

of rewinding – universally identified as a

significant contributor to lowering motor

efficiency levels.

W22 E3 Motor

5


www.bsc.com.au

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS

motorS

IE1 IE3

Energy Cost

COST BREAKDOWN OF MOTOR

$210

$215

$220

$225

Purchase Cost Maintenance Cost

COST

60 70 80 90 100 110 120 130

100

90

EFFI

CIEN

CY (%

)

PERCENT OF RATED OUTPUT

Constant e�ciency area

TYPICAL EFFICIENCY CURVE OF W22 LINE

80

Quarrying Application

CA

SE S

tu

Dy

Total Design Life Materials & Energy Saving of over $451,170

A major BSC quarrying customer in Victoria recently worked

with BSC’s Engineering Services to identify site improvement

opportunities that would enhance reliability, reduce ongoing

materials spend associated with replacements and rewinding

and deliver significant energy consumption reduction. Quarry

environments are tough and require mining class rated motors.

Following the survey and analysis, Engineering Services

identified a number of areas throughout the quarry where a

progressive change-out to the Super Long-Life High Efficiency

mining specification motor range would provide significant

benefits to our customer.

The outcome for the customer:

• Reduction in energy consumption of

223,778kwh per annum

• Reduction in CO2 emissions of 321 tonnes per annum

• Nett reduction in energy costs of $31,329 per annum

• Increased motor life of 335%.

The use of Variable Speed Drives (VSD) is

recognized to be one of the major driving

forces for energy efficiency because it can

adjust motor output to best suit load needs.

However, voltage spikes from the PWM

waveform can have harmful effects on the

motor winding, leading to premature failure

of the insulation system. This worsens as

switching frequency is increased. All W22 E3

motors are fitted with WISE insulation which

permits them to be operated by VSD – the

WISE system is composed of Class H wire

(200C), enhanced insulation materials and a

solvent-free resin. When used with a VSD, our

innovative WISE® insulation will deliver years

of reliable operation. Operating the W22 with

WEG’s CFW11 VSD, the patented Optimal

Flux® will provide further savings. For further

information on Optimal Flux® please refer to

the section in this catalogue on the CFW11.

Insulated bearings are expensive and, like any

load carrying rotating or sliding product, are

subject to wear which eventually requires

replacement. W22 E3 motors can be fitted with

a non-drive end shield where the bearing hub

is insulated. This component doesn’t wear and

guarantees longer operating hours.

W22 E3 Motor (CoNtINuED)

6

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS

motorS

COMPARISON BETWEEN W22 AND MEPS EFFICIENCY LEVELS

EFFI

CIEN

CY (%

)KW

W22 Top Premium E�ciency Minimum High E�ciency Level

W22 Premium E�ciency Minimum E�ciency Level

37 45 55 75 90 110 132 160 200 250 315 355

91

92

93

94

95

96

97

98

REDUCTION

321 T pa

The DE end shield has a patented design with

fins and reinforced structure that increases heat

dissipation, ensuring low bearing operating

temperatures. This results in extended

lubrication intervals and subsequently lower

maintenance costs and reduced TCO as

lubrication intervention relies upon personnel

and equipment. In the W22 E3 design,

extended lubrication intervals of up to 126%

are achieved through patented end shield

design and reduced bearing temperature rise.

W22 E3 motors are IP66 rated – the highest

Ingress Protection rating against solid objects

such as dust and the highest Ingress Protection

against water (powerful jetting) other than

totally immersible motors. This IP rating allows

for standardisation of motors throughout, in

most operating environments, as there is no

longer any need to carry motors of varying IP

ratings in inventory.

Premium Efficiency Motor Audit – Food & Beverage Industry

CA

SE S

tu

Dy

Energy consumption reduction equivalent to over $400,000 per annum

BSC’s Engineering Services was asked by one of our major

national customers, a multi faceted manufacturer with

production plants in most States throughout Australia,

to conduct a detailed audit of electric motor applications

with a view to identifying opportunities to reduce energy

consumption and increase reliability.

Utilising our Super Long Life High Efficiency motor range BSC

was able to provide an attractive solution which would provide

very significant savings.

At a glance:

• Reduction in energy consumption of 4.6 million kwh per

annum

• Reduction in CO2 emissions of 6,600 tonnes per annum

• Increased motor life of 335%

• No more rewinding costs

• IP66 standardisation opportunity

7


www.bsc.com.au

motorS

REDUCTION

6600 T pa

WEG CFW-11 variable speed drive for all industries.

Using state of the art technology, the CFW-11

variable speed drive is designed for control of

three-phase induction motors. CFW-11 utilises

precise sensorless vector control or closed

loop vector contol and since it is designed

for operating on either Normal or Heavy

Duty loads, it can be used in a wide range of

applications such as:

• pumps

• fans

• air compressors

• refrigeration compressors

• converyors

• ball mills

• mixers

• crushers

• hoists

• palletizers

Normal duty provides 110% overload for 60

secs every 10 minutes and 150% overload for

3 secs every 10 minutes. Heavy duty provides

150% overload for 60 secs every 10 minutes

and 200% overload for 3 secs every 10 minutes.

With rated ambient temperatures of 50°C and

maximum ambient temperature of 60°C (up to

frame size D), the CFW-11 is robust enough for

the most arduous conditions.

Improve Efficiency and Save Energy

The CFW-11 VSD provides the ability to directly

control motor speed and motor torque

to meet the process requirements. More

importantly the CFW-11 improves efficiency by

saving energy when controlling motor speed.

Operating a centrifugal pump or fan with a VSD

will provide high energy savings negating the

need for throttling control. Power consumed

by a pump is proportional to the cube of the

speed. Comparing the two operating points

shown in the graph below, VSD control shows

remarkably lower power consumption for the

same flow. A flow-on benefit of VSD control on

centrifugal pumps is reduced pressure within

the system. (See below)

Optimal Flux®

When working on Heavy Duty loads with

constant, or high, torque requirements

throughout a wide speed range, the patented

Optimal Flux® provides the most cost effective

and energy efficient solution. Optimal Flux®

automatically minimizes losses within the W22

motor negating the need to oversize the motor

to meet the torque requirements, and negating

the need for a separate forced cooling system

on the motor (further reducing the size of the

installation).

Optimal Flux® can reduce motor temperature

rise by up to 11% which can increase motor

winding life by over 200%.

CFW-11 VSD

8

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS

VSD - VArIAblE SpEED DrIVES

TYPICAL Q-H CURVES FOR A CENTRIFUGAL PUMP

A

C

B

ENER

GY

SAVE

D

FLOWCHANGE

Flow reducedby speed control

Flow (m3/h)

Head (m)

Flow reducedby throttling

H2

H1

Q1 Q2

Reduce the cost of the installation

An often overlooked aspect of a VSD is the

installation where costs can be incurred. The

CFW-11 has features that can reduce the cost

of the installation.

The design of CFW-11 allows the heatsink to be

mounted external from a panel, reducing the

temperature rise within the electrical cabinet

and reducing the cost of ventilation and

cooling. The internal components of the

CFW-11 are protected by an IP54 seal ensuring

reliable operation.

Automatic control of the speed of the heatsink

fan reduces the power consumed by the VSD

providing lower energy usage in favourable

ambient conditions.

With application functions such as Multipump

for multiplie pumps systems, crane, winder,

and a SoftPLC for customising, additional time

and equipment is not required for specific

applications. (See right)

Oriented Startup reduces time to configure

the drive by providing the minimum required

parameters necessary to control a motor. The

default configuration of the CFW-11 is suitable

for most applications out of the box. The

intuitive keypad and menu structure makes

a programming manual almost redundant.

Navigating the keypad is as simple as

navigating a mobile phone. (See right)

9


www.bsc.com.au


CA

SE S

tu

Dy A Major Food Processing Facility

In applications where braking is required,

typically braking resistors are needed. These

resistors are an additional cost and take up

additional installation space. With Optimal

Braking the need for these additional resistors is

reduced. (See above)

The CFW-11 is C-Tick compliant, comes in IP21,

IP54 variants for flexible installation, has DC link

reactors to improve power factor, has a high

ambient temperature rating, and has high start

torque/overload torque.

BSC can also provide other WEG Automation

products such models covering single phase

input, three phase input in low voltage and

medium voltage, IP ratings from IP20 to IP56,

and softstarters.

Energy savings of $6300

A major food processing facility had a problem with two screw

conveyors in their grain handling plant. The conveyors, driven

by 2 x 22kW motors were started with star-delta starters. The

star-delta starters were installed to replace previously used DOL

starters, in an effort to reduce the high starting currents. The

customer mentioned that during certain conditions when a

loaded conveyor was stopped due to bottlenecks within the

plant, the star-delta starters did not always get the conveyors

started due to the low starting torque. Operators would have

to manually unload the grain, which would take on average 2

hours, adding unnecessary down time and lost production.

The BSC solution was to offer two 22kW, heavy duty rated

CFW-11 WEG variable speed drives which could provide the

necessary starting torque and the added benefit of being able

to reduce conveyor speed in lightly loaded

conditions to save energy.

The CFW-11 can provide 200% starting torque for 3 seconds

followed by 150% overload for one minute – enough in this

instance to start the loaded conveyors, saving 2 hours of lost

production each time the loaded conveyor was stopped.

With the ability to control the speed of the screw conveyors to

match the loading, the CFW-11 variable speed drives were able

to provide energy savings of approximately $6300 based on

the loading of the conveyors during various production cycles.

Energy consumption was reduced by 52.,560kWh per annum

and CO2 emissions were reduced by 75 tonnes.

CFW-11 VSD (CoNtINuED)

10

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS


TYPICAL BRAKING TORQUE x SPEED GRAPH(FOR 10HP / 7.5 kW MOTOR DRIVEN BY A CFW-11)

Braking Torque (%)

0 20% 100%

100%

TB1

0200%

Dynamic Braking Torque CurveOptimal Braking Torque CurveDC Braking Torque Curve

REDUCTION

75 T pa

BSC’S Engineering Services

“

Tony Blair

If we are going to carry on growing, and we will, because no country is going to forfeit its right to economic growth, we have to find a way of doing it sustainably.


11www.bsc.com.au

Help your business enhance its

sustainability and improve profitability

and competitiveness.

Corporate sustainability encompasses

strategies and practices that aim to meet the

needs of stakeholders today whilst seeking

to protect, support and enhance the human

and natural resources that will be needed in

the future.

From a macro perspective, the challenge for

business is to lower greenhouse gas emissions

whilst remaining globally competitive.

At plant level the opportunities to achieve

lower operating costs through reduced energy

and resource consumption, reduced materials

spend and increased reliability....and in doing

so improve profitability and competitiveness...

by adopting environmentally sustainable

practices, are significant.

As one of Australia’s largest suppliers of

bearings, sealing and power transmission

products, BSC recognises the positive impact

that our specialised products and services

can, and do, have in helping our customers

become more sustainable across economic

and environmental objectives.

BSC has been actively working with our

customers to achieve these outcomes

for several years and we have achieved a

level of experience and market leadership

demonstrated with significant success

across all market segments.

BSC’s major priority in supporting our

customers in this area is electricity

consumption reduction. Electricity is the largest

resource consumed in the industrial process

and, with significant price/kwh increases in

recent years and forecast in coming years, the

critical priority for industry is the management

of electricity usage.

Our proven strategies are guaranteed to deliver

immediate reductions in energy consumption,

increasing reliability and reducing the total cost

of ownership for our customers.

Water consumption is generally a much

smaller input to industry costs than electricity

or gas; however business recognizes a social

obligation to the broader community to lower

water usage. BSC’s water management systems

and new technologies contribute notably to

achieving these goals.

Reducing lubricant usage and waste are also

important areas that contribute to an overall

level of sustainability and BSC’s expertise and

niche products again support these goals.

The products and services featured have been

carefully selected and designed to provide

BSC’s customers with the benefit of the latest

technologies that can support you build a

sustainable and competitive business by

reducing consumption & increasing reliability.

ENgINEErINg SErVICES

To partner our customers to achieve optimum plant reliability through the application of knowledge and technologies which deliver the highest level of service and results.

BSC Engineering Services provide a range

of services designed to assist you to achieve

optimum plant reliability. This can be through

a complete reliability program using a variety

of technologies and services. By utilizing

our complete program, BSC Engineering

Services will work in conjunction with clients

engineering and maintenance teams to

achieve agreed results that deliver improved

plant reliability and productivity whilst

reducing maintenance and capital costs.

BSC Engineering Services include:

• Energy Reduction Program –

Energy Audit Service (EAS)

• Predictive Maintenance PdM

using Condition Monitoring

• Stop Leak – Air Leak Detection

• Oil Analysis

• Infra Red Thermography

• In-situ Balancing

• Laser Alignment

• Failure Investigation

• Installation & Training

• Product Redesign

Engineering Services

12

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS


Energy consumption can be reduced up to 40% by analysing inefficient and poorly designed drives and adopting good drive design practices.

The path to becoming an environmentally

sustainable manufacturer begins with

understanding how much energy you

currently use and how you can reduce that

consumption. BSC is very active in the

reduction of our customers’ carbon footprint

via the BSC Energy Audit Service (EAS). The

program focuses upon the meaningful

reduction of energy consumption via power

transmission and covers AC motor survey,

analysis and upgrade recommendations to

premium high efficiency super long life motors,

gearbox analysis and upgrade, belt and chain

drives analysis and upgrades.

Energy reduction Program – Energy Audit Service

CA

SE S

tu

Dy Food Manufacturing

Energy Audits for energy savings.

BSC Engineering Services conducted

an Energy Audit at a manufacturer in

Smithtown. A total of 213 motors were

identified for improvement as a result of the audit. Utilising the

BSC super long life High Efficiency motor range

• Energy consumption reduction $21,216pa.

• Annual CO2 reduction >304 tonnes.

• Creation of an up-to-date Asset (motors) Register detailing

application, type and size.

• >300% increase in motor design life.

• Design life materials and energy savings of $887,581

• Project Payback – 16.6 months

BSC Engineering Sevices conducted a

detailed Energy Audit and Analysis of

AC motors at two sites of a large dairy

products manufacturer in Western Victoria

who are committed to manufacturing efficiency, quality and

sustainability. Utilising the super long life High Efficiency motor

range BSC provided an excellent outcome for both sites.

• Site 1

• Energy saving $44,748 pa

• Annual CO2 reduction 642 tonnes

• Design life materials and energy savings $1.3m

• Project Payback – 10 months

• Site 2

• Energy saving $27,198 pa

• Annual CO2 reduction 390 tonnes

• Design life materials and energy saving $1.1m

• Project Payback – 14 months

13


www.bsc.com.au

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS


REDUCTION

1032 T pa

REDUCTION

304 T pa

Predictive Maintenance PdM Program For Asset Optimization.

Predictive maintenance PdM aims to find

measures of machinery condition and use

them to prevent breakdowns. Establishing

trends allow accurate pinpointing of

machinery problems and their severity.

Increasing up time on machines is the primary

aim, while reduced likelihood of secondary

failures and less unnecessary maintenance are

additional benefits.

Condition Monitoring is most frequently

used as a Predictive or Condition-Based

Maintenance technique. Condition

Monitoring uses advanced technologies in

order to determine equipment condition, and

potentially predict failure.

BSC’s Predictive Maintenance Program

utilises Azima DLI technology. AzimaDLI

is a world leader in condition monitoring

services to industry delivering a wide range

of technologies and services reducing

maintenance costs whilst ensuring maximum

equipment reliability.

The BSC – Azima Watchman Remote is a

robust, automated monitoring and diagnostic

service that links industries critical equipment

with our best systems engineers and analysts

via automated alarms and advanced internet

technologies 24/7. When an alert occurs our

analysts are called into action immediately

reviewing detailed machine data to assess

condition and recommend the most cost

effective actions available. Remote program

benefits include reduced failure risk and allows

for just-in-time maintenance of equipment.

Our expertise spans all areas of condition based

maintenance, including:

• Vibration analysis

• Onsite data collection

• Lubrication analysis

• Infrared thermography

• Laser alignment

• Failure analysis

• In situ balancing

• Installation

14

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS


Basically, predictive maintenance differs from preventive maintenance by basing maintenance needs on the actual condition of the equipment, rather than on some predetermined schedule.

A predictive maintenance approach strives to detect the onset

of equipment degradation and to address the problems as they

are identified. This allows causal stressors to be eliminated or

controlled, prior to any significant deterioration in the physical

state of the component or equipment. This leads to both current

and future functional capabilities.

Recall that preventive maintenance is time-based. Activities

such as changing lubricant are based on time, like calendar time

or equipment run time. For example, most people change the

oil in their vehicles every 3,000 to 5,000 miles traveled. This is

effectively basing the oil change needs on equipment run time.

No concern is given to the actual condition and performance

capability of the oil. It is changed because it is time.

This methodology would be analogous to a preventive

maintenance task. If, on the other hand, the operator of the

car discounted the vehicle run time and had the oil analyzed

at some periodicity to determine its actual condition and

lubrication properties, he or she may be able to extend the oil

change until the vehicle had traveled 10,000 miles. This is the

fundamental difference between predictive maintenance and

preventive maintenance, whereby predictive maintenance is

used to define needed maintenance tasks based on quantified

material and equipment condition.

Advantages & Disadvantages

Advantages

• Provides increased component operational life & availability

• Allows for preemptive corrective actions

• Results in decrease in equipment and/or process downtime

• Lowers costs for parts and labor

• Provides better product quality

• Improves worker and environmental safety

• Raises worker morale

• Increases energy savings

• Results in an estimated 8% to 12% cost savings over which

might result from a predictive maintenance program

Disadvantages

• Increases investment in diagnostic equipment

• Increases investment in staff training

• Savings potential is readily seen by management

There are many advantages of using a predictive maintenance

program. A well-orchestrated predictive maintenance program

will all but eliminate catastrophic equipment failures. Staff will

then be able to schedule maintenance activities to minimize or

eliminate overtime costs. And, inventory can be minimized, as

parts or equipment will not need to be ordered ahead of time

to support anticipated maintenance needs. Equipment will be

operated at an optimal level, which will also save energy costs

and increase plant reliability.

Past studies have estimated that a properly functioning

predictive maintenance program can provide a savings of

8% to 12% over a program utilizing preventive maintenance

strategies alone. Depending on a facility’s reliance on a reactive

maintenance approach and material condition, savings

opportunities of 30% to 40% could easily be realized.

In fact, independent surveys indicate the following industrial

average savings resulted from initiation of a functional predictive

maintenance program:

• Return on investment: 10 times

• Reduction in maintenance costs: 25% to 30%

• Elimination of breakdowns: 70% to 75%

• Reduction in downtime: 35% to 45%

• Increase in production: 20% to 25%

The down side of using a predictive maintenance approach are

its initial costs. The up-front costs of starting this type of program

can be expensive. Much of the equipment requires expenditures

in excess of $50,000. And, training of in-plant personnel to

effectively utilize predictive maintenance technologies and

practices will require substantial additional funding. And,

beginning a predictive maintenance program requires an

understanding of the facility’s predictive maintenance needs and

the approaches which need to be undertaken. It is also essential

to have a firm commitment, by management and all facility staff

and organizations, to make

it work.

Predictive MaintenancePublished - u.S. Department of Energy - Energy Efficiency & renewable Energy

IND

uS

tr

y IN

fo

rm

AtIo

N

15


www.bsc.com.au


Printing Works

CA

SE S

tu

Dy

Air leaks are one of the biggest contributors to needless costs in any industrial plant/facility.

A leak is a costly drain on overall operating

costs. State-of-the-art ultrasonic equipment is

used to identify air leaks.

The “Operation Stop Leak” Process is the first

step in continuous improvement. Every

identifiable leak, including fittings, valves,

flanges and hoses are tagged with a number,

its location, severity and cost. From this, total

estimated savings are generated within a

corresponding report. The report provides a

detailed format for a targeted approach and

allows monitoring of progress by cfm and

dollars saved.

Objectives of Operation Stop Leak

• Identify Air and Fluid Leaks

• Reduce energy usage

• Reduce fluid loss

• Identify Cost Savings

• Energy savings translate into cost savings

• Reduce cleanup costs

• Increase Safety & Reliability

• Identifying air and fluid leaks enable

corrective action to be implemented

• Training in use of Loctite solutions reduces

rework and improves equipment reliability

operation Stop Leak

BSC Engineering Services utilising Ultrasonic Leak Detection has produced annual savings of $80,000 for a large Sydney based printing works.

Producing high volume magazine and brochure print requires

volumes of compressed air to be transported to machinery

throughout the plant as do many packaging processing

plants. This particular printer uses three large Atlas Copco

Compressors to service their plant and was concerned about

their inability to identify problem leaks.

Using the Ultrasonic Leak Detection service BSC Engineering

Services were able to tag and locate the costly leaks providing

a comprehensive report on the actions and products required

to repair the compressed air system. Three months later with

all the leaks rectified the company was able to

shut down one of their compressors as the third compressor

was just servicing their air leaks.

This was a cost saving of $80,000 in energy costs alone and

a substantial reduction in green house emissions! The third

compressor is used today as a back up and in time will be

decommissioned further reducing maintenance and

operating costs.

16

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS


REDUCTION

945 T pa

Highly efficient power transmission.

Gearboxes are used throughout industry to

achieve a speed reduction from the motor

shaft to the output shaft. Conversely, gearboxes

multiply torque as they reduce speed. There are

various forms of gearboxes and consideration

should be given to the efficiency of the

gearbox during the selection process.

NORD gear units are the right solution for your

application if the highest levels of efficiency are

required. Due to optimised gear design relative

to rolling motion, especially in NORD helical

and bevel gear units, mechanical losses caused

by friction are reduced to a minimum – the

drive is practically without losses!

A worm gear unit can have efficiencies

ranging from as low as 40% to as high as 93%

depending on the worm size, ratio and input

speed. A 2 stage helical-bevel box has an

efficiency of up to 98% and a 3 stage helical-

bevel of up to 95%. A large amount of energy

saving can be achieved by using helical-bevel

gear units instead of worm gear units.

Taking an example of a 3 inch worm box with

an output speed of 72 RPM and providing

239 Nm. This equates to 1.8kW of mechanical

power however, due to the low efficiency of

the worm box, it requires a 2.2kW motor to

operate. This worm gear unit has an efficiency

of 82%. Operating this unit 16 hours per day

with a cost of 15 cents/kWh, it costs $1880 per

annum in electrical energy.

An equivalent helical-bevel gear unit to provide

the same mechanical power would only

consume 1.83kW of electrical power.

Operating at 16 hours per day with a cost of

15cents/kWh, it costs $1603 per annum in

electrical energy. A 15% reduction compared to

the worm gear unit. This saving does not even

include the use of a W22, super high efficient

motor compared to a standard efficient motor

– which at 2.2kW can provide approximately 6

to 7% additional savings.

Multiplied by the number of gearboxes that

can installed on one production line, not to

mention the whole plant, installing helical-

bevel gearboxes can provide significant

savings, especially as the above comparison

was with a relatively high efficient worm gear

unit. In certain instances it is even possible

to reduce the motor size as the helical-bevel

boxes have higher torque ratings.

All NORD drives are built in the UNICASE™

housing design first developed by NORD in

1981. In addition to the high levels of efficiency

of the NORD gear drives helical and bevel gears

there are other key advantages for the user.

Greater operational reliability, high output

torques, high axial and radial loading capacity,

quiet running, high efficiency as well as

Nord Helical, Parallel shaft & Helical-bevel gear units

Nord Helical-bevel geared motor

17


www.bsc.com.au

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS

gEAr boXES

CA

SE S

tu

Dy Mixing Application

reduced maintenance requirements and a

longer service life of the product are the key

features of this series.

The main feature of the UNICASE™ housing

design is that all boreholes are integrated into

one housing block. All boreholes and sealing

surfaces are incorporated into a single-line. The

advantage: no screwed-on bearing surfaces

and therefore no sealing surfaces are subjected

to torque loads. Additional advantages of

this system are the high rate of production

accuracy, lowest tolerances and smooth,

quiet running.

Nord are a leading German drive manufacturer

for the global market with a range of gearboxes

from 0.12kW to 1MW, 19Nm to 200,000Nm.

Total Increase in Gearbox Efficiency of 88%

Major BSC confectionery customer in Tasmania recently

worked with the local BSC branch for 5 replacement specialty

inline gearboxes on mixers. The existing gearboxes that had to

be replaced had an efficiency of 51%.

After consultation with the customer and Nord, BSC offered

helical-bevel boxes which were ex-stock and had an efficiency

of 96%. Being a Nord standard gearbox configuration, the

purchase cost and lead time was lower compared to a direct

replacement from the original vendor.

The outcome for the customer:

• Reduction in energy consumption of 96, 910 kwh

per annum

• Reduction in CO2 emissions of 138 tonnes per annum

• Nett reduction in energy costs of $9,691 per annum

NorD HELICAL, PArALLEL SHAFt & HELICAL-BEVEL gEAr uNItS (CoNtINuED)

Nord UNicase HoUsiNg - cUtaway

18

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS

gEAr boXES

REDUCTION

138 T pa

Belt Drives & Energy Efficiency

“Dave Foreman

We must all work together in order to save the environment and the world that we live in from further change.

bEltSSustainability Solutions for Australian Industry

About one-third of the electric motors

in the industrial and commercial

industry sectors use belt drives. Belt

drives provide flexibility in the positioning

of the motor to the driven equipment.

Pulleys of varying diameters allow the speed

of the driven equipment to be increased

or decreased. A properly designed belt

transmission system provides high efficiency,

low noise, does not require any lubrication,

and presents low maintenance requirements.

However, certain types of belts are more

efficient than others, offering potential energy

cost savings.

The majority of belt drives use V-belts. V-belts

use a trapezoidal cross section to create a

wedging action on the pulleys to increase

friction and the belts power transfer capability.

Joined or multiple belts are specified for

heavy loaded drives. V-belts can have a

peak efficiency of 95% to 98% at the time

of installation. Efficiency is also dependant

on pulley sizes, driven torque, under or over

belting, belt tension and V-belt design and

construction. Efficiency can deteriorate by as

much as 5% to 15% (to nominal efficiency of

93%) because of the belts tension. If tension

is not applied correctly at installation

or is not periodically checked over

time slippage occurs thus dramatically

reducing efficiency levels.

In all drive systems the efficiency of a drive

system is at the mercy of its weakest link.

The maintenance industry has taken great

strides to improve efficiency and productivity

of motors and driven equipment. However,

little attention has been given to the power

transmission component connecting the

equipment. Ordinary wrapped belts waste

energy - an average typical operating

efficiency for wrapped V-belts is 90% to 94%.

There are two belt constructions that can

improve efficiency levels.

Raw Edge Cog Belts have cogs that run

perpendicular to the belts length and are

manufactured in raw edge construction.

The cogs improve the belts flexibility

reducing bend resistance and the raw-edge

premium rubber sidewalls allow better grip

characteristics reducing belt slip.

On average the raw edge cog belts will

run 4.5% more efficient than ordinary

wrapped belts.

Timing Belts are toothed and operate by

mating the tooth profile of the belt with that of

a sprocket. Timing belts are also called positive

or synchronous and offer efficiency levels of

about 98% and maintain this efficiency over

a wide load range. In contrast timing belts

do not have the sharp reduction in efficiency

at high torque due to increase in slippage as

v-belts do.

Energy savings of up to 20% can be realised

immediately by simply upgrading the belt

transmission used on the drive. Timing belts

are the most efficient choice, however cog

belts may be a better choice when vibration

damping is needed or shock loads are present

causing abrupt torque changes in the drive.

Cog belts also do not require any pulley

modifications as cog belts can be installed on

existing pulleys.

19www.bsc.com.au

gold Label raw Edge Cog Belts

CA

SE S

tu

Dy Fine Sediment Crusher

Gold Label Cog-Belts can reduce energy waste by 50% or more.

Ordinary v-belts waste energy and money.

Tests prove the Gold Ribbon Cog-Belt by

Carlisle is more energy efficient than ordinary

v-belts. The secret to the energy saving

power of the Gold Ribbon Cog-Belt is in its

unique design. The Gold Ribbon Cog-Belt has

raw-edge premium rubber sidewalls to grip

pulleys better and precision molded cogs for

improved flexibility and cooler running. Saving

energy on air moving systems is as easy as

taking old v-belts off the drive and installing

a factory matched set of the Carlisle Gold

Ribbon Cog-Belts. Gold Ribbon can be installed

on your existing drives without any special

drive modifications. Install Carlisle Gold Label

Cog-Belts on your existing V-Belt drive to realize

immediate energy savings without changing

pulleys or modifying your drive! Conventional

V-Belts deteriorate to a nominal efficiency of 93

percent. Carlisle Gold Label Cog-Belts maintain

higher efficiency ratings, resulting in significant

savings.

An Improved Crusher Drive Saving $1700 Annually

Standard wrapped V-Belts were lasting up to 6 weeks on a Fine

Sediment Crusher. The cost of the continual maintenance and

shut down of the machine was a large factor in the annual

maintenance budget for the plant. The abrasive environment

was considered the main root cause for the failures.

With the drive information supplied by the site, we were able

to use the Carlisle Drive Engineer 3.1 program to analyze the

drive. The change from the original “B” section to the high

power SPBX3000 Cogged Raw Edge belts ensured that the

drive had sufficient capacity for all situations. With the new

drive tensioning was also pointed out as the probable culprit of

some of the failures.

The drive was installed and run, with the New Carlisle

SPBX3000 running for nearly 9 months, more than 6 times

longer than the original set up. The plant noticed that the

drive no longer required maintenance due to belt problems.

The improved up-time and reduced maintenance meant time

could be invested in other problem areas. Altogether a saving

for the plant of more than $1700 annually.

20

bEltS

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS

ANNUAL BELT LIFE COMPARISON

262

42

DAYS0

100

200

300

Original Life New Life

CA

SE S

tu

Dy Stock Feed Plant

rPP Panther® Tests show that RPP Panther can effectively transfer power at 98-99% efficiency.

For maximum drive system efficiency, the

Carlisle RPP Panther high torque synchronous

belt can put some real teeth into your plant

maintenance energy conservation program.

The RPP Panther synchronous drive system

operates on a “teeth in mesh” principle for

positive engagement between belt and

sprocket. As a result, power is transferred

from the motor to the driven unit at a rate

of 98% efficiency. RPP Panther is the power

transmission system of choice on many

new installations. Because of the positive

engagement power transfer of Panther,

operating speeds can be controlled much

more closely than with ordinary v-belts. The

RPP Panther is ideally suited for modern

systems where inverter devices and / or

modern systems where inverter devices are

used because of its inherent high operating

efficiency. Also, if your belt drive pulleys or

chain sprockets are more than five years old,

these components are likely to be worn out

and wasting energy due to drive slippage and

tension loss. It’s probably time to replace these

worn out components. It is also an opportune

time to upgrade your existing power

transmission system from outdated chain or

v-belt drives to the modern and efficient RPP

Panther drive system. The payback in energy

savings is often recovered in just a few short

months.

Total Cost Savings $5,500 per individual auger

Premature failure of the roller chain drive on the auger was causing ongoing downtime losses every 4 months. Time was also being lost in having to lubricate the chain drive. This was not a regular program and the inevitable failure of the drive caused loss of production and unplanned downtime to replace the chain. The augers were difficult to access and operated in a hot, dry and dusty environment.

BSC’s objective was to design a drive that would extend life from the existing 4 months to a minimum 12 months. BSC recommended the new Panther Ultra Cord and completed a drive design for this application, the Dayware software selection offered a drive that would meet all space requirements and provided an adequate service factor for the application.

In most harsh environments Panther Ultra Cord belts last many

times longer than conventional chain. The new drive was installed and has been a success. The customer has already ordered some more belts for the other 8 augers as the trial is running so well.

Extended Life = 20 months… AND STILL GOING!

bEltS

21


www.bsc.com.au

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS

EXTENDED LIFE = 20 MONTHS +600

120

DAYS0

200

400

600

Original Life New Life

CA

SE S

tu

Dy Fan Drive refurbishment

Efficient raw edge and synchronous belts improve system performance.

Transmit more torque with less slippage.

Higher horsepower ratings translate into

greater design flexibility, reducing space,

weight and drive costs. Carlisle’s raw edge

construction creates outstanding operating

efficiency. More torque with less slippage

reduces energy costs. The Power-

Wedge Cog-Belt is heat and oil resistant and

static dissipating. It’s available in SPZX, SPAX,

SPBX, SPCX & SPPX cross sections lengths up

to 5000mm.

The Hi-Modulus cord carries high horsepower

loads with minimum stretch and improved belt

stability, requiring fewer take-up adjustments.

Fabric Laminates are located in the “Power

Zone” to maximize response to shock loads.

Raw Edge sidewalls provide greater contact

with the pulley surface and produces a

smoother running belt.

Power Wedge raw Edge Cog Belts

$10,000 energy saving per annum

A major industrial site had advised a need to refurbish the

existing fan drives as they were over 14 years old. The fans

we visually inspected and condition of the pulleys all had

shown signs of extreme wear. The site was also heavily into

conservation of resources so they expressed an interest in the

energy conservation options available

Using the Carlisle Design program each drive was checked

to ensure the latest belt types would be used to offer the

best drives for the purpose. As the pulleys would also be

looking at getting replaced there was an opportunity to

explore the timing belt option as a way to improve efficiency

and also lower the bearing usage from the site. The Carlisle

Power Wedge Cogged Raw Edge design was favoured as

the top performing V belt available and the

Megadyne Silver Series High Performance Timing Belts were

also an option.

The proposal for the total refurbishment included both belt

types. The extra cost for changing the drives to the Megadyne

Silver RPP profile timing belt was a $2,000 premium over the V

belt version.

The lower bearing loads by up to 30% that the timing belt

offered, plus the $10,000 energy saving over the V belt per

annum resulted in a payback period measured in only months..

22

bEltS

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS

REDUCTION

120 T pa

Super II

CA

SE S

tu

Dy

Energy savings of up to 20% can be realised immediately by simply upgrading the belt transmission used on the drive.

Many heavy-duty, industrial drive system

applications demand more than conventional

v-belts can stand. Punishing drives make

ordinary wrapped v-belts crack under pressure,

resulting in costly downtime. End the hassle

and expense of constant v-belt breakdowns

with Super II from Dayco. This rugged v-belt

is specifically designed to provide superior

performance on the most brutal v-belt drives

including rock quarry shaker screens, lumber

mill debarkers, pipe descalers, and any other

application known for being tough on v-belts.

The secret to the Super II v-belt’s durability is

its unique construction. Several innovative

Super II design features allow you to avoid

many problems common to ordinary wrapped

v-belts. Rugged multiple fabric plies on both

the top and bottom of the v-belt help relieve

stress on the centre cord, assist in minimizing

belt stretch, and help to control slippage under

heavy loads. The high modulus polyester

cord located in the mid-section of the v-belt

resists extreme shock loads without stretching,

increases v-belt flexibility for longer life, and

eliminates backside idler problems. Superior

grade 100% neoprene rubber compound

resists cracking from heat and flex fatigue

better than ordinary wrapped v-belts that use

cheaper, less effective rubber. Neoprene also

provides the best resistance available against

dirt, dust, ozone, oil, and grease. Unique fabric

loaded raw edge sidewalls grip pulleys better

than wrapped v-belts but still allow controlled

slippage during extreme shock loads for

increased productivity. The raw edge Super II

also dissipates heat quicker for cooler running,

longer lasting v-belts.

Aggregate PlantCarlisle Super II V-belts outlast wrapped belts up to 6 times longer.

A large Aggregate Plant using wrapped construction v-belts

was constantly having to change out the V-belt drives on

their shaker screens. Belts would only last 2-4 weeks on

average depending on the volumes being processed. The

constant changing of belts was a huge problem in belt costs,

maintenance time and down-time.

The maintenance supervisor was introduced to Carlisle Super II

V-belts. It was explained that the unique construction of Super

II having the characteristics of wrapped construction but the

performance of raw edge would make them ideally suited for

the off & on load cycles generated by the shaker screen drive.

After 8 weeks no belts had failed and the Super II was proving

to be a great success. The original set of Super II was eventually

replaced after 18 weeks in operation. Performing over 4 times

longer than the wrapped construction belt.

bEltS

23


www.bsc.com.au

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS

CA

SE S

tu

Dy Paper Mill

Use the Powermiser program to calculate the energy savings you can enjoy with efficient Carlisle Raw Edge V-belts and timing belts.

An area not often considered when looking at a cost of a belt is energy efficiency. The efficiency of a v-belt drive is a measure of the utilization of total energy input to the belt pulley system. A major source of energy loss in a v-belt is internal friction of the rubber, cover and cords when they are cyclically deformed while traversing a pulley. The magnitude of energy loss depends upon material properties and the amplitude of deformation.

Many original equipment manufacturers tend to standardise on traditional wrapped V-belts. These belts are generally designed

for long life, high load, power capability and smooth running. One of the design criteria of a wrapped belt is also its ability to slip somewhat on start-up, which tends to compensate for high starting torque or load, which can sometimes vary from 1-1/2 to 3 times the normal running torque of the motor. While these belts will provide exceptional performance on a drive, they generally have an overall efficiency rating of between 88% - 94%, which equates to a performance and energy loss between 6 to 12 percent. This unfortunately is a potential savings that is overlooked when doing system design or system maintenance.

This energy loss can be difficult to measure, however Carlisle Power Transmission has

developed a software program called POWERMISER that will enable end users to calculate the energy cost when changing to more efficient belt construction such as Raw Edge Cog or Timing Belts.

Features• Will allow you to calculate the energy

savings you can enjoy.• Input fields hours of operation per year,

Motor Power rating. Motor efficiency level, Utility rate, belt efficiency % increase.

• User friendly and Windows® based• Calculates the annual dollar savings based

on your utility costs.• Include V-belts and timing belts

Powermiser Software

Savings of $156,000 per annum

In today’s economic environment it is important that each industry operates efficiently and economically. BSC was asked to evaluate 132 belt driven machines in a Pulp and Paper mill to ascertain any problems and offer advice on improving belt performance and efficiencies

With the drive information supplied by the site, we were able to use the Carlisle Drive Engineer 3.1 program to analyze each drive. We checked for conformance to ISO design standards, noticeable drive warnings such as excessive shaft loadings and under designed drives. We advised remedial action for the

under designed and over designed drives and tensioning information for all drives to ensure best maintenance practices were followed.

The 9 drives evaluated as under designed could be the cause of at least 9 plant stoppages a year. With the cost of downtime at the plant at approx $16,500 per hour, the possible savings from a belt drive re-design was estimated in excess of $121,000 a year. Combined with an energy saving of up to $30,000 per year by using the most efficient belt drive types and tensioning drives correctly, the customer can enjoy the benefit of a $156,000 saving per annum.

24

bEltS

ENERGY SAVING

SOLUTIONS

ENERGY SAVING

SOLUTIONS

REDUCTION

286 T pa

Major Bottling Plant

CA

SE S

tu

Dy

The environmental choice, save money save the environment.

• Reducewaterusage

• Reducedpowerconsumption

• Reducenoise

• Smoothoperation

• Longlife

• Improvedreliability

Habasit’s TS option for Flat Top chain, uses

extra low friction resin technology, resulting in

the lowest coefficient of friction, with special

self-lubricating agents built into its molecular

structure.

Ideal for critical bottling applications, this chain

is well suited to dry running applications. The

benefits include, reduced water consumption

associated with top chain lubrication. The

extra low friction Habasit “TS” uses less energy

than standard low friction models, which also

contributes to smooth, effortless and quiet

operation.

Habasit TS, is dimensionally interchangeable

with most LF products on the market, so there

is no need to change out sprockets and wear

strips unnecessarily. However, Habasit can also

provide a special low noise sprocket option

complete with a patented split sprocket / split

bush and suitably compatible wear strips.

Habasit tS EXtrA Low Friction Flat top Chain

TS Series Habasit / KVP chain has been recently installed as the exclusive specification within a major bottling plant in Queensland.

In the past the plant had used standard low friction ‘LF’ acetal

table top conveying chains throughout the site. The ‘LF’ series

chains did the job, however this busy plant was consuming

over 11 Million litres per annum in potable water in order to

constantly lubricate the acetal conveying chains.

The significantly increasing cost of water plus the social

imperative to preserve what is the most precious and often

taken for granted resource on our planet, were driving factors

in the site’s decision-making process.

The self-lubricating properties of the TS Series chain have

resulted in the plant ‘turning off the taps’ as the need to water

lubricate no longer exists.

In straight water saving this saves the site over $15,000 per

annum in water consumption costs alone. An additional

benefit of moving from the ‘LF’ chains to the TS Series is the

240% - 270% extra life that will be achieved thanks to the

harder-wearing nature of the special TS material.

The TS Series table top conveying chain has proved to be a

significant weapon in the battle to reduce ongoing operational

costs in the areas of resource consumption and maintenance

expenditure.

25


www.bsc.com.au

WAtEr mANAgEmENt SyStEmS

WATER SAVING

SOLUTIONS

WATER SAVING

SOLUTIONS

“The Problem” Mechanical Seal water wastage and seal unreliability.

The most common methods of supporting mechanical seals with water are either flush/quench to drain or into the process fluid.

The two key impacting negatives here are the high water consumption and high cost of removing injected water by evaporation further along in the manufacturing process.

These methods typically waste huge amounts of water, and in some cases produce vast amounts of water effluent which subsequently needs to be treated, adding even more cost and consuming even more environmental resources.

Typical water consumption of a single mechanical seal in this arrangement is in the region of 12 litres per minute (3.17 gallons per minute), which gives a total consumption for

one pump of 6.3 million litres per year (1.7 million gallons per year).

Bearing in mind there is an initial cost attached to this water which multiplies upwards when we consider the cost of steam generation required to drive this flush water out of the process via the evaporator. This figure further escalates with the number of pumps associated in any given production line.

AES Water Management Seal Support Systems – “The Solution”

Rather than running water straight through the seal to drain, the AES standard water management system removes heat and lubricates the mechanical seal faces by use of the ‘thermosiphon effect’.

Colder water is supplied to the mechanical seal, which is in turn heated

up by the seal faces. This ‘warmer’ water then rises back into the vessel, raising the bulk temperature of the vessel. The vessel then loses heat to the atmosphere which results in an ‘equilibrium temperature’ being reached. Should the vessel be required to lose more heat to the atmosphere, the increased surface area of the system ensures that this can occur.

In order to prevent contamination of the system, a positive pressure is applied to the clean water in the system. This is achieved by connecting the system to the plant mains water supply and adjusting the integral water pressure regulator to the required pressure. This also ensures that if a small trace of water is lost into the process across the seal faces, this will be immediately replaced by water from the mains supply.

CA

SE S

tu

Dy Mechanical Sealing & Water Management

AESSEAL Water Management

Payback: the total cost of the redesign was $30,813.50, bringing the full payback period below 12 months and ensuring significant nett savings each following year of nearly $35,000pa.

BSC Engineering Services, working in conjunction with one of BSC’s national contract customers, analysed mechanical sealing and water management systems around 12 individual pump applications. The site had 10 pumps that were flushing to drain and 2 that were flushing to process.

Measuring the flow from the pumps that were flushing to drain revealed an annual usage of 24.2 million litres of water at a cost of $35,562 per annum.

BSC Engineering Services redesigned the mechanical seals to reliable double seal assemblies with AES SW02 water management systems fitted with flow and purge fuses.

The reduction in water usage was dramatic – reducing to only 450 litres per annum across all 10 pumps ...a saving of over 24 million litres per year.

In addition to the huge savings, the application of the flow and purge fuses had the benefit of removing the opportunity for bacterial growth within the system vessel. The flow fuse also provided a further benefit of protecting the final product from mass contamination in the situation of eventual momentary upset or failure of the mechanical seal.

26

WAtEr mANAgEmENt SyStEmS

WATER SAVING

SOLUTIONS

WATER SAVING

SOLUTIONS

CA

SE S

TU

DY cane train locomotives

Environmentally friendly lubricant.

Anti-friction bearings by their very nature are designed to be energy efficient. One particular area of modern bearing technology that does make a noticeable contribution to sustainability is the NSK Molded-Oil Bearing.

Molded-Oil Bearings are lubricated with NSK’s own oil-impregnated material, consisting of lubricating oil and polyolefin resin that has an affinity for oil. Oil slowly seeping from this material provides ample lubrication to the bearing for the life of the bearing.

The solid lubricant is resistant to both water

and dust and acts as a barrier to protect the bearing from penetration of contaminants. Bearing life in water or dust contaminated environments is consequently increased significantly.

A significant benefit of the Molded-Oil Bearing is that once fitted there is no subsequent need to worry about relubricating. Environmentally friendly as oil seeping from the Molded-Oil inside the bearing provides sufficient lubrication, troublesome oil refilling or grease repacking is not required and, as well as consumption of lubricant being negated, contamination of the environment is negligible.

Molded-oil™ Bearings

Total maintenance & materials savings > $270,000 PA

A Sugar Mill was experiencing ongoing life problems with the performance of crank bearings on its fleet of cane train locomotives resulting in frequent maintenance and re-greasing.

Normally the cranks are totally covered in grease which, apart from being environmentally unfriendly, results in contaminants sticking to the lubricant and eventually working their way into the bearing set-up and shortening bearing life. The bearings would need to be changed every year.

The cranks in each of the 16 locomotives would require 182 hours of re-greasing per season, using 26 barrels of grease each year.

Engineering asked BSC Cairns to assist by identifying a ‘better way’. The solution was to replace the bearings with NSK Molded Oil bearings which contain an integral solid lubricant with oil life designed to last approximately 8 years and are therefore maintenance-free.

The Molded Oil bearings have now completed two years and will remain in service for a third year with the likelihood of that extending out an additional year or two as the Mill is intending to run them until failure – no additional lubrication is required.

The maintenance and materials (grease) savings have been significant and will continue to be enjoyed in subsequent years.

In recent years, demand for hybrid vehicles has been rising rapidly due to their low fuel consumption and low emissions, realised through a more efficient integration of the engine and electric motor.NSK has developed low-torque ball bearings for hybrid vehicles designed to improve fuel efficiency.

In order to further improve fuel efficiency, there is a growing need to reduce torque loss in the bearings used in the transmissions (drivetrains) of new generation hybrid cars.

NSK has met this need with its low-torque bearings, which reduce frictional loss.

The new product will be featured in Toyota’s latest Prius model.

NSK has claimed to have found a way to cut torque by 50-65 per cent compared to existing bearings.

The number of balls has been reduced, and ball diameters, race dimensions and clearances have been optimised utilising analysis technology, which has allowed rolling friction losses to be minimised.

NSK’s new manufacturing processes overcame conventional hurdles to decrease the number of balls.

Losses have been reduced by agitating lubrication oils during operation via the introduction of specially shaped cages made of resin.

NSK has achieved compactness, lightness and low torque for automobiles via its four core technologies: tribology, materials, analysis and mechatronics.


27www.bsc.com.au

BEARINGS

ENVIRONMENTAL

SOLUTIONS

ENVIRONMENTAL

SOLUTIONS

NEW SOUTH WALES

SYDNEY STATE OFFICE

MOOREBANK Phone: (02) 9824 2100

BRANCHES

ARNDELL PARK (BEARINg TRADERS) Phone: (02) 9622 9322

DUBBO Phone: (02) 6884 5545

gRAFTON Phone: (02) 6642 2666

gRAFTON SOUTH Phone: (02) 6642 4588

LISMORE Phone: (02) 6621 2337

NEWCASTLE Phone: (02) 4954 6877

ORANgE Phone: (02) 6362 3555

WOLLONgONg Phone: (02) 4231 8500

WAggA WAggA Phone: (02) 6925 3711

ACT

CANBERRA Phone: (02) 6280 7517

VICTORIA

MELBOURNE STATE OFFICE

CLAYTON Phone: (03) 9560 3222

BRANCHES

BALLARAT Phone: (03) 5337 6001

DANDENONg Phone: (03) 9794 5624

gEELONg Phone: (03) 5272 2951

MORWELL Phone: (03) 5134 3633

SHEPPARTON Phone: (03) 5821 4911

SOMERTON Phone: (03) 9308 7000

SUNSHINE Phone: (03) 9311 4138

SWAN HILL Phone: (03) 5032 9444

WODONgA Phone: (02) 6024 3722

TASMANIA

HOBART DERWENT PARK Phone: (03) 6272 4344

BURNIE Phone: (03) 6431 5044

QUEENSLAND

BRISBANE STATE OFFICE

NORTHgATE Phone: (07) 3866 8333

BRANCHES

ARCHERFIELD Phone: (07) 3277 4488

BUNDABERg Phone: (07) 4153 3220

CABOOLTURE Phone: (07) 5495 6266

CAIRNS Phone: (07) 4225 3100

MACKAY Phone: (07) 4952 1399

ROCKHAMPTON Phone: (07) 4927 2033

SOUTHPORT Phone: (07) 5532 4888

TINgALPA Phone: (07) 3390 7099

TOOWOOMBA Phone: (07) 4634 4133

TOWNSVILLE Phone: (07) 4779 0500

WACOL Phone: (07) 3271 3444

YATALA NORTH Phone: (07) 3807 4971

WESTERN AUSTRALIA

PERTH STATE OFFICE

WELSHPOOL Phone: (08) 9251 4444

BRANCHES

O’CONNOR Phone: (08) 9337 3000

OSBORNE PARK Phone: (08) 9445 1811

SOUTH AUSTRALIA

ADELAIDE (WINgFIELD) Phone: (08) 8344 0800

LONSDALE Phone: (08) 8326 5459

C100

-001

9/10

explore our comprehensive product range onlinewww.bsc.com.au

bsc sustainability solutions catalogue

Documents

range of products

bsc product range

energy managementmotors

energy consumption

potential energy savings

power transmission products

years bsc

worlds electrical energy