Substantial savings to be made with revolutionary bearings

Phil Burge, Communication Manager for SKF, explores the options of motor replacement and repair looking in detail at the latest bearing technology that is enabling considerable energy savings to be realised.
 
Although industry is beginning to emerge from the global recession, the effects are still being felt by many companies. As a result, the pressure remains on maintaining operating margins, with little scope to increase prices, forcing managers to explore other avenues for opportunities.

The focus of attention is often drawn to taking cost out of a business. However, there is often little room for manoeuvre, as most manufacturers are already running extremely lean operations, with alternatives being further restricted by the continuing rise in raw material and energy prices. For example, annual input price inflation rose 13.4% in January 2011, with the cost of materials and fuels purchased by UK manufacturing industry increasing by 9.9% in the same period.
 
Energy efficiency continues to sit at the top of the political agenda, with the introduction of ever tougher environmental and climate change legislation, forcing all companies, especially those in the manufacturing sector, to cut their annual consumption of primary energy by 20% by 2020.

Clearly something has to be done and manufacturers need to take action, both to control costs and comply with legislation. An obvious solution is to reduce consumption, thereby saving cost and boosting the bottom line. In particular, the efficiency of electric motors is attracting more attention as this technology is responsible for consuming more than two thirds of all electricity in general industry, thus representing a large cost saving potential.
 
At first glimpse, the simplest course of action is to replace older motors with modern high efficiency equivalents. However, the latest motors usually come with a significant price premium so this is not always a viable option, even in cases where the total cost of ownership suggests a replacement, as cash flow and capex budgets are still incredibly tight.
 
One solution is to replace the bearing units in existing motors with modern energy efficient equivalents. This can be done both during initial manufacture and subsequent overhaul; in each case, energy consumption can be cut by up to 50%. This technology makes it possible to reduce frictional losses by at least 30%, even when compared with the most efficient traditional bearings, and by as much as 50% or more, when the comparison is with older product designs.
 
For example, one leading consumer healthcare company was able to reduce frictional losses by 46% when using the SKF energy efficiency deep groove ball bearings in cold water pump motors (22 kW), running at speeds of 2,990 rpm. Ultimately, this translated to energy savings of 4,583 kWh per year per motor.  
 
Energy efficient bearings also run more smoothly and at lower temperatures than standard bearings at equivalent loads and speeds, generating less heat, and extending grease life and relubrication intervals to allow maintenance costs to be reduced further still. Also, bearing service life is extended significantly, with it being more than doubled in some cases, which in turn, can have a considerable positive impact on the operating life of the average motor.
 
Having been specifically engineered and manufactured to reduce frictional moment, energy efficient bearings combine a series of design enhancements in a number of crucial areas. For instance, they feature an optimised internal geometry and tough yet lightweight polyamide ball cages, which are less susceptible to deformation, as well as featuring specially developed low friction lubricating greases, with each bearing being sealed for life to minimise the need for maintenance.
 
Just as importantly, these bearings can be exchanged during routine maintenance and are dimensionally interchangeable with equivalent ISO standard components, so there are no additional downtime costs.
 
Besides motors, energy efficient bearings can also deliver significant savings when used in other pieces of industrial equipment, including conveyors, fans, pumps and gearboxes, while advanced tapered roller bearings have also been developed to increase efficiency in automotive applications.
 
Reducing energy consumption is now a top priority for many companies to counter the effects of growing energy bills and increasing environmental responsibility. Thanks to developments in bearing technology and the introduction of energy efficient solutions, plant managers are now able to realise dramatic energy savings and increased productivity and reliability, leading to enhanced business performance at a time when it matters most.

For further information, e-mail: phil.burge@skf.com or e-mail: info.skfbearings@4cm.co.uk  Refer to next page

New plastic four-bolt flange mounting
blocks with insertbBall bearings from QBC

Quality Bearings & Components (QBC) announces a new line of standard duty four-bolt flange mounting blocks that have a polyester housing, removable acetal bearing insert, with 316 stainless steel balls. They are identified as the BBPBLD... Series and are designed to fit shafts ranging from 1/2" to 1-1/4" in diameter. Plastic two-bolt flange mounting blocks with insert ball bearings are also stocked. These new elements help make machinery efficient, more functional, and most importantly, safer. By giving careful consideration to these basic design features, efficiency and reliability increase. Quotes plus online orders are available at our new QBC eStore

QBC has in stock: miniature bearings, plastic bearings, rod end bearings, spherical bearings, pillow blocks, sintered bronze bushings, radial ball bearings, thrust bearings & washers, sleeve bearings, needle bearings, inner races, roller clutches, guide wheels & rail systems, linear ball bearings, inner and outer ring spacers and shafting. QBC stocks both inch and metric sizes. New to the Web site is our eStore which allows you to check price and availability, place an order or request a quote anytime. QBC also provides custom-made bearings and shafting to the customer print. We also offer on-site relubing of bearings in a certified class 1000 clean room.  

Detailed technical specifications are contained in catalog B620, available free upon request.

For further information, view website: http://www.qbcbearings.com/Press/MountingBlocks2htm                                                                               

COOPER Crouse-Hinds delivers
portable IEC Ex-Power solutions to 2rent 

COOPER Crouse-Hinds has successfully delivered the first of three batch deliveries of portable industrial IEC power equipment to 2rent, the largest provider of industrial tools and equipment in The Benelux.

The contract with 2rent includes the supply of 155 power converters, 570 extension cords, 230 distribution boards and 765 single plugs, all supplied by COOPER Crouse-Hinds.

The project team at COOPER Crouse-Hinds developed a brand new solution for 2rent by using a wide variety of customer specific IEC plugs and receptacles. The industrial portable power converters and industrial cable assemblies are designed for use in non-hazardous, industrial installations, in this particular case, to provide power during shutdown for one of Total's plants located in Belgium.

Juergen Schmitt, Product Manager at COOPER Crouse-Hinds GmbH comments: "Although COOPER Crouse-Hinds is renowned the world over as a specialist provider of electrical components and systems for hazardous area applications, the project with 2rent involves the supply of portable electrical power equipment for non-hazardous areas. This project demonstrates our capabilities in providing custom engineered, portable electrical servicing and maintenance solutions for both hazardous and non-hazardous industrial applications".

For this project, the power converters and cable assemblies supplied by COOPER Crouse-Hinds are protected to IP66, using a 24V DC SELV (Separated Extra Low Voltage) power source and a customer-specific 2-pole design for the plugs according to IEC 60309. The equipment supplied also features integrated RFID tags, enabling the customer to identify equipment remotely, as well as for traceability and inventory control.

For further information, view website: www.ceag.de or e-mail: Gordon.Low@CooperIndustries.com  Refer to page 111

New Ex e bus-bar system enables faster assembly
and more efficient distribution of electrical energy

COOPER Crouse-Hinds, a leading manufacturer of explosion-protected electrical equipment, has launched a new range of explosion-proof (Ex e) bus-bar systems for metal and moulded plastic enclosures. The system is suitable for use in hazardous environments with extreme ambient conditions.

The new GHG 758 bus-bar system utilises undrilled clamp technology for the connection of cabling, therefore enabling faster, more cost effective assembly and more efficient distribution of electrical energy.

The GHG 758 bus-bar system is designed to operate in ambient temperatures from -55 deg C to +55 deg C. The system is available in high rated currents for 250A and 315A in Ex e certified technology for Zone 1 hazardous areas. The system can be used in conjunction with COOPER Crouse-Hinds' modular range of GHG 619 enclosures and is a more cost effective solution for many Ex e IIC applications.

In addition, the innovative design of the GHG 758 provides users with an increased length of usable bus-bar rail of up to 6,300mm. An optional removable plastic cover is also available, which also provides additional cut-outs for measurements.

For further information, e-mail: sales.cch.de@cooperindustries.com or view website: www.coopercrouse-hinds.eu  Refer to page 111