Industrial bearing remanufacturing services

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Products, services and solutions from SKF Industrial Market
g Issue 103 | Summer 2015
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Industrial bearing remanufacturing services
INDUSTRY FOCUS
APPLICATION FOCUS
Solutions boost food
industry efficiency
Industrial pumps
Rail industry technologies
Centralised lubrication in
off-highway vehicles
g PAGE 10
g PAGE 16
g PAGE 14
g PAGE 18
SKF Certified
The standard for rebuilder service excellence
Scotland
n WGM Engineering
www.wgmengineering.co.uk
North East
Team Rewinds
www.teamrewinds.co.uk
n
North West
Wainwright & Gibson
www.wainwrightandgibson.com
n
South and West Yorkshire,
Hull and York
n Westin Drives Ltd.
www.westindrives.com
Midlands
n Fletcher Moorland
www.fletchermoorland.co.uk
South East
Mid-Kent Electrical Engineering
www.mke.co.uk
n
South West
Anstee & Ware
www.ansteeware.co.uk
n
Stop the cycle of motor repairs
It is no secret that electric motor reliability can be a problem. Electric motors are among the highest in
reliability incident reports, a problem that can lead to a continual cycle of costly repairs and unplanned
downtime. Coupled with this, between 40 to 70% of electric motor failures are bearing related.
Most motor rebuilders are not trained to investigate the underlying causes of bearing failure.
Many simply replace the bearings and return the motor to service, even though it is once again,
doomed to failure.
Trust the SKF certification advantage
Demand that your electric motor rebuilder is SKF Certified. SKF Certified technicians undergo specialised
training in motor repair, with an emphasis on root cause failure analysis, bearing installation, lubrication
and condition monitoring. SKF Certified Rebuilders are also regularly audited to ensure compliance with
SKF’s rigorous programme standards.
Contact your local SKF Certified Rebuilder today for further information.
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The Power of Knowledge Engineering
® SKF is a registered trademark of the SKF Group © SKF Group 2015
facebook.com/SKFGroup
linkedin.com/company/skf
twitter.com/skfgroup
In this issue
youtube.com/user/SKFOfficial
Michael Crean
Sales Director
SKF Industrial Market,
South West Europe
INDUSTRIAL PUMPS
g PAGE 14
RAILWAY SOLUTIONS
g PAGE 16
Dear Business Partner,
Welcome to this edition of FOCUS, SKF’s magazine
for the industrial market in the UK and Ireland.
The year is already nearly halfway through and the
economic uncertainty that came with the UK General
Election is finally over, allowing the continued gentle
improvement in manufacturing to maintain its
positive effects. We now need to look forwards, and
continue finding ways to improve business efficiency,
productivity and profitability. As always, SKF is ready
to help.
It is 96 years since SKF introduced the spherical
roller bearing to the world, and in this edition we will
look at how SKF continues to deliver performance
benefits through further improvements to the design.
We will also discuss the advantages (commercial
and environmental) of bearing remanufacturing
over buying new bearings, and how SKF has been
working alongside Vantage Drilling Inc. to improve
ship reliability and develop its condition-based
maintenance programme.
Continuing the attention to benefits in both
commercial and environmental arenas, we turn
specific attention towards pumps, which are the
most energy-expensive systems in many plants,
accounting for 30% of UK industrial energy, and
consider how SKF is helping companies improve the
efficiency and service life of their pumps. You will
also hear about the self-monitoring SKF Insight
bearing, and SKF’s range of solutions for the
food and railway industries, as well as how SKF’s
lubrication systems are being used in heavy-duty
vehicles. All good practical examples of technology
delivering value to industry.
Enjoy this issue of FOCUS!
CENTRALISED LUBRICATION
g PAGE 18
CONDITION MONITORING
g PAGE 21
REGULARS
FEATURES
04 News
08 SKF Insight
The latest local and international news
Intelligent bearings offer early warning
07 New Market Offers
09 Remanufacturing
20 Maintenance
10 Food and beverage industry
21 Condition monitoring
12 Spherical roller bearings
22 Customer case study
14 Industrial pumps
New taconite seal, quick fit bolt tensioner
Tools for accurate belt and shaft alignment
Analysing critical environmental conditions
SKF and Vantage cooperate to improve
drilling ships reliability
23 Literature
How to extend bearing service life
SKF solutions help boost production efficiency
Upgrades to bearings extend service life
End to end pump solutions
16 Rail industry
The latest brochures and catalogues
Tools to manage assets throughout their
entire lifecycle
24 Reader reply service
18 Centralised lubrication
25 Competition
PUBLISHER: SKF (U.K.) LIMITED
EDITOR:
PHIL BURGE
EDITORIAL: 4 CREATIVE MARKETING
DESIGN:
ROLO SEHDEV
HOW TO CONTACT US
T: 01582 490049
F: 01582 848091
[email protected]
www.skf.co.uk
SKF (U.K.) LIMITED
SUNDON PARK ROAD,
LUTON LU3 3BL
Automatic lubrication systems increase mean
time between planned stops
® SKF is a registered trademark of the SKF Group.
TM BeyondZero is a trademark of the SKF Group.
© Copyright SKF 2015
The contents of this publication are the copyright of the publisher and may
not be reproduced (even extracts) unless permission is granted. Every care
has been taken to ensure the accuracy of the information contained in this
publication but no liability can be accepted for any loss or damage whether
direct, indirect or consequential arising out of the use of the information
contained herein.
Certain image(s) used under the license from Shutterstock.com
TECHNICAL HELPDESK
T: 01582 496534
[email protected]
FOCUS 103 f Summer 2015
03
SKF UK NEWS
GG #SKF has gone social
GG SKF innovation helps Scuderia Ferrari
GG SKF Racing sponsors Formula Student team
SKF provides remote diagnostics for predictive
maintenance to the Edison Chouest Offshore fleet
SKF has been selected to provide a remote
monitoring and diagnostics solution to enable worldclass predictive maintenance on a large fleet of
vessels for Edison Chouest Offshore.
The SKF remote monitoring service will provide
Edison Chouest Offshore (ECO) with an ideal solution
for effective monitoring and diagnostics of key
assets in the main propulsion line. This includes the
thrusters, diesel generators, electric motors, main
drive shaft and auxiliary equipment. Continuous
monitoring of these assets will enable ECO to
optimise maintenance and significantly reduce the
risk of unexpected failures and consequential costly
downtime.
The solution provided by SKF is ideal for marine
businesses as it transmits condition monitoring and
asset integrity data from each vessel. The data is
automatically collected and transmitted via an online
#SKF has gone social
Did you know that SKF has over 138,000 followers
on Facebook, over 53,000 on LinkedIn and nearly
6,000 on Twitter? Social media offers SKF new ways
to interact with its customers, distributors, local
communities and the world at large!
Keep up-to-date with our regular posts – like,
follow, comment, share and become part of our social
community. Learn more about our personal initiatives,
our unique history, and our community and charityfocused events. Be the first to know about our new
product launches, special promotions and exhibitions.
04
Summer 2015 g FOCUS 103
See behind the scenes of innovation, as we
showcase our services and product diversity in
multiple industry sectors, whilst providing useful
product and technical information and solutions.
Connect to the world of SKF and be part of the
community.
facebook.com/SKFGroup
@twitter.com/skfgroup
uk.linkedin.com/company/skf
youtube.com/skfofficial
system to the SKF global cloud server. The data will
be analysed in detail at SKF’s remote diagnostics
centre by certified machine reliability experts and
then fed back via customised reports to the technical
team at ECO. Vessel and fleet operators will then be
able, in the event of excessive wear on the machinery,
to proactively intervene before it reaches failure.
“The SKF remote monitoring service is the ideal
solution for ECO’s large fleet. By monitoring the
condition of equipment on each vessel remotely,
predictive maintenance can be implemented costeffectively for both the short- and long-term,” said
Gavin Coull, Key Account Manager Marine, at SKF.
Mark Duns Project Manager for ECO commented,
“SKF was selected as a partner because of its
extensive expertise in rotating equipment, remote
diagnostics and specialist knowledge of the marine
industry.”
ECO companies are recognised today as the most
diverse and dynamic marine transportation solution
providers in the world, operating a growing fleet
of over 200 vessels. The fleet of vessels operate in
various locations around the world including Europe,
South America and Africa.
www.chouest.com
SKF UK NEWS
SKF innovation helps Ferrari
Future events
If you are looking for dedicated engineering
solutions that add real value to your business,
then come and talk to our specialists at one of
the following events:
SPE Offshore Europe exhibition
SKF is continuing its partnership with Scuderia
Ferrari with the development of specialised
components and systems to reduce weight and
frictional power losses.
SKF has worked closely with Scuderia Ferrari
to produce bearing sets manufactured from
specially developed tool steel. By adapting the heat
treatment process, SKF has been able to optimise
the surface hardness properties. This makes each
bearing extremely resistant to surface fatigue and
able to withstand the exceptionally high contact
stresses found in Formula One applications. As a
result, bearings can be downsized without affecting
performance or reliability.
The new bearing sets are now being used in the
latest gearbox, where the ability to downsize has
E-learning improves
distributor support
helped reduce overall weight by more than 20%.
Gearbox performance is improved still further by the
use of ceramic bearing rollers and optimised internal
geometries.
In a further development, Scuderia Ferrari is also
using the latest condition monitoring technology from
SKF. This is based on the company’s modular SKF
Multilog On-line System IMx platform, which has been
re-engineered to meet the specific demands of the
Formula One Team.
Installed on the engine and turbo test rigs, and
using advanced SKF Observer software, the condition
monitoring system provides asset protection, improved
operational efficiency, preventive maintenance, and an
increased speed of development.
www.ferrari.com
8 to 11 September 2015
Stand 1H41, Hall 1
Aberdeen Exhibition and Conference Centre
The largest exploration and production event in the
eastern hemisphere, with around 1,500 exhibitors
attracting some 60,000 visitors.
www.offshore-europe.co.uk
Aviation Week MRO Europe 2015
13 to 15 October 2015
Stand 966, ExCeL London
Europe's leading conference and exhibition where
stakeholders converge to explore and define the
aviation maintenance industry.
www.mroeurope.aviationweek.com
International Tidal Energy Summit
November 2015
Victoria Park Plaza Hotel, London
The 9th annual summit is the largest and most
comprehensive commercial networking forum
dedicated to the global tidal energy industry.
www.tidaltoday.com/tidal-conference
In a recent survey of SKF Distributor College
participants, 99% of respondents claimed the courses
contribute in allowing them to help customers select
the most appropriate solution for their application.
SKF Distributor College is an e-learning platform
for SKF Authorized Distributors with 44 courses
currently available. Its continuing goal is to train
distributors in the proper use of SKF products and
services, as well as the critical applications in which
they are typically used, making them even better able
to support their customers.
SKF Distributor College has proven to be
extremely popular, with participation growing
exponentially over the last couple of years and the
number of completed certificates surpassing 250,000.
www.skfdistributorcollege.com
dFOCUS 102 COMPETITION WINNERS
FIRST PRIZE of a Russell Hobbs Espresso Machine goes to: Chris Adams - ERIKS UK Ltd
SECOND PRIZE WINNERS each receive an SKF Mini Maglite torch: Steven Bones - Metreel Ltd, Cindy
Calverley - Emerson & Renwick Ltd, Jim Rana - ERIKS UK Ltd, Lyn Seldon - DS Smith, Jon Sidwick Acorn Industrial Services Ltd
THIRD PRIZE WINNERS each receive an SKF multi-function tool: Malcolm Battye - ERIKS UK Ltd, John
Edwards - Sterling Corporation, Phil Gibbons - ERIKS UK Ltd, James Henderson - Iggesund Paperboard,
Graham Hudson - Cargill, M. Bhatt - Sterling Corporation, Tony McKay - British Sugar, Malcolm
Partington - ERIKS UK Ltd, David Savage - Babcock International, Ian Wilson - Brammer UK Ltd
Hillhead exhibition
21 to 23 June 2016
Stand F2, Hillhead Quarry, Buxton, Derbyshire
This international show for quarrying, recycling and
heavy construction has static displays and physical
demonstrations from 460 exhibitors, attracting over
17,000 visitors.
www.hillhead.com
Evolution magazine
Evolution is our Group-produced business and
technology magazine issued by SKF since 1994. It
reaches some 500,000 readers across 80 countries.
The print version is published four times a year,
together with an online version:
www.evolution.skf.com
For portable reading, an iPad
edition is available for free
download from the App Store.
To receive your own printed
copy, please complete the
Reader Reply Form on the
inside back cover.
FOCUS
102
ff
Summer
Spring 2015
FOCUS
103
05
SKF UK NEWS
SKF Racing sponsors
Formula Student team
Madhavi Kotecha, SKF Racing Application Engineer (front left) and Guy Miller, SKF Racing Business Engineer
(front right) pictured with members of the UH Racing team.
SKF Racing has been involved with the University
of Hertfordshire (UH) Formula Student team for a
number of years, and the relationship will continue
through the 2015 season.
UH Racing is one of the most successful UK
Formula Student teams, currently ranked 29th
in the world out of over 500 teams. Founded in
1997, during UH Racing’s 18-year history, countless
awards have been won and the team has entered
competitions worldwide with cutting edge petrol,
electric and hydrogen powered cars.
Formula Student is Europe’s most well-
established educational motorsport competition, run
by the Institute of Mechanical Engineers. Backed
by industry, and high profile engineers such as its
Patron, Ross Brawn OBE, the competition aims to
inspire and develop enterprising and innovative young
engineers. Universities from across the globe are
challenged to design and build a single-seat racing
car in order to compete in static and dynamic events,
which demonstrate their understanding and test the
performance of the vehicle.
www.racing.herts.ac.uk
www.formulastudent.com
Bearings supplied for next
generation aircraft engines
SKF will supply CFM International with mainshaft
and gearbox bearings for the LEAP engine program,
a high-bypass aircraft turbofan engine.
The ceramic hybrid mainshaft bearings that have
been developed for the LEAP engine program will
help contribute to a lighter, quieter and more fuel
efficient aircraft engine, which emits up to 16% less
06
Summer 2015 g FOCUS 103
carbon than its predecessor, the CFM56.
LEAP is a next-generation aircraft engine being
designed and developed with a focus on improving
fuel consumption and reducing emissions and noise
levels. Variations of the LEAP engine will equip the
Airbus A320neo, Boeing 737 MAX and COMAC C919
aircrafts. www.cfmaeroengines.com
Supplier award
received from
General Motors
General Motors (GM) has recognised SKF as meeting
or exceeding a stringent set of quality performance
criteria, and achieving the cross-functional support of
the entire GM organisation.
This is the third year GM is honoring suppliers who
are making noteworthy contributions to GM’s goal of
providing the best overall customer experience in the
automotive industry.
“The suppliers receiving these awards have
demonstrated their commitment to quality excellence
and their outstanding performance is essential to GM’s
efforts to provide its customers with the best products
and services in the industry,” said Sheri Hickok, GM
executive director Supplier Quality.”
SKF supplies bearing and sealing solutions to GM
for multiple applications such as wheel end, suspension,
steering, driveline, engine and e-powertrain.
www.gm.com
NEW MARKET
OFFERS
New SKF Taconite Seal for SKF @ptitude
contaminated environments Connect offers
Suitable for the
most demanding
applications, the
new SKF Taconite
Seal delivers
an increased
level of bearing
protection in
split plummer
block bearing
housings that operate in extremely contaminated and
wet environments. This greater level of protection
from dust, grit and moisture helps achieve maximum
bearing service life, while optimising machine
performance and uptime.
This latest SKF Taconite Seal is a compact,
multi-stage labyrinth cartridge seal, with an internal,
low friction V-ring that forms an additional barrier
to contamination and provides an effective grease
purge. The rotating labyrinth ring faces the bearing
housing to deflect and fling water away. It has been
specifically designed for use in industries such as
mining, mineral processing, and pulp and paper,
where contaminant ingress leads to premature
bearing failure, causing expensive unplanned
machine shutdown.
The new SKF Taconite Seal design is available
for most SKF split plummer block bearing housings
starting from 50 mm shaft diameter, and fits into the
seal groove of the bearing housing. As an alternative
solution, larger SKF Taconite Seals (≥ 340 mm shaft
diameter) are also available for ‘bolt-on’ mounting
to specially prepared bearing housings. All the seals
feature a circumferential groove on the outer surface
that simplifies and speeds up the alignment and
assembly process.
In extreme environments, reliability can be further
improved by combining the new SKF Taconite Seal
with an upgraded sealed SKF Explorer spherical roller
bearing and a grease barrier between them, in an
SKF bearing housing for the ultimate SKF threebarrier solution.
HYDROCAM bolt tensioner
range optimises bolt tightening
A new quick fit bolt tensioner from SKF has been added to the
existing range of HYDROCAM bolt tensioners. These enable
reliable and repeatable bolt tightening for customers in a variety of
applications, including marine, traditional power, aeronautics and
mining. The HYDROCAM tensioner range includes both manual and
automatic systems and can tighten bolts from 5 to 500 mm.
The HYDROCAM range ensures that high performance of each
bolted assembly is achieved, therefore preventing seal leakage,
avoiding shear stresses on the bolts, resisting spontaneous
loosening effects, and, most importantly, ensuring that they are
capable of supporting external loads. This range eliminates the poor
implementation of tightening methods, boosting reliability and safety in the process, enabling customers to
benefit from maintenance cost reductions.
The standard range of HYDROCAM bolt tensioners covers a wide range of bolt dimensions, from M8 to
M160, and enables pre-tightening loads ranging from 50 kN to 8,500 kN. The latest ETQR Quick Connect Nut
and HTQR Quick Connection Tensioner extend the range still further, while helping to reduce installation and
setup times.
SKF also offers customised tensioners in the event that the standard range does not meet the needs of a
customer’s application. If this is the case, SKF can easily customise a standard range tensioner by adapting the
brace, skirt, socket or reaction nut of the tensioner to fit the customer’s size and accessibility constraints.
cloud-based
monitoring
SKF @ptitude software has been extended to
offer SKF @ptitude Connect, a cost-effective cloud
computing resource. The service provides instant
access to SKF condition monitoring software,
enabling customers to improve plant performance
and efficiency.
SKF @ptitude Connect enables any business to
implement plant-wide condition-based maintenance
(CBM) and/or predictive maintenance (PdM)
programs via the internet. Using the SKF cloud
service, engineers can access machine data, analyse
or display machine conditions and view printable
diagnostic reports.
SKF @ptitude Connect addresses a common
problem faced in many facilities, which is that there is
not enough time or money to purchase and manage
the required software. By using the system to access
subscription-based software, customers can boost
equipment reliability and availability without costly
investment.
SKF @ptitude Connect is compatible with SKF
handheld or online condition monitoring data
collection devices, enabling end-users to operate
their CBM or PdM programs just as they would with
on-site software, bringing reduced IT operating
and maintenance costs. Compliant with ISO 27001
and SSAE16, SKF's cloud protects data integrity
in key areas of concern, such as data access, data
transmission, data storage and data centre access.
FOCUS 103 f Summer 2015
07
SKF INSIGHT
Intelligent bearings
offer early warning
Bearings that can diagnose and report on their own surroundings offer huge
potential benefits to engineering applications from trains to wind turbines.
When a warning light flashes on your dashboard, it
usually means that something has failed. The fuel
pump, perhaps, or an electronic component.
Replacing the part usually fixes the problem.
But what if component problems could be routinely
diagnosed before they needed replacement? It is not
very common on a car, but is becoming far more
prevalent in industry – where machinery can cost
millions rather than thousands – and every minute
of downtime equates to a lost fortune.
For this reason, condition monitoring has become
well-established, allowing maintenance engineers
to measure a range of conditions, such as excessive
bearing vibration, by fitting an array of sensors to
the machine. This reduces the total cost of asset
ownership and extends machine operating life,
while maximising machine uptime and minimising
downtime.
Although this approach helps to avoid catastrophic
failures, there is a downside: by detecting a vibration
problem in the bearing, it means that damage has
already begun to occur. Vibration signals are normally
produced when fragments of steel begin to spall from
the raceway surface of the rings or rolling elements.
Once things have reached this stage, it is too late:
the bearing has already suffered damage that affects
operating performance and lifetime.
Bearing transformation
Now, a more elegant approach to condition
monitoring has emerged, which puts diagnostics
at the heart of the machine by transforming a
fundamental component – the bearing – into its own
sensor. Intelligent bearings are equipped with a selfpowered, wireless sensor that can transmit process
data to a central point, to identify potential problems
very early. This takes it beyond the capabilities of
traditional condition monitoring, giving maintenance
engineers a powerful new diagnostic tool.
The bearings could be used in previously
inaccessible locations such as rotating gearboxes:
here, leading wires in (to supply power) and out (to
deliver data) would be impossible, but intelligent
bearings could cope with ease.
08
Summer 2015 g FOCUS 103
The ability to use them at the heart of a machine,
where sensors are normally impossible to embed,
would provide much more detail of the operating
environment. Having such a deep understanding of
operating conditions – in real time – could even make
it possible to uprate a machine, extending its life or
power rating beyond its initial specification.
SKF has commercialised an intelligent bearing,
in the shape of its SKF Insight technology.
It surpasses traditional condition monitoring by
measuring the critical parameters that lead to early
bearing failure, such as lubricant contamination or
excessive temperature. This means it can anticipate
and prevent damage to bearings and to the machine
itself.
Why develop?
SKF Insight was developed because it was recognised
that bearings rarely fail in service under normal
operating conditions. Instead, the usual cause of
failure is misuse: insufficient lubrication, for example,
or running the bearing under conditions outside
those originally specified.
The concept has been developed with challenging
applications in mind. In steel manufacturing, for
example, SKF has fitted smart bearings into a
continuous caster – an environment far too hostile for
cables and external sensors – to monitor key process
parameters, thanks to embedded self-powered
wireless sensors.
Further ahead, there may be applications for
wheel end bearings in the rail industry. These
safety-critical components are normally changed at
set intervals, regardless of their condition. Intelligent
bearings would provide more accurate data, allowing
change-out intervals to be determined based on
actual – rather than predicted – operating conditions.
Business justification
However, it is wind turbines that could benefit most
from this kind of technology. In some offshore
applications, the cost of changing a wind turbine main
bearing is so high that it undermines the business
case for building the turbine in the first place.
It makes sense then to record lubrication conditions
in service, and take action to avoid damaging
conditions.
Smart bearings that can monitor bearing speed,
vibration, temperature and lubrication levels are
being explored for wind turbines. They will allow
dynamic bearing information to be measured in the
true operating state and wirelessly communicated
to remote monitoring centres or local maintenance
crews. Because technology such as SKF Insight can
be retro-fitted, it could enhance the efficiency of both
new and existing turbines.
For now, intelligent bearings are squarely aimed
at these high end applications. In the future though,
they, like many innovative technologies, may find
their way further downstream, even into the prime
example of consumer engineering: the car. Now that
really would revolutionise the maintenance process!
BEARING
REMANUFACTURING
How to extend bearing life
Unless you have the good fortune to operate
your production or process equipment under
theoretically perfect conditions, then it is an
unfortunate fact of life that all rotating and
moving components will eventually wear.
Advances in technology
This is particularly true of bearings, which often have
to function under extremely demanding conditions
of load or environment, sometimes with poorly
maintained lubrication, or on shafts and in machines
that are incorrectly aligned and operated.
SKF bearings are engineered to meet these
challenges and offer the highest levels of reliability
and operating life. Despite this, and however benign
the maintenance, lubrication or operational routine,
it is impossible to escape the reality of physics: that
two surfaces moving against each other will generate
friction, which in turn causes wear.
You have a choice
The first step is to identify the rate at which a
bearing is wearing while it is still in service, using
vibration and temperature detection tools as part of
a condition based monitoring programme. Having
predicted the point at which a bearing will begin to
exceed its specified operational parameters it is then
possible to schedule its replacement at a time that
causes the least disruption to production schedules.
Once a bearing has been removed, the question
is whether to replace or repair. Both options
have a cost. For many bearings, especially large
or specialised units, the cost of replacement is
considerably higher than the cost of remanufacturing.
There may also be long lead-times for new bearings,
while for those companies with strong corporate
social responsibility (CSR) policies, the fact that
manufacturing new bearings creates a much larger
carbon footprint than that of remanufacturing can be
a decisive factor.
Whichever option is chosen it should not be
forgotten that any bearing, large or small, is
essentially an investment, and the goal should be to
extract maximum value by extending the operating
life of the asset for as long as possible.
Remanufacturing is one of the services offered
by SKF to help you achieve this goal.
How does remanufacturing work?
Remanufacturing can be particularly cost effective
for large size bearings, for bearings in specialised
applications, and for high volume applications where
multiple bearings can be remanufactured together.
In practice, it is possible to save up to 80% of the
cost of a new bearing.
The process of remanufacturing should begin with
an understanding of why the bearing has worn or
failed. The most likely cause will be from elsewhere in
the operating environment. It is therefore important
to understand
this if future
problems are to
It is estimated that 90%
be avoided. SKF
of all bearings never
provides a range
reach their calculated
of tools, including
the Root Cause
service life
Failure Analysis
(RCFA) service,
which draws on
our long experience of bearing manufacturing, and
on our proven bearing analysis methodology and ISO
classifications.
The next step is to disassemble the bearing and
identify the degree of damage to its component parts,
using a number of specialist tools; these can include
visual inspection and crack detection, plus surface
hardness and dimensional measurement.
For SKF bearings, which use advanced bearing steels,
damage is normally only seen on the outer bearing
surfaces, not in the sub-surface layers.
A customer report is then produced before
remedial work is undertaken. Depending on the
level of damage, remedial work can range from
grinding of scratches and grooves, polishing and
demagnetisation, to re-plating or component
replacement.
Once work is completed and the remanufactured
bearing has been lubricated, tested and repacked, a
full report is generated and the product is returned
to the customer.
Bottom line saving
It is worth noting that although estimates vary,
the common consensus is that up to 90% of all
bearings in operation around the world never
reach their calculated service life. Even if the actual
figure is considerably lower than this estimate, the
fact remains that too many companies are failing
to receive the best return on investment on their
bearing assets.
Bearing remanufacturing, especially if used in
conjunction with techniques such as condition based
monitoring, can therefore play an important role in
helping manufacturing and processing companies
reduce their costs, cut their carbon footprint, and
improve their return on investment.
FOCUS 103 f Summer 2015
09
FOOD AND BEVERAGE
SOLUTIONS
SKF solutions help food industry
boost production efficiency
SKF solutions – from food-grade lubricants
to vibration monitoring equipment – help
food processors maintain high efficiency in
the face of harsh operating conditions.
The food industry faces many challenges, all of
which can disrupt the smooth operation of process
machinery. There is high humidity, which can promote
the corrosion of metal parts. Then there is the need
for frequent wash downs with corrosive chemicals:
this can affect seals, causing lubricant leakage and
contamination. And then there are the elevated
temperatures, which can cause deterioration in all
kinds of components.
These issues must be solved, or at least managed,
otherwise they will impact productivity through
machine breakdowns and downtime – leading to lost
revenue. As if this were not challenging enough, it
must all be done while remaining compliant with strict
health, safety and environmental legislation.
Lubricant importance
SKF has proven solutions for these industry
challenges, and many more. Take the issue of
lubrication, for example. The food industry can require
temperatures in excess of 150 °C in order to cook food
properly. However, these high temperatures can cause
lubrication greases to carbonise or oxidise, requiring
expensive and time-consuming re-lubrication.
Items like chains and belts need to be reliable
in order to maximise productivity. But as well as
ensuring the lubricant is safe for food use, it must also
be applied in a way that does not interrupt production.
One way to minimise cost and effort is to use
a system such as the SKF ChainLube oil projection
10
Summer 2015 g FOCUS 103
system. A pump draws lubricant from a reservoir and
delivers a precise volume of oil directly to the friction
points of the chain while it is running. A control unit
can be programmed to do this at a pre-set time.
Because the spraying nozzles have no mechanical
contact with the chains there is no dirt accumulation
or applicator wear.
Productivity remains high because the chain does
not need to be stopped. Decreased wear on the chain
leads to a longer service life, while the reduced friction
lowers energy consumption. By keeping lubricant
use, and waste, to a
minimum, operators
can reduce
environmental and
operator safety
issues. For chains
with a medium
pitch (50-300 mm),
moving at less than
two pitches per second, lubricant
can simply be applied on to the chain. This supports
the HACCP (Hazard Analysis and Critical Control Point)
process by significantly reducing the potential for
contamination of food by the lubricant; if the pitch is
smaller – or the chain moving more quickly – it can be
applied using air-assisted oil projection.
Of course, food grade lubricants are used. They
offer standard lubricating properties to resist wear,
friction, corrosion and oxidation, but operate under
stringent control: SKF Food Grade Lubricants are NSF/
H1, Kosher and Halal approved, and include general
purpose, high temperature, low temperature, chain oil
and gear oil grades.
In fact, it is becoming more common for the food
industry to use food grade lubricants across their
entire operation – and not just in food processing
machinery. This reduces the risk of applying non-food
grade grease where one is required.
Food grade bearings
The new SKF Food Line range of stainless steel deep
groove ball bearings – designated VP311, which
indicates their suitability for use in the food industry
– use high quality NSF H1 certified grease, and meet
another key industry requirement: they include FDAapproved blue seals, which aid detection in the rare
case of failed seals adulterating the food. They are due
to be launched onto the market later in 2015.
“Both the blue seal and special lubricant were
developed and tested for performance in food and
beverage applications,” says David Oliver, Europe
Industry Manager Food and Beverage at SKF. “This
is unique to SKF: none of our competitors can offer
the full package of food grade grease, plus sealing by
FDA-approved blue coloured seal in their stainless
steel deep groove ball bearings.”
The Food Line family includes 19 different standard
sizes of bearing from SKF’s
extensive range, in diameters
ranging from 8 to 40 mm.
The SKF stainless steel,
deep groove ball bearings
offer high resistance to
corrosion, so help withstand
the industry’s aggressive wash
down regimes. The blue seal
offers peace of mind
because it is easy
to identify and
remove – in the
unlikely case of it being dislodged.
Meeting needs
Food manufacturers can also improve lubrication
management procedures through an SKF Client Needs
Analysis (CNA). The CNA is a survey of around 40
question which are put to the maintenance operations
team. It generally takes half a day of interviews to
gather the relevant information. SKF then generates
an immediate score on a company’s maintenance
performance – revealing instant ways to boost
procedures and cut costs. In addition, the report
provides a ‘roadmap’ for future improvements.
Lubrication typically accounts for 1-5% of
a maintenance budget, but the impact of poor
lubrication can be far more significant: insufficient
lubrication is estimated to account for around half
of all bearing failures, for example. Yet the payback
on correct lubrication is very high: the Institution of
FOOD AND BEVERAGE
SOLUTIONS
Mechanical Engineers says that investment in a good
lubrication regime yields a 40:1 return – so a £1,000
investment typically saves £40,000.
Operator benefits
Condition-based monitoring equipment can make
a huge different to a factory, flagging up potential
production problems before they become serious.
But these instruments – such as vibration monitoring
sensors – are ineffective without the trained operators
who understand what to do with the collected data.
Operator Driven Reliability (ODR) is an approach
that encourages operators to use their skills and
knowledge to detect and report upon very early
changes in equipment conditions – whether it is
abnormal readings and strange sounds or signs of
leaks and pressure drops. From their position on the
front line, operators play a vital role in managing
assets and minimising downtime.
It empowers front-line operators to take a
proactive role in communicating their findings
and carrying out early corrective action. In this
way, operations teams become an integral part
of a reliability-based asset management strategy,
minimising unplanned downtime while increasing
plant productivity and safety.
Typical benefits of ODR include: improved
productivity and profitability; reduced maintenance and
repair costs; less unplanned downtime; and reduced
energy and operating costs. It also encourages
operations and maintenance
departments to communicate
more effectively and work together
to achieve business goals.
A number of SKF tools and
technologies are critical in
helping to empower operators
and embed ODR into working
practices. The SKF Microlog
Inspector is
an advanced
inspection
system that
integrates
condition
monitoring, workflow management, safety and
regulatory inspections. If abnormal conditions are seen
and recorded, it prompts operators to take corrective
action. The data collected in this way is fed through
the SKF @ptitude Monitoring Suite, which can plot
trends in order to identify small process changes that
do not yet trigger an alarm, but are heading towards a
potential problem situation. This can be fed back to the
operator for corrective action. Results collated in this
way can – through SKF
@ptitude Decision Support – be transmitted across
the business, or stored for later use and analysis.
Extra tools
Other tools are available to help maintain machine
health. The SKF Machine Condition Advisor (MCA),
for example, is an ergonomically designed, handheld
device that simplifies machine maintenance and
prevents costly failures.
The MCA provides an overall velocity vibration
reading that measures vibration signals from the
machine and automatically compares them to preprogrammed guidelines. An alert or danger alarm
displays when measurements exceed those guidelines.
Simultaneously, an enveloped acceleration
measurement is taken and compared to established
bearing vibration guidelines to verify conformity or
indicate potential bearing damage. The MCA also
measures temperature using an infrared sensor to
indicate uncharacteristic heat.
Similarly, the SKF Machine Condition Indicator
(MCI) is an affordable way to monitor non-critical
machinery. The MCI combines a vibration sensor and
alarm indicator in a single unit. It requires no wired
or wireless connections, and installs directly onto
machinery for permanent, periodic vibration and
temperature monitoring. A light on the unit illuminates
when it detects developing issues – alerting
maintenance technicians that the machine needs to
undergo a root cause analysis. To conserve energy, it
‘sleeps’ most of the time, waking up eight times per
day at pre-set intervals to take measurements.
If this array of technology seems daunting, then
help is at hand. SKF can organise specific training to
help operators and managers get the best out of their
technology. To start with, there is product training, to
understand the intricacies of each piece of technology.
In addition, SKF offers online interactive training to
take students through everything – from the basics of
bearings, lubrication and thermography right through
to advanced instruction on maintenance techniques.
Face-to-face training is also available – by visits to a
customer’s site or even through hands-on sessions at
SKF facilities across the UK.
So, whatever the needs of food industry customers,
SKF can help to train, maintain and sustain the entire
operation.
FOCUS 103 f Summer 2015
11
SPHERICAL ROLLER
BEARINGS
Upgrades to SKF spherical roller
bearings further extend service life
Spherical roller bearings have come a long way since SKF introduced them to the market way back in 1919.
Recent improvements – including the use of superior materials and better heat treatment – have further extended
service life, as well as opening up opportunities in more challenging environments.
The centenary of the spherical roller bearing is almost
upon us, because it was back in 1919 that SKF first
introduced it to the world. Since then, the company
has continuously upgraded and enhanced its products.
Since 2011, for instance, several upgrades to SKF
Explorer spherical roller bearings – including the
use of high-quality steel and a new heat treatment
process – helped to double their service life in
comparison with the earlier generation.
Sealed for cleanliness
The range of SKF Explorer spherical roller bearing
with integral seals – which lengthens bearing service
life in highly contaminated environments – is now
available in a greater range of sizes. These bearings
are pre-lubricated with specially formulated grease,
and protected with highly effective contact seals.
This resists the ingress of contaminants that might
otherwise adversely affect the bearing and lubricant,
or cause premature failure.
The enhanced cleanliness within a sealed spherical
roller bearing – in comparison with an open bearing –
offers the potential, when operating in a contaminated
environment, to downsize without reducing either
service life or performance. For example, a size 20
(100mm diameter) sealed spherical roller bearing
could potentially have the same SKF rating life
as the same series size 26 (130mm diameter)
equivalent bearing without seals. In both cases,
calculation considered standard SKF bearing grease,
an equivalent load of 90kN and a rotation speed 500
revolutions/minute was used.
In many applications, the sealed bearings can
be considered lubricated for life, which completely
removes the interval of relubrication. This significantly
reduces the cost of buying, applying and disposing of
grease. Such a reduction in maintenance costs will, in
many cases, reduce the total cost of ownership of an
application.
In summary, the benefits are: significant reduction
in maintenance needs; lower grease consumption and
environmental impact; and a substantial improvement
in uptime.
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Summer 2015 g FOCUS 103
Special applications
SKF spherical roller bearings are available in a range
of performance classes – from vibratory applications
to energy efficiency.
To withstand the high linear acceleration
associated with vibratory applications, SKF Explorer
spherical roller bearings for vibratory applications
are equipped with a special, hardened cage and
hardened guide ring. This enables them to withstand
higher acceleration forces while running at cooler
temperatures. These bearings are successfully used in
vibratory applications such as vibrating screens and
road rollers.
They are also available
with a PTFE-coated bore,
which virtually eliminates
fretting corrosion
against the shaft. They
are available in sizes
22308-22348.
One satisfied
customer, a
manufacturer of vibratory
screens, said: “The SKF
spherical roller bearing for vibratory applications
makes it possible to run our screens even harder, to
make them better than those of our competitors.”
SKF E2 spherical roller bearings
SKF Energy Efficient bearings, meanwhile, use special
low friction grease and have an optimised internal
geometry and new cage design. Spherical roller
bearings in this performance class are characterised
by at least 30% lower
frictional moment
and consequently
a lower operating
temperature than
an SKF Explorer
spherical roller
bearing of the same
size operating under
the same conditions.
This allows reference speeds to be increased by up
to 40%, as well as extending grease life. In light- to
medium-load applications, the bearings can improve
machine efficiency and save energy. E2 bearings are
part of the SKF BeyondZero portfolio, which comprises
products that help reduce CO2 emissions and
environmental impact. E2 spherical roller bearings are
available in sizes 22209-22213.
Solid Oil bearings
In most applications, standard greases and oils
provide adequate lubrication. However, where
accessibility makes it impossible or very difficult to
relubricate, Solid Oil is an excellent solution. Solid
Oil is an oil-saturated polymer matrix that fills the
entire free space in the bearing, encapsulating and
protecting both the rolling elements and cage from
low to moderate levels of contamination. Sufficient
oil is released from the
polymer matrix to
lubricate the bearing
when in operation,
with any excess
being reabsorbed.
For highly
contaminated
environments,
sealed spherical roller
bearings can also be
supplied with Solid Oil. SKF spherical roller bearings
with Solid Oil can operate at temperatures of up to
85 °C and at low speeds. Almost any size can be
supplied as a Solid Oil bearing.
Self-alignment
Spherical roller bearings have two rows of rollers –
a common sphered outer ring raceway and two
inner ring raceways inclined at an angle to the
bearing axis. The centre point of the sphere in the
outer ring raceway is at the bearing axis. This makes
the bearings self-aligning when they operate in
applications in which the inner ring rotates relative
to the radial load, and therefore insensitive to
SPHERICAL ROLLER
BEARINGS
misalignment of the shaft relative to the housing
(which can be caused, for example, by shaft
deflection).
Applications that need to deal with misalignment
and thermal elongation of the shaft traditionally use
a locating/non-locating bearing system with two
spherical roller bearings. The non-locating bearing has
a loose outer ring fit, enabling it to slide on its seat
in the housing. This can cause a stick-slip condition
that induces vibrations, additional axial loads on the
bearings and heat – all of which can cut bearing
service life. The SKF self-aligning bearing system
overcomes this by using a spherical roller bearing
at the locating position and a CARB toroidal roller
bearing in the non-locating position.
CARB toroidal roller bearings
SKF’s development of the CARB bearing was a high
water mark in bearing development. CARB combines
the self-aligning capability of spherical roller bearings
with the axial displacement ability of cylindrical roller
bearings. CARB can be made with the compact crosssection and high load-carrying ability of needle roller
bearings, but for convenience is most often made with
the boundary dimensions of spherical roller bearings –
with which it is nearly always used.
This means it can accommodate relative thermal
expansion or contraction between the shaft and
housing or structure, without inducing internal axial
loads. Because both inner and outer rings of a CARB
bearing can be mounted with an interference fit,
problems associated with rotating outer ring load and
a loose outer ring fit – such as fretting corrosion – can
be avoided.
In one example, SKF helped to rebuild an industrial
fan using the self-aligning system. Replacing one of
two spherical roller bearings with a CARB bearing
helped to bring down bearing operating temperatures
from 26 °C above ambient to just 12-18 °C above
ambient. This temperature reduction had a direct,
positive effect on the relubrication interval.
Gearbox manufacturer Benzlers is just one of
many companies that have found SKF spherical roller
bearings critical to its business.
“Our customers require 80,000 hours of service
life,” said its application engineering manager,
Wolfgang Böhm. “I need to have bearings with
performance that I can trust.”
FOCUS 103 f Summer 2015
13
INDUSTRIAL PUMPS
End to end pump solutions
Despite the constant introduction of new
processes and technologies, industrial
pumps remain key components in a wide
range of applications, from HVAC to water
treatment works, oil refineries, and food
and beverage production.
Pumps can, however, use considerable quantities
of energy. Estimates vary, but typically energy
consumption accounts for up to 45% of a pump’s
total cost of ownership. In addition, pumps can be
relatively high maintenance. This can be an issue in
terms of cost, labour and even location, as the very
nature and role of pumps means that they are often
situated in hard to reach locations.
Keeping pumps healthy for longer
Despite the best efforts of pump manufacturers,
operational failure, whether it is due to inadequate
lubrication, overheating or general wear and tear,
has long been accepted as the downside of pump
ownership.
The good health of a pump is very much
reliant on the state of its components, especially
the operation and efficiency of its bearings. SKF
bearings are widely used in all types of pumps, and
are designed to withstand extremes of temperature,
high operating speeds and heavy loads, with minimal
intervention or downtime.
Even under the most benign of operating
conditions, and the most rigorous maintenance
regime, pump components will eventually wear.
Our customers share our pragmatic approach to
14
Summer 2015 g FOCUS 103
pump maintenance; that a wholesale replacement of
a pump is often unnecessary while there are parts,
solutions and regular health checks available that can
give a pump an extended operating life.
The SKF pump upgrade service has been
developed to bridge the gap between part
replacement and pump replacement, so the user only
replaces a complete pump when absolutely necessary.
Repair and upgrade
Addressing heat-related, noise and vibration issues,
as well as environmental concerns, a pump upgrade
starts with a detailed assessment that determines the
level of pump degradation and what maintenance
problems are present.
Based on SKF’s recommendations and findings,
a customer may opt for a total pump solution, which
incorporates the entire upgrade package, including
automatic lubrication systems. Alternatively, there
is the flexible option of a combination of upgrade
packages which cover components, lubrication
systems and services, based on the needs of the
customer and the pump in question.
The SKF team of service engineers possesses the
hands-on experience to effectively analyse operating
conditions and perform all types of on-site pump
support work, as well as the know-how to recognise
what is causing pump failure and how to prevent
further problems.
For anyone thinking about a pump maintenance
programme, but who may be having doubts as to its
value, it is worth considering the following.
Poor and irregular maintenance may result in a
loss of 10 to 15% pump efficiency, which in turn will
lead to further degradation and a shorter life for
the pump. By implementing a Proactive Reliability
Maintenance (PRM) solution or Operator Driven
Reliability (ODR) solution into a pump maintenance
programme, unplanned downtime is reduced and
the likelihood of part failure decreases, which
subsequently keeps costs down as well.
The pump upgrade solution often includes
the upgrading of existing components. These can
include changing to new types of bearings, seals and
lubrication systems, such as those described below.
Angular contact ball bearings
Ideal for small and medium pumps and designed
to hold up against even the most testing of pump
conditions and workloads, angular contact ball
INDUSTRIAL PUMPS
optimum condition. With many pumps installed in
awkward locations, the lubrication process can be
arduous, labour intensive and potentially dangerous.
It is therefore worth giving serious consideration
to a fully automatic lubrication system, which SKF
lubrication experts will be able to specify in line with
your requirements. This can be an attractive and
ultimately cost-efficient alternative that protects
both the integrity of bearings and reduces overall
operating costs, and far from being a one size fits all
solution, the lubricant can be tailored to meet specific
factors, including vertical shaft, resistance to solids
and chemical aggression.
Providing a greener alternative
bearings (ACBBs), depending on the standard, have
the capability to play a significant part in improving
performance, reliability, and uptime while reducing
maintenance costs, noise, vibration levels and even
lubrication consumption.
ACBBs are available in both the ‘SKF Explorer’
performance class and as standard bearings. SKF
Explorer class, which sets an industry benchmark for
quality and resistance to wear, tear and damage,
include high load capabilities, higher speed ratings
and can last up to three times as long as standard
bearings.
Double row angular contact ball bearings
Faced with demand for a product that keeps
downtime and failure to a lower level still, SKF has
designed and engineered double row angular contact
ball bearings (DRACBB) for the pump market. Energy
efficient and requiring less axial space than the
single row ACBBs, it is the combination of a highfunctioning Polyamide cage interior filled with lowfriction grease, and an effective exterior where each
side is capped with steel shields that has resulted in a
bearing solution that is truly fit for pump purpose.
Cutting mechanical friction by around 30% compared
with standard bearings, which in turn brings down
operating temperatures by 30°C, the installation of
DRACBBs means that each pump has less chance of
overheating or failing.
Emphasising and optimising lubrication
Of course, bearings are just part of the pump
maintenance story. In the world of pump operation,
in which more than a third of premature bearing
failures occur due to inadequate or incorrect
lubrication, there is no margin for error.
SKF offers a wide range of lubricants, tools
and techniques that will help keep your pumps in
It is not just pump parts that are on the minds of
pump operators; of equal importance is the amount
of energy a pump consumes, and the impact that this
has on the cost of ownership. With pumping systems
responsible for around 20% of the global demand
on electricity, and on a more specific level, between
20 and 25% of energy usage at an industrial plant,
it is no surprise that there is a genuine demand for
energysaving solutions and processes within this
environment. Nor should it come as a revelation
that a raft of stringent environmental legislation has
impacted on pump governance, pushing energy
consumption further up the agenda. It is a set
of concerns that we take very seriously, which is
why the SKF BeyondZero commitment to reducing
environmental impact and decreasing energy output
continues to have a strong influence on both our
product and solutions portfolios.
pumping systems can be improved by up to 20%
without affecting pump performance, functionality or
life; that’s a saving that can feed directly to the bottom
line.continues to have a strong influence on both our
product and solutions portfolios.
The case for wastewater
disposal
Of all the applications for an industrial
pump, one of the most crucial is for the
disposal or transfer of wastewater.
Although a large amount of this would be
sewage treatment discharge and human
effluent, wastewater covers a multitude of
products and materials, including washing
water (greywater), septic tank discharge
and industrial and pharmaceutical waste.
Along with a host of potentially toxic
material, this is the water most likely to
carry bacteria and organic particles in
its untreated state. As it is also likely to
contain a range of aggressive solids and
particulates, and as these pumps are
more likely to be located in difficult areas,
the last thing the owner/operator wants
to consider is downtime, leakage or
contamination due to pump failure.
This is why wastewater pumps are
ideal candidates for SKF pump upgrade
solutions and part replacement.
By partnering with SKF’s team of pump
specialists, anyone that operates a
wastewater pump can feel assured that
their equipment is fit for purpose, and
can handle and treat even the harshest of
substances with the absolute minimum of
downtime or worry.
An holistic approach to pump protection
While a number of products, such as sealing and
ceramic solutions, can play a role in keeping a
pump operational and helping to reduce energy
consumption, a more effective solution, and one that
takes into account the overall condition of a pump
rather than the individual elements, is to implement
energy monitoring. Performed by SKF’s experienced
team of specialists, this thorough health check
determines whether a pump needs modifying,
repairing or even replacing.
Reviewing the conditions under which each pump
operates to allow it to run at optimum efficiency can
have real and lasting benefits. Indeed, a recent study
demonstrated that the energy efficiency of many
FOCUS 103 f Summer 2015
15
RAILWAY SOLUTIONS
Solutions for the
rail industry
SKF is at the forefront of developments in rail technology to produce faster,
quieter, safer and more efficient trains; and provides tools to manage these
assets throughout their entire lifecycle for maximum productivity.
Cost-saving portable analyser kit
The SKF Microlog CMXA75 analyser kit significantly
improves the efficiency of data collection both in
workshop and operational condition monitoring
programs. The portable device can be used for the
sophisticated analysis of bearings, rotative parts in
traction motors, gearboxes and other rotating rail
application equipment.
The device collects data from accelerometers
placed on the subsystem that needs to be checked.
Signals are processed by the handheld analyser, and
alarm parameters set in the SKF @ptitude Observer
software enable fast and accurate condition
monitoring of key systems. The kit can be used
as both a troubleshooting tool and for routine
operational condition monitoring. Used in combination
with the SKF @ptitude Observer software, the SKF
Microlog constitutes a complete entry level condition
monitoring system for train operators.
The SKF Microlog CMXA75 helps achieve a more
efficient maintenance strategy by helping reduce
the duration of maintenance and unplanned service
disruptions. Used as part of a predictive maintenance
regime, it will help operators achieve savings in
maintenance costs due to extended service intervals,
reduce passenger inconvenience as a result of
reducing service disruption, improve workshop testing
quality procedures and bring about a more efficient
use of downtime.
Efficient wireless railway bogie
condition monitoring
The new SKF Multilog On-line System IMx-B, is a
wireless full bogie condition monitoring system for
all types of locomotives and passenger rail vehicles,
which enhances service, reliable operation and train
maintenance efficiency. The system offers added value
by bringing a wireless solution that is easier to install
for operators who are looking to move their fleets
from time-based maintenance to a condition-based
maintenance regime.
Vibration, temperature and speed data are
collected and processed by the SKF Multilog On-line
System IMx-B from railway-specific sensors on the
bogie. Intelligent capabilities built into the system
recognise stable running conditions as the time to
collect data and calculated values can be processed
16
Summer 2015 g FOCUS 103
locally on the train for immediate feedback, or sent
wirelessly to the cloud for further remote analysis
in SKF @ptitude Observer software. This enables
the maintenance department to swiftly evaluate all
the bogie rotative component conditions of motors,
gearboxes, axleboxes and wheels. SKF software
access is flexible and can be purchased outright by
the customer or utilised on a subscription basis. Data
is sent wirelessly and analysis can be made by the
customer’s staff, or as an outsourced service by the
SKF remote center for expert analysis and reporting.
The SKF Bogie Monitoring System offers wide area
network wireless/3G compatibility, and fulfils railway
standards for bogie mounted electronic systems. The
full condition monitoring capability includes acceleration
enveloping for early bearing fault detection, 16
analogue channels and compatibility with many
different sensor types. It can be retrofitted to existing
trains without costly wiring overheads due to its
wireless capabilities and is suitable for both high and
low speed mainline trains and metro vehicles.
RAILWAY SOLUTIONS
Customised lubrication solutions Compact unit
for rail wear and noise reduction enables higher
rail freight loads
The comprehensive product portfolio includes wheel
flange lubrication systems to reduce wheel wear and
wayside lubrication systems to reduce wear on the
gauge face. Suitable for rail, metro and tramway
applications, both systems minimise rail wear and
noise emission, including curve squealing.
Due to the large number of variables present
in a total system approach, an in-depth analysis
of customer conditions is necessary to ensure
optimum results. Initially, the current annual cost of
replacing and re-working rails and wheels should
be determined. Though it is difficult to weigh the
economic value associated with noise reduction,
comparison calculations can be performed to evaluate
various technologies used to reduce noise and comply
with regulations. Upon completion of the survey,
potential cost savings are determined, as well as the
required investment and maintenance costs for the
lubrication system. This enables the customer to make
an informed decision.
Wayside lubrication systems
Wayside systems include gauge face lubrication
and top-of-rail conditioning systems. In tramway
applications, the lubricant is usually delivered via
drilled lubrication holes, whereas railways require
applicators to be mounted on the rail, as drilling is
not an option. Depending on the calculated lubricant
consumption, drum, reservoir and cartridge pump
stations can be selected. All SKF pump options can
produce up to 350 bar, allowing long tube lines
between the pump and application point.
Wheel flange lubrication systems
Depending on the line distance between the pump and
spray nozzle near the wheel, there are various types
of wheel flange lubrication systems. These systems
range from a grease reservoir that is pressurised with
compressed air to systems with pneumatic piston
pumps and separate grease containers. In cases
where using on-board compressed air is not feasible,
there are also airless systems that can apply grease or
metallic paste directly on to the wheel or rail.
Wheelset service life improved for
enhanced passenger rail efficiency
The new tapered roller bearing unit (TBU) for
passenger railway applications will boost bearing
service life by up to 40% compared to existing
solutions. It can also help reduce fatigue failures,
enabling OEMs and end users to increase safety and
maximise profit.
This next generation bearing unit, for maximum
speeds of 100-155 mph, meets the needs of
railway operators who are looking for ways to cut
maintenance costs and time without impacting safety.
The new bearing enables OEMs to offer extended
bearing service intervals to match those of wheelsets;
this means that rail operators can align maintenance
intervals to avoid service interruptions and keep as
many trains as possible in operation. Enabling two
maintenance operations in one stop with potentially
fewer bearing replacements also means a significant
reduction in overall maintenance costs.
Operational features of the new TBU include higher
resistance to hoop stress due to residual compressive
The new Compact
Tapered Bearing
Unit (CTBU) from
SKF enables
increased weight to
be carried in freight
cars designed for
heavy loads. The
CTBU has an axle
load rated to 45
metric tons, which means that operators can increase
profitability by hauling more product with the same
length and train configuration.
The CTBU is the only heavy haul bearing rated
to 45 ton operational axle load on the market. This
represents a transportation capacity increase from
the existing 35.5 ton, thus allowing customers to
increase transported weight of product in existing or
new wagon fleets. The new solution was developed
as a direct result of customer requests and meets the
needs of railway operators who are trending towards
carrying heavier loads.
Damage to rolling stock and infrastructure, plus
delays to shipment, represent the biggest costs
for rail operators, but the improved bearing life of
the new class CTBU means less bearing fatigue.
The result is freight cars with longer maintenance
intervals and higher performance.
stresses in the surface, higher wear resistance and
slower crack propagation. The optimised contact
geometry of the bearing unit decreases friction and
maintains carrying capacity, reducing operating
temperature for a longer grease life and extending
the maintenance
interval. Also, SKF
has shown in testing
that the specially
enhanced central
spacer included
in the design
contributes to less
fretting corrosion
and thus longer
grease life.
FOCUS 103 f Summer 2015
17
LUBRICATION
SYSTEMS
Centralised lubrication
for off-highway vehicles
Centralised lubrication can reduce costs, increase the mean time between
planned stops, and extend component life and performance by applying precise
amounts of lubricant at controlled intervals.
Many maintenance engineers have concerns about
their off-highway equipment running low on
lubricant, but often make a critical error when trying
to solve the problem: they over-lubricate, which
can be just as damaging as too little, as it increases
friction, raises temperature, and can damage seals.
This can be made worse if the wrong specification
of lubricant is applied: equipment performance and
lifespan will then be reduced, while both maintenance
and downtime spiral out of control. It all adds
unwanted costs to the balance sheet.
An increasingly popular solution is to fit a
centralised automatic lubrication system, which
applies a metered volume of lubricant at controlled
intervals. Engineers prescribe the most suitable
lubricant for a piece of equipment, and the system
delivers a precise volume exactly where – and when
– it is needed, thus removing the feast or famine
approach that most manual lubrication routines
promote.
This can have a dramatic effect. As well as
reducing the amount of lubricant
needed,
it also saves huge amounts of time. Depending
on the machine type, manual lubrication can take
around 30 minutes every day, or at the very least, a
significant proportion of the available production time
in any given working day or shift. Automatic systems
are also more accurate than manual application,
delivering lubricant to moving parts more effectively
and reliably.
The potential benefits offered by automated
lubrication comes at a critical time for the industry:
a 2014 report from KPMG, Construction Barometer,
says that operating margins in the industry fell to
1.2% – from a high of 2.8% in 2010. Automated
lubrication could help push these margins back
up again.
Easy retrofitting
Construction machinery without centralised
lubrication systems can be retrofitted with relatively
little effort. SKF’s
retrofitting kits have
been manufactured according to the specifications
of leading OEMs, and meet their requirements and
lubrication standards. Retrofit systems are available in
all designs, as are the repair and replacement parts for
these systems. To ensure that retrofitting or repair can
be performed without complications, SKF can provide
complete systems with all the necessary components,
plus the plans and instructions for assembling a
centralised lubrication system for most types of
construction machinery. Installation can be performed
by our highly trained and experienced SKF Lubrication
Systems Distributors and partners, with SKF service
technicians available if required.
Setting the level
Automatic lubrication systems have proved their
worth in a wide range of both off- and on-highway
equipment, from excavators and bull dozers to fleet
haulage trucks, utility vehicles and many more. The
more lubrication points a machine has, the greater the
potential advantage from having a centralised system.
For small and medium-sized equipment, devices
such as the SKF ProFlex progressive lubrication system
ensure that a correct amount of grease is delivered to
every point. The system comprises of a piston pump,
with either integrated or on board controls, to deliver
lubricant to progressive feeders, which in turn supply
the exact quantity of grease to each lubrication point.
The pump is mounted to provide best access
and security from any hazardous environment, or
alternatively located in a protected compartment,
again with ease of access.
For larger equipment, where bearings require
a greater volume of lubricant or the distance to
the pump is increased, higher pressures are
needed. In many cases there are also more
lubricant points to handle. In these cases, a
single-line lubrication system such as the
Lincoln Centro-Matic is a better solution.
Lubrication unit for hydraulic
hammers
Hydraulic hammers used in demolition
can also be lubricated, but require
a different lubricant, compared, for
example, to an excavator. Experience
shows that customers use this
type of attachment
independently from
the machine's
main lubrication
systems. The
challenge for
LUBRICATION
SYSTEMS
SKF ProFlex progressive lubrication
system
• Designed for small and medium-sized
machines
• Suitable for oil, semi-fluid grease and
hard grease NLGI grades 000 to 2
• Lubricates up to 150 points with
grease or oil
SKF’s engineers was to develop a pump unit that was
autonomous and space saving, but also required little
maintenance.
The result was the SKF HS04 hydraulically driven
lubricator, which is designed to feed these special
lubricants with high solids content – known as chisel
pastes. The lubricator is mounted directly on to the
tool and connected to the machine’s existing hydraulic
system. Once the tool starts to operate – and the
hydraulic system is activated – the pump lubricates
the connected lubrication points. It is also possible to
regulate the quantity of lubricant delivered. Instead of
a conventional grease reservoir, the SKF HS04 has a
standard-thread cartridge that is easily accessed and
convenient for operators to replace.
two particular vehicles – a small wheel loader and a
45-tonne crawler excavator.
When maintained daily and used according to
instructions, centralised lubrication saved around
28% for the entire fleet – equivalent to 668 kg. These
savings could be boosted by a further 20% because, in
practice, operators tend to press an additional stroke of
grease into the grease nipple rather than use too little.
An important factor here was the use of CANbus technology, which enhances operator control.
Its integration with other on-board equipment and
superior diagnostic facility enhanced Weil’s long-term
operation of machinery.
The benefits of CAN-bus can be felt more widely.
In mining, for instance, it allows each section of
a hydraulic excavator – such
as slewing ring, boom, arm
and bucket – to be lubricated
When maintained daily and used
independently, according to its
according to instructions, centralised
needs and specific operating
lubrication saved around 28% for the
conditions. It also allows separate
entire fleet – equivalent to 668 kg
control and monitoring of each
section, alerting operators to errors
before major problems develop.
The lubricator’s technical highlight is its patented,
Weil used CAN-bus to fit an Atlas wheel loader
sophisticated drive system. Mounting on a hydraulic
with a single pump unit to serve a zoned lubrication
hammer places high demands on a lubrication unit.
system, with each zone controlled by electronic valves.
As well as the expected environmental hazards
Lubrication is fully integrated with the on-board
encountered during operation, the unit must also
computer via electronic control. It can be configured
withstand hard jolts and vibrations.
through the on-board display so operators can view
The lubricator can be used for more than
the precise location of any problems that may occur.
just hydraulic hammers, and is suitable for other
Functional monitoring is performed using proximity
hydraulically driven attachments and tools that do
or cycle switches, and reservoir level detection, which
not have their own power supply, such as demolition
are both designed to detect problems such as a
grapples and screening buckets.
blocked lines, low lubricant levels or failure to perform
the required re-lubrication protocol. This is a major
Construction advantage
advantage on large multipoint, complex machines
One construction company, Elz-based Albert Weil, cut
where downtime is very costly.
its lubricant consumption by nearly one-third after
It remains to be seen whether the construction
SKF helped it to adopt centralised lubrication on a fleet industry can improve its operating margins, but
of 50 off-highway machines, ranging in size from 3 to
centralised lubrication systems could help many
87 tonnes.
operators boost their own efficiency levels through
SKF estimated the saving by accurately modelling
controlled, managed, programmed re-lubrication of
the impact of a centralised lubrication system on
their key assets.
Lincoln Centro-Matic system
• Designed for large equipment
• Can service one machine, different
zones, or even several separate
machines
• Can be designed with air-operated,
electric, manual or hydraulic pumps
SKF hydraulic-driven lubricator HS04
• Designed for hydraulic hammers and
breakers
• Fitted directly on the hammer
• Delivers optimised lubrication during
operation
FOCUS 103 f Summer 2015
19
ALIGNMENT
Accurate alignment
Accurate belt and shaft alignment can prevent a large number of machinery
breakdowns and reduce unplanned downtime that results in a loss of production.
SKF Shaft Alignment Tool TKSA 11
By using mobile devices the instrument intuitively
guides the user through the whole alignment
process. The TKSA 11 is designed to be a very
easy-to-use instrument and is especially suitable
for entry level shaft alignment.
SKF Shaft Alignment Tool TKSA 41
An advanced laser alignment system with large sized detectors and
bright lasers that allow precise measurements in even the most
challenging conditions. The ergonomic display unit with intuitive
touch screen navigation makes alignment fast and easy.
SKF Shaft Alignment Tool TKSA 80
The system has a complete built-in alignment process to increase users’
knowledge of alignment.
The programme takes users from preparation and evaluation all the way
through to correction and finally a report of the result. It offers a unique
database to store the machine set-up data for future use, visual inspections
on oil leakage, oil level, foundation bolt status and wear indications.
SKF Belt Alignment Tools TKBA series
SKF Machinery Shims
TMAS series
Single slot pre-cut shims are
available in five different
dimensions and in ten different
thicknesses.
Made of high quality stainless
steel, allowing reuse, the shims
are easy to fit and remove.
20
Summer 2015 g FOCUS 103
SKF offers a range of three different belt alignment tools to
enable accurate alignment for almost all applications. The tools
are designed to be easy to use without any special training.
The laser position indicates the nature of misalignment allowing
easy and accurate adjustment.
CONDITION
MONITORING
Basic condition monitoring
To help you achieve the maximum service life from your bearings, SKF has developed a
wide range of instruments for analysing the critical environmental conditions which have
an impact on bearing and machine performance.
SKF Stroboscopes TKRS series
Portable, compact and easy-to-use, they enable
the motion of rotating or reciprocating machinery
to appear frozen.
They allow applications such as fan blades,
couplings, gear wheels, machine tool spindles
and belt drives to be inspected while running.
SKF Endoscopes TKES 10 series
They help minimise the need to disassemble
machinery for inspection, saving time and money.
The compact display unit, with 3.5” backlit
screen, allows images and video to be saved and
recalled, or to be downloaded and shared.
SKF Infrared thermometers TKTL series
These devices are extremely user-friendly; simply aim and
pull the trigger and the temperature is shown on the display.
Equipped with a back-lit display and laser sighting,
they are fitted with a bright LED illuminator to allow the
application object to be seen even in poorly lit environments.
SKF Ultrasonic Leak Detector TMSU 1
A high quality, user-friendly instrument enabling the
detection of air leaks by means of ultrasound.
The operator simply guides the instrument to the
loudest point, which helps locate the leak location.
FOCUS 103 f Summer 2015
21
CUSTOMER
CASE STUDY
SKF and Vantage cooperate to improve drilling
ships reliability and extend dry dock intervals
SKF and Vantage Drilling, Inc., a leading international
offshore drilling contractor which operates and
manages a fleet of modern, high specification
drilling rigs have combined resources to improve
the reliability of the Vantage Titanium Explorer and
Platinum Explorer drill ship fleet. These vessels
operate in the deepest waters off the Gulf of Mexico
and other offshore global basins and are specifically
designed for oil and gas exploration.
Based on SKF’s expertise in the
application of condition monitoring
systems and Vantage’s philosophy of
improving the mechanical reliability
of its drilling ships, these ships will
be equipped with a comprehensive
monitoring system for the propulsion
and positioning thrusters.
SKF undertook a careful study of
the thruster mechanical system, including bearings,
lubrication, gearboxes and drive motors to design a
condition monitoring solution, supported by remote
diagnostics services that will provide Vantage with
timely information about the mechanical health
22
Summer 2015 g FOCUS 103
of their thrusters along with advanced warning of
issues that could impact drilling or propulsion system
operation.
Application of this system coupled with the remote
diagnostics services provided by SKF will enable
Vantage to comply with American Bureau of Shipping
(ABS) guidelines for condition-based maintenance
procedures. Through the application of these systems
We have known SKF for
many years as a quality
supplier of critical
mechanical components
and processes, Vantage will now be able to extend
the mandatory overall interval required for physical
inspection of the thrusters until the operational
condition of the asset requires it. This will create a
major cost savings over the life of the asset and
contribute to significant improvements in operational
utilisation of the drill ships.
“Vantage Drilling and their personnel are
recognised in the industry as providing superior
technical support to their clients who comprise several
of the major international and national oil companies.
SKF is proud to be affiliated with them and to help
push the boundaries still further,” said James Henry,
End User Director for SKF’s Gulf of Mexico market.
“We have known SKF for many years as a quality
supplier of critical mechanical components and
found their condition monitoring system and remote
diagnostics services well suited for our strategy of
improving the reliability and availability of our newest
ships. We have been impressed with the professional
support and timely implementation of the SKF
solution,” said Bill Thomson, Vice President Technical
Services, Supply Chain and Projects, Vantage Drilling.
An important factor in maintaining ABS certification
is the monitoring strategy and data analysis process
that SKF will provide from their recently certified SKF
Solution Factory.
www.vantagedrilling.com
Avoid fake bearings
SKF can support with verifying authenticity
Falsely labelled machine components are a big issue for buyers of premium parts today, as
counterfeiters have become very skilled at disguising cheap generic bearings to look like quality
branded products such as SKF. For you as a customer it is easy to get cheated, especially if
you have sourced the products through non-authorized distributors, resulting in the unreliable
performance of your machinery.
If you are uncertain about the authenticity of your bearings, SKF offers a verification service that
is both quick and easy.
The best way to safeguard
authenticity is to buy from an
SKF Authorized Distributor.
Take photographs of the complete packaging showing all markings on the package, as well
as of the product (if possible). E-mail the photographs together with a copy of the invoice to:
[email protected]
Follow us on:
The Power of Knowledge Engineering
® SKF is a registered trademark of the SKF Group © SKF Group 2015
LITERATURE
Literature from SKF
Here you will find some of the latest brochures and catalogues available from SKF. To receive your own personal copies simply complete
the relevant section of the reader reply service on the inside back cover and return to SKF.
Hydraulic seals Spherical plain bearings and rod ends
Training courses 2015
Ref no: SE/P1 12393 EN
Ref no: BU/P1 06116/1 EN Ref. no.: SR/T9 14778 EN
This 356-page catalogue
contains the standard
assortment of SKF
hydraulic seals and guides
typically used in hydraulic
cylinders. This includes
piston, rod and buffer, and
wiper seals, guide rings
and strips, O-rings and
back-up rings.
This 220-page catalogue
profiles the range of
bearings suitable for
oscillating movements
that can accomodate
misalignment. Includes
design and application
recommendations, types,
product tables and also
selection charts.
This 44-page catalogue
profiles e-learning.
classroom training, handson workshops, onsite
mentoring, instrument and
software-specific training,
as well as a complete
training needs analysis.
Rolling bearings and seals in motors
Y-bearings and Y-bearing units
Transmission chains
Ref. no: 54/P7 13459 EN
Ref no: BU/P1 13728 EN
Ref no: PT/P1 13747 EN
A 266-page catalogue
detailing the range of
conventional SKF ball
bearing units. These
units can accommodate
moderate initial misalignment, but normally do not
permit axial displacement.
They are supplied as
ready-to-mount and
ready-to-use units.
A 148-page handbook
specifically designed for
the industrial designer and
end-user of electric motors.
Recommendations include
advice on tolerances and
fits, lubrication, bearing
mounting, dismounting
and motor testing, bearing
damage and corrective
actions.
This 100-page
catalogue contains
standards and compliance
details, selection
procedures and design
guidelines. 20 different
chain ranges are profiled,
together with lubrication
systems and maintenance
information.
Machined seals
High temperature bearings
Roller screws
Ref no: SE/P2 15235 EN
Ref no: BU/P2 14961 EN
Ref no: MT/P1 14489 EN
This 60-page catalogue
outlines the machined
seal on-demand
alternative to moulded
seals. Sealing materials
are profiled together
with product range
specifications and housing
information.
dd For further literature, please visit: www.skf.co.uk/literature
This 64-page catalogue
highlights the range of
bearings suitable for
operating temperatures
up to 350 °C. The full
assortment and product
tables are also provided.
Typical applications
include metals, food and
beverage, and automotive
manufacturing.
This 140-page catalogue
provides a selection guide,
details of planetary, Ultra
Power, inverted and
recirculating roller screws.
Typical applications
include plastic moulding,
factory automation, oil
and gas, aerospace,
railways and metals.
FOCUS 103 f Summer 2015
23
READER REPLY
On li n e re ade r
rep ly se r v ic e
For immediate access to publications, simply
go to our new online FOCUS reply website,
where you can enter our competition and
select any literature you would like to receive.
We will automatically send you an email with
the links to download, delivering a quicker
response time, and helping SKF reduce the
environmental impact of printed publications.
onic
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onse
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cusreply
k/fo
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Or if you prefer, fill in your contact details below, and then simply tear off and return to SKF for printed publications.
Products, systems and solution brochures
NN Bearing maintenance and repair training courses
NN Upgraded SKF spherical roller bearings
NN Condition monitoring training courses
NN CARB toroidal roller bearings
NN Asset management training courses
NN Industrial pump solutions
NN SKF Taconite Seals
NN Railway industry solutions
NN HYDROCAM bolt tensioners
NN Off-highway automatic lubrication systems
NN SKF @ptitude Connect
NN Belt and shaft alignment tools
NN Industrial bearing remanufacturing
NN Basic condition monitoring instruments
NN Food and beverage industry solutions
NN If other please specify:
Catalogue request service
NN Hydraulic seals
For further information and/or to enter the competition please enter your
details below (BLOCK CAPITALS PLEASE):
NN Spherical plain bearings and rod ends
Mr/Mrs/Miss/Ms First name:
NN Training courses 2015
Surname:
NN Rolling bearings and seals in motors
NN Y-bearings and Y-bearing units
NN Transmission chains
NN Machined seals
Job title:
Company name:
Address:
NN High temperature bearings
NN Roller screws
NN If other please specify:
Town:
Postcode:
Tel no:
E-mail:
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NN Please cancel my copy of FOCUS and remove my details from the database
FOCUS 103 f Summer 2015
24
After reading the magazine
simply tick the three correct
answers opposite for your
chance to win one of the
following prizes. 1st prize:
Ice Cream Maker and Book,
2nd prize: x 5 SKF leather
passport holders, 3rd prize:
x 10 SKF leather CD cases.
To enter, please go online or
send this page together with
your contact details entered
overleaf by 31 July 2015 to
Tom Jones.
What colour are the FDA-approved seals
included in SKF Food Line deep groove
ball bearings?
Blue
Red
Green
What percentage of the cost of a new
bearing can potentially be saved by
remanufacturing?
60%
70%
80%
On li n e re ade r
rep ly se r v ic e
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on LinkedIn?
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www.s
Tom Jones
Industrial Market
SKF (U.K.) Limited
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Luton LU3 3BR
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