UP-TIME 15.1: Focus on Cement & Aggregate

Focus on Cement & Aggregate

Kaman’s Innovative Solutions Quarterly Volume 15, Issue 1

Bearings that visually inform installer when correct tightness is achieved.

Page 3

MagnaGear XTR reducers are ideal for rugged environments.

Page 4

Multi-purpose lithium complex grease increases wear protection.

Page 6

Link belts reduce drive vibration, increase belt and bearing life.

3

Bearing isolators prevent dust and water from damaging bearings.

Page 17

Cement and aggregate operations are tough on chain, so make sure you know your chain is safe.

Page 7

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Table of Contents

Rexnord Industries, LLC .......................3

Baldor – A Member of the ABB Group....4

Gates Corporation ...............................5

LUBRIPLATE Lubricants .......................6

Timken Drives, LLC .............................7

Timken ...............................................8

ITW Polymers Adhesives ......................9

Schaeffler Group USA, Inc. .................10

SKF USA, Inc. ....................................11

Nidec Motor Corp. .............................12

Fenner Drives ...................................13

NSK .................................................14

SPX Hydraulic Technologies ...............15

Altra Industrial Motion ........................16

Garlock ............................................17

LEESON Electric, A Regal Brand ..........18

NTN Bearing Corporation of America ...19

At Kaman, our goal is to keep your plant running smoothly and efficiently. Harsh environments, like those in the cement and aggregate industries, require products that can accomplish their tasks in remote areas and extreme conditions.

This issue of UP-TIME features some of the newest equipment, technologies, products and services for aggregate and other heavy-duty applications. From hostile-duty motors, wearing compounds, aggregate-duty roller bearings and inflatable jacks to chain wear gauges, Kaman’s suppliers are producing safe, productive and reliable solutions that can stand up to the most intense conditions.

Your account representative can not only recommend the best products and services to suit your applications but can also work with you to apply the solutions to help you drive bottom-line results for your operation.

Contact your Kaman or Kaman division representative today to help you find the right solutions and products for your facility.

Regards,

Steve Smidler, President

A letter from the president

UP-TIME is published quarterly by

1-800-526-2626 • www.kamandirect.com • www.kamanace.com 3

The problem stemmed from the set screw design on the existing pillow block bearings. An improper fit of the bearing on the shaft caused the shaft to move from the fan vibration. This movement led to the set screws damaging the shaft, which became a bigger and more expensive problem. To prevent this from happening in such a critical application, plant personnel had been replacing the existing pillow block bearings almost every two months. These preemptive replacements were costing the company thousands of dollars per year.

Rexnord recommended replacing the existing bearings with SHURLOK adapter mount roller bearings. With its exclusive Spyglass™ Optical Strain Sensor (OSS) technology, the SHURLOK bearing visually informs the installer when the correct tightness is achieved. This not only makes installation easier and faster, but minimizes vibration by achieving a better fit as the shaft is kept precisely in the center of the bearing. With the bearing installed correctly, damage to the bearing and shafting is eliminated.

Although the initial cost of the SHURLOK bearings was slightly higher, the similar installation costs and the longer life expectancy of SHURLOK bearings convinced the cement supplier to install them. After 21 months of service — already three

times longer than the previous bearings — the SHURLOK bearings were removed simply because they had lasted so long that the customer had become anxious. Upon removal, the customer found no damage to the shaft. Convinced of their superior performance, the customer installed new SHURLOK bearings, which continue to perform. By reducing the number of replacement installations, the cement supplier achieved 65% in savings per year.

Rexnord increases your operation’s efficiency and profitability by reducing installation errors, maintenance costs and downtime.

SHURLOK bearings keep vibration and costs down for cement supplier.A leading cement and aggregate supplier was experiencing premature failure of the bearings

used on the shaft of a fan used to cool red-hot clinker conveyed in its plant. With such intense

temperatures, it was imperative that the fan continued to run at all times. Otherwise, the plant

ran the risk of the clinker melting its conveyors and the plant shutting down.

4

A company that designs and builds conveyors was challenged with building a nearly 4,000-foot-long conveyor to transport coal. The only way to move the coal was by river barge, which involved thousands of feet of conveyors down to the river for load-out plus a system to off-load the coal from the dock to the prep plant. The conveyor needed to be high enough off the ground to evade river flooding, and the only way to reach key equipment during a flood would be to walk a narrow catwalk 20 feet off the ground. For this project, the customer needed a reliable gearbox that would not require a lot of attention and be small enough to fit in a confined space, but powerful enough to do the job.

The solution was the Baldor•Dodge MagnaGear XTR. MagnaGear XTR reducer’s simple power-dense design offers torque ratings from 100,000 to 3,500,000 in-lb, assuring increased reliability in a more compact, economical heavy-duty package. With this torque range, MagnaGear XTR reducers accommodate horsepowers of over 7,200, making the reducer well-suited for this application. MagnaGear XTR reducers are ideal for rugged environments, and with their universal housing they can be configured and mounted to suit your application.

To learn more, contact your Kaman representative today.

MagnaGear XTR: Reliable. Easy to maintain. Maximum value.When you need a reducer with maximum reliability, ease of maintenance and superior

performance in rugged environments, choose

the Baldor•Dodge MagnaGear XTR®.

The MagnaGear XTR was chosen because of its reliable, compact, power-dense design. Each reducer is connected to a Baldor-Reliance® Mining Industry motor with a Baldor•Dodge Grid-Lign™ coupling (located behind the yellow safety cover).


At one cement production plant, V-belt slippage was reducing efficiency and airflow for cooling on a 200 horsepower, 1750 RPM machine. Changing to a Gates Poly Chain® GT® Carbon™ belt drive, which won’t stretch or slip, saved $117,000 in just over one year. In addition to the dollar savings, the change also resulted in a 63% width reduction and a 31% weight reduction, all while increasing output from 283 horsepower to 496 horsepower.

To further increase productivity, reduce maintenance and decrease downtime, the plant also invested in the Gates Belt Drive Preventive Maintenance program, which is designed to help troubleshoot faulty conditions. This saved additional money and time while teaching proper inspection and installation procedures, leading to longer belt life.

The numbers don’t lie – at 63% narrower, 31% lighter and 175% more powerful, the Gates Poly Chain drive improves performance.

H O R S E P O WE R

1 2 3 4 5 6 77

Head to Head: Poly Chain GT Carbon vs. Low-Cost V-Belts.Don’t underestimate the power that belt drives have over the entire operation. From rock

crushers to shaker screens, V-belts keep virtually every critical piece of equipment running,

yet they are less efficient and require a larger drive package than synchronous drives.

Instead, consider using high-performance, high-efficiency synchronous belts to reduce

the risk of downtime.

6

Applications like mining, quarry, aggregate and construction can be harsh environments where special, heavy-duty greases are a must. Lubriplate’s lithium complex grease LTR-2 is one solution. This heavy-duty, tacky, extreme-pressure red grease is highly water-resistant and withstands higher temperatures than traditional lithium greases.

Lubriplate SYN-1602 is a fully synthetic, multi-purpose, lithium complex grease. Formulated with 100% polyalphaolefin (PAO) base fluids, SYN-1602 is a high-performance grease offering superior oxidation stability, increased wear protection and a wide temperature range. SYN-1602 is fortified to prevent rust and

corrosion, and can reduce grease-bleed in an application.

Lubriplate LTR-2 and SYN-1602 are available in a variety of different package sizes.

To learn more about Lubriplate Lubricants, contact your local Kaman representative.

Lubriplate’s LTR-2 and SYN-1602: Premium lithium complex greases.For over 140 years, Lubriplate has been manufacturing only the highest quality lubricants.

Whether you are looking for heavy-duty, tacky, red grease or a general multi-purpose

synthetic grease, Lubriplate Lubricants offers premium lithium complex greases for all

lubrication requirements in tough environments like the cement and aggregate industries.

Heavy-duty, tacky, extreme pressure red grease.

Fully synthetic, multi-purpose, lithium complex grease.


It is faster and easier than ever to assess when to replace your chain, even in tough cement and aggregate operations.

Avoid the hassle of measuring the chain or misinterpreting plastic wear indicators. Instead, insert the Drives EZ Wear Gauge into a link. If the EZ Wear Gauge slides past the marker for that chain size, it is time to replace the chain.

The general rule is to replace chain when it has stretched 3% or more. When chain is too elongated, it cannot move properly and may create shock loads that could severely damage your sprockets, possibly causing a sudden stop.

To increase efficiency and avoid high costs of unexpected downtime, replace your chain promptly. Overall, you could save up to $20,000 a year in maintenance, new sprockets and other costs.

To learn more, contact your local Kaman representative.

Cement and aggregate operations are tough on chain, so make sure you know your chain is safe.

Detect chain wear with Timken Drives

EZ Wear Gauge.It takes just a moment to know whether it is time to replace your chain. Waiting too long

can damage sprockets or even stop production. Simply slide the Timken Drives™ EZ Wear

Gauge® inside a link to see if it has elongated. If the tool slips through too far, it is time to

replace your chain. Use this fast, efficient tool and avoid unexpected downtime due to a

worn-out chain.

Drives EZ Wear Gauge easily inserts into a link to measure stretch wear.

8

Timken Type E housed units improve grease retention and significantly reduce ingress of contaminants, water, mud and slurry in harsh environments like those found in the cement and aggregate industries. The high-performance seals have a double-lip contact design that optimizes lip contact and minimizes torque.

More reasons to trust the Timken Type E housed unit include:

• Its rotating collar acts as an initial flinger

• Electro-deposition coating (E-coat) has better corrosion resistance than black oxide or powder

• Increased locking power reduces set screw back-out even in the most severe applications

Choose Timken Type E housed units for enhanced performance and lower total cost of ownership.Contact your local Kaman representative to learn more.

Double-lip contact seals offer two layers of protection against contaminant ingress.

Timken makes Type E bearings with super-clean, high-alloy bearing steel.

Lower total cost of ownership with the best-performing housed unit.If buying a cheaper housed unit means faster breakdowns, more frequent replacement and

lost uptime, are you really saving money at all? Timken® Type E housed units help strengthen

the performance of your equipment with industry-leading premium tapered roller bearings.

Timken bearings’ 12% higher load capacity results in a 47% increase in bearing life.


DFense Blok family of products.

Devcon DFense Blok products are targeted for use in facilities processing abrasive substances, whether dry or slurry. Devcon DFense Blok outperforms traditional wearing compounds 3 to 1. DFense Blok is also available in a fast-cure formula (DFense Blok FC #11350) that allows you to be up and running in two hours.

At a concrete processing plant, a clinker chute had to be shut down every three months to allow the entire impact zone to be replaced with abrasion-resistant (AR) steel plates. This process halted production for two full days and took two people to accomplish.

Devcon DFense Blok (#11330) Wearing Compound was applied to the chute to replace the AR plates. After 11 months, DFense Blok is still protecting the

chute and the customer has not needed new AR plates. This eliminated downtime, reduced costs by 66% and significantly increased productivity.

Contact your Kaman sales representative to learn more about the Devcon DFense Blok line and how it can protect your equipment.

Revolutionizing wear and abrasion protection in the mining industry.With the expertise that comes from 60 years of MRO experience, Devcon® developed the

DFense BlokTM family of products. This was accomplished by utilizing a revolutionary

polymer that offered exceptional adhesion characteristics and superior wear, sliding

abrasion, side-impact and drop-impact resistance.

DFense Blok being applied to chute.

10

Thanks to Schaeffler’s SuperTac II Taconite seals, this crucial decision is now a no-brainer. Developed as a drop-in solution to fit FAG’s SAF-series housings as well as competitors’ designs, SuperTac II seals combine a grease-packed radial labyrinth with a grease-purged axial labyrinth to create a practically impermeable web of protection against contamination. As a result, your bearings last longer.

Featuring a non-contact seal design that eliminates shaft wear, exceptional high-speed capabilities as well as the ability to accept greater misalignments than lip seals, FAG SuperTac II Taconite seals from Schaeffler will keep your machines’ downtime to a minimum.

Remember: less contamination equals longer-lasting bearings, less machine downtime and bigger profits. With FAG SuperTac II seals from Schaeffler, less is indeed more.

SuperTac II seals provide virtually impenetrable protection for your bearings.In the cement and aggregate industries, bearings are constantly under attack from

contaminants such as dirt, abrasive materials, caustic chemicals, extreme heat and

heavy shock loads. Consequently, selecting the right seal arrangement to protect against

contamination is often the most important consideration when choosing a bearing and

housing assembly.

FAG SuperTac II Taconite Seal.

Virtually impenetrable protection — even here.


SKF solved this mine’s challenge using ConCentra units. The ConCentra roller bearing units are robust, ready-to-mount bearing units adjusted, lubricated and sealed at the factory for maximum service life. The units make installation and dismounting fast, easy and error-free. ConCentra roller bearing units include the SKF Explorer spherical roller bearing with the patented SKF stepped sleeve shaft locking method and highly effective bearing sealing.

The mine installed these units without any modification to the frame because they are interchangeable with the SAF 500 series installed there previously. This installation resulted in a longer service life of the bearing and virtually eliminated contamination issues. Each unit was mounted in under eight minutes, which also increased safety by reducing the hours of exposure.

Increase mine safety and uptime with SKF ConCentra roller bearing units.The conveyor pulleys in a North American mine were unsafe, confined and in a contaminated

environment. A longer-lasting, easy-to-mount bearing unit that could withstand these harsh

conditions was needed to increase safety and reduce costly downtime.

12

Electric motors are an integral part of mining and mineral processing, especially high-altitude mining where rigorous atmospheric challenges add to the usual dusty, dirty environments of a mine. U.S. MOTORS brand hostile-duty motors are used extensively in all mining applications. General-purpose, NEMA Premium® hostile-

duty totally enclosed fan-cooled motors reduce operating costs and are suited for rugged applications where the motor runs continuously and energy efficiency is a must. Double-shielded bearings, heavy-gauge steel fan covers and conduit boxes provide protection from the harshest operating conditions.

U.S. MOTORS brand hostile-duty motors are available in TEFC ratings from 1 – 200 HP, 50/60

Hz capable. Cast iron construction, corrosion-resistant mill and chemical-duty paint,

heavy-gauge steel fan covers and conduit boxes are some of the

features of this heavy- duty workhorse.

For more information on U.S. MOTORS brand hostile-duty motors, contact your local Kaman representative.

Nidec Motor Corporation, 2014; All Rights Reserved. U.S. MOTORS® is a registered

trademark of Nidec Motor Corporation.

Electric motor and system efficiency drives mining industry.The mining and aggregate industries present unique challenges for electric motors. Dirt,

dust, moisture, extreme heat and biting cold can wreak havoc on motor life and efficiency.

When you need a motor that will provide peak performance in extreme conditions, U.S.

MOTORS® brand hostile-duty motors are built tough for the most punishing environments.


Fenner Drives conducted an 18 month study on an Ash Crusher Machine in a power plant to determine the specific cost savings realized by using SuperTLink wedge belts instead of rubber V-belts. The company saw an 81% reduction in belt costs due to increased belt life and improved bearing life due to reduced drive vibration.

Problem

• Rubber V-belts were failing twice a month, causing expensive machine downtime

• Belt installation required three workers two hours each due to welding and dismantling drive components

• Bearings had to be changed at least once per month due to failure from drive vibration

Solution

• SuperTLink wedge belts lasted 36 times longer than rubber V-belts in the harsh conditions of this application

• SuperTLink belts are easily made to the required length in seconds. No need to move or dismantle any drive component

• Link belt design drastically decreases drive vibration which results in increased bearing life

Fenner Drives link belting offers significant cost reduction in harsh applications.Fenner Drives link belting is engineered specifically to replace rubber V-belts and offer a better

solution for rubber V-belt drives. SuperTLink® is the only link belt available in wedge profiles

and runs on standard 3V and 5V pulley grooves. Link belts can be made to any length by hand in

seconds, eliminating the need to stock different-length V-belts. Combined with PowerTwist Plus®,

Fenner Drives truly offers a one-stop shop solution for your storeroom needs.

14

Decades of NSK R&D experience have delivered products like NSK’s Tough Steel material. Tough Steel provides superior durability and reliability under harsh, contaminated conditions. This technology has been used extensively in cement plants, from slurry pumps to spherical roller conveyor bearings.

If you have contaminated bearing applications that are causing downtime, NSK Tough Steel may be the solution. Contact your local Kaman representative to find out how NSK Tough Steel can help you.

Previous Bearing Life: 2-3 Months NSK TF Steel Bearing Life: 1 Year Cost Savings: $60,000

NSK Angular Contact Roller Bearings.

Slurry Pump Application.

NSK Tough Steel (TF) extends bearing life and saves $60,000.A cement plant was experiencing premature bearing failures due to contamination in their

slurry pumps. Bearings were lasting only two to three months causing frequent downtime

and high maintenance costs. NSK was contacted to evaluate the problem using its Asset

Improvement Program (AIP). NSK Tough Steel bearings were installed and extended bearing

life to more than one year, saving the customer $60,000.


Foundation repair companies are frequently faced with the need to break concrete structures by inserting inflatable jacks into a small area of the concrete form. With collapsed widths of less than one inch, Power Team inflatable jacks can be initially inserted into small areas requiring substantial force and expansion.

Power Team IJ Series inflatable jacks offer the following benefits:

• Repeatable use design

• Non-conducting, durable, high-quality rubber material with multi-layer aramid fiber reinforcement

• Top and bottom surfaces feature a skid resistant, interlocking pattern to assist in alignment of two jacks used together

• Heavy-duty handles are provided on the two largest jacks to aid in positioning and/or lifting

• Field replaceable coupler

• Works with pneumatic pressure up to 116 psi

• Optional hand-held controller for single jack operation offers relief-valve protection, pressure gauge and extend-and-retract control

• Inflation systems offer color-coded (red and yellow) hoses for use with more than one inflatable jack

• Full complement of adjacent Power Team accessory products is available inclusive of shut-off hose, pressure-reducing valve, quick couplers and connectors

For more information on Power Team IJ Series inflatable jacks, contact your local Kaman representative.

Power Team inflatable jacks serve many applications.Power Team inflatable jacks offer a reliable and durable solution for many cement and

aggregate applications. Typical applications include lifting, spreading and holding as well

as moving and breaking cement walls or forms. Power Team inflatable jacks offer a broad

range of sizes from small jobs to large jobs with rated lifting capacity up to 75 tons of force.

16

BK and BF Series gear motors.

A major international asphalt mixing plant OEM required rugged-duty geared motors for use on various applications within their plants.

Bauer application engineers provided technical advice during many visits with customer engineering teams. Ultimately, Bauer gear motors were selected over competitive units due to Bauer’s reputation for high-quality, well-engineered products, responsive delivery times and extensive global sales and service support.

To meet the customer’s various application torque and speed change requirements, as well as space limitations, Bauer BK Series gear motors, size 40 to 90, were supplied for use on the various asphalt conveyors and an elevator. Each dryer required four BF Series gear motors.

Product Features:

• BK and BF Series geared motors feature a hardened wear sleeve and spray ring

• Complies with NA and international standards, including NEMA, IEC, CSA, and CE

• Torque rating to 18500 Nm

• Low noise gearing

• IP65 Enclosure (Standard), IP66 (Optional)

• Completely enclosed, sealed against dust and moisture

• Corrosion protection CORO1, CORO2 and CORO3

• Connection standard with CAGE CLAMP®

Bauer gear motors meet the demands of harsh environment in asphalt plant.Bauer ® Gear Motor has been a provider of solutions within geared motors for more than

three quarters of a century. Bauer provides products of the highest quality with a focus on

flexible solutions, reliability and customer understanding.


The abrasiveness of dust and water was accelerating the wear of a lip seal used in a cement plant. This led to premature bearing failure and equipment was constantly down for maintenance. In this instance, a Garlock MICRO-TEC II bearing isolator was installed. The MICRO-TEC II traps contaminants before they can enter the bearing chamber. The labyrinth design prevents larger particles from entering the chamber and provides protection from liquid up to 26 gpm spray. Contamination from smaller particles is prevented when the innovative microcellular foam traps the dust.

The unique design does not require any type of air or grease purge system. This makes

MICRO-TEC II the ultimate seal for dusty and wet environments in the aggregate industry as well as other harsh environments, providing long-lasting, maintenance-free solutions.

For more information, contact your Kaman representative.

Bearing isolators prevent dust and water from damaging bearings.Dust and water are the main enemies in cement plants and other aggregate industries.

Preventing these contaminants from entering mechanical equipment ensures that the plant

is up and running making profits. Garlock® KLOZURE MICRO-TEC® II bearing isolator offers

an innovative solution to this long standing problem.

Garlock KLOZURE MICRO-TEC II Bearing isolator with microcellular filter.

Troubled equipment exposed to dust and rain.

18

With more than 40 years of experience, Leeson products from crushers to conveyors offer the reliability you would expect. You will find LEESON motors across the cement, aggregate and other industries that demand protection for long motor life and dependability. LEESON Wattsaver Plus severe duty motors are designed specifically for use in severe-duty environments, feature an inverter rated insulation system, IP55 and a three year standard warranty. Additionally, the

traditional Lincoln severe duty line of motors can be custom engineered up to 400 HP

to meet your design requirements. Speak with your local Kaman

representative about the products that LEESON can provide or design to help your operation run efficiently and reliably.

Lincoln crusher duty motors are ideally suited for reduction equipment including rock crushers and pulverizers.

LEESON offers a wide range of electric motor solutions.LEESON has designed a full line of motors specifically to maximize the uptime of your

cement and aggregate applications. LEESON understand the challenges you face daily to

keep operations running efficiently in dirty and dusty environments.


One of the toughest industrial equipment applications for bearings is vibrating or shaker screens. Heavy-loading, vibration and contamination are all working to cause a failure. The key is a spherical roller bearing specifically designed for use in vibrating equipment.

NTN shaker-screen spherical roller bearings have a robust cage that is resistant to vibration-induced cracking and longer rollers to increase capacity; thus extending bearings also have special tolerances on the bore, O.D. and internal clearance.

These tighter tolerances ensure uniform housing and shaft fits and uniform clearance under loading and mounting. Additionally, NTN’s line of Ultra-Class™ mounted units and heavy-duty spherical roller bearing

mounted units is designed to offer extreme reliability in conveyor applications.

To learn more about NTN bearings for heavy-duty applications, contact your local Kaman representative.

From demanding requirements of shaker screens and crushers to the harsh environments of conveyors, NTN has a premium bearing to exceed all your requirements.

Rock-solid bearings for the aggregate and concrete industries.As a top manufacturer of premium bearings, NTN has an extensive line of products

designed for the aggregate industry. From heavy-loading to high misalignment, every

potential failure mode is present. As a key supplier to top mining, construction and

agricultural equipment OEMs, NTN understands these demands and has developed

bearings for long lasting performance.

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UP-TIME 15.1: Focus on Cement & Aggregate

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Transcript of UP-TIME 15.1: Focus on Cement & Aggregate