solutions Installing Baldor's Dodge ULTRA KLEEN

solutions Installing Baldor's Dodge ULTRA KLEEN
solutions
PRSRT STD
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Little Rock, AR
Permit No. 175
A Publication Featuring Baldor Electric Company Products
magazine
Number 8
Installing Bal
dor's
Dodge ULTR
A KLEEN
Ball Bearings
®
Moves Machine
from Leas
t Reliable to
Most Reliable at
ConAgra Foods® the
Lamb Weston
Potato Product
s
Plant
P.O. Box 2400, Fort Smith, AR 72902-2400, USA, Ph: (1) 479.646.4711, Fax: (1) 479.648.5792, International Fax: (1) 479.648.5895
baldor.com
©2012 Baldor Electric Company
Solutions0112
All Rights Reserved. Printed in USA.
1/12-AG-13M
Pl u s
Choosing the Right Partner
Baldor Products Featured
Helps Paragon Products Create More Success
on Flexco State-of-the-Art Test Rig
Cover: PG 16
Contents
Solutions Magazine
For decades, ABB variable speed drives and Baldor
motors have set the standard for quality, reliability and
energy savings. Now, industrial customers in the U.S.
can buy these products and receive expert support
from a single source. Call 479-646-4711 to locate the
district office nearest you.
Two trusted names. One local source for sales and
support. Only from ABB and Baldor.
baldor.com
• Local Sales & Support
• Energy Efficiency
• Industrial Motors & Drives
Number 8
Featuring Baldor•Reliance® & Baldor•Dodge® Products
baldor.com
2
Briefings
6
Choosing the Right Partner
Helps Paragon Products Create More Success
12
Baldor Products Improve Reliability
16
Installing Baldor's Dodge® ULTRA KLEEN Ball Bearings
22
Basin Electric Power Plant Selects
Baldor Equipment
of Critical Fuel Enhancement System at Great River Energy's Coal Creek Station
Moves Machine from Least Reliable to Most Reliable at the ConAgra Foods®
Lamb Weston Potato Products Plant
to Prevent Unplanned Downtime
28
Baldor Products Featured
on Flexco State-of-the-Art Test Rig
• Unmatched Customer Service
Baldor’s mission is to be the best (as determined by our
customers) marketers, designers and manufacturers
of industrial electric motors, mechanical power
transmission products, drives and generators.
©2011 Baldor Electric Company
Solutions Magazine is published by the Marketing Communications Department of Baldor Electric Company.
For more information, please email [email protected]
baldor.com
Cover: PG 16
Contents
Solutions Magazine
For decades, ABB variable speed drives and Baldor
motors have set the standard for quality, reliability and
energy savings. Now, industrial customers in the U.S.
can buy these products and receive expert support
from a single source. Call 479-646-4711 to locate the
district office nearest you.
Two trusted names. One local source for sales and
support. Only from ABB and Baldor.
baldor.com
• Local Sales & Support
• Energy Efficiency
• Industrial Motors & Drives
Number 8
Featuring Baldor•Reliance® & Baldor•Dodge® Products
baldor.com
2
Briefings
6
Choosing the Right Partner
Helps Paragon Products Create More Success
12
Baldor Products Improve Reliability
16
Installing Baldor's Dodge® ULTRA KLEEN Ball Bearings
22
Basin Electric Power Plant Selects
Baldor Equipment
of Critical Fuel Enhancement System at Great River Energy's Coal Creek Station
Moves Machine from Least Reliable to Most Reliable at the ConAgra Foods®
Lamb Weston Potato Products Plant
to Prevent Unplanned Downtime
28
Baldor Products Featured
on Flexco State-of-the-Art Test Rig
• Unmatched Customer Service
Baldor’s mission is to be the best (as determined by our
customers) marketers, designers and manufacturers
of industrial electric motors, mechanical power
transmission products, drives and generators.
©2011 Baldor Electric Company
Solutions Magazine is published by the Marketing Communications Department of Baldor Electric Company.
For more information, please email [email protected]
baldor.com
B r ie f in g s
B r ie f in g s
tHe New balDor•DoDge® tyPe eXl offers eNHaNceD features
for iNcreaseD reliability
The new Type EXL tapered roller
bearing incorporates a cartridge-style
inner unit into a two-piece
housing. This new design
provides both misalignment
and expansion capability,
while maintaining industry
standard Type E mounting
dimensions.
The split-housing design
allows the inner unit to
swivel freely in the housing,
allowing up to +/- 4 degrees
of static misalignment. Standard
Type E products offer virtually no
misalignment and are not available in an
expansion design. Mounting dimensions
are equivalent to any standard Dodge
or competitor’s Type E dimensioned
product.
seal for increased protection in harsh
environments. The housing is made
from ductile iron for added strength
versus cast iron products.
Baldor is pleased to offer new genset
models and a new towable generator
that meet emission standards set by the
Environmental Protection Agency.
The Type EXL utilizes the new Dodge
tapered roller bearings manufactured
in Marion, North Carolina. The
new bearing design offers a 13% to
14% increase in load ratings over the
previous tapered bearing design. The
new design is available in both two- and
four-bolt pillow blocks and utilizes the
same inner unit for both expansion and
non-expansion housings. Bore sizes
range from 1-3/16 to 5 inches.
The EPA rules affect stationary and
mobile diesel generator sets used for
back-up emergency power, peaking
power and other on-site power
generation applications in the U.S. The
rules, part of the mandated Clean Air
rules, are designed to reduce nitrogen
oxide emissions and fine particle
pollution.
The Type EXL will increase reliability
and decrease downtime by offering
better sealing, misalignment capability
and load ratings versus the competition.
The totally sealed inner unit
incorporates the Dodge XTS triple-lip
balDor large ac motors iN stocK
This is a reminder that Baldor stocks
a wide variety of medium-voltage
2-4-6 pole TEFC severe duty motors
from 200 through 1000 HP and WPII
designs through 1250 HP.
Additionally, Baldor’s Quick-Ship
program for Athens 440- and 5000frame TEFC motors allows the
selection of custom 200- to 800-HP
motors built for 460, 575 or 2300/4000
volt operation with a simple selection of
options. These motors are engineered
and built in the Athens plant with a
three- to four-week lead time.
Only anti-friction (ball and roller
bearing) general purpose motors will
be in the Athens Quick-Ship program.
More complicated and sleeve bearing
motors will continue to be built in the
Kings Mountain motor plant.
2 | Solutions Magazine | Number 8
With the addition of our Quick-Ship
program, customers will have a choice
of immediate shipment of a fullfeatured medium-voltage motor from
stock or a three- to four-week lead time
on one made specifically to their needs.
balDor offers New geNerators DesigNeD to meet u.s. eNviroNmeNtal
ProtectioN ageNcy staNDarDs
Program details are outlined on flier
FL435 found on baldor.com.
Baldor is now the North American
sales channel for large ABB induction
and synchronous motors through
100,000 HP. Contact your local
district office for more details.
Baldor’s new TS225 towable generator
will add another model to the great
TS product line. The TS225 will offer
a rating of 225kVA/180kW while
meeting an EPA Tier 3 Emission
level. For EPA mobile applications,
the TS225 will carry a Flex Emissions
Label. Like all other TS models, the
TS225 is available in towable or skidmounted designs.
Two new Baldor industrial diesel liquid
cooled (IDLC) generators meet current
EPA emission standards. Utilizing
Mitsubishi engines, the IDLC10
meets EPA Tier 4 standards, while the
IDLC20 meets Interim Tier 4 Emission
requirements. Each model is available
with an open or basic sound-attenuated
enclosure to meet individual customer
needs.
rPm ac PermaNeNt magNet ProDuct liNe eXPaNDs
Baldor has expanded its RPM AC range
of permanent magnet (PM) product
offering up to 1200 HP.
frame sizes 180, 210, 250, 280 and
440 with permanent magnet rotor
construction.
The Baldor•Reliance RPM AC PM
motor product line performs like a high
horsepower servo motor with low rotor
inertia and
high power
density,
and is now
available in
NEMA
The addition of the finned laminated
440 frame (FL440) size extends the
product line’s horsepower range to
800 HP enclosed blower cooled and
1200 HP using open force ventilated
construction.
®
PM rotor technology
offers improved
efficiency that
can translate
into increased
power density
and synchronous
(non-slip) speed
performance. This
is achieved by virtue
of its highly power-dense, low-loss rotor
design where the permanent magnets
are actually embedded within the rotor
laminations.
Typical applications for RPM AC PM
motors include automotive testing
stands, extruders, winder/unwinders,
metal forming and bending machinery,
machine tool/spindle applications
and replacement of square frame DC
motors.
The RPM AC PM product line is
currently available in both NEMA and
IEC (112, 132, 160, 180 and 280) frame
sizes. These motors are all designed
to provide continuous constant torque
performance from zero speed up to base
speed for use with closed-loop PM AC
drives.
Number 8 | Solutions Magazine | 3
B r ie f in g s
B r ie f in g s
tHe New balDor•DoDge® tyPe eXl offers eNHaNceD features
for iNcreaseD reliability
The new Type EXL tapered roller
bearing incorporates a cartridge-style
inner unit into a two-piece
housing. This new design
provides both misalignment
and expansion capability,
while maintaining industry
standard Type E mounting
dimensions.
The split-housing design
allows the inner unit to
swivel freely in the housing,
allowing up to +/- 4 degrees
of static misalignment. Standard
Type E products offer virtually no
misalignment and are not available in an
expansion design. Mounting dimensions
are equivalent to any standard Dodge
or competitor’s Type E dimensioned
product.
seal for increased protection in harsh
environments. The housing is made
from ductile iron for added strength
versus cast iron products.
Baldor is pleased to offer new genset
models and a new towable generator
that meet emission standards set by the
Environmental Protection Agency.
The Type EXL utilizes the new Dodge
tapered roller bearings manufactured
in Marion, North Carolina. The
new bearing design offers a 13% to
14% increase in load ratings over the
previous tapered bearing design. The
new design is available in both two- and
four-bolt pillow blocks and utilizes the
same inner unit for both expansion and
non-expansion housings. Bore sizes
range from 1-3/16 to 5 inches.
The EPA rules affect stationary and
mobile diesel generator sets used for
back-up emergency power, peaking
power and other on-site power
generation applications in the U.S. The
rules, part of the mandated Clean Air
rules, are designed to reduce nitrogen
oxide emissions and fine particle
pollution.
The Type EXL will increase reliability
and decrease downtime by offering
better sealing, misalignment capability
and load ratings versus the competition.
The totally sealed inner unit
incorporates the Dodge XTS triple-lip
balDor large ac motors iN stocK
This is a reminder that Baldor stocks
a wide variety of medium-voltage
2-4-6 pole TEFC severe duty motors
from 200 through 1000 HP and WPII
designs through 1250 HP.
Additionally, Baldor’s Quick-Ship
program for Athens 440- and 5000frame TEFC motors allows the
selection of custom 200- to 800-HP
motors built for 460, 575 or 2300/4000
volt operation with a simple selection of
options. These motors are engineered
and built in the Athens plant with a
three- to four-week lead time.
Only anti-friction (ball and roller
bearing) general purpose motors will
be in the Athens Quick-Ship program.
More complicated and sleeve bearing
motors will continue to be built in the
Kings Mountain motor plant.
2 | Solutions Magazine | Number 8
With the addition of our Quick-Ship
program, customers will have a choice
of immediate shipment of a fullfeatured medium-voltage motor from
stock or a three- to four-week lead time
on one made specifically to their needs.
balDor offers New geNerators DesigNeD to meet u.s. eNviroNmeNtal
ProtectioN ageNcy staNDarDs
Program details are outlined on flier
FL435 found on baldor.com.
Baldor is now the North American
sales channel for large ABB induction
and synchronous motors through
100,000 HP. Contact your local
district office for more details.
Baldor’s new TS225 towable generator
will add another model to the great
TS product line. The TS225 will offer
a rating of 225kVA/180kW while
meeting an EPA Tier 3 Emission
level. For EPA mobile applications,
the TS225 will carry a Flex Emissions
Label. Like all other TS models, the
TS225 is available in towable or skidmounted designs.
Two new Baldor industrial diesel liquid
cooled (IDLC) generators meet current
EPA emission standards. Utilizing
Mitsubishi engines, the IDLC10
meets EPA Tier 4 standards, while the
IDLC20 meets Interim Tier 4 Emission
requirements. Each model is available
with an open or basic sound-attenuated
enclosure to meet individual customer
needs.
rPm ac PermaNeNt magNet ProDuct liNe eXPaNDs
Baldor has expanded its RPM AC range
of permanent magnet (PM) product
offering up to 1200 HP.
frame sizes 180, 210, 250, 280 and
440 with permanent magnet rotor
construction.
The Baldor•Reliance RPM AC PM
motor product line performs like a high
horsepower servo motor with low rotor
inertia and
high power
density,
and is now
available in
NEMA
The addition of the finned laminated
440 frame (FL440) size extends the
product line’s horsepower range to
800 HP enclosed blower cooled and
1200 HP using open force ventilated
construction.
®
PM rotor technology
offers improved
efficiency that
can translate
into increased
power density
and synchronous
(non-slip) speed
performance. This
is achieved by virtue
of its highly power-dense, low-loss rotor
design where the permanent magnets
are actually embedded within the rotor
laminations.
Typical applications for RPM AC PM
motors include automotive testing
stands, extruders, winder/unwinders,
metal forming and bending machinery,
machine tool/spindle applications
and replacement of square frame DC
motors.
The RPM AC PM product line is
currently available in both NEMA and
IEC (112, 132, 160, 180 and 280) frame
sizes. These motors are all designed
to provide continuous constant torque
performance from zero speed up to base
speed for use with closed-loop PM AC
drives.
Number 8 | Solutions Magazine | 3
B r ie f in g s
B r ie f in g s
abb aND balDor Now Have siNgle sales force
for iNDustrial motors aND Drives
New HarsH Duty accessories available for balDor's DoDge®
torque-arm ii™ reDucers
ABB and Baldor now have a single
U.S. sales force to sell and support the
complete line of ABB and Baldor lowand medium-voltage industrial drives
and industrial electric motors.
Dense Nickel Composite (TDNC)
coating. The TDNC coating provides
maximum corrosion resistance,
making this an ideal choice for
grain handling or water treatment
plant applications. Bushings,
backing plates and snap rings
have the TDNC coating and
come with corrosion-resistant
bolts and lock washers.
ABB and Baldor Electric Company,
a member of the ABB group, believe
industrial customers will see many
benefits from this transition, including:
•
•
•
•
A single point of contact for
ABB and Baldor industrial
motors, drives and generators
24-hour local sales and service
Broadest range of industrial
drives and motors in the
marketplace from one source
Full line of products for
energy-efficient motor-driven
systems
Vice President and General Manager of
Low Voltage Drives for ABB US Aaron
Aleithe commented, “We are proud
to provide our customers with the
highest-quality drives in the industrial
marketplace. By selling them through
the same sales force as Baldor industrial
electric motors, we also can provide
them with the high level of customer
service they expect. We believe this
transition will make buying industrial
motors and drives easier for our
customers.”
“Customers have long understood the
value that comes from using a premium-
efficient motor,” said Ron Tucker, CEO
and President of Baldor. “By pairing a
Baldor premium-efficient motor with
an ABB industrial drive, customers have
the opportunity to further decrease
their energy consumption significantly.
ABB and Baldor both have a long
history of manufacturing industrial
electric motors and drives. Together, we
believe we can take better care of our
industrial customers than anyone else.”
Baldor's DoDge magNagear reDucers Now iN stocK for emergeNcy NeeDs
®
day shipping. The in-stock program
is designed to help customers quickly
replace failed competitor units to get
their operation back up and running.
The MagnaGear reducer, engineered
with Dodge proven planetary and
helical gear technology, is a powerdense, economical, heavy-duty package
that is well-suited for a variety of
applications. The product has a proven
track record of performance, reliability
and ease of maintenance.
When delivery is critical,
Baldor now offers customers
the most common sizes and ratios of
Dodge MagnaGear reducers for next
Baldor’s
Dodge
Torque-Arm
II, the best selling belt
driven shaft-mount gear reducer,
is designed for application flexibility
and built for harsh environments. Now,
optional harsh duty accessories are
available to further extend the service
life of the reducer.
The exclusive Dodge Twin Tapered
bushing system that provides sturdy,
concentric grip of the driven shaft
on both sides of the reducer is now
available with an optional Thin
Dimensional drawings are readily
available for customer evaluations.
Standard accessories including twintapered bushings, shaft fans and end
covers are also available as part of the
in-stock program.
Dodge TDNC Twin Tapered Bushing System for
Harsh Duty Applications
4 | Solutions Magazine | Number 8
All shaft-mounted reducers
rely on the tie rod system to
prevent rotation of
the gearbox under heavy
load. Because of this,
Baldor•Dodge tie rods are
designed to handle heavy
shock loads and maintain
performance. Responding
to customer requests for a
corrosion- resistant tie rod
for the Torque-Arm II line,
we now offer a selection of
zinc-electroplated tie rod kits for
harsh duty applications. Utilizing an
environmentally friendly chromating
process, the product is highly corrosion
resistant, even
in the most
demanding
environments.
The kit includes
Standard Filter Breather
a zinc-plated
turnbuckle, two
zinc-plated threaded rod extensions,
a zinc-plated fulcrum and zinc-plated
hardware kit.
A harsh duty V-ring
seal is another option
available. The seal acts
as a flinger, keeping
contaminants from
coming in contact
with the excluder seal.
The seal is easy to
install and makes the
sealing system more
resistant to water
spray, typically found
in mild wash-down
applications.
Optional V-ring Finger Seal Kit
When a standard filter breather is not
enough, end-users can now choose the
optional Hydra-Lock line of harsh duty
desiccant breathers. Designed to deliver
maximum protection from humidity
and contaminants, these breathers
not only filter moisture, but also filter
particles down to 3 microns. HydraLock harsh duty breathers eliminate
rust-forming condensation, prevent
sludge deposits and water-contaminated
oil, and provide longer oil and filter
life.
Hydra-Lock
Breathers
Tie Rod Kit
Number 8 | Solutions Magazine | 5
B r ie f in g s
B r ie f in g s
abb aND balDor Now Have siNgle sales force
for iNDustrial motors aND Drives
New HarsH Duty accessories available for balDor's DoDge®
torque-arm ii™ reDucers
ABB and Baldor now have a single
U.S. sales force to sell and support the
complete line of ABB and Baldor lowand medium-voltage industrial drives
and industrial electric motors.
Dense Nickel Composite (TDNC)
coating. The TDNC coating provides
maximum corrosion resistance,
making this an ideal choice for
grain handling or water treatment
plant applications. Bushings,
backing plates and snap rings
have the TDNC coating and
come with corrosion-resistant
bolts and lock washers.
ABB and Baldor Electric Company,
a member of the ABB group, believe
industrial customers will see many
benefits from this transition, including:
•
•
•
•
A single point of contact for
ABB and Baldor industrial
motors, drives and generators
24-hour local sales and service
Broadest range of industrial
drives and motors in the
marketplace from one source
Full line of products for
energy-efficient motor-driven
systems
Vice President and General Manager of
Low Voltage Drives for ABB US Aaron
Aleithe commented, “We are proud
to provide our customers with the
highest-quality drives in the industrial
marketplace. By selling them through
the same sales force as Baldor industrial
electric motors, we also can provide
them with the high level of customer
service they expect. We believe this
transition will make buying industrial
motors and drives easier for our
customers.”
“Customers have long understood the
value that comes from using a premium-
efficient motor,” said Ron Tucker, CEO
and President of Baldor. “By pairing a
Baldor premium-efficient motor with
an ABB industrial drive, customers have
the opportunity to further decrease
their energy consumption significantly.
ABB and Baldor both have a long
history of manufacturing industrial
electric motors and drives. Together, we
believe we can take better care of our
industrial customers than anyone else.”
Baldor's DoDge magNagear reDucers Now iN stocK for emergeNcy NeeDs
®
day shipping. The in-stock program
is designed to help customers quickly
replace failed competitor units to get
their operation back up and running.
The MagnaGear reducer, engineered
with Dodge proven planetary and
helical gear technology, is a powerdense, economical, heavy-duty package
that is well-suited for a variety of
applications. The product has a proven
track record of performance, reliability
and ease of maintenance.
When delivery is critical,
Baldor now offers customers
the most common sizes and ratios of
Dodge MagnaGear reducers for next
Baldor’s
Dodge
Torque-Arm
II, the best selling belt
driven shaft-mount gear reducer,
is designed for application flexibility
and built for harsh environments. Now,
optional harsh duty accessories are
available to further extend the service
life of the reducer.
The exclusive Dodge Twin Tapered
bushing system that provides sturdy,
concentric grip of the driven shaft
on both sides of the reducer is now
available with an optional Thin
Dimensional drawings are readily
available for customer evaluations.
Standard accessories including twintapered bushings, shaft fans and end
covers are also available as part of the
in-stock program.
Dodge TDNC Twin Tapered Bushing System for
Harsh Duty Applications
4 | Solutions Magazine | Number 8
All shaft-mounted reducers
rely on the tie rod system to
prevent rotation of
the gearbox under heavy
load. Because of this,
Baldor•Dodge tie rods are
designed to handle heavy
shock loads and maintain
performance. Responding
to customer requests for a
corrosion- resistant tie rod
for the Torque-Arm II line,
we now offer a selection of
zinc-electroplated tie rod kits for
harsh duty applications. Utilizing an
environmentally friendly chromating
process, the product is highly corrosion
resistant, even
in the most
demanding
environments.
The kit includes
Standard Filter Breather
a zinc-plated
turnbuckle, two
zinc-plated threaded rod extensions,
a zinc-plated fulcrum and zinc-plated
hardware kit.
A harsh duty V-ring
seal is another option
available. The seal acts
as a flinger, keeping
contaminants from
coming in contact
with the excluder seal.
The seal is easy to
install and makes the
sealing system more
resistant to water
spray, typically found
in mild wash-down
applications.
Optional V-ring Finger Seal Kit
When a standard filter breather is not
enough, end-users can now choose the
optional Hydra-Lock line of harsh duty
desiccant breathers. Designed to deliver
maximum protection from humidity
and contaminants, these breathers
not only filter moisture, but also filter
particles down to 3 microns. HydraLock harsh duty breathers eliminate
rust-forming condensation, prevent
sludge deposits and water-contaminated
oil, and provide longer oil and filter
life.
Hydra-Lock
Breathers
Tie Rod Kit
Number 8 | Solutions Magazine | 5
f e at u r e s
F e at u r e s
Choosing the
Right Partner
Helps Paragon Products
Create More Success
6 | Solutions Magazine | Number 8
Installed in more than 20,000 locomotives worldwide,
Paragon’s products decrease costly downtime and keep
things moving reliably on the rails. As the market leader in
a sector that never stands still, Paragon Products continues
to set new industry standards for truly innovative products.
Number 8 | Solutions Magazine | 7
f e at u r e s
F e at u r e s
Choosing the
Right Partner
Helps Paragon Products
Create More Success
6 | Solutions Magazine | Number 8
Installed in more than 20,000 locomotives worldwide,
Paragon’s products decrease costly downtime and keep
things moving reliably on the rails. As the market leader in
a sector that never stands still, Paragon Products continues
to set new industry standards for truly innovative products.
Number 8 | Solutions Magazine | 7
F e at u r e s
Sometimes as a small business it’s hard
to get the attention of large suppliers,
getting the engineering support and
service that’s required for a small
company to achieve exponential
growth. That was the case with
Paragon Products, a company based
in El Dorado Hills, California, which
designs and manufactures the most
technologically advanced fuel pumps
for large diesel engines used in the rail,
mining, marine and power industries.
About six years ago, an uneasy
relationship with its key motor supplier
became even more stressful when the
manufacturer eliminated production
of one critical Paragon product. But
what could have been a major setback
F e at u r e s
to the business turned out to be the best
thing that could have happened because
Paragon Products found a new supplier
that would become the true partner it
had been looking for.
Keith Wright, engineering manager for
Paragon Products, says when Baldor’s
Jim Cooke from the Hayward district
office told him Baldor could handle its
motor production, he was so relieved.
The situation, he says, went from very
bad to something very positive.
“Not only did Baldor step in and take
the order for the 12-gallon motor we
needed, but we found that Baldor could
offer us a much better solution,” says
Wright. “Having a real motor expert
call on us was a great way to start the
relationship; plus, from the beginning
we were so well treated by Baldor
manufacturing.”
But again and again, Baldor has met
these challenges. I’m amazed that a
manufacturer is so willing to work like
this.”
Understanding the Product
Support from the Plant
From that first project, the relationship
between the two companies has only
grown stronger. Cooke believes one
of the reasons why is the way Baldor
engineers studied the application.
Because the pump motors are
submerged in diesel, biodiesel or
kerosene, Baldor engineers worked
hard to ensure that the motors would
perform in all of these fuels. That
meant looking at everything from the
varnish on the wires, to the insulation,
to the way the motor is laced. He
says these engineers understand that
Paragon builds complex and highly
engineered pumps that are critical
components in a large engine.
Beyond the engineering support,
Wright says he is also impressed with
the employees at Baldor’s Westville
motor plant who take such great care
while building motors for Paragon.
It’s more than just building a motor
to Paragon specifications; he says the
employees have also done a great job in
the special handling that is required to
keep all surfaces smooth. In a normal
application, a small scratch may not
make a difference in performance, but
for a motor in a fuel pump, Wright says
a minor imperfection can have serious
consequences.
“That’s why Baldor has done a great
deal of testing and collecting data
to ensure that every component of
the electrical system is compatible,”
explains Cooke. “We build samples to
send to Paragon for testing in their lab.
Because each fuel behaves differently,
we have to make sure that the materials
going into the motor will stand up
to each of these fluids for 10 years,
which is Paragon’s guarantee to their
customers.”
The engineering partnership has been
so successful that Paragon’s Senior
Electrical Engineer, Zack Marin,
says he no longer has to detail basic
specifications; instead, he can focus
on performance issues that involve
voltage, frequency, torque and speed
requirements. Marin says what he
appreciates most is how Baldor
engineers listen and then deliver.
“We build small, very specialized
products, and we usually ask for
voltages that are very uncommon,”
explains Marin. “Sometimes we ask
for almost the impossible – so much
power coming out of a small package.
After rotors have been attached to pump brackets, they are ready for final assembly.
8 | Solutions Magazine | Number 8
“This is critical because at the end of
the motor shell, there is an O-ring that
seals the pump, and if it’s scratched, it
can leak,” explains Wright. “If fuel leaks
on a big diesel engine, you can end up
with a fire. In the past, it’s been tough
for us to get motor manufacturers
to understand this critical issue. But
not the Westville plant, because these
employees pay attention to all of the
details.”
“Sometimes we ask for
almost the impossible –
so much power coming
out of a small package.
But again and again,
Baldor has met these
challenges.”
Zack Marin, senior
electrical engineer,
Paragon Products
According to Paragon officials, one of the reasons why the two companies have a great relationship is the
way Baldor engineers took time to study the application to fully understand the complexity of a motor that
is fully submerged in fuel. They appreciate the way Baldor engineers tested the varnish on the wires and
insulation and the way the motor is laced to ensure that every component of the motor will perform and
last for 10 years.
Number 8 | Solutions Magazine | 9
F e at u r e s
Sometimes as a small business it’s hard
to get the attention of large suppliers,
getting the engineering support and
service that’s required for a small
company to achieve exponential
growth. That was the case with
Paragon Products, a company based
in El Dorado Hills, California, which
designs and manufactures the most
technologically advanced fuel pumps
for large diesel engines used in the rail,
mining, marine and power industries.
About six years ago, an uneasy
relationship with its key motor supplier
became even more stressful when the
manufacturer eliminated production
of one critical Paragon product. But
what could have been a major setback
F e at u r e s
to the business turned out to be the best
thing that could have happened because
Paragon Products found a new supplier
that would become the true partner it
had been looking for.
Keith Wright, engineering manager for
Paragon Products, says when Baldor’s
Jim Cooke from the Hayward district
office told him Baldor could handle its
motor production, he was so relieved.
The situation, he says, went from very
bad to something very positive.
“Not only did Baldor step in and take
the order for the 12-gallon motor we
needed, but we found that Baldor could
offer us a much better solution,” says
Wright. “Having a real motor expert
call on us was a great way to start the
relationship; plus, from the beginning
we were so well treated by Baldor
manufacturing.”
But again and again, Baldor has met
these challenges. I’m amazed that a
manufacturer is so willing to work like
this.”
Understanding the Product
Support from the Plant
From that first project, the relationship
between the two companies has only
grown stronger. Cooke believes one
of the reasons why is the way Baldor
engineers studied the application.
Because the pump motors are
submerged in diesel, biodiesel or
kerosene, Baldor engineers worked
hard to ensure that the motors would
perform in all of these fuels. That
meant looking at everything from the
varnish on the wires, to the insulation,
to the way the motor is laced. He
says these engineers understand that
Paragon builds complex and highly
engineered pumps that are critical
components in a large engine.
Beyond the engineering support,
Wright says he is also impressed with
the employees at Baldor’s Westville
motor plant who take such great care
while building motors for Paragon.
It’s more than just building a motor
to Paragon specifications; he says the
employees have also done a great job in
the special handling that is required to
keep all surfaces smooth. In a normal
application, a small scratch may not
make a difference in performance, but
for a motor in a fuel pump, Wright says
a minor imperfection can have serious
consequences.
“That’s why Baldor has done a great
deal of testing and collecting data
to ensure that every component of
the electrical system is compatible,”
explains Cooke. “We build samples to
send to Paragon for testing in their lab.
Because each fuel behaves differently,
we have to make sure that the materials
going into the motor will stand up
to each of these fluids for 10 years,
which is Paragon’s guarantee to their
customers.”
The engineering partnership has been
so successful that Paragon’s Senior
Electrical Engineer, Zack Marin,
says he no longer has to detail basic
specifications; instead, he can focus
on performance issues that involve
voltage, frequency, torque and speed
requirements. Marin says what he
appreciates most is how Baldor
engineers listen and then deliver.
“We build small, very specialized
products, and we usually ask for
voltages that are very uncommon,”
explains Marin. “Sometimes we ask
for almost the impossible – so much
power coming out of a small package.
After rotors have been attached to pump brackets, they are ready for final assembly.
8 | Solutions Magazine | Number 8
“This is critical because at the end of
the motor shell, there is an O-ring that
seals the pump, and if it’s scratched, it
can leak,” explains Wright. “If fuel leaks
on a big diesel engine, you can end up
with a fire. In the past, it’s been tough
for us to get motor manufacturers
to understand this critical issue. But
not the Westville plant, because these
employees pay attention to all of the
details.”
“Sometimes we ask for
almost the impossible –
so much power coming
out of a small package.
But again and again,
Baldor has met these
challenges.”
Zack Marin, senior
electrical engineer,
Paragon Products
According to Paragon officials, one of the reasons why the two companies have a great relationship is the
way Baldor engineers took time to study the application to fully understand the complexity of a motor that
is fully submerged in fuel. They appreciate the way Baldor engineers tested the varnish on the wires and
insulation and the way the motor is laced to ensure that every component of the motor will perform and
last for 10 years.
Number 8 | Solutions Magazine | 9
F e at u r e s
F e at u r e s
when Cesena says she needs something
from Baldor, she gets it.
“You guys are very easy and pleasant
to do business with, and it’s such a nice
change from other motor vendors,”
says Cesena. “In the past it was often
frustrating getting what we needed, when
we needed it. But Baldor is so responsive,
and it’s such a nice change.”
Calling Baldor flexible and reliable,
Cesena says when Paragon really needs
help on a project, the Baldor team will
pull together to get it done. She says it’s
that kind of support that has led to a very
trusting relationship.
Each Paragon product is thoroughly tested in-house prior to being shipped to the customer. This test, the
first of many, is designed to check all seams and welds to make sure there are no leaks.
“We get the feeling that we are important
to Baldor – that’s how they treat us,” says
Cesena. “We trust Baldor because time
and time again they have come through
for us, proving that they care about our
success.”
“We trust Baldor because time and time again they
have come through for us, proving that they care
about our success.”
Sharon Cesena, materials manager,
Paragon Products
Wright was equally impressed with
the Westville plant when Paragon
needed help packaging a stator into
an aluminum housing for the first
time. Paragon’s customer needed the
product quickly, which meant Paragon
would only have one chance to get it
right and meet the deadline. Wright
says his engineering team believed all
its calculations were correct but was
relieved when Baldor invited one of its
technicians to travel to the plant, so they
could work on it together.
Paragon officials say Baldor employees have done a great job in the special handling that is required to keep all the surfaces smooth for the Paragon product. A
minor imperfection can have serious consequences for a motor in a fuel pump, and officials say they are impressed with the way Baldor employees pay attention to
all the right details.
10 | Solutions Magazine | Number 8
“This is something Baldor knows how
to do, and they wanted to help us get it
right,” explains Wright. “We might have
been able to figure it out on our own,
but there was no room for error. The
folks at the plant helped us get it done,
and without this kind of support, this
project could have gone very wrong.
The bottom line is that with Baldor’s
help we got it right, and we got it to
the customer on time – making it a
huge success.”
A Good Partner Makes Your Life
Easier
Paragon’s Materials Manager, Sharon
Cesena, deals with Baldor as much, or
perhaps more, than anyone else in the
company because she’s the one who
sets the master production schedule,
secures inventory and expedites
orders. From the beginning to the end
of each project, Cesena is the conduit
between Paragon and Baldor, making
sure everything runs smoothly. And
Paragon fuel transfer pumps with Baldor brushless
AC motors are maintenance-free and provide
installation versatility and reliable performance.
Number 8 | Solutions Magazine | 11
F e at u r e s
F e at u r e s
when Cesena says she needs something
from Baldor, she gets it.
“You guys are very easy and pleasant
to do business with, and it’s such a nice
change from other motor vendors,”
says Cesena. “In the past it was often
frustrating getting what we needed, when
we needed it. But Baldor is so responsive,
and it’s such a nice change.”
Calling Baldor flexible and reliable,
Cesena says when Paragon really needs
help on a project, the Baldor team will
pull together to get it done. She says it’s
that kind of support that has led to a very
trusting relationship.
Each Paragon product is thoroughly tested in-house prior to being shipped to the customer. This test, the
first of many, is designed to check all seams and welds to make sure there are no leaks.
“We get the feeling that we are important
to Baldor – that’s how they treat us,” says
Cesena. “We trust Baldor because time
and time again they have come through
for us, proving that they care about our
success.”
“We trust Baldor because time and time again they
have come through for us, proving that they care
about our success.”
Sharon Cesena, materials manager,
Paragon Products
Wright was equally impressed with
the Westville plant when Paragon
needed help packaging a stator into
an aluminum housing for the first
time. Paragon’s customer needed the
product quickly, which meant Paragon
would only have one chance to get it
right and meet the deadline. Wright
says his engineering team believed all
its calculations were correct but was
relieved when Baldor invited one of its
technicians to travel to the plant, so they
could work on it together.
Paragon officials say Baldor employees have done a great job in the special handling that is required to keep all the surfaces smooth for the Paragon product. A
minor imperfection can have serious consequences for a motor in a fuel pump, and officials say they are impressed with the way Baldor employees pay attention to
all the right details.
10 | Solutions Magazine | Number 8
“This is something Baldor knows how
to do, and they wanted to help us get it
right,” explains Wright. “We might have
been able to figure it out on our own,
but there was no room for error. The
folks at the plant helped us get it done,
and without this kind of support, this
project could have gone very wrong.
The bottom line is that with Baldor’s
help we got it right, and we got it to
the customer on time – making it a
huge success.”
A Good Partner Makes Your Life
Easier
Paragon’s Materials Manager, Sharon
Cesena, deals with Baldor as much, or
perhaps more, than anyone else in the
company because she’s the one who
sets the master production schedule,
secures inventory and expedites
orders. From the beginning to the end
of each project, Cesena is the conduit
between Paragon and Baldor, making
sure everything runs smoothly. And
Paragon fuel transfer pumps with Baldor brushless
AC motors are maintenance-free and provide
installation versatility and reliable performance.
Number 8 | Solutions Magazine | 11
F e at u r e s
F e at u r e s
Baldor Products
Improve Reliability
Critical Fuel
Enhancement System
at Great River Energy’s
Coal Creek Station
of
Failing gearboxes on conveyors feeding dried coal into the furnace threatened the reliability of the system. In 2009, the plant’s maintenance team installed size
168 Baldor•Dodge Quantis right-angle helical bevel gear drives. The team reports these units have performed without fail and only require regularly scheduled
maintenance.
®
Great River Energy is owned by 28 electric distribution cooperatives throughout
Minnesota, making it the second largest power producer in the state.
®
Coal burns; water doesn’t. That is the
founding principle behind DryFining™,
an innovative technology developed
by Great River Energy and partners to
reduce the moisture and refine lignite
coal. Lignite, a softer coal that naturally
contains more water, is transformed
through this unique process into a
product with increased energy density
that burns cleaner and improves overall
power plant efficiency.
In 2009, after years of research and
development, Great River Energy
installed the DryFining system at
12 | Solutions Magazine | Number 8
its Coal Creek Station power plant,
located in Underwood, North Dakota.
Today, 7.5 million tons of lignite
per year is DryFined at Coal Creek
Station, yielding more energy with less
emissions.
But from the beginning, issues with
failing gearboxes on coal conveyors
in the new facility threatened the
reliability of the system, a situation
that needed to be remedied to ensure
maximum uptime. Damian Meier,
maintenance mechanic and coal drying
specialist at Coal Creek Station, says
there were two different problems he
and the rest of the team had to deal
with.
“Initially we were having temperature
problems with the gearboxes,” explains
Meier. “The duty cycle on this box was
rated for the load they were carrying,
but they were overheating. Another
problem we had to deal with was
twisting and breaking shafts.”
First, the maintenance team tried
installing a larger size of the same
gearbox, in essence over-sizing the
Number 8 | Solutions Magazine | 13
F e at u r e s
F e at u r e s
Baldor Products
Improve Reliability
Critical Fuel
Enhancement System
at Great River Energy’s
Coal Creek Station
of
Failing gearboxes on conveyors feeding dried coal into the furnace threatened the reliability of the system. In 2009, the plant’s maintenance team installed size
168 Baldor•Dodge Quantis right-angle helical bevel gear drives. The team reports these units have performed without fail and only require regularly scheduled
maintenance.
®
Great River Energy is owned by 28 electric distribution cooperatives throughout
Minnesota, making it the second largest power producer in the state.
®
Coal burns; water doesn’t. That is the
founding principle behind DryFining™,
an innovative technology developed
by Great River Energy and partners to
reduce the moisture and refine lignite
coal. Lignite, a softer coal that naturally
contains more water, is transformed
through this unique process into a
product with increased energy density
that burns cleaner and improves overall
power plant efficiency.
In 2009, after years of research and
development, Great River Energy
installed the DryFining system at
12 | Solutions Magazine | Number 8
its Coal Creek Station power plant,
located in Underwood, North Dakota.
Today, 7.5 million tons of lignite
per year is DryFined at Coal Creek
Station, yielding more energy with less
emissions.
But from the beginning, issues with
failing gearboxes on coal conveyors
in the new facility threatened the
reliability of the system, a situation
that needed to be remedied to ensure
maximum uptime. Damian Meier,
maintenance mechanic and coal drying
specialist at Coal Creek Station, says
there were two different problems he
and the rest of the team had to deal
with.
“Initially we were having temperature
problems with the gearboxes,” explains
Meier. “The duty cycle on this box was
rated for the load they were carrying,
but they were overheating. Another
problem we had to deal with was
twisting and breaking shafts.”
First, the maintenance team tried
installing a larger size of the same
gearbox, in essence over-sizing the
Number 8 | Solutions Magazine | 13
F e at u r e s
F e at u r e s
gearbox to ensure it could more than
handle the load. But that didn’t solve
all of the problems. And while failing
gearboxes never prevented the plant
from drying coal, Meier says they
could have, and he and the rest of the
maintenance team worried about it all
of the time.
Dockter calls the gear reducer
exceptional and bases his opinion on
the way the reducer performs in one of
the hottest locations in the plant, close
to where coal is delivered to the dryers.
He says this area can be as hot as 100
degrees in the winter and can reach 120
degrees in the summer.
“This was a constant concern because
it’s our responsibility to keep the coal
flowing,” says Meier. “We understand
that we need to always be up and
running – that we can’t afford to be shut
down. We were under pressure to solve
the problem and get this right.”
“In the past, the competitor’s gearbox
ran so hot that it was just not pulling
the belt the way it should,” explains
Dockter. “We just knew that we would
really burn through reducers in this
“Since we installed these
Quantis units, we have
not had one problem
– not one issue.”
location. However, despite the heat,
the Quantis unit maintains a constant
operating temperature – it just runs
great with no issues.”
Based on the success with Quantis
reducers, when the plant ordered a
new transfer hopper, Dockter and
Meier specified Baldor products on the
equipment. The transfer hopper drops
wet coal on the feed belts leading to the
dryers. Meier says they changed systems
so they could better control the flow of
coal.
Damian Meier,
maintenance mechanic
and coal drying specialist,
Coal Creek Station
Local Motion Industries Branch
Manager Craig Taylor and Baldor’s
Dodge Mechanical Sales Engineer, Jeff
Schall, both frequent visitors to the
plant, were asked to come up with a
solution. Les Dockter, the plant’s welder
mechanic and coal drying specialist, says
these two went through everything on
the conveyors to figure out what was
needed.
“Installing the Dodge gearboxes has
taken the pressure off of us,” says
Dockter. “These products are giving us
the reliability that we need; plus, they
don’t require a lot of attention. We
really appreciate the great service we
get from Craig and Jeff in helping us be
successful.”
“We get exceptional service from
Craig and Jeff, and they have always
been very helpful,” says Dockter.
“We’re also familiar with Baldor’s
Dodge® brand of gearing, so when they
proposed installing Dodge Quantis®
gear reducers, we were open to the
suggestion. They were both convinced
that this was the solution, so we decided
to install them.”
Initially, four Quantis reducers were
installed on coal conveyors feeding
dried coal into the furnace, with each
unit pulling 250 feet of conveyor. The
next unit was installed on a 325-foot
conveyor that feeds wet coal into two
dryers. Since their installation in 2009,
Meier says, they have not had one
moment of concern.
“Since we installed these Quantis units,
we have not had one problem – not one
issue,” says Meier. “They are easy to
take care of, and really all we do is our
regular preventive maintenance, like
sampling oil and taking vibrations tests.
We just don’t have to do much with
them.”
14 | Solutions Magazine | Number 8
Based on the success with Quantis reducers, plant officials specified Baldor equipment on a new coal
transfer hopper. The OEM chose Baldor’s Dodge MagnaGear reducer, a power-dense, heavy duty reducer
well suited for a variety of high torque applications.
Designed for greater torque density in a compact housing, the Quantis RHB product features a helicalbevel-helical gear train that offers cost-effective, high- and low-speed solutions. Replacing failing gearboxes
with the size 168 Quantis units has meant no unplanned downtime at the plant. The maintenance team
responsible for keeping coal running reports that since installing the units, it has not had one moment of
concern because the units run great with no issues.
“We ordered this piece about a year
after we installed the Quantis units,”
explains Meier. “We told the OEM that
since the Dodge reducers were working
so well for us, we would like a similar
Dodge gearbox on these feeders. The
equipment was delivered with four 100K
MagnaGear™ reducers coupled with
20 HP Baldor•Reliance® motors.”
Both Meier and Dockter report that
since replacing problem reducers with
Dodge gearing, they no longer worry
about conveyors. Neither of them miss
the stress involved in scrambling to
repair gearboxes to keep coal flowing.
Dockter says maximizing uptime is
even more critical now, as additional
plants will soon be relying on Coal
Creek Station to supply them dry coal.
A total of four MagnaGear reducers coupled with
Baldor•Reliance motors power the transfer hopper
that drops wet coal on the feed belts leading to the
dryers. Maintenance team members say the new
system allows them to better control the flow of
the coal.
Number 8 | Solutions Magazine | 15
F e at u r e s
F e at u r e s
gearbox to ensure it could more than
handle the load. But that didn’t solve
all of the problems. And while failing
gearboxes never prevented the plant
from drying coal, Meier says they
could have, and he and the rest of the
maintenance team worried about it all
of the time.
Dockter calls the gear reducer
exceptional and bases his opinion on
the way the reducer performs in one of
the hottest locations in the plant, close
to where coal is delivered to the dryers.
He says this area can be as hot as 100
degrees in the winter and can reach 120
degrees in the summer.
“This was a constant concern because
it’s our responsibility to keep the coal
flowing,” says Meier. “We understand
that we need to always be up and
running – that we can’t afford to be shut
down. We were under pressure to solve
the problem and get this right.”
“In the past, the competitor’s gearbox
ran so hot that it was just not pulling
the belt the way it should,” explains
Dockter. “We just knew that we would
really burn through reducers in this
“Since we installed these
Quantis units, we have
not had one problem
– not one issue.”
location. However, despite the heat,
the Quantis unit maintains a constant
operating temperature – it just runs
great with no issues.”
Based on the success with Quantis
reducers, when the plant ordered a
new transfer hopper, Dockter and
Meier specified Baldor products on the
equipment. The transfer hopper drops
wet coal on the feed belts leading to the
dryers. Meier says they changed systems
so they could better control the flow of
coal.
Damian Meier,
maintenance mechanic
and coal drying specialist,
Coal Creek Station
Local Motion Industries Branch
Manager Craig Taylor and Baldor’s
Dodge Mechanical Sales Engineer, Jeff
Schall, both frequent visitors to the
plant, were asked to come up with a
solution. Les Dockter, the plant’s welder
mechanic and coal drying specialist, says
these two went through everything on
the conveyors to figure out what was
needed.
“Installing the Dodge gearboxes has
taken the pressure off of us,” says
Dockter. “These products are giving us
the reliability that we need; plus, they
don’t require a lot of attention. We
really appreciate the great service we
get from Craig and Jeff in helping us be
successful.”
“We get exceptional service from
Craig and Jeff, and they have always
been very helpful,” says Dockter.
“We’re also familiar with Baldor’s
Dodge® brand of gearing, so when they
proposed installing Dodge Quantis®
gear reducers, we were open to the
suggestion. They were both convinced
that this was the solution, so we decided
to install them.”
Initially, four Quantis reducers were
installed on coal conveyors feeding
dried coal into the furnace, with each
unit pulling 250 feet of conveyor. The
next unit was installed on a 325-foot
conveyor that feeds wet coal into two
dryers. Since their installation in 2009,
Meier says, they have not had one
moment of concern.
“Since we installed these Quantis units,
we have not had one problem – not one
issue,” says Meier. “They are easy to
take care of, and really all we do is our
regular preventive maintenance, like
sampling oil and taking vibrations tests.
We just don’t have to do much with
them.”
14 | Solutions Magazine | Number 8
Based on the success with Quantis reducers, plant officials specified Baldor equipment on a new coal
transfer hopper. The OEM chose Baldor’s Dodge MagnaGear reducer, a power-dense, heavy duty reducer
well suited for a variety of high torque applications.
Designed for greater torque density in a compact housing, the Quantis RHB product features a helicalbevel-helical gear train that offers cost-effective, high- and low-speed solutions. Replacing failing gearboxes
with the size 168 Quantis units has meant no unplanned downtime at the plant. The maintenance team
responsible for keeping coal running reports that since installing the units, it has not had one moment of
concern because the units run great with no issues.
“We ordered this piece about a year
after we installed the Quantis units,”
explains Meier. “We told the OEM that
since the Dodge reducers were working
so well for us, we would like a similar
Dodge gearbox on these feeders. The
equipment was delivered with four 100K
MagnaGear™ reducers coupled with
20 HP Baldor•Reliance® motors.”
Both Meier and Dockter report that
since replacing problem reducers with
Dodge gearing, they no longer worry
about conveyors. Neither of them miss
the stress involved in scrambling to
repair gearboxes to keep coal flowing.
Dockter says maximizing uptime is
even more critical now, as additional
plants will soon be relying on Coal
Creek Station to supply them dry coal.
A total of four MagnaGear reducers coupled with
Baldor•Reliance motors power the transfer hopper
that drops wet coal on the feed belts leading to the
dryers. Maintenance team members say the new
system allows them to better control the flow of
the coal.
Number 8 | Solutions Magazine | 15
F e at u r e s
F e at u r e s
Installing Baldor's
®
Dodge ULTRA KLEEN
Ball Bearings
Moves Machine
from Least Reliable
to Most Reliable
at the
ConAgra Foods
®
Lamb Weston
Potato Products Plant
16 | Solutions Magazine | Number 8
Number 8 | Solutions Magazine | 17
F e at u r e s
F e at u r e s
Installing Baldor's
®
Dodge ULTRA KLEEN
Ball Bearings
Moves Machine
from Least Reliable
to Most Reliable
at the
ConAgra Foods
®
Lamb Weston
Potato Products Plant
16 | Solutions Magazine | Number 8
Number 8 | Solutions Magazine | 17
F e at u r e s
ConAgra Foods is dedicated to making
the food people love and doing so in
an environmentally responsible way.
F e at u r e s
As part of its sustainability strategy,
the company has set aggressive goals
to reduce greenhouse gas emissions,
water usage, waste and packaging. In
an effort to help achieve those goals,
the company is working with its supply
chain to encourage continuous plant
improvements, partnering with suppliers
that deliver innovative products that
increase plant efficiency.
Jake Washburn, procurement manager
for ConAgra Foods’ Lamb Weston,
a leading producer of quality frozen
potato, sweet potato and other vegetable
products, says it’s not about finding
the cheapest products, but rather the
products that will reduce total cost of
ownership. He says the company is
looking for partners that will help it
with its goal to increase continuous
improvement savings.
“It’s amazing how this
machine has moved from
least reliable to most
reliable just by changing
bearings.”
Colin Walters,
plant maintenance
manager,
Lamb Weston potato
products plant
“The best suppliers offer solutions
versus sales, and we want a partner who
will share their industry and product
knowledge and bring us up-time
opportunities,” says Washburn. “We
want reliable products that will prevent
unplanned downtime and increase our
operational equipment effectiveness.
At the end of the day, if we keep our
plant up and running, it helps drive our
efficiencies and helps reduce waste.”
Bearing failures on this roll sizer machine were causing significant downtime at the Lamb Weston potato products plant. After installing Baldor’s Dodge ULTRA
KLEEN stainless steel ball bearings, this machine went from being the least reliable to the most reliable.
18 | Solutions Magazine | Number 8
In early 2010, increasing plant uptime became a major project at the
Lamb Weston potato products plant
in Connell, Washington. This plant
makes french fries and other potato
products primarily for the commercial
Baldor•Dodge ULTRA KLEEN stainless ball bearings feature stainless steel inserts and are 100% filled
with H1 food-grade grease. The patented QuadGuard™ sealing system and the exclusive Maxlife™ cage help
retain lubrication and prevent washout in wet environments.
®
marketplace. Plant Maintenance
Manager Colin Walters worked with
a corporate team to identify the
top downtime-producing pieces of
equipment in the plant. They pored
over data that had been collected over a
two-year period, identifying equipment
failures and whether the downtime was
associated with operational issues or if
it was a mechanical or electrical failure.
Walters says the numbers pointed to a
piece of equipment called a roll sizer
as one of the least reliable pieces of
equipment in the plant.
failures led to bearing failures, which
sometimes damaged other drive
components.
“Because the bearings were always at
different states of wear on this machine,
they caused uneven wear on sprockets,
and failures with drives and chains,”
says Walters. “We believed that if we
installed a better bearing, we could
significantly reduce downtime on this
machine.”
“In fiscal year 2010, the plant ran 48
weeks of production,” explains Walters.
“During 29 of those 48 weeks, we
experienced at least one downtime
event on this roll sizer, which added up
to 2,700 minutes of capacity loss. We
took a closer look and found that the
majority of the failures were related to
the bearings on the machine.”
To help find that better bearing,
Walters called Jeff Stroben at Applied
Industrial Technology’s Pasco Service
Center. Stroben, who has called on the
Connell plant for the past 21 years,
visited, discussed the issues and took a
closer look. He says poor sealing was
the primary factor in bearing failure.
Once he understood the problem, he
says, he had a good idea of what would
work.
There are 22 bearings on the roll sizer,
one on each end of the 11 tapered
rollers that drop cleaned and peeled
potatoes by size into the appropriate
flume, carrying them to the knives to
be cut into fries. Walters says sealing
“I recommended the new Baldor•Dodge
ULTRA KLEEN stainless steel ball
bearing,” says Stroben. “This bearing
offered a patented triple-lip sealing
system plus a new cage design that
holds in the grease and prevents it from
Number 8 | Solutions Magazine | 19
F e at u r e s
ConAgra Foods is dedicated to making
the food people love and doing so in
an environmentally responsible way.
F e at u r e s
As part of its sustainability strategy,
the company has set aggressive goals
to reduce greenhouse gas emissions,
water usage, waste and packaging. In
an effort to help achieve those goals,
the company is working with its supply
chain to encourage continuous plant
improvements, partnering with suppliers
that deliver innovative products that
increase plant efficiency.
Jake Washburn, procurement manager
for ConAgra Foods’ Lamb Weston,
a leading producer of quality frozen
potato, sweet potato and other vegetable
products, says it’s not about finding
the cheapest products, but rather the
products that will reduce total cost of
ownership. He says the company is
looking for partners that will help it
with its goal to increase continuous
improvement savings.
“It’s amazing how this
machine has moved from
least reliable to most
reliable just by changing
bearings.”
Colin Walters,
plant maintenance
manager,
Lamb Weston potato
products plant
“The best suppliers offer solutions
versus sales, and we want a partner who
will share their industry and product
knowledge and bring us up-time
opportunities,” says Washburn. “We
want reliable products that will prevent
unplanned downtime and increase our
operational equipment effectiveness.
At the end of the day, if we keep our
plant up and running, it helps drive our
efficiencies and helps reduce waste.”
Bearing failures on this roll sizer machine were causing significant downtime at the Lamb Weston potato products plant. After installing Baldor’s Dodge ULTRA
KLEEN stainless steel ball bearings, this machine went from being the least reliable to the most reliable.
18 | Solutions Magazine | Number 8
In early 2010, increasing plant uptime became a major project at the
Lamb Weston potato products plant
in Connell, Washington. This plant
makes french fries and other potato
products primarily for the commercial
Baldor•Dodge ULTRA KLEEN stainless ball bearings feature stainless steel inserts and are 100% filled
with H1 food-grade grease. The patented QuadGuard™ sealing system and the exclusive Maxlife™ cage help
retain lubrication and prevent washout in wet environments.
®
marketplace. Plant Maintenance
Manager Colin Walters worked with
a corporate team to identify the
top downtime-producing pieces of
equipment in the plant. They pored
over data that had been collected over a
two-year period, identifying equipment
failures and whether the downtime was
associated with operational issues or if
it was a mechanical or electrical failure.
Walters says the numbers pointed to a
piece of equipment called a roll sizer
as one of the least reliable pieces of
equipment in the plant.
failures led to bearing failures, which
sometimes damaged other drive
components.
“Because the bearings were always at
different states of wear on this machine,
they caused uneven wear on sprockets,
and failures with drives and chains,”
says Walters. “We believed that if we
installed a better bearing, we could
significantly reduce downtime on this
machine.”
“In fiscal year 2010, the plant ran 48
weeks of production,” explains Walters.
“During 29 of those 48 weeks, we
experienced at least one downtime
event on this roll sizer, which added up
to 2,700 minutes of capacity loss. We
took a closer look and found that the
majority of the failures were related to
the bearings on the machine.”
To help find that better bearing,
Walters called Jeff Stroben at Applied
Industrial Technologies' Pasco Service
Center. Stroben, who has called on the
Connell plant for the past 21 years,
visited, discussed the issues and took a
closer look. He says poor sealing was
the primary factor in bearing failure.
Once he understood the problem, he
says, he had a good idea of what would
work.
There are 22 bearings on the roll sizer,
one on each end of the 11 tapered
rollers that drop cleaned and peeled
potatoes by size into the appropriate
flume, carrying them to the knives to
be cut into fries. Walters says sealing
“I recommended the new Baldor•Dodge
ULTRA KLEEN stainless steel ball
bearing,” says Stroben. “This bearing
offered a patented triple-lip sealing
system plus a new cage design that
holds in the grease and prevents it from
Number 8 | Solutions Magazine | 19
F e at u r e s
F e at u r e s
environment, but these bearings hold up
to all of it.”
Walters is proud that the solution
found for this machine is helping the
plant move closer to achieving the
company’s sustainability goals, a success
that has been shared with continuous
improvement teams throughout the
company. He is also happy to report that
the roll sizer has been removed from the
tracking list, allowing the maintenance
team to focus on other projects.
“In the past, keeping this roll sizer
up and running was a real challenge,”
says Walters. “Unplanned downtime is
costly in so many ways, and it's also very
disruptive to the planned preventive
maintenance work that we do in the
plant. With this problem solved, we can
move to other improvement projects.
Solving the problem has been a big win
for us.”
Eleven tapered rollers on this roll sizer machine drop clean potatoes by size into the appropriate flume,
carrying them to the next step in the process. Before making the conversion to the Baldor•Dodge ULTRA
KLEEN product, bearings on both ends of the rollers were failing due to sealing issues.
®
ConAgra Foods® Standardizes on Baldor’s Dodge Mounted Bearings
The success achieved at a ConAgra Foods Lamb Weston
potato products plant is a success that ConAgra Foods wants
repeated in all of its facilities throughout North America.
That’s why ConAgra Foods, with help from its distributor
partner Applied Industrial Technologies, has standardized on
Baldor’s Dodge mounted ball bearings as part of its newly
launched MRO strategy.
Lamb Weston Plant Maintenance Engineer Colin Walters says he is impressed with the quality of the engineering work done on the ULTRA KLEEN bearing,
from the way the bearing is sealed to the Maxlife cage design. He calls it a superior bearing that offers superior performance.
being washed out. I believed this bearing
had a good chance of succeeding in this
application.”
At first, Walters considered only
changing out half the bearings, but then
quickly decided that in order to get an
accurate comparison, all of them needed
to be changed. It didn’t take long for
him to realize that he had made the right
decision.
20 | Solutions Magazine | Number 8
“Since installing these Dodge bearings
in the first week of August 2010, we
have had no downtime event caused by
bearings on this machine,” says Walters.
“Again, the numbers tell the story about
this success, because we have run the
plant 56 consecutive weeks without
experiencing any bearing or drive type
failures. It’s amazing how this machine
has moved from least reliable to most
reliable just by changing bearings.”
As a mechanical engineer, Walters
is impressed with the quality of the
engineering work done on the ULTRA
KLEEN bearing, from the way the
bearing is sealed to the Maxlife™ cage
design. He calls it a superior bearing
that offers superior performance.
“This is a very tough application due to
the natural vibration of the machine,"
explains Walters.” It’s also a very wet
Mathew Boots, ConAgra Foods’ procurement manager, says
the initiative is focused on total cost of ownership, choosing
products that offer solutions instead of just focusing on price.
During the selection process, Boots says, other
bearing manufacturers participated and were
considered, but Baldor’s Dodge bearings were
chosen because they offered what he describes
as the best quality-to-cost ratio.
“While this is not a formal equation, it does help
us determine what something will cost us in the long run,”
explains Boots. “We believe Dodge bearings offer quality and
reliability and will ultimately deliver cost savings by increasing
operational equipment effectiveness (OEE), which to us means
we’ll have less downtime.”
Another reason for selecting this product line, according
to Boots, is the added value that Baldor and AIT will offer
ConAgra Foods plants all over North America. He says part
of the value will come from Baldor’s continued research and
development of new and innovative products, and the other
part will come from field support.
“Our plants will have full access to Baldor and AIT experts
who will help identify ways to improve our processes
and applications,” says Boots. “By offering solutions,
this partnership will be able to deliver the continuous
improvement cost savings back to us, helping us achieve our
goals.”
Today, ConAgra Foods plants are using a wide variety of
bearings from assorted manufacturers. But
Boots believes that standardizing on what
he describes as the best bearing is the right
strategy. He’s confident it will work because of
the positive numbers from a couple of plants
that have already started to use the bearings,
like the Connell, Washington, plant.
“Here is a plant that has less downtime and really high
numbers on the OEE scale,” says Boots. “That’s great news, but
what about all the other plants? If we can help all our facilities
be this successful, then the win is so much bigger – that’s the
goal of standardizing on Dodge bearings.”
ConAgra Foods, headquartered in Omaha, Nebraska,
is one of North America’s leading food companies, with
brands in 97% of American households.
Number 8 | Solutions Magazine | 21
F e at u r e s
F e at u r e s
environment, but these bearings hold up
to all of it.”
Walters is proud that the solution
found for this machine is helping the
plant move closer to achieving the
company’s sustainability goals, a success
that has been shared with continuous
improvement teams throughout the
company. He is also happy to report that
the roll sizer has been removed from the
tracking list, allowing the maintenance
team to focus on other projects.
“In the past, keeping this roll sizer
up and running was a real challenge,”
says Walters. “Unplanned downtime is
costly in so many ways, and it's also very
disruptive to the planned preventive
maintenance work that we do in the
plant. With this problem solved, we can
move to other improvement projects.
Solving the problem has been a big win
for us.”
Eleven tapered rollers on this roll sizer machine drop clean potatoes by size into the appropriate flume,
carrying them to the next step in the process. Before making the conversion to the Baldor•Dodge ULTRA
KLEEN product, bearings on both ends of the rollers were failing due to sealing issues.
®
ConAgra Foods® Standardizes on Baldor’s Dodge Mounted Bearings
The success achieved at a ConAgra Foods Lamb Weston
potato products plant is a success that ConAgra Foods wants
repeated in all of its facilities throughout North America.
That’s why ConAgra Foods, with help from its distributor
partner Applied Industrial Technologies, has standardized on
Baldor’s Dodge mounted ball bearings as part of its newly
launched MRO strategy.
Lamb Weston Plant Maintenance Engineer Colin Walters says he is impressed with the quality of the engineering work done on the ULTRA KLEEN bearing,
from the way the bearing is sealed to the Maxlife cage design. He calls it a superior bearing that offers superior performance.
being washed out. I believed this bearing
had a good chance of succeeding in this
application.”
At first, Walters considered only
changing out half the bearings, but then
quickly decided that in order to get an
accurate comparison, all of them needed
to be changed. It didn’t take long for
him to realize that he had made the right
decision.
20 | Solutions Magazine | Number 8
“Since installing these Dodge bearings
in the first week of August 2010, we
have had no downtime event caused by
bearings on this machine,” says Walters.
“Again, the numbers tell the story about
this success, because we have run the
plant 56 consecutive weeks without
experiencing any bearing or drive type
failures. It’s amazing how this machine
has moved from least reliable to most
reliable just by changing bearings.”
As a mechanical engineer, Walters
is impressed with the quality of the
engineering work done on the ULTRA
KLEEN bearing, from the way the
bearing is sealed to the Maxlife™ cage
design. He calls it a superior bearing
that offers superior performance.
“This is a very tough application due to
the natural vibration of the machine,"
explains Walters.” It’s also a very wet
Mathew Boots, ConAgra Foods’ procurement manager, says
the initiative is focused on total cost of ownership, choosing
products that offer solutions instead of just focusing on price.
During the selection process, Boots says, other
bearing manufacturers participated and were
considered, but Baldor’s Dodge bearings were
chosen because they offered what he describes
as the best quality-to-cost ratio.
“While this is not a formal equation, it does help
us determine what something will cost us in the long run,”
explains Boots. “We believe Dodge bearings offer quality and
reliability and will ultimately deliver cost savings by increasing
operational equipment effectiveness (OEE), which to us means
we’ll have less downtime.”
Another reason for selecting this product line, according
to Boots, is the added value that Baldor and AIT will offer
ConAgra Foods plants all over North America. He says part
of the value will come from Baldor’s continued research and
development of new and innovative products, and the other
part will come from field support.
“Our plants will have full access to Baldor and AIT experts
who will help identify ways to improve our processes
and applications,” says Boots. “By offering solutions,
this partnership will be able to deliver the continuous
improvement cost savings back to us, helping us achieve our
goals.”
Today, ConAgra Foods plants are using a wide variety of
bearings from assorted manufacturers. But
Boots believes that standardizing on what
he describes as the best bearing is the right
strategy. He’s confident it will work because of
the positive numbers from a couple of plants
that have already started to use the bearings,
like the Connell, Washington, plant.
“Here is a plant that has less downtime and really high
numbers on the OEE scale,” says Boots. “That’s great news, but
what about all the other plants? If we can help all our facilities
be this successful, then the win is so much bigger – that’s the
goal of standardizing on Dodge bearings.”
ConAgra Foods, headquartered in Omaha, Nebraska,
is one of North America’s leading food companies, with
brands in 97% of American households.
Number 8 | Solutions Magazine | 21
Basin Electric
Power Plant
Selects Baldor
Equipment
to Prevent
Unplanned
Downtime
24 | Solutions Magazine | Number 8
Number 8 | Solutions Magazine | 25
Basin Electric
Power Plant
Selects Baldor
Equipment
to Prevent
Unplanned
Downtime
24 | Solutions Magazine | Number 8
Number 8 | Solutions Magazine | 25
F e at u r e s
F e at u r e s
“Since being installed
in the fall of 2009, the
Quantis reducers have
performed flawlessly.”
Dave Soma,
mechanical supervisor,
Leland Olds Station
job done. We knew this was not a
good situation, and we decided that we
needed to do something about it.”
What they did was call on a trusted
distributor to find them a reliable
solution. Craig Taylor, the manager
of the Motion Industries branch in
Bismarck, North Dakota, was a frequent
visitor at the plant and had helped
Soma and his team with several other
projects. Taylor, familiar with the issue
of the failing units, didn’t hesitate to
recommend Baldor’s Dodge® Quantis®
right-angle helical bevel gear reducer.
“I have had really good success using
Dodge Quantis gearboxes in many
other customer locations over the past
six years,” explains Taylor. “They have
such a good service record that there
was no question about what the plant
needed. I was so confident that the
Dodge reducer was the right solution
– I didn’t look at any other gearbox for
the LOS project.”
But Taylor recommended more
than just the gearbox. For maximum
reliability, he suggested a complete
Baldor package that, in addition to
the Quantis reducer, also included a
Baldor•Reliance Super-E premium
efficient explosion-proof motor, a
Dodge pulley and shafting, and Dodge
ISAF bearings.
Taylor chose to work with Baldor’s
System-1 group, a team that
facilitates the design, quotation and
order processing of multiple power
transmission and electrical products
into a completely packaged solution.
Taylor says it’s a real benefit to deal with
one company and get one quote; plus,
he believes the customer gets a much
better package and a better price. Soma
and other plant officials agreed, and
they ordered six of them.
™
Since being installed in the fall of 2009, Quantis right-angle helical bevel (RHB) reducers, coupled with Baldor•Reliance Super-E premium efficient explosionproof motors, have performed flawlessly. Maintenance team members say these units run great and only require regularly scheduled maintenance.
®
Dave Soma, the mechanical supervisor
at Leland Olds Station, a coal-fired
power plant near Stanton, North
Dakota, says he and his maintenance
team care deeply about keeping the
plant running and providing people
electricity, especially in the dead of
winter. That’s why in 2009 he and his
team began looking for a better gearbox
to use on the plant’s coal conveyors.
The plant is owned by Basin Electric
Power Cooperative, one of the largest
electric generation and transmission
cooperatives in the United States,
generating and transmitting wholesale
bulk electric power to 2.8 million
customers in nine states.
24 | Solutions Magazine | Number 8
Leland Olds Station went on-line
in 1966; unit two began commercial
operation in 1975. Originally, chain
cases were used on gearboxes, but due
to issues with grease and improving
plant cleanliness, it switched to belt
drives. According to Soma, the change
from chains to belts added too much
tension and overloaded the bearings
in the gearboxes, and that’s when the
maintenance headaches began.
“For years, we have been playing
musical gearboxes on these conveyors,”
says Soma. “We would take a failing
gearbox off and replace it with our spare,
and hope that we could fix the gearbox
before we needed the spare somewhere
®
else on the line. Most of the time, we
were scrambling to make these things
work and keep the conveyors running.”
Extra time was also needed to realign
belts after a gearbox was installed, a job
Soma describes as critical, requiring skill,
time and effort. The change-outs were
also complicated because of where the
gearboxes are located: confined, hardto-reach spaces, with not much room to
work.
“This was a big deal because failing
gearboxes threatened our ability to
generate power,” explains Soma. “While
we never did lose generation, we had
to sweat it out a few times to get the
In the past, keeping coal conveyors running was a constant concern for the plant’s maintenance team because of consistently failing gearboxes. That’s why in 2009
plant officials installed a more reliable product, Baldor’s Dodge Quantis reducers.
Number 8 | Solutions Magazine | 25
F e at u r e s
F e at u r e s
“Since being installed
in the fall of 2009, the
Quantis reducers have
performed flawlessly.”
Dave Soma,
mechanical supervisor,
Leland Olds Station
job done. We knew this was not a
good situation, and we decided that we
needed to do something about it.”
What they did was call on a trusted
distributor to find them a reliable
solution. Craig Taylor, the manager
of the Motion Industries branch in
Bismarck, North Dakota, was a frequent
visitor at the plant and had helped
Soma and his team with several other
projects. Taylor, familiar with the issue
of the failing units, didn’t hesitate to
recommend Baldor’s Dodge® Quantis®
right-angle helical bevel gear reducer.
“I have had really good success using
Dodge Quantis gearboxes in many
other customer locations over the past
six years,” explains Taylor. “They have
such a good service record that there
was no question about what the plant
needed. I was so confident that the
Dodge reducer was the right solution
– I didn’t look at any other gearbox for
the LOS project.”
But Taylor recommended more
than just the gearbox. For maximum
reliability, he suggested a complete
Baldor package that, in addition to
the Quantis reducer, also included a
Baldor•Reliance Super-E premium
efficient explosion-proof motor, a
Dodge pulley and shafting, and Dodge
ISAF bearings.
Taylor chose to work with Baldor’s
System-1 group, a team that
facilitates the design, quotation and
order processing of multiple power
transmission and electrical products
into a completely packaged solution.
Taylor says it’s a real benefit to deal with
one company and get one quote; plus,
he believes the customer gets a much
better package and a better price. Soma
and other plant officials agreed, and
they ordered six of them.
™
Since being installed in the fall of 2009, Quantis right-angle helical bevel (RHB) reducers, coupled with Baldor•Reliance Super-E premium efficient explosionproof motors, have performed flawlessly. Maintenance team members say these units run great and only require regularly scheduled maintenance.
®
Dave Soma, the mechanical supervisor
at Leland Olds Station, a coal-fired
power plant near Stanton, North
Dakota, says he and his maintenance
team care deeply about keeping the
plant running and providing people
electricity, especially in the dead of
winter. That’s why in 2009 he and his
team began looking for a better gearbox
to use on the plant’s coal conveyors.
The plant is owned by Basin Electric
Power Cooperative, one of the largest
electric generation and transmission
cooperatives in the United States,
generating and transmitting wholesale
bulk electric power to 2.8 million
customers in nine states.
24 | Solutions Magazine | Number 8
Leland Olds Station went on-line
in 1966; unit two began commercial
operation in 1975. Originally, chain
cases were used on gearboxes, but due
to issues with grease and improving
plant cleanliness, it switched to belt
drives. According to Soma, the change
from chains to belts added too much
tension and overloaded the bearings
in the gearboxes, and that’s when the
maintenance headaches began.
“For years, we have been playing
musical gearboxes on these conveyors,”
says Soma. “We would take a failing
gearbox off and replace it with our spare,
and hope that we could fix the gearbox
before we needed the spare somewhere
®
else on the line. Most of the time, we
were scrambling to make these things
work and keep the conveyors running.”
Extra time was also needed to realign
belts after a gearbox was installed, a job
Soma describes as critical, requiring skill,
time and effort. The change-outs were
also complicated because of where the
gearboxes are located: confined, hardto-reach spaces, with not much room to
work.
“This was a big deal because failing
gearboxes threatened our ability to
generate power,” explains Soma. “While
we never did lose generation, we had
to sweat it out a few times to get the
In the past, keeping coal conveyors running was a constant concern for the plant’s maintenance team because of consistently failing gearboxes. That’s why in 2009
plant officials installed a more reliable product, Baldor’s Dodge Quantis reducers.
Number 8 | Solutions Magazine | 25
F e at u r e s
F e at u r e s
have a built-in-roll-back clutch, instead
of a separate piece of equipment that
took up space and required additional
maintenance. Fewer moving parts means
there is a lot less for us to deal with.”
Soma is equally pleased to have a
Baldor•Reliance motor as part of the
package, especially the premium efficient
design for energy savings.
“We have a lot of Baldor•Reliance
motors in the plant and we’ve had
good luck with them,” says Soma.
“We have used other brands that haven’t
performed as well. So it was really
positive when we could get the brand
of motor we prefer on the gearbox we
needed from the same company.”
Baldor’s Dodge ISAF bearings have also
been well received by the maintenance
team. In the past, set screw bearings
were used but caused severe damage
to the shaft over time, which meant
machining a new shaft as well as
replacing the bearings. According to
Soma, because of the way the adapter
mount style of the Dodge bearing
attaches to the shaft, it offers a
concentric grip that reduces shaft
damage.
Plant officials were pleased to get Baldor•Reliance Super-E premium efficient explosion-proof motors as part of Baldor’s System-1 package. They appreciated being
able to get the brand of motor they prefer on the gearbox they needed, from the same company. The package also included Baldor’s Dodge pulleys and shafting,
and Dodge Imperial bearings.
“It was so nice when the packages
arrived,” says Soma. “We didn’t have to
do a bunch of assembly here at the plant
because the drum was mounted on the
shaft, and the bearings were mounted.
When we got this assembly into
position, all we had to do was mount the
gearbox and motor package – then our
electricians hooked it up and away we
went.”
26 | Solutions Magazine | Number 8
An End to Musical Gearboxes
Since being installed in the fall of 2009,
Soma reports that the Quantis reducers
have performed flawlessly. They run
great and his team only looks at them
while performing their regularly
scheduled preventive maintenance
program. He says it’s a nice change not
to be worried about failing gearboxes,
but he and his team also appreciate the
benefits of getting the power they need
from a compact unit.
“Because space is a premium in the
locations where gearboxes are used,
having a smaller unit makes it so much
easier for us to get to all of the other
equipment,” explains Soma. “Another
nice feature is that these gearboxes
Baldor’s Dodge Imperial bearings have been well received by the plant’s maintenance team. The team likes
the adapter mount style because of the way it attaches to the shaft with 360 degrees of support. The team
reports that these bearings don’t cause any shaft damage and are easy to maintain.
“This is the thing that we really like
about these bearings, the way they offer
360 degrees of support,” explains Soma.
“They support the shaft so much better,
won’t cause any damage and are easy to
maintain. These bearings have been the
answer to a lot of problems.”
Soma reports that he and his team are
enjoying maintaining the plant without
the panic they experienced in the past
from constantly failing gearboxes. Now
when peak demand hits, he doesn’t
worry about meeting critical demand,
because the Quantis reducers, and other
Baldor products, have proven to be so
reliable. He believes the plant’s strategy
of choosing a package based on total
cost of ownership was the right decision
and he couldn’t be happier about the
outcome.
“The headaches have gone away,” says
Soma. “It would be nice if everything
worked this way.”
Left: The Leland Olds Station coal-fired
power plant is owned by Basin Electric Power
Cooperative, one of the largest electric generation
and transmission cooperatives in the United States.
The Cooperative transmits wholesale bulk electric
power to 2.8 million customers in nine states.
Number 8 | Solutions Magazine | 27
F e at u r e s
F e at u r e s
have a built-in-roll-back clutch, instead
of a separate piece of equipment that
took up space and required additional
maintenance. Fewer moving parts means
there is a lot less for us to deal with.”
Soma is equally pleased to have a
Baldor•Reliance motor as part of the
package, especially the premium efficient
design for energy savings.
“We have a lot of Baldor•Reliance
motors in the plant and we’ve had
good luck with them,” says Soma.
“We have used other brands that haven’t
performed as well. So it was really
positive when we could get the brand
of motor we prefer on the gearbox we
needed from the same company.”
Baldor’s Dodge ISAF bearings have also
been well received by the maintenance
team. In the past, set screw bearings
were used but caused severe damage
to the shaft over time, which meant
machining a new shaft as well as
replacing the bearings. According to
Soma, because of the way the adapter
mount style of the Dodge bearing
attaches to the shaft, it offers a
concentric grip that reduces shaft
damage.
Plant officials were pleased to get Baldor•Reliance Super-E premium efficient explosion-proof motors as part of Baldor’s System-1 package. They appreciated being
able to get the brand of motor they prefer on the gearbox they needed, from the same company. The package also included Baldor’s Dodge pulleys and shafting,
and Dodge Imperial bearings.
“It was so nice when the packages
arrived,” says Soma. “We didn’t have to
do a bunch of assembly here at the plant
because the drum was mounted on the
shaft, and the bearings were mounted.
When we got this assembly into
position, all we had to do was mount the
gearbox and motor package – then our
electricians hooked it up and away we
went.”
26 | Solutions Magazine | Number 8
An End to Musical Gearboxes
Since being installed in the fall of 2009,
Soma reports that the Quantis reducers
have performed flawlessly. They run
great and his team only looks at them
while performing their regularly
scheduled preventive maintenance
program. He says it’s a nice change not
to be worried about failing gearboxes,
but he and his team also appreciate the
benefits of getting the power they need
from a compact unit.
“Because space is a premium in the
locations where gearboxes are used,
having a smaller unit makes it so much
easier for us to get to all of the other
equipment,” explains Soma. “Another
nice feature is that these gearboxes
Baldor’s Dodge Imperial bearings have been well received by the plant’s maintenance team. The team likes
the adapter mount style because of the way it attaches to the shaft with 360 degrees of support. The team
reports that these bearings don’t cause any shaft damage and are easy to maintain.
“This is the thing that we really like
about these bearings, the way they offer
360 degrees of support,” explains Soma.
“They support the shaft so much better,
won’t cause any damage and are easy to
maintain. These bearings have been the
answer to a lot of problems.”
Soma reports that he and his team are
enjoying maintaining the plant without
the panic they experienced in the past
from constantly failing gearboxes. Now
when peak demand hits, he doesn’t
worry about meeting critical demand,
because the Quantis reducers, and other
Baldor products, have proven to be so
reliable. He believes the plant’s strategy
of choosing a package based on total
cost of ownership was the right decision
and he couldn’t be happier about the
outcome.
“The headaches have gone away,” says
Soma. “It would be nice if everything
worked this way.”
Left: The Leland Olds Station coal-fired
power plant is owned by Basin Electric Power
Cooperative, one of the largest electric generation
and transmission cooperatives in the United States.
The Cooperative transmits wholesale bulk electric
power to 2.8 million customers in nine states.
Number 8 | Solutions Magazine | 27
Number 8 | Solutions Magazine | 31
Number 8 | Solutions Magazine | 31
F e at u r e s
In late summer of 2011, Flexco,
a Downers Grove, Illinois-based
manufacturer of products that enhance
belt conveyor productivity, began
running a new custom-made test rig
built to accelerate the design and testing
of new products. Founded in 1907,
Flexco manufactures a wide array of
products, including mechanical belt
fastening systems, trackers, cleaners,
plows, rollers and lagging.
Flexco’s diversified offering, combined
with increased belt tensions and
the continuing evolution of belt
construction, prompted the company
to invest in the new test rig. Greg
Westphall, the director of engineering at
Flexco, calls it a one-of-a-kind machine
F e at u r e s
designed to ensure that Flexco products
continue to undergo rigorous in-house
testing before being placed in the field.
Westphall says the 120,000-lb. capacity
test rig is running successfully, thanks
in part to the quality of Baldor products
and the expertise of Baldor engineers
who offered a complete solution with
specific products.
“We make conveyor belt fasteners, so
we don’t have experience specifying
motors, drives, gearboxes, bearings and
pulleys,” says Westphall. “Selecting
these components is somewhat foreign
to our engineers. So, our decision to
choose Baldor as our partner was based
not only on the strong Baldor brand
name, but also the added technical value
that Baldor is able to provide.”
Flexco Mechanical Engineer Dan Dailey
says the first line of project support
came from Baldor’s Dodge® Field Sales
Engineer Nick Roseto, who not only
helped with installation and mounting
questions, but was also the link to all of
the other Baldor engineers who worked
on the design and product selection.
“Nick was more than just a sales guy;
he had technical knowledge and stayed
with us through the entire project,”
says Dailey. “When I had a question or
needed something, he is who I turned
to for help. Nick was a valuable asset,
because he consistently answered my
“Our decision to choose
Baldor as our partner
was based not only on
the strong Baldor brand
name, but also the
added technical value
that Baldor is able to
provide.”
Greg Westphall,
director of engineering,
Flexco
Because Flexco engineers want the flexibility to make pulley changes, they asked for a bearing they
could get on and off the shaft easily, with no damage. Baldor recommended the Dodge Hydraulic
ISAF pillow block bearing, with built-in hydraulic pistons that tighten and loosen the bearing for easy
installation and removal. The patented adapter mounting system provides full shaft contact that reduces
or eliminates fretting corrosion.
questions, plus coordinated the efforts
from others on the Baldor team.”
Flexco’s new 120,000-lb.-capacity test rig measures 24 feet high and 12 feet wide and weighs approximately 60,000 lbs. Baldor engineers worked with the Flexco
engineering team to ensure the optimal horsepower of the Baldor•Reliance® Super-E® motor and the Baldor•Dodge® MagnaGear™ reducer. Baldor engineers also
specified the Baldor•Dodge Hydraulic ISAF bearing and the design and specification of the six engineered pulleys used on the test rig.
30 | Solutions Magazine | Number 8
Some of the Baldor engineering effort
was focused on developing the correct
pulley specifications for such a unique
application. Westphall explained that
unlike a conventional bulk material
conveyor in which only the drive or
head pulley sees maximum tension and
the belt width is fixed, all six pulleys
see maximum tension on the Flexco
Flexco will use belts from 10 to 36 inches wide
on the new test rig, which concentrates the load
in the center of the pulley, causing a great deal of
stress. Flexco relied on Baldor engineers to design
all six pulleys to handle maximum tension and the
extreme loads.
Number 8 | Solutions Magazine | 31
F e at u r e s
In late summer of 2011, Flexco,
a Downers Grove, Illinois-based
manufacturer of products that enhance
belt conveyor productivity, began
running a new custom-made test rig
built to accelerate the design and testing
of new products. Founded in 1907,
Flexco manufactures a wide array of
products, including mechanical belt
fastening systems, trackers, cleaners,
plows, rollers and lagging.
Flexco’s diversified offering, combined
with increased belt tensions and
the continuing evolution of belt
construction, prompted the company
to invest in the new test rig. Greg
Westphall, the director of engineering at
Flexco, calls it a one-of-a-kind machine
F e at u r e s
designed to ensure that Flexco products
continue to undergo rigorous in-house
testing before being placed in the field.
Westphall says the 120,000-lb. capacity
test rig is running successfully, thanks
in part to the quality of Baldor products
and the expertise of Baldor engineers
who offered a complete solution with
specific products.
“We make conveyor belt fasteners, so
we don’t have experience specifying
motors, drives, gearboxes, bearings and
pulleys,” says Westphall. “Selecting
these components is somewhat foreign
to our engineers. So, our decision to
choose Baldor as our partner was based
not only on the strong Baldor brand
name, but also the added technical value
that Baldor is able to provide.”
Flexco Mechanical Engineer Dan Dailey
says the first line of project support
came from Baldor’s Dodge® Field Sales
Engineer Nick Roseto, who not only
helped with installation and mounting
questions, but was also the link to all of
the other Baldor engineers who worked
on the design and product selection.
“Nick was more than just a sales guy;
he had technical knowledge and stayed
with us through the entire project,”
says Dailey. “When I had a question or
needed something, he is who I turned
to for help. Nick was a valuable asset,
because he consistently answered my
“Our decision to choose
Baldor as our partner
was based not only on
the strong Baldor brand
name, but also the
added technical value
that Baldor is able to
provide.”
Greg Westphall,
director of engineering,
Flexco
Because Flexco engineers want the flexibility to make pulley changes, they asked for a bearing they
could get on and off the shaft easily, with no damage. Baldor recommended the Dodge Hydraulic
ISAF pillow block bearing, with built-in hydraulic pistons that tighten and loosen the bearing for easy
installation and removal. The patented adapter mounting system provides full shaft contact that reduces
or eliminates fretting corrosion.
questions, plus coordinated the efforts
from others on the Baldor team.”
Flexco’s new 120,000-lb.-capacity test rig measures 24 feet high and 12 feet wide and weighs approximately 60,000 lbs. Baldor engineers worked with the Flexco
engineering team to ensure the optimal horsepower of the Baldor•Reliance® Super-E® motor and the Baldor•Dodge® MagnaGear™ reducer. Baldor engineers also
specified the Baldor•Dodge Hydraulic ISAF bearing and the design and specification of the six engineered pulleys used on the test rig.
30 | Solutions Magazine | Number 8
Some of the Baldor engineering effort
was focused on developing the correct
pulley specifications for such a unique
application. Westphall explained that
unlike a conventional bulk material
conveyor in which only the drive or
head pulley sees maximum tension and
the belt width is fixed, all six pulleys
see maximum tension on the Flexco
Flexco will use belts from 10 to 36 inches wide
on the new test rig, which concentrates the load
in the center of the pulley, causing a great deal of
stress. Flexco relied on Baldor engineers to design
all six pulleys to handle maximum tension and the
extreme loads.
Number 8 | Solutions Magazine | 31
F e at u r e s
Baldor UL 2200
Gensets
UL Verified Components
Tested as a Complete System
Not every UL 2200 genset on the market
is fully tested as a complete system. Many
are open units that are upgraded with
third party components and shipped to
customers without a complete system test
to verify performance and reliability.
Every Baldor UL 2200 genset is a complete
system designed, manufactured AND
tested at our plant. We use only UL verified
Data acquisition, including tracking motor speed, is critical to Flexco engineers, who specified an encoder
be added to the Baldor•Reliance Super-E motor.
components and every genset is tested
as a complete system before it leaves our
rig, and belt width will vary from 10 to
36 inches, making it a very demanding
application.
“The Baldor conveyor expert working
on this project understood the challenge
of running different belt widths on this
test rig,” says Westphall. “Concentrating
the load in the center of the pulley adds
a great deal of stress, so we needed a
pulley engineered to withstand extreme
loads. We relied on Baldor to design
and manufacture the pulleys we needed
based on our specifications.”
Baldor engineers also worked with
the Flexco engineering team to
ensure the optimal horsepower of the
Baldor•Reliance Super-E motor and the
Baldor•Dodge MagnaGear reducer for
the test rig. But Westphall says he and
his team are perhaps most grateful for
the help selecting the right bearing. In
32 | Solutions Magazine | Number 8
the past, bearing removal was not only
difficult but often caused damage.
“Again, unlike a typical conveyor
application, we want the flexibility to
make pulley changes, which means we
want a bearing that comes off the shaft
without damaging anything,” explains
Westphall. “We want to re-use the
bearing time and time again, and when
Baldor recommended the Hydraulic
ISAF bearing, we were very interested.
We believe this product meets our
needs and are confident we have found
the solution.”
When Flexco engineers began this
project, they, with the full support of
the company’s board of directors, were
determined not to sacrifice quality
or settle for second best. Today, they
say they are proud to have Baldor
equipment on their rig, and Flexco
factory. Once each genset passes rainwater
Flexco engineers say that using a variable
frequency drive is critical to not only jog the
conveyor forward and backward, as well as control
the speed very precisely.
Product Development Engineer Joe
Immordino credits Baldor engineers for
helping make sure they got the right
equipment for this unique application.
“Because it’s the only rig of its kind,
we needed a company that had the
experience to help us achieve a very
high level of performance,” says
Immordino. “Because it’s a test unit, it
has to have much tighter tolerance than
a typical conveying system – we need
a high level of precision and reliability,
and it has to last 30-plus years. We got
the technical expertise from Baldor
engineers to help us accomplish all
these goals.”
ingress tests, hipot alternator tests, air
blockage and flammability tests, proper
safety shutdown checks and verification
that component temperatures are below
combustion levels, then and only then will
we apply the UL label and the Baldor name.
baldor.com
479-646-4711
©2011 Baldor Electric Company
F e at u r e s
Baldor UL 2200
Gensets
UL Verified Components
Tested as a Complete System
Not every UL 2200 genset on the market
is fully tested as a complete system. Many
are open units that are upgraded with
third party components and shipped to
customers without a complete system test
to verify performance and reliability.
Every Baldor UL 2200 genset is a complete
system designed, manufactured AND
tested at our plant. We use only UL verified
Data acquisition, including tracking motor speed, is critical to Flexco engineers, who specified an encoder
be added to the Baldor•Reliance Super-E motor.
components and every genset is tested
as a complete system before it leaves our
rig, and belt width will vary from 10 to
36 inches, making it a very demanding
application.
“The Baldor conveyor expert working
on this project understood the challenge
of running different belt widths on this
test rig,” says Westphall. “Concentrating
the load in the center of the pulley adds
a great deal of stress, so we needed a
pulley engineered to withstand extreme
loads. We relied on Baldor to design
and manufacture the pulleys we needed
based on our specifications.”
Baldor engineers also worked with
the Flexco engineering team to
ensure the optimal horsepower of the
Baldor•Reliance Super-E motor and the
Baldor•Dodge MagnaGear reducer for
the test rig. But Westphall says he and
his team are perhaps most grateful for
the help selecting the right bearing. In
32 | Solutions Magazine | Number 8
the past, bearing removal was not only
difficult but often caused damage.
“Again, unlike a typical conveyor
application, we want the flexibility to
make pulley changes, which means we
want a bearing that comes off the shaft
without damaging anything,” explains
Westphall. “We want to re-use the
bearing time and time again, and when
Baldor recommended the Hydraulic
ISAF bearing, we were very interested.
We believe this product meets our
needs and are confident we have found
the solution.”
When Flexco engineers began this
project, they, with the full support of
the company’s board of directors, were
determined not to sacrifice quality
or settle for second best. Today, they
say they are proud to have Baldor
equipment on their rig, and Flexco
factory. Once each genset passes rainwater
Flexco engineers say that using a variable
frequency drive is critical to not only jog the
conveyor forward and backward, as well as control
the speed very precisely.
Product Development Engineer Joe
Immordino credits Baldor engineers for
helping make sure they got the right
equipment for this unique application.
“Because it’s the only rig of its kind,
we needed a company that had the
experience to help us achieve a very
high level of performance,” says
Immordino. “Because it’s a test unit, it
has to have much tighter tolerance than
a typical conveying system – we need
a high level of precision and reliability,
and it has to last 30-plus years. We got
the technical expertise from Baldor
engineers to help us accomplish all
these goals.”
ingress tests, hipot alternator tests, air
blockage and flammability tests, proper
safety shutdown checks and verification
that component temperatures are below
combustion levels, then and only then will
we apply the UL label and the Baldor name.
baldor.com
479-646-4711
©2011 Baldor Electric Company
solutions
PRSRT STD
US POSTAGE
PAID
Little Rock, AR
Permit No. 175
A Publication Featuring Baldor Electric Company Products
magazine
Number 8
Installing Bal
dor's
Dodge ULTR
A KLEEN
Ball Bearings
®
Moves Machine
from Leas
t Reliable to
Most Reliable at
ConAgra Foods® the
Lamb Weston
Potato Product
s
Plant
P.O. Box 2400, Fort Smith, AR 72902-2400, USA, Ph: (1) 479.646.4711, Fax: (1) 479.648.5792, International Fax: (1) 479.648.5895
baldor.com
©2012 Baldor Electric Company
Solutions0112
All Rights Reserved. Printed in USA.
1/12-AG-13M
Pl u s
Choosing the Right Partner
Baldor Products Featured
Helps Paragon Products Create More Success
on Flexco State-of-the-Art Test Rig
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