INPRO/SEAL’S DEVICES ARE NON-CONTACTING REPLACEMENTS FOR SEALS THAT CONSUME ZERO POWER
npro/Seal Company — a Rock Island, bearing protection devices, such as mag- ential cost for power over time is weighed
I IL based supplier of bearing isolators
— may have the key to energy conser- vation and be able to alleviate the need for immediate new power plant construc- tion in the U.S. and increase productivity netic face seals are also sold. Combined with lip seals, they account for some 6,000 MW of power consumption while functioning and effectively sealing. against the cost of a new motor and the benefits of greater efficiency and enhanced reliability. The vast majority of the time, the root cause of electric motor failures have been because of mechanical and plant reliability in the process. Use with electric motors rather than electrical problems. Inpro/Seal Company, is a leader in the Since their inception by Edison and Add to that the fact that bearing-pro- manufacture and application of non-con- Steinmetz back in the 1920s, industrial tected motors have proven to last at least tact, non-energy consumptive bearing electric motors were manufactured and twice as long as the motors that they protectors that are designed to replace put into severe-duty services without ade- replaced. This is because the major, doc- contact sealing devices that have proven quate bearing protection. Until recently, umented cause of motor failure remains to consume electrical energy while oper- only a close clearance between the shaft bearing deterioration. It has been estimat- ating. and end-bell served to limit contamina- ed that the insulation on the windings is Contacting lip seals were introduced tion ingress into the bearing environment. good for 130 years because it was over 70 years ago. Convenient and cheap, Reliability suffered as lifecycle costs for designed for severe resistive heating that when it came to protecting bearings, they energy and maintenance had significant does not present itself in the modern day went on to capture a 99% market share. negative impact on the process indus- super-efficient motor. Today, in the U.S., about thirty eight mil- tries’ production numbers. lion of them are manufactured for thou- In 1994, Institute of Electrical A savings windfall sands of industrial applications in the Engineers introduced their IEEE-841 If the 38 million contacting lip seals U.S. including: pumps, gearboxes, fans, Motor, an industrial-duty motor that was addressed above were replaced with non- paper machine rolls and other types of designed to improve reliability, efficiency contacting, non-energy consuming bear- rotating equipment. Most of these can be and performance by establishing simple ing isolators, the savings would be sub- replaced with non-contact labyrinth style guidelines. Immediately after its introduc- stantial. The net energy savings in the bearing isolators that consume zero tion, forward-looking process plants U.S. would be some 5,586 MW or the power. found that by switching to IEEE-841 equivalent of about 10 fossil-fueled In the 1970s, the bearing isolator was Motors energy consumption also power plants. invented by David C. Orlowski (patent improved. In 1995, after a process plant The process industries would save #4,022,479). A non-contacting labyrinth switched to 2,000 of these new motors, over $3.7 billion every year in electrical seal, it gave the end-user the choice of they directly attributed $5 million in sav- power costs. Tons of carbon dioxide, a permanent bearing protection and elimi- ings in efficiency and enhanced reliability. greenhouse gas (GHG) that is said to be a nated the need for continual maintenance. As part of its specification, all IEEE- major contributor to global warming, The size range of bearing isolators is 841 motors incorporate non-contact would no longer be produced. 0.625 inches - 57 inches. Inpro/Seal bearing isolators as standard The bearing isolators would stay in Comprised of a unitized rotor and sta- equipment. Recently the newer NEMA service for at least 20 years, eliminating tor that do not come into contact with Premium motor, which has at least a one the duty cycle and replacement expense. each other, it operates without contact and point energy edge, has become readily Operating costs would stabilize and thus does not consume energy. Because available with Inpro/Seal bearing isola- process industry manufacturers would they never wear out, bearing isolators can tors as a standard option. This kind of realize productivity increases and remain be used over and over for many years. permanent bearing protection greatly competitive on a global basis. Contact seals have a 100% failure rate. enhances reliability and reduces Mean For more information, “Introduction Lip seals consume power — lots of it. Time Between Failures (MTBF). To Bearing Isolators”, “Are Lip Seals In fact, it costs more to operate a lip seal Documentation shows that the investment Obsolete?” or a complete CD interactive than it does to procure one. When effec- for enhanced efficiency and reliability package are available from Terri tively sealing and protecting bearings, regularly yields an internal rate of return Hageman at: Inpro/Seal Company, P.O. each lip seal consumes, on average, 147 of more than 100%. Box 3940, Rock Island, Illinois 61204. watts of power. After about 2,000 hours It has been said there are some Phone numbers are: (800) 447-0524 or of operation (2.7 months), a lip seal will 40,000,000 industrial-grade electric (309) 787-4971. Fax number is: (309) fail, lose contact with the rotating shaft motors in use in the United States. These 787-6114. In addition, am Excel module: and stop consuming power. motors, on average will last about 5.7 Motor Energy Savings Justification At that point in time they either must years before they need to be repaired or Worksheet and other information can be be replaced or the rotating equipment replaced. This decision is usually based found at: www.inpro-seal.com or operates until the bearings become conta- around an energy analysis. www.bearingisolators.com minated or run out of oil. This is some- Will a new motor have an energy-sav- thing like running your car on a flat tire ing return on investment great enough to until it self-destructs. Other contacting rationalize the capital outlay? The differ-
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