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Test Your Knowledge | Safe or Risky?

We recently asked our subscribers to review some scenarios and decide wether they would consider them risky or safe. Here’s how everyone voted…

Scenario 1

A hydraulic pump in a production line fails. The replacement pump matches the flow rate (20 gallons per minute) but is rated for 3,000 PSI, while your system hits 3,400 PSI during short bursts. The team suggests the pump can handle brief pressure spikes since they last only seconds.

90% of you said this was too risky.

Answer: Risky
Explanation: Exceeding the pump’s pressure rating, even briefly, risks leaks, wear, or catastrophic failure, compromising safety. A safe choice requires a pump rated for at least 3,400 PSI.

Scenario 2

Your conveyor’s V-belts wear out every six months due to heat (160°F) from nearby machinery. A heavy-duty V-belt is rated for higher durability and heat resistance (up to 180°F), with the same size as your current belts. Your equipment runs at moderate speeds, well within the belt’s limits.

92% of you said this was safe.

Answer: Safe
Explanation: The heavy-duty belt’s heat resistance and durability match the operating conditions, likely extending service life without affecting performance. A risky choice would involve a belt unsuited for heat or speed, but this option fits perfectly.

Scenario 3

A roller chain sprocket in a material handling system needs replacing. The original was stainless steel to resist rust in a humid environment (70% humidity). A cheaper carbon steel sprocket is available, and the team suggests frequent greasing to prevent corrosion, citing lower cost.

72% of you said this was too risky.

Answer: Risky
Explanation: Carbon steel corrodes faster in humid conditions, even with greasing, risking sprocket failure and chain damage. Stainless steel provides long-term reliability. A safe choice requires rust-resistant material.

Scenario 4

A 3-phase motor (10 horsepower, 1,800 RPM) in a pump system fails. The replacement motor matches power and speed but is designed for 460 volts, while your system supplies 480 volts. The supplier says most motors handle a 10% voltage difference, and the team wants to install it to avoid delays.

58% of you said this was safe.

Answer: Risky
Explanation: Running a 460V motor at 480V risks overheating or premature failure, as the voltage exceeds typical tolerances. A safe choice requires a 480V motor or voltage adjustment.

Customer Stories

We also asked customers to describe a time they had to take a risk or improvise on the job. We were blown away by the responses. Here’s a few of our favorites.

Rick - Kentucky
Yeti Mug

*AI Generated Image

David - Washington
Yeti Mug

*AI Generated Image