Machinery & Equipment MRO April 2014 by Annex Business Media

MACHINERY AND EQUIPMENT

Are you ready for ISO 55000? Confined space training: A matter of survival Rewind shop questions standard procedures

Vol. 30, No. 2

Alternative created for hazardous asbestos gaskets

APRIL 2014

Fireball! Maintenance issues cited in mill explosion SPECIAL SECTION

Oil/Gas/ Mining MRO CASE STUDY Fighting condensation in PLCs at minus 40 TECHNOLOGY LNG offloading uses cryogenic floating hoses SOLUTIONS Alliance formed to solve oil and gas problems

Bearing Blunders Mail Agreement #40069240

Are you making these common mistakes?

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BEARINGS

SEALS

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P R O D U C T

SP TLIGHT

Machinery & Equipment MRO

Electric motor line expands to include 28 additional ratings

cies are offered on all models, including designs for closecoupled pumps. Baldor Electric Online Reader Inquiry No. 342

Snap-on Industrial’s extra-long sealed ratchet, a 1/4-in. drive, 9-in. handle tool (part number TLL72), allows access to hard-to-reach fasteners in narrow spaces. The ratchet comes with Dual80 technology, which features dual pawls with seven teeth in contact with the gear, providing strength and durability with 25% less ratcheting arc. Features include up to 90 lb.-ft. of torque to free rusted and seized fasteners, a seal mechanism that provides permanent lubrication and keeps out dirt and other contaminants, alloy steel for strength and durability, and

mirror finish with nickel chrome plating to prevent corrosion. Snap-on Online Reader Inquiry No. 343

Condition monitoring system helps keep machines running in mills

Ratchet’s extra-long handle gives added leverage in tight spaces

Baldor Electric has announced the addition of 28 ratings to its portfolio of Baldor-Reliance Super-E motors with an internal Aegis bearing protection ring. These ratings consist of 1-hp to 40-hp, open drip-proof motors, 200 V and 575 V, as well as 5-hp to 15-hp totally enclosed fan-cooled designs for 200 V. The company now offers 152 ratings for its inverter-driven motors with a shaft-grounding device factory installed. This internally mounted design minimizes the effects of shaft currents that can be present in adjustable-speed motor applications. The motors are constructed with heavy-duty frames and cast endplates, are suitable for mounting in any position and feature a Class H inverter-ready insulation system. NEMA Premium efficien-

April 2014

The SKF Multilog On-line System IMx-S monitors the condition of critical steel mill assets 24/7 and detects faults early to help prevent machine failures. The system provides timely and true simultaneous measurements of key operating parameters and, depending on the model, incorporates either 16 or 32 analogue signal inputs configurable for a variety of sensors. This robust, programmable and modular technology can be tailored to accommodate a wide range of challenging mill conditions, including

harsh operating environments, process parameter changes between steel grades, variable and low-speed equipment, shock loads and frequent roll changes. Typical applications include main drive roughing and finishing stand gearboxes and pinion stands, rolling mill work and backup roll bearings, and fans, among others. SKF Canada Online Reader Inquiry No. 341

Heavy-duty grinding wheel cuts through the hardest metals

Designed for the toughest, most demanding grinding jobs for a range of industry metal fabrication shops such as steel mills, mining, oil and gas, and ship building, the Xcavator ultra-high removal grinding wheel from Walter Surface Technologies delivers heavy-duty performance and the highest level removal rate in the Walter range of grinding wheel products. The extra-aggressive,

Keeping Industry Up and Rolling coarse front layer of enriched Zirconium grain easily handles such hard resources as tungsten carbide, tempered steel, Inconel, Hardox and Boron steel. The wheel features an extra-strong disc base/backing and the company’s UHR multi-layer manufacturing technology to prevent edge flakiness, keeping the wheel edge symmetrically round. Created for use with powerful grinding machines, the durable wheel is said to remove over 30% more grams per minute compared to other UHR wheels, while at the same time absorbing vibrations. Walter Surface Technologies. Online Reader Inquiry No. 344

Small-bore diagnostic hose speeds response time

Nothing is more frustrating than shutting down a machine, even an entire production line because of a bearing failure. Baldor•Dodge® bearings represent the best quality and reliability industry has to offer. From punishing mining applications to corrosive washdown environments, and everything in between, there’s a Baldor•Dodge bearing perfectly suited for the task at hand. Keep your machinery healthy, strong and efficiently rolling along with the widest choice of industrial bearings in the world…only from Baldor•Dodge. baldor.com

479-646-4711

• Unmatched Quality • Superior Reliability • Energy Efficient • American Made Since 1880

Parker Hannifin manufactures diagnostic hoses for use on heavy construction, agriculture and other mobile equipment where hydraulic systems are monitored. The 56DH and TEMA hoses, from the company’s Parflex division, are available in micro bore sizes (4 mm, 2 mm, 1/8 in., 3/32 in.) and in pressure ranges from 6,000 to 9,200 psiw. The smaller bore allows the hose to fit into tighter routings, and the high-tensile, aramid reinforcement minimizes response time and signal loss due to minimal volumetric expansion. The 56DH hose is available with a Parker Pressure Diagnostic port integrated into the hose fitting to speed up assembly time by eliminating the stack of hose fitting, bulkhead adapter and PD nipple. In addition, the hose can be produced in longer lengths, allowing for fewer connection points to provide the faster response needed for critical mobile applications. Parker Hannifin, Parflex Division Online Reader Inquiry No. 345

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Obtain free additional information about any of these items by using our online reader reply card at www.mromagazine.com/rsc.

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C O N T E N T S

Machinery & Equipment MRO

April 2014

in this issue Special Section Oil/Gas/Mining

A matter of survival / 10

What is it like to train for and perform a rescue from a confined space? Carroll McCormick takes a close look. Are you ready for ISO 55000? / 12

This new-school version of asset management is coming soon to a facility near you (maybe). Questioning electrical repair procedures / 14

When rewinding and repairing the coil of a 10,000-lb. magnet, this British Columbiabased service shop learned it is sometimes more effective to problem-solve by combining knowledge and common sense, and by questioning standard procedures, than by operating on blind trust alone.

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Companies form alliance to solve oil and gas problems / 21

departments Editor’s Notebook / 6 Industry Newswatch / 7 Business Briefs / 8

The Chevron GE Technology Alliance will develop and commercialize technologies to solve critical issues for the oil and gas industry.

Mr. O, The Practical Problem Solver / 9 Maintenance 101 / 19 The Safety File / 20

Fighting condensation at minus 40 / 22

MRO on the Road / 30

Ruggedized PLCs boost processing uptime at remote gold mine.

Product News Product Spotlight / 2

LNG offloading uses floating hoses / 24

The latest development in cryogenic LNG floating hoses is set to become a key component in offloading systems for future offshore FLNG projects. Oil industry giant gets lean / 25

Cart that effortlessly rolls heavy equipment into place without relying on a crane is built with lean manufacturing methods.

Focus on Bearings / 26 Focus on PPE / 27 Focus on Sealing Products / 28

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columns Mr. O, the Practical Problem Solver / 9

Why it should be OK to take home your hearing protection. Solving ongoing start-up problems / 19

Maintenance 101: Join us as we tackle step three in our maintenance assessment at an Ontario food plant. Fireball! / 20 Bearing blunders: Are you making these common mistakes? / 16

Mistaken ideas handed from one generation of maintenance engineers to the next help perpetuate many of these easily avoidable bearing problems.

The Safety File: WorkSafeBC cites maintenance issues in mill explosion. MRO on the Road / 30

We discover what’s interesting for the industrial aftermarket at the second-ever Fabtech Canada show in Toronto.

Big bearing ensures smooth process for pipe mill / 17

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A special cylindrical roller bearing with an outer diameter of 3.3 m solves problems for a three-roller planetary steel pipe rolling mill. Non-asbestos gasket material developed / 18

NA 1122 sheet proves to be a good alternative to asbestos-based gasket material.

‘Had the people who rewound the magnet the first time searched for the reason for the failure, the customer would have saved hundreds of thousands of dollars.’ Cosimo Geracitano / 14 ‘Bearings should not be hot to the touch. True or false?’ Ian A. Rubin / 16 ‘Given the toxicity of asbestos, manufacturers have been committed to finding safer alternative materials.’ Bill Searle / 18

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editor’s selections

‘Does everyone know what their responsibilities are? Does everyone have the tools they need to do their jobs properly?’ Peter Phillips / 19 ‘Friction within the motorreducer V-belt guard was a possible ignition source.’ WorkSafe BC / 20

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E D I T O R’ S

N O T E B O O K

Machinery & Equipment MRO

April 2014

seems you can’t hear or read any news reports these days without the term ‘skills shortage’ being mentioned. The feds, the provinces and territories say it’s an ongoing problem, so it must be true. And they plan to do something about it. Trouble is, that’s the same old song we’ve all been hearing for years and years. It seems they, honestly, don’t know what to do about it at all – or the problem would have been solved by now. Here’s what I think the real problem is with the skills shortage. I have the privilege, as editor of this magazine, to be able to talk to an awful lot of people in industry. I meet them at trade shows, inMRO_Mag_Full-Page_Movie-Ad_April_2013.pdf 1 4/4/13 dustry conferences, association meet-

ings, press conferences, plant tours and through a large network of connections. And you know what I hear a lot? It’s not that companies can’t find people with skills – it’s that they can’t find workers who want to actually work! It’s unbelievable, but finding a willing worker, somebody who doesn’t mind getting sweaty and dirty on a shop floor, in a production facility, a factory, a mine or a mill, is pretty damn rare. Many of the bosses I talk to say they’d take anyone who is somewhat intelligent, even nonskilled, off the streets and train them up, if they demonstrate a willingness to really want to work. 4:08 PM The academics and governments

sound career choice’ (see MRO On The Road on page 30), it’s still going to continue to be a challenge to find employees willing to do hard work. I’m not sure if this is the real problem, but if it’s the guys who don’t want to get dirty, let’s give the girls a shot. Speakers at the recent Fabtech Canada conference supported this. One said grade four girls are already being educated about technical career choices. If you agree or disagree, or have your own point of view on this matter, e-mail me at broebuck@mromagazine.com, and let’s get a discussion going. I’m willing listen to any logical arguments – and rants as well. ©Ridvan Çelik/iStock/Thinkstock

A skills-shortage rant

can argue for hours that the system is to blame for industry not having a ready supply of skilled workers for all those waiting jobs. But there are an awful lot of young people out there who don’t like to get dirt under their fingernails. From what I hear, many would rather be hired in a white-collar job as a manager first off – and that’s just not going to happen. I think that despite all the government rhetoric, the job skills shortage is going to continue. There’s an attitude problem that nobody knows how to solve. Despite employers saying they want college skills and university thinking (see the news item on page 7), despite admonitions by organizations like the SME that ‘young people would be wise to look to manufacturing as a

Bill Roebuck Editor & Associate Publisher

MACHINERY AND EQUIPMENT

MAINTENANCE, REPAIR AND OPERATIONS

APRIL 2014 Volume 30, No. 2 Established 1985 www.mromagazine.com www.twitter.com/mromagazine EDITORIAL Bill Roebuck, Editor & Associate Publisher 416-510-6749 broebuck@mromagazine.com Hwee Kuan Choo, Art Director Contributing Editors Simon Fridlyand, Steve Gahbauer, Carroll McCormick, Peter Phillips, Robert Robertson, Angela Webb BUSINESS Jim Petsis, Publisher 416-510-6842 jpetsis@mromagazine.com Jay Armstrong, Sales Manager 416-510-6803 jarmstrong@mromagazine.com Kimberly Collins, Advertising Production 416-510-6779 Melinda Marasigan, Subscription Enquiries 416-442-5600 x3548 Machinery & Equipment MRO is published six times a year to help improve the effectiveness, productivity and practical knowledge of maintenance professionals in Canada’s manufacturing, utilities and resource industries. AWARD-WINNING MAGAZINE

Editorial & sales office: 80 Valleybrook Drive, Toronto, ON Canada M3B 2S9; tel: 416-442-5600, 1-800-268-7742; fax: 416-510-5140. Subscription rates. Canada: 1 year $58.95, 2 years $94.95. United States: 1 year $85.95. Elsewhere: 1 year $87.95. Single copies $10 (Canada), $16.50 (U.S.), $21.50 (other). Add applicable taxes to all rates. On occasion, our subscription list is made available to organizations whose products or services may be of interest to our readers. If you would prefer not to receive such information, please contact us via one of the following methods – phone: 1-800-668-2374, e-mail: privacyofficer@businessinformationgroup.ca, fax: 416-442-2191, mail to Privacy Officer-Business Information Group, 80 Valleybrook Drive, Toronto, ON Canada M3B 2S9. ©2014. Contents of this publication are copyright and may not be reproduced in whole or in part in any form without written consent of the publisher. The publisher cannot assume responsibility for the validity of claims in items reported or advertised. Machinery & Equipment MRO is published by BIG Magazines LP, a div. of Glacier BIG Holdings Company Ltd. Bruce Creighton, President, BIG; Alex Papanou, Vice-President, BIG; Tim Dimopoulos, Executive Publisher, BIG. Publications Mail Agreement No. 40069240. Return postage guaranteed. ISSN 0831-8603 (print). ISSN 1923-3698 (digital). Return undeliverable Canadian addresses and change of address notices to: MRO Circulation Dept., 80 Valleybrook Drive, Toronto, ON Canada M3B 2S9. MRO, USPS 012-846 is published six times per year by Business Information Group. US office of publication: 2424 Niagara Falls Blvd., Niagara Falls, NY 14304-0357. Periodicals Postage Paid at Niagara Falls, NY. US postmater: Send address changes to Machinery and Equipment MRO, PO Box 1118, Niagara Falls NY 14304.

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We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund of the Department of Canadian Heritage.

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Machinery & Equipment MRO

Employers want college skills and university thinking

get skills that match the job market,” said Linda Franklin, president of Colleges Ontario. Enrolment in first-year college programs in Ontario, for example, is up 5% in 2014 to more than 125,000 students. About 220,000 students are enrolled in programs overall, numbers that are made up not only of first-time students but also by university graduates seeking more marketable skills. According to the latest data available from the Association of Canadian Community Colleges, there are currently 1.5 million students at colleges, institutes and polytechnics, one million of which are students earning credits in certificate, diploma, degree and apprenticeship programs. But while interest in job-specific training tends to go up in hard economic times, this latest bump seems determined to outlast the recession, experts say. “We’ve gotten past some of those ideas about who should go to college and who should go to university,” said Jessica McCormick, chairperson for the Canadian Federation of Students. Prospective students now see the value of a college education, she added, and “that it’s for everybody … [and not just for those who] don’t get into university.” This year, the top program choices were business, practical nursing, social work, electrical engineering technician and culinary management, according to Colleges Ontario. Computer programmers, machine operators and welders are also among the most in-demand trades, although mechanics, carpenters, hair stylists and plumbers are also needed. Ottawa is looking for ways to expand paid co-op opportunities that combine classroom-based education with practical work experience, but also to ‘reinvent’ vocational high schools.

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Benjamin Tal, an economist with CIBC, suggests that’s a step in the right direction, noting that it’s both “backwards and expensive” to have university graduates later end up in colleges for practical training. “I think the key to solve the mismatch in the labour market in Canada is to get rid of the stigma that’s associated with colleges,” he said. And while a university degree comes with its own benefits, Tal said, the two systems should work together more closely to allow people to follow their passion and find a reasonable way to make a living. “I don’t see anything wrong with a degree in history and a minor in plumbing,” said Tal. Andrea Plotnick of the Hay Group, a global management consulting firm based in Toronto, says she’s struggling to understand why university degrees seem to have lost some of their lustre. Whatever the reason, she argues it’s important to for a student to develop their critical thinking skills so they can become leaders in their field. “We shouldn’t be taking a cookie-cutter approach to thinking about our labour force,” said Plotnick. “We need higher-order thinking. We need people that are more technically inclined – we need it all.” ©The Canadian Press

3D LASER IMAGING RECREATES POWER PLANT DOWN TO NUTS AND BOLTS

EASA REBRANDS AS ‘THE ELECTRO-MECHANICAL AUTHORITY’ Bensenville, IL - Over the past 25 years, members of the Electrical Apparatus Service Association (EASA) have changed in various ways to meet the demands of its their customers, adding services and/or products. As a result, these changes have required them to become even more technical, their product offerings to be more sophisticated, and their business practices to be more efficient. EASA’s technical expertise and training programs also have evolved and grown to help members meet these demands. In seeing this evolution, as well as an increase in outside influences negatively Photo: EASA

Both college and university students can find satisfying jobs in industry.

makes clear that members work on both electrical and mechanical equipment, and they are the experts in doing so. The previous tagline was ‘Reliable Solutions Today!’ The new logo design is intended to: maintain the stable image of the past as the foundation via its deep blue colour, boldly proclaim EASA as the The Electro•Mechanical Authority for industrial and commercial markets, tie in the important international focus with a stylized globe that also points back to the new tagline, represent the industry in a unique way via the rotation reflected in the globe design, and demonstrate the recycling nature of the business via the green colour of the globe. Members can download the new logo from www.easa.com/logo.

New logo gives EASA a much more up-to-date brand.

impacting the electrical service industry, the association’s Board of Directors made one of its objectives to strengthen its position as the recognized authority in electro-mechanical systems. Its Marketing and Industry Awareness Committee recently oversaw the rebranding of EASA to include a new logo and tagline that would reflect the association’s rich history and international representation, while also defining it and its members as a progressive and a powerful resource. Along with the logo’s new design, the committee chose the tagline, ‘The Electro•Mechanical Authority’, which

Toronto - Several hundred Ontario engineers gathered at the Ontario Science Centre in Toronto on the night of March 6, 2014, to learn more about the magic of 3D laser imaging. Held as part of Engineering Month, the ‘Engineering Innovations in 3D Imaging’ event was organized by Professional Engineers Ontario. Peter Srajer, P.Eng., advanced technology manager with MMM Group, gave the first presentation. The company is using 3D laser scanning on a range of projects – everything from huge power plants to tunnels and bridges and historical buildings. Srajer showed highly detailed and colourful 3D images reconstructed from millions and billions of data points. A power substation, for example, was detailed right down to the smallest pipes and bolts, to an accuracy of 2 millimetres. The data points are exported directly to a CAD or BIM program for modelling. With this information, the plant owner can identify problems like ‘bottlenecking’ in the pipe layout and correct them. One of the advantages of 3D laser imaging is speed: the scan can be done in a few hours. It also saves having to send people close to dangerous situations, since the scanning can be done from a distance. Srajer showed a 3D scan of a large tunnel collapse, where the cause of the collapse could be seen without someone having to get closer than 150 metres. At the 58-storey Bow building in Calgary, the technology was used to show where electrical conduit and other services were hidden behind walls. And at the historical Gage building in Hamilton, ON, a 3D scan recorded the existing status of the building before renovations were done. At Edmonton Airport, 3D imaging of the airside portion of the terminal was done and then the results were overlaid on a photograph to create an attractive graphic presentation. Every pixel in the photograph had a 3D coordinate. The event’s speakers suggested that the possibilities for 3D scanning to create a virtual representation of reality are endless. The only thing standing in the way at present is limited computing power, which has not kept up, they agreed. These technologies eat up billions of bytes. Srajer also noted that the technologies are evolving so quickly that a device will easily become obsolete in five years. And 3D imaging is not always practical, Srajer cautioned. While the scanning can be done quickly, it takes a huge amount of time to process the

data, making it costly. And the technology doesn’t work well on relatively flat areas, or where there is grass or vegetation. In the latter cases, LiDAR is preferable, he suggested. The Engineering Innovations Forum has been held as part of Engineering Month since 1990. Sponsors this year include Morrison Hershfield, Hatch, MMM Group, PEO and the Ontario Society of Professional Engineers. By Bronwen Parsons

PTDA FOUNDATION ESTABLISHES AWARD TO RECOGNIZE TRAILBLAZING WOMEN Chicago, IL − To honour the memory of Wendy Burdon McDonald, CM OBC LL.D. (Hon.) D.Tech. (Hon.), one of the power transmission/motion control industry’s true pioneers, the PTDA Foundation has established the Wendy B. McDonald Award. The award will acknowledge a woman who has established herself as a critical contributor to her company’s success and has affected positive change within the power transmission/motion control industry. Wendy B. McDonald, known to many in industry simply as ‘Mrs. Mac’, served over 60 years as a leader in her family-owned international industrial distribution company, BC Bearing En-

Wendy B. McDonald was the head of BC Bearing Engineers, Burnaby, BC.

Photo: Bill Roebuck

April 2014

Toronto – A college education is becoming an increasingly attractive option for many prospective students who are seeking the right skills to fit an evolving job market. “There’s a definite shift in attitude about college and more of an understanding, that as the economy changes, colleges are a really good opportunity to

N E W S W A T C H

gineers Ltd. of Burnaby, BC. (The company was acquired by Motion Industries Inc. in 2010.) A trailblazing business owner, Mrs. McDonald left many legacies through her long career in the industry. Her charm and grace are legendary, as well as her philanthropy and commitment to give back to the industry and the communities that led to her success. Mrs. McDonald was born on June 13, 1922, and she passed away at the age of 90 on December 30, 2012. When merited, the Wendy B. McDonald Award will be presented annually during the PTDA Industry Summit. Nominations are now being accepted through May 31, 2014, for the 2014 summit October 23-25 in Orlando, FL, and will be judged by the following criteria: Nominees must be female and employed by a PTDA member company in any capacity. There are no criteria with respect to title, position in the company or years of experience. Nominees must exemplify leadership and integrity in all business relationships. Although all nominees are considered, those employed by Canadian companies or distributors receive extra consideration. Details of the criteria and a nomination form can be downloaded at www. ptda.org/WBMcDonaldAward. The not-for-profit PTDA Foundation, whose work is funded solely by donations, was founded in 1982 to enhance knowledge, education, professionalism and productivity within the power transmission/ motion control (PT/MC) industry. For more information, visit www.ptda.org/ foundation. MRO Visit www.mromagazine.com for current news and more detailed versions of the items here.

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N E W S W A T C H

Machinery & Equipment MRO

April 2014

Business Briefs

News and views about companies, people, product lines and more Photo: Lafert NA

• Stephen Anderson has which provides leadership, educajoined Lafert NA, Missistion and certification in world-class sauga, ON, as a new outside maintenance and asset managesalesperson, with a focus on ment practices in Canada. the oil and gas industry. He The Life Membership award is has over 30 years of experigranted by PEMAC upon a memence in the motor industry, ber’s retirement from a formal working on large projects in leadership position within the asthe low- and medium-voltage sociation and recognizes the motor ranges. member’s contribution to PEMAC, Stephen • Roop Lutchman, leader of and by extension the contribution Anderson GHD’s business consulting to the maintenance and asset team in North America, based management profession. Lutchin Mississauga, ON, recently received the man has been active with PEMAC since Life Membership award from the Plant its inception, serving continuously on the Engineering and Maintenance Association Board of Directors until February of of Canada (PEMAC). This membership 2013, playing an active part in the develrecognizes his contribution to PEMAC, opment of the MMP program, and acting

as an early instructor of that program. He was registrar and chair of the Education and Professional Development Committee until recently and remains active as a member of that committee. He has been instrumental in helping PEMAC make the transition into promoting excellence in asset management and was the lead instructor in the association’s first offering of the new workshop, ‘Introduction to Asset Management for Senior Leaders’. Lutchman describes his commitment to PEMAC as a ‘win-win’ situation for the organization’s members, GHD and himself. “PEMAC has enabled me to give something back to the maintenance and asset management profession and the broader community,” he said. “It has given me a platform to share my knowledge with other practitioners, and broadened my insights into the profession and my role at GHD. It has also enabled me to contribute to shaping Canada’s mainte-

Photo: Igus

Superior cleaning of industrial contaminants

nance and asset management practices. • Snap-on Industrial Brands has announced that Torque Products Canada, a division of M & L Testing, is now an authorized CDI Torque Wrench Warranty Repair & Calibration Service Centre. M & L Testing, in its 54th year of business, is one of the country’s largest distributors of industrial-quality torque wrenches, torque testing and calibration equipment. The shop is located in Dundas, ON. CDI, a Snap-on Industrial Brand, manufactures and sells professional-grade torque products. Snap-on Industrial is a division of Snap-on Inc., a manufacturer and marketer of tools, diagnostics, and equipment, software and service solutions for professional users. • To celebrate 30 years of its plastic bearings, Igus of East Providence, RI, has retrofitted a Mercedes-Benz Smart car with 56 iglide bearings. These components are in all areas of the car, including the pedals, alternator, window regulators, convertible top, gearshift and more. The company says 200 million plastic iglide bearings were already installed in cars and trucks last year, and now Igus is putting them to the test on a 20-country, nine-month world tour. Starting in February 2014 in India, the car will be shipped across oceans,

Tour will take 56 plastic bearings around the world.

CB 100

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For more information, visit: walter.com or contact your Walter Representative.

Online Reader Inquiry No. 119

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VIDEO DEMO

and then driven around continents, stopping along the way at Igus subsidiaries, partners, customers, trade shows, expos, and Manus winners. In late July, the car will make its way to North America, beginning a tour of the US and Canada in Anchorage, Alaska, where it will make its way from ocean to ocean until early October. For more information about the car’s world tour, visit www.iglide.com/30, or visit the company’s blog, with photos from the worldwide adventure and the retrofit process, at www.blog.igus.com. • Catalys Lubricants Inc., Delta, BC, is a new company competing in western Canada’s industrial lubricants sector. Catalys is a subsidiary of Groupe Crevier, Montreal, which has operated in Eastern Canada for over 70 years. As the Western Canadian division of the company, Catalys is responsible for the sale and distribution of lubricants in the Lower Mainland, Fraser Valley and Vancouver Island. The company is an established, Chevron-branded First Source Elite certified lubrication marketer and one of the leading Chevron marketers in North America. • Canadian-based customers now can order Sioux Tools brand tools and equipment through local authorized Snap-on Industrial Brands distributors – a move aimed to streamline and simplify the ordering process. Founded in 1914, Sioux Tools supplies pneumatic hand-held power tools for a variety of industrial markets. With this Canadian consolidation, authorized distributors throughout Canada will be able to offer more than 7,500 Williams, CDI and Bahco brand products.

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I N D U S T R Y

Machinery & Equipment MRO Photo: Gray Tools Canada

April 2014

• A new stand-alone company has been created out of the former pneumatics business unit at Bosch Rexroth. Due to a change in ownership, the mediumsized company is now operating under the name Aventics. Aventics is a globally active manufacturer of pneumatic components and systems. The company is also a specialist supplier of drive and control solutions for the marine industry and commercial vehicles, as well as inverted tooth chains for production processes. The former subsidiary of Bosch Rexroth has been operating as a standalone company since the start of 2014. The pneumatics specialists have global headquarters in Laatzen, German. In the US, headquarters remain in Lexington, KY, and in Canada, headquarters remain in Burlington, ON. • After months of development, several rounds of design options, and many interviews with customers, Gates has launched an all-new website at www.gates.com. An improved search functionality makes it easier to find specific information regarding the company’s OE-quality parts, solution kits and tech tips. Gates is a supplier of power transmission and fluid transfer solutions. A new organizational structure allows visitors to browse the site and explore its content more easily than before. The most popular features of the previous site are still available, including the VIN Decoder and the parts lookup application. The company’s Canadian office is based in Brantford, ON. • Gray Tools Canada, Brampton, ON, an industrial tool manufacturer and distributor, has donated $3,500 to the Canadian Breast Cancer foundation. The funds

N E W S W A T C H

Gray Tools Canada donated $3,500 to breast cancer research.

were raised through the auction of nine limited-edition pink tools chests signed by company chairman Alex Gray. The auctions were held during the months of November and December 2013, and received more than 50 bids per chest on eBay. • The Timken Company, Canton, OH, has entered into an agreement with United Wagon Company (UWC), which is involved in building, leasing, engineering and servicing freight cars in Russia, to establish a joint venture to manufacture Timken AP-2 rail bearings in Russia. The joint venture will advance the safety, reliability and efficiency of the local rail industry, equipping customers’ freight cars with premium Timken bearings. The joint venture is contingent upon various regulatory approvals and other commercial and customary conditions. Russia expects to acquire nearly one million new freight cars by 2030 as part of an aggressive investment program to renew and upgrade its rolling stock. MRO

Mr.0 The Practical Problem Solver

Take your earplugs home Problem: Most of us know why we need good hearing protection at work. But your employer should also encourage you to take hearing protectors home, says Howard Leight’s Theresa Y. Schulz, PhD. Solution: “Noise hazards are not exclusive to the workplace,” says Dr. Schulz, hearing conservation manager for Howard Leight, “but compensation claims for noise-induced hearing loss often are. Lawn mowers, chain saws, home workshop tools, even personal listening devices (e.g., mp3 players), and cranked up stereo systems can all add to hearing damage, but it’s usually the employer who ends up paying the price.” Encouraging workers to wear hearing protection off the job as well as on makes sense for other reasons as well, says Dr. Schulz. “One of the most difficult tasks safety managers face with regard to hearing conservation is convincing employees of the risk. Talking about noise hazards present in everyday activities brings the hearing conservation message ‘home’ in a very meaningful way. It gets workers’ attention, helps make earplug use habitual, and more often than not, gets the neighbours attention as well. “Employees should not be made to feel that they are pilfering, or that management is simply looking the other way,” she said. Rather, the message should be loud and clear. She recommends posting signs by disposable earplug dispensers recommending employees ‘Pocket a Pair for Home,’ and making particular mention of the policy in training sessions and group meetings. Do you have a solution for a maintenance problem? Send it in and if it’s published, we’ll send you a Mr. O Problem Solver T-shirt. Include your name, company, address, and telephone number or e-mail address. Provide complete details and, if possible, include a sketch to help explain your tip. Send your tips to Mr. O, c/o broebuck@mromagazine.com, or by post to: Machinery & Equipment MRO, 80 Valleybrook Drive, Toronto, ON M3B 2S9.

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Photos: Carroll McCormick

Machinery & Equipment MRO

April 2014

A Matter of

SURVIVAL What is it like to train for and perform a rescue from a confined space? Carroll McCormick takes a close look.

3. It takes teamwork to install and operate the four-to-one haul system on the roof of the trainer. Brakes require frequent repositioning during the lift, the backup line must be kept taut and the rigging team must communicate with the rescuers below. The victim’s head must be kept clear of the hatch rim to prevent injury by the powerful haul system.

Photo 5: Clarence Germain

1. Two rescuers have located the victim and pulled him to a spot beneath the roof hatch. While attaching the haul system to his harness, they must also keep their own air hoses and lifelines from tangling. So far, the rescue has taken about 20 minutes. The tasks are realistic, completely absorbing and quite strenuous. 2. This rescuer pulls himself across a space barely 18 in. high. Then, without getting his emergency tank, air hose or lifeline tangled in his partner’s gear or otherwise caught on something, he wriggles up through a small hole and across another cramped level to locate the victim. Then he and his partner retrace their route with their completely uncooperative victim.

4. For some of the exercises, two hard-working rescuers enter the trainer wearing supplied-air breathing apparatus, with air delivered through long hoses from pressurized tanks. The designated air supply officer monitors the air cart gauges and switches to full air bottles about every 10 minutes. To simulate an air supply failure, he shuts off the tanks without warning, forcing the rescuers to turn on their own emergency air supply tanks.

5. Called a SKED, this carpet-like piece of gear is used to tightly package a victim for easier extraction. Unless the victim is very fortunate, however, the chances are very good that rescuers will be using it for a removal, not an extraction. Our author is wrapped up tight, but he’s fine. 6. The crew of Secunda Canada’s offshore support vessel Scotian Sea is ready for the sweaty part of their confined spaces rescue training. From left to right: Sandy Smith, deckhand; Clarence Germain, chief engineer; Mike Childs, master; Andrew Walbourne, deck hand; Nathan Scott, third engineer. 7. Using specialized climbing knots and applied physics, the crew learns to build a four-to-one haul system, complete with brakes, called Prussicks (the orange and green ropes). It requires 12.5-mm rescue rope, 5,000-lb.-test carabiners and Prussick minding pulleys. Hung from tripod or davit access and retrieval systems, it reduces a nearimpossible 200-lb. lift to a manageable 50-lb. effort.

umans have a powerful urge to race to the rescue when someone succumbs to a hazard in a confined space. Yet that is the worst possible reaction. Proper training and equipment, teamwork, cool heads and a disciplined sense of self-preservation are absolute necessities before ever trying to rescue anyone in a confined space. “Every year, more people die attempting confined-spaces rescues than die in confined spaces at first,” states James Buntain, safety representative and industrial specialist at Survival Systems Training Ltd. (SSTL) in Dartmouth, NS. Like insects drawn to a honey trap, many workers have rushed to help fallen colleagues in confined spaces, only to die themselves.

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Buntain is talking to the five-man crew of the Scotian Sea, an offshore support vessel belonging to St. John’s-based Secunda Canada. They are in Dartmouth to take SSTL’s three-day Confined Spaces Entry & Rescue (24 hours) course as part of maintaining their certification to perform confined-spaces rescues. I have joined them for the course. The crew has already taken the Confined Spaces Entrant/Attendant course, so for them day one is a classroom review of regulations, hazards, techniques and fatal incidents. “Most confined space rescues are recoveries. The chances of getting someone out alive are slim to nil,” Buntain warns. A confined space is defined as follows:

It is enclosed or partially enclosed and has limited access/egress. It is not designed for human occupancy and can contain toxic fumes or substances. Physical hazards include the risk of slipping, tripping or falling, heat, cold, corrosive chemicals, animals, poisonous spiders and sludge or scale. Atmospheric hazards in confined spaces include hydrogen sulphide, carbon monoxide, oxygen deficiency or oxygen enrichment. “You always test oxygen levels first. Then test flammable range, then toxic gasses,” Buntain reminds us. Buntain reviews elements of a confined spaces safety program; e.g., identify all confined spaces, hazard assessment, entry procedures, training and

the confined spaces permit. He discusses gas detection equipment, lower and upper explosive limits and ventilation techniques. He reviews the rescue team positions, such as incident commander, rescue supervisor, rigging team and air supply officer. After a few hours of lecture, films, and question and answer sessions, we pull on our coveralls and head outside to familiarize ourselves with the equipment and do some confined spaces rescues. The rest of the story is told in the photo captions. MRO Carroll McCormick is MRO Magazine’s senior contributing editor. He is based in Montreal.

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Machinery & Equipment MRO

April 2014

It’s coming soon to a facility BY CLIFF WILLIAMS near you (maybe).

2014

will see the unleashing of the ISO 55000 suite of asset management systems on the world. What will that mean to you? For you to understand a little better what the answer may be,

perhaps we should first look at where this standard came from. In the late 1990s early 2000s, there were problems with the utilities infrastructure in the United Kingdom. People were having to do without water or hydro,

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Are you ready for ISO 55000? and there were accidents on the railways – there was a problem! Many of these industries had been recently privatized and there was concern that the companies that had taken on the responsibility of running them did not fully understand the implications of managing such large assets. This ultimately led to the issue of Publicly Accessible Specification number 55 or PAS55 back in 2004. It was issued by the Institute for Asset Management and the British Standards Institution, and was followed by a revision in 2008. This led to the realization that there was no real international standard for asset management and so the idea of ISO 55000 was formulated through the International Standards Organization. It has taken until 2014 for this work to come to fruition, with 27 countries participating and a further 10 playing the role of observers. The standard, which is being published in 2014, is made up of three parts: 1) ISO 55000:2014 Asset management: Overview, principles and terminology 2) ISO 55001:2014 Asset management: Management systems – Requirements 3) ISO 55002:2014 Asset management: Management systems – Guidelines for the application of ISO 55001. It should be made clear that this is not an asset management standard and even though it does contain far more prescriptive language than most ISO standards, it really is like a standard for the systems you may use. For those of us who have been involved in maintenance and reliability, we may be surprised that we only fulfil one of the functions required by this system – we operate in the useful life section of the system. What has changed is that our role will have influence on the other functions within the system. Before we go much further, I think it would be wise to understand the definitions of ‘asset’ and ‘asset management’ as per ISO 55000. An ‘asset’ is something that has potential or actual value to an organization and so you see that it will include more than the equipment we typically look after. ‘Asset management’ involves the coordinated activities to realize value from the assets – so it’s not simply just managing assets. The first step of the new asset management is understanding the stakeholder/regulator/customer/market requirements of your organization – today and in the future. From there, an Organizational Strategic Plan must be developed,

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taking into consideration the input from the aforementioned. This will drive Asset Management Strategy and Planning and arrive at Asset Management Objectives that will include the level of service and desired outcomes that are required. During this stage, a review of possible future demands, current capabilities, current state of assets and availability, or method of raising funds to replace or expand the assets, will need to be carried out. Even though maintenance and reliability professionals may not be included at this stage, their input as far as the current state of assets should be requested. We then move to an actual Asset Management Plan, which details the activities that the organization will need to accomplish so that it may meet the objectives and maintain the level of service required. The Plan may include operational and maintenance regimes, along with information on the current assets and their performance. It may include how funds will be realized to expand the asset portfolio or to renew older assets. There may also be training or education plans if they are deemed to be necessary to achieve or maintain the level of service. In fact, the Asset Management Plan is an ‘interrelated set of activities or interacting elements to establish the Asset Management Policy, the Asset Management Objectives and the processes to achieve those objectives’. Running parallel to this flow is one that ensures that the necessary support or enabling functions for achieving the Asset Management Strategy are in place. These functions will include the Asset Information, which will describe what data will be required to make the most informed decisions on the optimal Asset Maintenance Strategy, or the renewal or retirement of assets. This will include location, current condition, likelihood and impact of failure, regulatory requirements and impact on the overall performance. The Asset Knowledge side will identify the level of knowledge required for the above categories to ensure that the accuracy and relevance of the information is maintained. The Asset Information Systems are typically the software or systems that you will use to store, classify and analyze the information. For maintenance and reliability types, this would take the form of a computerized maintenance management system (CMMS), whether it be a part of a bigger Enterprise Asset Management (EAM) system or a stand-alone setup. The information – or at least the analysis – must be easily communicable to any other systems included in this process (purchasing, logistics, production planning, etc.) During this portion of the process, we would also ensure that any training, competency level, resource requirements, etc., are clearly identified and documented. Once all of these things are in place, then it’s back to business as normal for us maintenance and reliability types – well, almost normal. The same strategies for maintaining equipment are used, planning and scheduling are still important, having the right parts at the right time is still necessary. But what has changed is the context in which we think of these things. Let’s remember the definition of an asset – an ‘asset is something that has potential or actual value to an organization’. And so we have to think in the context of what value do these actions bring to the organization. Many times we see that equipment is maintained way beyond its intended life; that’s a success story right? But what if

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13 Machinery & Equipment MRO

we could actually replace this piece of equipment with a new, more energy-efficient model, one that produces 50% more product and one that will cost far less to maintain – life-cycle wise – because of improvements? Do the actions actually provide value? This is a new part of asset management – the decision-making around the optimal time to replace, renew or dispose of assets. The review of performance, complications or constraints that develop during the ‘useful life’ portion of the system form a continuous feedback loop back to the starting point – the Organizational Strategy – which in turn modifies, changes or encourages the system all over again. So will ISO 55000 tell you how to do all of this? No, but it will describe what your management system should contain for you to be ISO 55000-certified.

So that begs the question – who would want to be certified? • There will be those who will be regulated (it’s expected the utilities, etc., in the UK will be and there is movement to take it to US Congress as a best practice for OSHA, EPA, etc.). • There will be those who want to receive lower insurance premiums for being certified – some insurers have already hinted this will happen. • There are those who, just like the early days of ISO 9000, just want to fly the flag. • Then there are those who will be required to by their customers – you may not see big oil and gas certified, but you probably will see it in their carriers – the pipelines, railways, etc. • Last of all, you will see the smart ones certified – those that see value in asset management as an operating principle and who have chosen to certify with ISO 55000 as a demonstra-

tion of their commitment. To sum up ISO 55000, I’ll use its four fundamentals • Value - Assets exist to provide value to the organization and its stakeholders. • Alignment - Asset management translates the organizational objectives into technical and financial decisions, plans and activities. • Leadership - Leadership and workplace culture are determinants of the realization of value. • Assurance - Asset management assures that assets will fulfil their required purpose. MRO Cliff Williams is an author, speaker and avid follower of all things maintenance, and in his spare time is corporate maintenance manager at ERCO Worldwide in Toronto. If you’d like to discuss asset management or ISO 55000, drop Cliff at note at cwilliams@ercoworldwide.com.

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Questioning Procedures When rewinding and repairing the coil of a 10,000-lb. magnet, this

British Columbia-based service shop learned it is sometimes more effective to problem-solve by combining knowledge and common sense, and by questioning standard procedures, than by operating on blind trust alone. BY COSIMO GERACITANO Photos: Electro Motors Co. Ltd.

Left: The first layer of turns on the coil is shown. Centre: These are the second and third layers of turns. Right: The new coil, mounted on a large winder, is almost completed.

ewinding and repairing large magnets is one of the specialties at Electro Motors Co. Ltd. Its team of skilled people is trained not only to rewind/repair to the original manufacturer’s specifications, but also to identify the reason for failure and make improvements where needed to prolong the life of the motors, generators and magnets it rebuilds. A few years ago, we were approached by a large company asking us if we could quote on the rewinding of the coil of a

10,000-lb. magnet. They told us they had four magnets and all of them had failed a few times in the past 10 years. We quoted and our price was acceptable to them, but since the magnet was already at another rewind shop, they decided to let it do the rewinding and told us that if they had another magnet failure in the future, they would contact us. This year, another magnet that was rewound only a few years ago failed, and they shipped it to us to rewind. We removed the coil and set it up on our large coil winder to

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unwind and count the number of turns. The top layer of turns was discoloured due to the heat generated by the coil. We noticed that the second layer of turns was even darker and the third layer of turns was completely burnt. We expected all of the remaining layers of turns to be completely burnt, since as you get closer to the centre of the coil, more heat is generated. However, to our surprise, the next three layers of turns were the same as the first three layers: the first layer discoloured, the second layer darker, and

the third layer completely burnt. This same pattern repeated itself up to the end of the large coil. We learned that the manufacturer of the magnet recommended the use of high-temperature varnish for every third layer of turns, and every time a coil failed in the past, the various shops that rewound them brushed a coat of varnish on every third layer as suggested in the manufacturer’s instructions, and then baked the completed coil to cure the varnish. The coil was wound with aluminum wire wrapped with 0.0025-in. Nomex paper, half of it overlapping. The temperature rating of the coil was 150°C. At that high temperature, the aluminum wire needed to expand, but every third layer of turns was prevented from expanding because the cured/hardened varnish created a high bond between turns, which damaged the Nomex paper insulation wrapped around the wire. We made the improvements necessary to allow the aluminum wire to expand at the rated temperature. As a result, we are very confident that the magnet we rewound will last for many years to come. Since then, another one of our customer’s four magnets failed and we will be rewinding it with the same improvements. There is a lesson here to be learned by everyone: it is sometimes more effective to problem-solve by combining knowledge and common sense, and by questioning standard procedures, than by operating on blind trust alone. Had the people who rewound the magnet the first time its coil burned searched for the reason for the failure, the customer would have saved hundreds of thousands of dollars over the past 10 years. MRO Cosimo Geracitano is the manager of Electro Motors Co. Ltd., Port Coquitlam, BC. For more information, visit the website at www.electromotors.ca.

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April 2014

Mistaken ideas handed from one generation of maintenance engineers to the next help perpetuate many easily avoidable bearing problems. BY IAN A. RUBIN

he wheels of industry dations. These will give amounts and turn on bearings, so intervals as suggested starting points, why do the wheels but actual lubrication intervals may often vibrate, clatter, vary quite a bit, depending on load, squeak, drag and speed, temperature or environmental overheat? Bearings can fail conditions. for lots of reasons. Most failApplications with higher speeds, ures (as shown in Figure 1) temperatures or heavy contamination are related to lubrication sometimes require frequent re-lubricaand contamination, but mistion, possibly weekly or daily. taken ideas handed from one By contrast, a mounted ball bearing generation of maintenance in a lightly loaded, low-speed, clean enengineers to the next help vironment may need re-lubrication only perpetuate many easily every 12 to 24 months. Certain applicaavoidable problems. tions may need to be monitored and luFigure 1: Sources of bearing wear or failures. These mistakes can be brication intervals/amounts adjusted sorted into three general accordingly. categories: installation, misapplication Re-lubrication replenishes grease but certain applications may run higher and lubrication. Do you know if these when the current grease breaks down or lower. Most bearings are rated for statements are true or false? or deteriorates because the base oil -20°F to 220°F, but can be supplied with breaks down due to temperature. Withspecial grease, seals or heat stabilizing INSTALLATION MISTAKES out this, the lubricating property is processes that allow them to operate at Installation mistake #1: It’s okay to gone and the result is metal-to-metal higher temperatures. hammer a bearing into position if needed. contact. Re-lubricating the bearing reBearings normally run hotter at False. Never strike a direct blow to plenishes the oil, maintaining the start-up or right after re-lubrication bebearing. The rolling elements and raceproper film. cause excess grease increases drag and way are hardened, but can still be damPumping new grease into a bearing friction in the bearing. Spikes up to aged. A hammer blow can leave dents in also helps flush away contamination. 50°F are normal at start-up – and up to the raceway that can cause noise and Many mounted bearings are designed to 30°F after re-lubrication. dramatically reduce bearing life. If inallow grease to enter the bearing cavity As the rolling elements purge excess stallation is difficult, first check the as close to the rolling elements as possigrease through the seals, the bearings shaft diameter, and look for burrs, dirt ble. As more grease is added, the old should return to steady-state temperaor corrosion on the shaft. If needed, use grease is pushed out of the seals (if the tures. a press to slide the bearing on. Apply seals are purgeable). The purging Application mistake #2: Bigger bearpressure equally on the face of the inner grease carries out contaminants and ings are always better. ring to avoid damaging the raceways keeps dirt away from the seals. False. Bigger bearings with a higher and rolling elements. Lubrication mistake #2: Always add load capacity may show a higher faInstallation mistake #2: Off-the-shelf grease until it purges from the seal. tigue life, but if the load does not TGP shafting is the best option. False. If you pump grease into the achieve the minimum requirement, the False. It’s much more important to bearing until it purges out the seal, you rolling elements can skid along the know the tolerance range of turned, probably have completely filled the raceway, instead of ground and polished TGP shafting to be sure it meets your bearing manufacSurface smearing, peeling and skidding are forms of adhesive wear that occur when operating with insufficient oil film thickness. Under turer’s spec for diameter these conditions, sliding occurs between the rolling elements and and roundness. Review raceways, causing surface deformation, cold welding and/or the bearing manufacturmaterial transfer. er’s recommendations and measure/specify the correct shaft diameter. Installation mistake #3: bearing cavity. Excess grease can inrolling. This can cause high It’s fine to hand-tighten setcrease operating temperature and may temperatures, excessive wear, lubrication screws one at a time. create enough pressure to blow the seal breakdown and bearing failure. False. Setscrews should be tightened out. However, in low-speed or dirty conApplication mistake #3: Sealed/ to the manufacturer’s recommend ditions, where contamination may easlubed-for-life bearings will last forever. torque. Under-tightening can allow the ily enter the seals, filling a bearing False. Bearing life depends on grease bearing to slip on the shaft. Over-tightwith grease may help improve perforlife, which is affected by the operating mance. Application experience will dicening can distort the raceway or crack conditions (speed and load) and environment (temperature and contamination). tate when the entire bearing cavity the inner ring. Use the ‘half-full/full’ rule Grease life can be improved with enshould be filled with grease. for tightening setscrews – tighten the hanced seals, proper installation and Lubrication Myth #3: If a bearing first setscrew to half the recommended proper grease selection. Ultimately, the makes noise, grease should be added. torque, the second setscrew to the full best bearing is the properly lubricated False. If a bearing is making noise, torque, then go back to the first setscrew bearing. internal damage likely has occurred. for the full torque. This increases over time, with the poLUBRICATION MISTAKES tential for catastrophic failure. Adding APPLICATION MISTAKES Lubrication mistake #1: Re-lubrication grease may provide temporary relief, Application mistake #1: Bearings once a year is sufficient. but a noisy bearing should be closely should not be hot to the touch. False. Start by reviewing the bearing monitored and replaced at the first opFalse. Normal bearing operating temmanufacturer’s lubrication recommenportunity. peratures can range from 80°F to 150°F,

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Images: Emerson Power Transmission Solutions

Are you making these common mistakes? Scratching, gouging and general wear in the bore of an inner ring and on the OD of a shaft are indications of loss of lock. Sometimes, the setscrew tips will also be worn. Fretting wear can be present on the surfaces and is sometimes a precursor form of wear prior to loss of lock. This can be caused by improper tightening of the locking mechanism, undersized/worn/ damaged shafting, frequent start/stop operation, or hardened or stainless steel shafting that prevents set screw penetration or holding.

The root of the failure should also be investigated either with independent or manufacturer failure analysis (manufacturer analysis requires removal of the bearing as soon as possible to aid in a more accurate diagnosis of the problem). Lubrication mistake #4: Any grease will do. False. Greases do differ. Some may be incompatible because of the different thickeners (soaps) used. When two incompatible greases are mixed, they may thicken and harden or become thin and

Before lubricating a bearing, make sure the grease fitting is clean so contamination is not introduced into the bearing during relubrication.

leak out of the bearing. For example, many electric motors use a polyurea thickener, while some mounted ball bearings use lithium-complex thickeners. These greases are borderline compatible, and depending on the actual make up, may not work together. Grease types can also be incompatible based on the viscosity or type of oil in the grease, so consulting a lubrication supplier is always recommended. Lubrication Mistake #5: Just shoot grease through the fitting. False. Always clean grease fittings and the grease gun tip. It’s good practice to put the grease gun tip in an oil bath or wrap it with a plastic cover to protect it. Your plant’s uptime and overall equipment effectiveness (OEE) may turn on your bearings’ good health. If you are not achieving the desired operational life for some of them, a bearing manufacturer can assist you with proper selection and MRO troubleshooting. Ian A. Rubin is director of marketing, mounted bearings, for Sealmaster, System Plast and Browning-branded products at Emerson Power Transmission Solutions. For more information, visit powertransmissionsolutions.com.

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Machinery & Equipment MRO

Big bearing ensures smooth process A special cylindrical roller bearing with an outer diameter of 3.3 m is being used in a three-roller planetary steel pipe rolling mill.

Photos: NKE Austria GmbH

he German company ESW Röhrenwerke manufactures seamless steel pipes that are used worldwide as structural tubes in machinery, steel construction, in the automotive industry, as boiler tubes and as pipelines and supply lines for combustible liquids, gases and oil worldwide. A total of 70,000 tonnes of steel pipes are produced each year in the three-roller planetary rolling mill process. This high-reduction technology at the unique planetary rolling mill has made ESW one of the leading producers of seamless hot rolled steel pipes in particularly high qualities. The steel pipes are available in outer diameters of 70 mm to 244.5 mm and with a wall thickness of between 7.1 mm and 60 mm. Depending on the application and customer requirements, grades ranging from plain carbon steel to high alloy steel are processed. To manufacture the pipes, steel billets up to 2 m long are heated up to rolling temperature in a rotary hearth furnace. After an initial hot rolling stage in a hollow block cross rolling mill, the hollow blocks are transported to the threeroller planetary rolling mill for the second stage of the forming process. Three rollers form the hollow block into a tube using a mandrel bar. While each roller rotates around its own axis, all three rollers also circulate around the rolled steel like planets. In the third stage of forming, the steel is then rolled out into finished pipes. The subsequent manufacturing steps are slow cooling, the subdivision into cooling bed lengths and adjustment of the pipes to ensure they are straight. An essential component for the threeroller planetary rolling mill process is a

Assembly of the cylindrical roller bearing took place in Austria.

large bearing that acts as the front support for the rolling head assembly. As ESW Röhrenwerke owns only one rolling mill, failure of the bearing presents a particularly high risk. Therefore, a regular replacement of the bearing is required. When it became necessary to replace the bearing recently, ESW Röhrenwerke opted for a special bearing from NKE. The special cylindrical roller bearing with a solid steel cage has an outer diameter of 3.3 m and weighs 2.2 tonnes. The large bearing was loaded with a supporting force of 76.3 tonnes and operates at a speed of 125 rpm; the supported rotating mass being around 200 tonnes. The oil lubrication is very low at 10 l/min.

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The special bearing has a service life of between six and eight years. ESW Röhrenwerke already had very good experience in the past with NKE in terms of product quality. The critical factor in the decision to go with NKE was the fast availability of the large-size bearing. “NKE is a competent and reliable partner in bearing technology,” says Lothar Schmitz, head of maintenance and engineering at ESW. “The short lead times in the production of

Special cylinder roller bearing is used as a step bearing in the planetary cross rolling mill.

large-size bearings for our planetary inclined rolling mill was a major factor behind our decision on this project.” Alongside large bearings for the rolling mill industry, NKE also develops customized special bearings for other high-end applications. Examples include bearings for use in tidal current power stations, wind

turbines and mining machinery.

MRO

NKE Austria GmbH is a bearing manufacturer headquartered in Steyr, Austria. NKE’s products are distributed through more than 240 distribution outlets in 60 countries; in Canada the distributor is Global Bear Inc., Dorval, QC.

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April 2014

Non-asbestos gasket developed

saturated and superheated steam applications. It is also suitable for sealing petroleum derivates, ethanol, chemical products and general services. Field tests as well as laboratory tests have confirmed that, even under severe application conditions, NA 1122 sheet has exceptional performance without leakage. Laboratory tests have confirmed that NA 1122 sheet reached its target of work above 800°F and 1,480 psi without leak-

P x T Diagram

NA 1122 sheet proves an alternative to asbestos-based gasket material. BY BILL SEARLE

can result in significantly impaired lung function, respiratory infection, tumours (mesothelioma), and even death due to heart failure or lung cancer. Given the toxicity of asbestos, materials and gasket manufacturers alike have been committed to finding safer alternative materials that avoid the problems associated with using asbestos in the workplace. A major challenge in the development of alternative materials has been to not only achieve the same performance characteristics as asbestos sheet, but to also develop a cost-effective solution. Cost is a particularly important consideration as many applications require large gaskets: if the sheet cost is high, large gaskets cut from the sheet would be prohibitively expensive. The problem of developing a suitable substitute for asbestos-based gaskets was taken on by Teadit, a manufacturer of CNA (Compressed Non-Asbestos) sheet. Teadit’s challenge was to develop a nonasbestos sheet that would support the cost-effective provision of gaskets as large as 96 in. in diameter, and which would be

soft, flexible, and easy to handle and install. Critically, the new material would have to be resistant to a wide range of chemicals and support a high range of temperatures and pressures, including thermal cycling. Temperature (°F) The result of Teadit’s deGeneral Suitability Consultation is Technical velopment effort was the recommended consultation is mandatory NA 1122 premium sheet. For applications near or above the “peak” curve, contact Teadit. NA 1122 sheet is a compressed non-asbestos Above left: Gasket made from NA 1122 sheet. sheet gasket material Above: Pressure vs. temperature graph. produced from a combinaage. The maximum temperature limits of tion of inorganic fibres and special fillers, the Teadit NA 1122 product is 1022°F, and bonded with nitrile rubber (NBR). It is the maximum pressure limit is 2,177 psi. manufactured through the hot calendar Field performance is no less impresprocess under rigorous quality control sive. For example, CRGI is currently fieldstandards, including ISO 9001. testing NA 1122 sheet in a mining appliNA 1122 sheet was specifically develcation where the maximum recorded temoped to have superior thermal stability perature is 780°F, and where the most in order to replace compressed asbestos critical chemical concern was SO2 gas at gasket sheets in thermal cycling applica5%-15% as off-gas system moisture. tions. It is specifically recommended for Pressure (psi)

or over 50 years, the fluid sealing industry has been attempting, with limited success, to find an ideal solution to replace asbestosbased gaskets. However, a new product has now come on to the market that meets the needs of users and avoids all the hazards of using asbestos-containing products. This new material is NA 1122 premium sheet, available from Teadit North America of Houston, TX. On June 30, 2013, the last Canadian manufacturer of asbestos sheet product, from which asbestos-based gaskets are made, announced that it would no longer be supplying asbestos sheet. This has left a number of large users of asbestos-based gaskets looking for suitable alternatives to service their needs. Despite the known hazards, asbestosbased gaskets do have some appealing performance characteristics. Asbestosbased gaskets have very high temperature and pressure limitations, and the material is resistant to a wide variety of aggressive chemicals used within industry. Despite these performance advantages, many well-known firms such as Suncor, Exxon, Shell, Ontario Power Generation (OPG) and ArcelorMittal have banned its use within their operations due to the toxicity of the material. Asbestos-based gaskets have been linked to asbestosis, an occupational lung disease caused by the ingestion or inhalation of asbestos fibres. Such fibres can be given off by an asbestos-based gasket as it deteriorates and degrades. Asbestosis is a chronic inflammatory and fibrotic disease of the lung caused by the presence of asbestos fibres within the lung. The disease

Typical Physical Properties of the Material Tests are based on 1/16˝ (1.6mm) sheet thickness

Density

ASTM F1315

1.46 g/cm3

After 1 hour at 210°F (100°C) Compressibility

ASTM F36A

12-22%

Recovery

ASTM F36A

40% min.

Tensile Strength

ASTM F152

9MPa

Torque Retention

DIN52913

43 MPa

Thickness Increase • ASTM Oil IRM 903, 5h/300°F (150°C)

15% max.

• Fuel B, 5h/77°F (25°C)

15% max.

Weight Increase

30% max.

• Fuel B, 5h/77°F (25°C)

20% max.

Up to 5000 H.P. & 30,000 Lbs Lifting Capacity

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In this test, a 73-in. NA 1122 test gasket was installed directly across from the original asbestos gasket application. All the same service conditions were present for both gaskets side by side, with no variance in either case. Both gaskets have been in service since January 8, 2014. The NA 1122 gasket is being monitored and inspected very closely, and it is performing as expected. In this particular application, the NA 1122 gasket has met all of the customer’s requirements to-date. Probably the most impressive of all the requirements satisfied to date is the safe, reliable performance of the gasket, combined with the gasket cost. In this case, the finished fabricated cut gaskets were supplied to the customer at 2.6 times the price of the previous asbestos gaskets. Gaskets cut from the NA 1122 sheet can meet most, if not all, applications that traditionally have been serviced by asbestos-based gaskets. Gaskets produced from NA 1122 sheets are now a preferred choice for severe-service applications. MRO Bill Searle is a technical sales specialist with Canada Rubber Group Inc. (CRGI), Bowmanville, ON. CRGI is a provider of fluid sealing products and services.

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tices and identify gaps that need to be addressed. During our first two visits to the

START-UP PROBLEMS Join us as we tackle step three in our maintenance assessment at an Ontario food plant. BY PETER PHILLIPS

n our previous column, we took a break from talking about our maintenance assessment at a food factory in Ontario. The assessment and improvement process we embarked on has expanded now into work processes and responsibilities across the whole plant. In January 2014, we made our third visit to the plant to carry on with our operational improvements. This column covers the improvements that were made during the January visit and tasks we expect the plant to accomplish before we return in March. The purpose for this visit was to review work carried out during our previous visit to identify the progress and further needs, address the issue of re-occurring maintenance problems, and continue to analyze the problems with current start-up practices and identify gaps that need to be addressed. Lets start with the review of the work we left the plant to do after our previous visit and see what improvements have been made or have been noticed by personnel. • Set-up personnel have been included in maintenance team meetings as they are now under the management of the maintenance department. • Radios issued to set-up personnel have provided means of communication and have increased their response time to set-up issues.

• Specific Product Set-up sheets are being developed to ensure proper set-up. • Operations Communication logbooks have been placed on each line to document changes made. The books have resulted in improved communications from shift to shift regarding equipment issues. • Lights have been ordered to indicate the status of the production line. We wanted a visual way to indicate the status of the line, i.e., whether it is ready for production or not. • Set-up personnel are scheduled for CMMS training in February. Set-up will then be able to record work order repairs. • Poor communication practices on the radios have been addressed and will be mentioned at monthly maintenance meetings. • The maintenance planner has been reporting work completed and planned work at morning production meetings to keep everyone aware of what is taking place on the equipment. • Work required on the equipment that is reported by production during their morning meeting is being entered in the CMMS. • Issues around PMs requiring updated instructions and new equipment needing to be entered in the CMMS have been addressed by the maintenance planner and the plant’s IT person will enter the changes into the CMMS. • A separate maintenance/production meeting is now taking place at 8 a.m.

every morning to discuss the previous day’s equipment issues. This has reduced the time needed for the the 10 a.m. production meeting. Next, lets review the issue of re-occurring maintenance problems. Re-occurring problems do arise and must be investigated for the root cause. As a team, production and maintenance need to meet to figure out and address these equipment and process problems. Specifically, they need to select one problem and determine the root cause, take remedial action, and make a long-term plan. The plant maintenance personnel enter all repair work orders in the CMMS. However in order to do an analysis of equipment repairs, there has to be methods put in place to extract the data from the CMMS in the form of reports. When we examined the CMMS, we found that the information that was currently being placed in the system did not make it easy to create valuable reports. There are fields in the program that need to be populated in order to produce the desired reports. For example, the Failure and Action Codes need to be populated when the maintenance person closes the work order. The planner will train the maintenance personnel to enter the data. The problem of re-occurring issues will be addressed again when sufficient data has been gathered. Next up is to continue to analyze the problems with current start-up prac-

SOLVING ONGOING

plant, we recognized that there are significant issues around the daily start-up on the production lines. Therefore, we are going to concentrate on investigating start-up procedures and responsibilities over the next few visits. Our analysis identified communication issues during quick production changeovers and morning start-ups. The current thinking of plant staff is that start-up procedures and communications need to change to ensure that the line starts smoothly. Everyone needs to understand it is their job to make sure the line starts and runs every day. The issues we see so far are: 1. Start up: Maintenance and production have Pre-Start-up sheets that are completed each day. These sheets need to be reviewed to see if the checked items are accurate and that the work was actually completed. It is important that these sheets are not pencil-whipped. When problems occur due to items not being done before start-up, it is important that the people are held accountable for the items that have been checked off as completed. These sheets are important and they must continually be monitored. Are the items actually completed? Do they need to add items to be checked? 2. Responsibilities: Since it is everyone’s job to see that the line runs, does everyone know what their responsibilities are? Does everyone have the tools they need to do their jobs properly? To answer these questions, we are asking the heads of each department to complete the employee start-up responsibilities for their department. Each department head has been given a form to fill out for each of the job positions in their areas. They have been asked to document the responsibilities, as well as the tools and documents that each position requires to perform a line start-up. 3. Failures: Incidents that affect the start-up of the line must be addressed in the morning production meeting and the root cause of the problem must be investigated and corrective actions must be taken to ensure that the problem does not occur again. These items – Responsibilities and Failures – will be reviewed on our next visit in March. We will be concentrating on line start-up. It is essential that every person knows what they need to do to ensure the line starts without issues. It is management’s job to ensure that people succeed at their duties and responsibilities every day. MRO Peter Phillips of Trailwalk Holdings, a Nova Scotia-based CMMS consulting and training company, can be reached at 902-798-3601 or by e-mail at peter@trailwalk.ca.

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orkSafeBC has released an Incident Investigation Report (IIR) into the cause and underlying factors that led to two deaths and 20 injuries in a catastrophic fire and explosion at the Babine Forest Products Ltd. mill on January 20, 2012. An IIR provides analysis and conclusions with regard to cause, as well as information on the underlying factors of an incident. The IIR makes short statements regarding scope and synopsis. The remainder of the report is organized in four sections: factual information; analysis; conclusions; and health and safety action taken. IIR Scope. The report addresses causes and underlying factors. The report does not address issues of enforcement. IIR synopsis. During the afternoon shift on January 20, 2012, there was an explosion at the Babine Forest Products Ltd. sawmill. A large fireball burst

April 2014

WorkSafeBC cites maintenance issues in mill explosion. through the roof of the northeast side of the mill, while the explosion travelled east to west through the operating and basement levels. Fire spread through the premises, completely destroying the mill. Two workers were killed in the fire and explosion and 20 others were injured. IIR factual information. This sawmill, located on First Nations land, was acquired by Hampton Affiliates in 2006. Hampton holds an 89% interest and the

Burns Lake Native Development Corp. holds 11%. Information is provided on the workforce, sawmill layout, work process, the dust collection system, spark detection system and other wood dust accumulation prevention measures. The final comments in this section relate to the sequence of events in the months, weeks and days before the incident, along with a description of the event itself. IIR analysis. Analysis of the incident

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addresses: The cause of the incident — an explosion that resulted in fires in various areas of the sawmill; How the various components required for an explosion were present in the sawmill; The progression of the explosion and fires; An analysis of the deaths of the lead hand and the cut-off saw operator based on the evidence at the scene; Changing conditions at the sawmill that may have contributed to the incident; Previous incidents — including a BC Safety Authority investigation into a dust explosion and significant fire on February 23, 2011; and WorkSafeBC involvement with Babine Forest Products. What the investigator asks. Was this a preventable incident? It states that it was, in that: There was knowledge that the dust collection system was undersized; An electrical upgrade to accommodate this was challenging to Babine but there were no reductions in production while an upgrade was planned and production increased; Four of the components required for a wood dust explosion were not controlled — containment, ignition, dust as fuel and dispersion of dust (the fifth component is oxygen); There was considerable investment in upgrading production capability and improving the dust management system by opening floors, pressurizing the MCC panels and improving the waste conveyor system; Some work had been done on the sawmill dust collection system and extra clean-up efforts were made following the February 23, 2011, explosion and fire; Moving the collection ducting from trim saws and edgers to the bandsaw and debarkers meant some areas had no dust collection; No adequate actions were taken to reduce or control the levels of airborne wood dust even though this was the root cause of the violation cited in December 2011; Effective action should have been taken to control airborne dispersion of dust and excessive accumulation on floors and surfaces. IIR conclusions. The report concludes that all of the elements for a wood dust explosion were present and addresses: The concentration of dispersed wood dust in the air; Friction within the motor-reducer V-belt guard as an ignition source; Ineffective wood dust control measures; Ineffective inspection and maintenance of a solid guard at the motor reducer assembly’s location; Conditions of the wood and the effect of weather; Waste conveyor configurations that increased airborne wood dust; and a volume of coarser wood dust and debris that exceeded the capacity of the waste conveyor system; and Inadequate supervision of clean-up and maintenance staff. IIR health and safety action taken. The IIR notes actions taken by WorkSafeBC and industry at the time of the Babine and Lakeland (another mill explosion and fire in BC) incidents. A more current update on actions taken is provided on www.worksafebc.com. Current inspections. Officers announced sites would be inspected from November 2013 through to the end of January 2014. A dedicated team of 10 officers conducted inspections of 146 sawmills. By mid-January, 131 sawmills had been inspected; 86 orders had been written; 12 stop work orders had been issued; three warning letters had been issued and 19 penalties were under consideration. Next steps. WorkSafeBC officers are considering enforcement action under the authority of the Workers Compensation Act in regard to Babine Forest Products. Any orders or penalty orders issued are provided first to the employer and to the employer’s counsel. MRO

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Oil, Gas & Mining MRO

April 2014

©Janet Koelling/Hemera/Thinkstock

Florence, Italy − Chevron Energy Technology Company and GE Oil & Gas have joined together to create the Chevron GE Technology Alliance, which will develop and commercialize valuable technologies to solve critical issues for the oil and gas industry. The Alliance builds upon a current collaboration on flow analysis technology for oil and gas wells and will leverage research and development from GE’s newest Global Research Center, the first dedicated to oil and gas technology. “GE brings its leading manufacturing capabilities, worldwide marketing, distribution, and extensive R&D capabilities not only for oil and gas, but also other business sectors to this alliance,” said Paul Siegele, president of Chevron Energy Technology Company and chief technology officer. “Together, we hope to bring impactful new technologies to the industry.” “Chevron’s deep understanding of the oil and gas industry, combined with GE’s long tradition of technology development and close collaboration with strategic partners, will uniquely position this new alliance to address the industry’s technology needs,” said Lorenzo Simonelli, president and CEO, GE Oil & Gas. In addition to the flow metering collaboration, which is being conducted with the Measurement & Control business within GE Oil & Gas, the Alliance also is managing a coatings project and will be taking on additional highvalue projects in the near future.

Oil sands projects drive Alberta’s investment growth

©SGV/iStock/Thinkstock

Edmonton − Capital investment has been the largest contributor to Alberta’s economic growth since the mid-nineties, according to the latest Economic Commentaries report from the province. In 2013, it said total investment grew by an estimated 8.6%, in part due to surging oil sands investment. For 2014, investment is not expected to be a major driver of economic growth as energy investment growth moderates. Within in the oil and gas sector, investment for conventional oil and gas projects rose from $8.1 billion in 1996 to $19.4 billion in 2008, while oil sands investment surged from just over $1 billion in 1996 to $20.7 billion by 2008. The

Capital investment in Alberta grew by an estimated 8.6% in 2013, in part due to surging oil sands investment.

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oil and gas sector’s share of total investment in Alberta averaged 45% over that time period. In 2013, oil sands investment was estimated at a record $32.7 billion, while conventional oil and gas investment came in at $20.7 billion. The oil and gas sector’s share of total investment was 50% in 2013. In 2013, oil sands investment accounted for 29% of total Alberta investment.

Demand for shale gas and tight oil to reach $98b Cleveland, OH − Demand for products and services related to the development of shale gas and tight oil resources in the US is forecast to rise 3.5% annually to $98 billion in 2017. According to analyst Lee Steinbock, “Growth in tight oil applications will continue to be strong, supported by high oil prices and the development of newer liquids-rich plays.” In addition, the outlook for dry gas plays is expected to improve as natural gas prices increase, especially after 2017. Overall, the focus of activity will shift toward maximizing output from maturing plays (e.g., Bakken and Marcellus), although drilling and completions will continue to be supported by growth in newer formations such as Eagle Ford, Niobrara and Utica. These and other trends are presented in Shale Gas & Tight Oil: Products & Services, a new study from The Freedonia Group Inc., a Cleveland-based industry market research firm. Shale Gas & Tight Oil (published 02/2014, 397 pages) is available for US$5200. For details, visit www.freedoniagroup.com.

Energy East not the boon for Atlantic refiners it’s cracked up to be: report Calgary − The proposed Energy East pipeline won’t be the boon to Eastern Canadian refineries that supporters claim because the vast majority of the oil in it would be bound for export markets, environmental groups argue. The $12-billion project would likely use the lion’s share of its 1.1-million barrel per day capacity to send unrefined oilsands crude to markets like India, Europe and possibly the United States, says the report, penned by The Council of Canadians, Ecology Action Centre, Environmental Defence and Equiterre. The pipeline would run 4,600 km from Alberta to Saint John, NB, using repurposed pipe already in the ground for roughly two thirds of the way. The company planning to build it, TransCanada Corp., aims to file a formal regulatory application in the summer of 2014. Backers in industry and government have said Energy East will help ailing refineries in the East — reliant on high-cost crude from abroad — by connecting them with a stable, low-cost supply from Western Canada.

Policy offers a fact-based examination of the economic benefits of Canada’s energy sector. Author Trevor Tombe shows that over the past decade, growth in Canada’s energy trade has been nothing short of historic, with energy exports equivalent to nearly $9,000 for every Canadian household in 2012. And this number is not expected to drop, as Tombe reveals that forecasts for the next two decades suggest exports may double. Concerns over the negative implications of the energy sector often do not take into account the benefits of the sector to workers, as well as the economy. “The energy sector adds much to Canada’s economy, with valueadded and productivity higher than any other sector. And, when it comes to labour compensation, oil and gas extraction is the highestpaying sector in the country.” The report can be found at the website http://policyschool.ucalgary.ca/?q=content/ taming-skew-facts-canadas-energy-trade.

Proposed Nova Scotia LNG plant gets conditional approval Halifax − A proposed liquefied natural gas (LNG) plant project on Nova Scotia’s east coast has cleared a significant hurdle after conditional approval was granted by an environmental panel. The three-member panel says the plant planned for Goldboro by Calgary-based Pieridae Energy Canada can proceed after it assessed a number of environmental and ©Mirrorimage-NL/iStock/Thinkstock

Companies form alliance to solve oil and gas problems

at $2.6 billion. Up to 1,000 people worked at the site during construction and the mine will employ more than 600 highly-skilled workers during operation. The majority of the workers are residents of Saskatchewan’s north.

New uranium mine to employ 600 skilled workers in Saskatchewan Saskatoon, SK − Ore production has begun at Cameco Corp.’s Cigar Lake uranium mining operation in northern Saskatchewan. The mining system and underground processing circuits are operational and ore is being transported to the McClean Lake mill operated by AREVA Resources Canada Inc., which is located 70 km northeast of the minesite. “Cigar Lake is among the most technically challenging mining projects in the world,” said Tim Gitzel, president and CEO of Cameco, the operator and 50.025% owner of Cigar Lake. “The start of ore production is a tremendous achievement and I want to thank the many hundreds of people who helped to bring this exceptional orebody into production. “Uranium from Cigar Lake is expected to fuel clean electricity production around the world for many years while providing quality employment and business opportunities for a generation of Saskatchewan people.” The McClean Lake mill is expected to begin processing the ore to uranium concentrate by the end of the second quarter of 2014. The mill is expected to produce between 2 million lb. and 3 million lb. of uranium concentrate in 2014 and ramp up to its full production rate of 18 million lb. by 2018. As at December 31, 2013, the total capital cost of the Cigar Lake project was estimated

The Energy East pipeline would run 4,600 km from Alberta to Saint John, NB.

The proposal also includes export terminals in Quebec and New Brunswick, from which some of oil can be sent overseas by tanker, getting producers a better price for their crude. But the report says the three refineries along the Energy East route — including Suncor Energy Inc.’s in Montreal, Valero Energy Corp.’s near Quebec City and Irving Oil Ltd.’s in Saint John, NB — have a combined capacity of 672,000 barrels per day. Of that, the groups figure 550,000 barrels per day can come from elsewhere — offshore crude in Atlantic Canada, booming US shale resources and, eventually, via Enbridge Inc.’s recently approved reversed Line 9 pipeline between southwestern Ontario and Montreal. That leaves just 122,000 barrels per day of refining capacity that can be served by Energy East, the report says. ©The Canadian Press

Report reveals energy sector adds $9,000 per household Calgary − By any reasonable standard, Canada exports a lot of energy. Public perception towards energy trade in our country is often negative, especially when it comes to oilsands and pipelines. However, a new report from The University of Calgary School of Public

socio-economic factors, including the effects on groundwater and air quality, local marine and terrestrial habitat, the fishery, property values and employment. “The impacts ... would be minimal to moderate, and should be largely curtailed by the mitigation and management plans proposed by Pieridae, or through those recommended by the panel and interveners,” the report states. But it says the project, which is estimated to cost at least $5 billion, would also result in a number of “residual effects,” such as an increase in the province’s greenhouse gas emissions by about 18% above 2010 levels by 2020. It says a number of fisheries in the general area would be compromised as well. The panel says it believes the economic benefits tip the scale in favour of the project’s development. The report says the Goldboro project is projected to contribute 0.5% of the annual national greenhouse gas emissions for Canada and that provincial emissions and targets must be carefully considered. It says Pieridae argues the increase will be offset in large part by foreign customer’s replacement of coal by the company’s natural gas. ©The Canadian Press O/G/M

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Fighting condensation at ‐ 40° Photos: ABB

Above: Agnico Eagle’s mine in northern Finland is 150 km inside the Arctic circle near the town of Kittila.

Left: The XC PLC is an ‘extreme conditions’ variant of the AC500 PLC family with built-in protection against a very wide variety of threats posed by harsh environmental and operating conditions.

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Ruggedized PLCs boost processing uptime at remote Lapland gold mine.

he automation system at Agnico Eagle’s gold mine in Lapland is being upgraded with eight of ABB’s ruggedized PLCs for controlling equipment in harsh conditions and extreme climates. The PLCs will control the sedimentation process of the concentrating mill at Europe’s largest gold mine: Agnico Eagle’s mine in northern Finland, which is 150 km inside the Arctic circle near the town of Kittila. ABB won the original contract for the main automation system at the gold mine, and configured and installed electrical automation based on its 800xA Extended Automation system and industrial IT architecture. The project involved a large amount of ABB automation components, including its 800 series operator interface panels and AC500 PLCs for the underground control of pumps, air conditioning, the motors used in ore crushing and processing, etc. However, a number of items of plant equipment came with automation from other vendors, including PLCs that were supplied with the sedimentation facility that forms part of the mine’s concentrating mill. The PLCs were normal industrial-grade types, but housed in freeze-protected cabinets located outdoors. Since installation however, this facility has suffered a number of process stoppages because of the environment at the mine -which includes very wet and humid conditions and winter temperatures as low as -40°C. If a process stoppage happens in winter, the impact can be severe, as the weather can quickly add to the problem by freezing and blocking pipelines. There have been some four or five stoppages a year, stemming from power outages, extreme cold temperatures, or water droplets that formed on the PLC modules when the cabinet doors were opened. In wintertime, condensation can happens in seconds -- almost the instant the cabinet doors are opened and the benefits of the cabinet’s ingress protection are lost -- because of the very low temperatures and the moisture-laden air around the concentrating mill. The same problem can also happen in springtime, as temperatures can swing between -25°C and +15°C from night to day -- leading to heavy condensation. The mine operators decided to upgrade this part of the control system to improve reliability and uptime. They were very happy with the PLCs that provided control in the hot and humid underground environment and

turned to the supplier of these -- main automation vendor ABB -- who proposed a solution based on the XC PLC. XC is an ‘extreme conditions’ variant of the AC500 PLC family that is installed underground. It has built-in protection against a very wide variety of threats posed by harsh environmental and operating conditions, including high and low temperatures, high humidity, low air pressure, salt mist and hazardous gases, and vibration and shock. In this case, the new XC PLCs will be installed at the mine’s above-ground processing centre -- with some I/O modules located at a remote water-pumping location and connected using ProfiNET, the standard for industrial automation using a computer network. Mining is one of the key target applications for this PLC. The harsh environment at Kittila poses no problem for the XC PLC, which can operate in temperatures from -30°C, with reliable system start-ups in temperatures as low as -40°C, more than meeting the problems that might arise. Its circuit boards are conformably coated to protect against moisture ingress. And the PLC is protected against vibration and shock and will tolerate a lot of mechanical stress -- such as accelerations up to 4 g from random vibrations up to 500 Hz or 2 g from sinusoidal vibration. This built-in protection means that the PLCs are being installed in standard un-insulated stainless steel cabinets -without any need for freeze-protection heaters. “Ruggedized PLC technology opens up new design possibilities, allowing automation to be sited right where the control I/O is needed, in many cases without high-specification environmental protection -- as this mine is deep inside the Arctic circle” says Risto Haavisto of ABB Finland. Agnico Eagle’s gold mine in Finland is located in Kittila, in the northern Lapland region. With an estimated lifetime to 2037, Kittila’s reserves are estimated at almost 33 million tons. The mine employs over 600 staff and contractors, most of whom are local residents, making a big contribution to the regional economy. Ore was originally mined from two open pits, starting in 2008. Since 2010, the mining has moved underground. Some 3,000 tons of ore is currently transported daily to the surface crusher using underground haul trucks via a 3-km-long ramp access system. O/G/M This article was provided by ABB, Lachine, QC. For more information, visit www.abb.com/plc.

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LNG offloading uses floating hoses The latest development in cryogenic LNG floating hoses is set to become a key component in offloading systems for future offshore FLNG projects.

erived from existing and proven technologies, the latest development in cryogenic LNG floating hoses is set to become a key component in offloading systems for future offshore floating liquefied natural gas (FLNG) projects. By enabling offshore transfer of LNG in tandem configuration, the cryogenic floating hose will pioneer a step change in the safety of this critical operation. This innovative system will also allow FLNG projects to be considered in harsher conditions, without excessive downtime due to offloading system availability, and with significantly reduced risk. “The environmental conditions of the current FLNG locations are at present quite mild and only require the use of the most straightforward technology for the unloading of the LNG,” says Vincent Lagarrigue, marketing and project manager at Trelleborg Industrial Solutions. “But, with prospective new FLNG locations moving away from these ‘mild’ areas, to sites where sea states, wind and currents can be much more severe, this equipment isn’t enough and could result in plant shut down. “Instead, where conditions are much more demanding, tandem offloading solutions, which rely on the use of flexible hoses, are a viable alter-

native for the industry [as they] not only limit downtime, but also improve safety. “We wanted to partner with Saipem to develop a new solution that would not only meet the LNG operator and contractor’s offloading requirements related to safety, flowrate capacity and operation availability, but also enable LNG transfer operations to take place in difficult environmental conditions by providing offshore operators with a highly flexible, reliable and durable system.” Tandem offloading, where vessels line up stern to bow, allow vessels to keep more distance between them (328 ft./100 m distance between FLNG and LNGC or more) and more easily cope with greater wave heights. This highly limits the risk of collision between the two vessels, enhancing safety, but also greatly simplifying naval operations in approach, berthing and residence. “So, in the absence of any mature tandem offloading solutions using floating hoses, we took the initiative to work with Saipem to develop our own,” says Lagarrigue. “As a key technical component of the tandem offloading solution, our cryogenic floating hose has been further enhanced to meet the parameters required

Above right: As offshore LNG operations move to rougher seas, better technology is needed. Above left: Connector for Cryoline LNG floating hose. Right: Tandem offloading, where vessels line up stern to bow, allow vessels to keep more distance between them.

for the new system. For example, the choice of a 20-in./50-cm inner-diameter LNG hose was required as this enables operators to transfer LNG at least as fast as standard LNG loading arms on traditional jetties, for example, up to 423,776 cu. ft. per hour or 12,000 cu m/h.” The floating hose is designed to operate in sea states with significant wave heights of up to 11.5 ft./3.5 m at connection and 13 ft./4 m during transfer and disconnection, even with non-collinear wind or current directions. These figures guarantee very good offloading availability in almost any location in the world.

Trelleborg was responsible for the development of the 20 in./50 cm inner diameter cryogenic floating flexible hoses, while Saipem developed the offloading system and equipment to store/handle the hoses. Derived from existing and field-proven technologies, The new floating cryogenic hose is made up of the several key components, including an inner cryogenic hose, an outer protective hose, an efficient insulation layer and an integrated leak monitoring system. O/G/M For more information, visit www.trelleborg.com.

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O I L / G A S / M I N I N G

Machinery & Equipment MRO Photo: Hamilton Caster

Oil industry giant gets lean Cart that effortlessly rolls heavy equipment into place without relying on a crane is built with lean manufacturing methods.

simple request for a caster from gas-and-oil drilling giant Helmerich & Payne (H&P) led to a custom-designed dolly and collaboration on lean enterprise with manufacturer Hamilton Caster. H&P is primarily engaged in contract drilling of oil and gas wells for exploration and production companies and is one of the major land and offshore platform-drilling contractors in the world. H&P contracted with Mike Brunson, a lean manufacturing expert, to streamline its processes and increase efficiency. Brunson asked Hamilton Caster about a specific caster and learned it could also design custom-built trailers perfectly suited to the lean manufacturing methods Brunson envisioned for H&P. Hamilton Caster itself is a lean manufacturing practitioner and John Yater, a Hamilton design engineer, is one of the company’s biggest proponents of the concept. Yater worked closely with Brunson to determine how best to satisfy the lean design he had in mind for H&P. “The trickiest part is getting a clear understanding of

the customer’s application, intentions and desires,” Yater said. “We strive to solve customers’ problems and forge a relationship of trust.” After a series of phone calls and e-mails, a Hamilton Caster team flew from the company’s headquarters in Hamilton, OH, to Oklahoma to meet with Brunson and get a first-hand look at the requirements of the new process they were helping design. “I needed something that could handle extreme weight and had a low profile,” Brunson said. “Hamilton Caster solved the problem by creating a cart that effortlessly rolls heavy equipment into place without relying on a crane that is more dangerous and time-consuming.” The modular dolly system that Hamilton Caster developed moves massive pieces of oil-field equipment and parts safely and efficiently, decreasing wasted time, energy and manpower, all core principles of lean manufacturing. Hamilton Caster’s first project with H&P was so successful that it has since led to other projects with the company. “Working with Hamilton Caster is a pleasure,” Brunson

OIL SANDS:

Following the money To 2035, total oil sands-related employment is expected to rise from 2.4% to 3.5% of total Canadian employment, as growth in oil sands activity will outpace the economy as a whole.

n a recent study from the Conference Board of Canada, The Regional Economic Impacts of Oil Sands Production, it is reported that oil sands development and production has rapidly moved to the forefront of Canadian energy policy. Since the turn of the century, the combination of high oil prices and improving oil sands extraction technology has driven a surge in investment and production. However, the development of the oil sands is still very much a work in progress, according to the report, which was released in October 2013. Hundreds of billions of dollars of investment and significant changes in how the industry operates are expected over the next 20 years. As such, understanding how oil sands operations will have an impact on the Canadian economy is important. Even today, the industry’s economic footprint is considerable. Oil sands operations generated $49.3 billion in revenues in 2011, which directly supported 30,700 jobs in Alberta. In addition, the industry generates supply chain effects associated with businesses that supply oil sands operators and induced effects that result from people spending the wages they earn in jobs supported by the direct and supply chain effects. The end result is that 226,400 jobs were supported by oil sands operations across Canada in 2011, equivalent to 1.3% of total Canadian employment. It accounts for an even larger share of national GDP, at 2.7%, when all three effects are included. Focusing on the supply chain effects of oil sands operations, which support 129,500 jobs across Canada, we see the largest effects in a variety of services industries. Financial and related services experience the largest effect, due in part to the ownership structure of the industry, which results in sizable effects for holding companies. This is followed by professional, administrative and oilfield services. In the professional services sector, engineering services experience the largest effects, but a variety of other industries, such as management consulting, computer services, environmental consulting, and accounting services also benefit. Within the administrative services sector, employment services are the single-largest beneficiary, followed by services to buildings and facilities, and office administration. Regionally, nearly one-third of the total employment effects associated with oil sands operations occur outside of Alberta. Ontario garners the largest effects, with 36,100 jobs in the province being supported by oil sands operations. Ontario is followed by British Columbia (14,400 jobs), Quebec (11,300 jobs), and the Prairies (6,900 jobs). Relative to employment in the province, the effects are

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highest in Alberta, where 7.4% of employment is supported by oil sands operations. Alberta is followed by British Columbia and the Prairies, where 0.6% of employment is supported by oil sands operations in each of those regions. Looking forward, the economic footprint of the industry is expected to grow with the increase in oil sands production. In fact, with oil sands production expected to rise from 1.7 million barrels per day (mmbd) in 2011 to 5.1 mmbd by 2035, total employment associated with oil sands operations is expected to rise to 664,500. In addition, there will be employment supported by oil sands investment over this period. When the two are added together, oil sands-related employment across Canada is expected to reach 731,400 by 2035. As a result, total oil sands-related employment (including operational and investment effects) is expected to rise from 2.4% to 3.5% of total Canadian employment, as growth in oil sands activity will outpace the economy as a whole. Given the outlook for continued strong growth, it is a worthwhile exercise to identify areas where the supply chain linkages within Canada can be strengthened. Oil sands operations and investment result in billions of dollars worth of imports, with most of them consisting of manufactured goods. These international imports represent considerable opportunities for further development of interprovincial supply chains related to the oil sands. Our oil sands-related imports generally fall into three categories: those where provinces outside Alberta have production strength; those where Canada’s production strength is localized in Alberta; and those where Canada has limited production capacity and strength. The first category is the one where improving domestic supply chain linkages are likely to prove the easiest, because it is likely to require only retooling existing production capacity rather than developing new areas of expertise. For example, Alberta imports $237 million annually in motor vehicle parts as a result of oil sands operations; everything from engines, to power train components, to electronics. At the same time, Ontario has a well-developed motor vehicle parts industry. Some of the specialized vehicles used by oil sands operators may use parts not easily sourced from Ontario, but there are likely opportunities for Ontario producers to retool their production for the types of vehicles in use in the oil sands industry. Other potential opportunities are apparent in the equipment,

The modular dolly system moves massive pieces of oil-field equipment and parts safely and efficiently, decreasing wasted time, energy and manpower, all core principles of lean manufacturing.

said. “It’s nice to find an American manufacturer who has been around for 100 years, and is taking appropriate steps to be around for another 100 years.” For more than a century, Hamilton has built trucks, custom-engineered trucks and trailers, and developed innovations like its Ultralast wheels and HPI swivel caster technology. Family-owned since its inception, the fourth generation remains as committed to the company as its founder, John Weigel. O/G/M

primary metals and chemicals industries, as well as measuring and control instruments. Since changes in technology can be disruptive to established supply chains, they too can potentially provide opportunities to further develop domestic supply chains. Key technological developments include changes in the extraction process, ways to improve the environmental footprint of the industry, and techniques to reduce the development costs of oil sands projects. These objectives can often overlap. For example, efforts to reduce the steam-to-oil ratio in steam-assisted gravity drainage projects can simultaneously reduce operating costs, decrease the use of water and natural gas, and shrink the amount of equipment needed at the well head. The oil sands represent a vast resource with the potential to generate significant economic benefits. Of course, policy-makers have an understandable desire to maximize the benefits Canadians receive from this non-renewable resource. Beyond tools such as royalties and corporate taxes, developing the domestic supply chain linkages and domestic technology solutions as fully as possible is a key means to this end. As such, identifying how those linkages currently work and how they can be improved upon is a key objective. O/G/M

April 2014

M R O

For more information, visit www.conferenceboard.ca.

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Online Reader Inquiry No. 133

14-04-09 2:11 PM

P R O D U C T

N E W S

Machinery & Equipment MRO

April 2014

What’s new in bearings Long-life grooved roller bearing comes in several configurations

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Deep groove ball bearing range extends to larger motors

SKF has extended the range of its Energy Efficient (E2) deep groove ball bearings to target larger electric motors, up to 350 kW (500 hp). These bearings reduce friction losses by at least 30% compared to standard SKF bearings and increase the expected service life of the motor. They are designed for light-to-normal load applications such as electric motors, pumps, gearboxes and conveyors. SKF Canada Online Reader Inquiry No. 324

EDT’s Poly-Round Plus plane bearing insert has a stainless pin on the outer diameter to facilitate drop-in installation into bearing housings without using a set-screw as an anti-rotation device. The pin eliminates the necessity of drilling and tapping a hole through a housing to assure the bear ing inser t can align but not rotate. The bearings are self-aligning inserts manufactured from a variety of polymer materials for various operating conditions. They operate with no grease, no seals or shields, are unaffected by washdown and do not rust. EDT Corp. Online Reader Inquiry No. 325

Automatic bearing heater is easy to use

The Super Cone Mount automatic bearing heater from Cone Mounter is an automatic light/heavy-duty heater for bearings with inside diameters from 20 mm to 205 mm (3/4 in. to 8 in.). It features automatic shutoff at 250°F, after which this temperature is maintained. By heating the inner race prior to installation, the user allows the bearing to expand and slide easily onto the shaft. All units come with a simple instruction sheet, safety guard and a 250°F temperature indicating crayon. Units are available in 120 V or 220/240 V configura-

The design of the FAG SNS plummer block from Schaeffler ensures optimum load distribution in the fitted spherical roller bearings, increasing their operating life by up to 50%, the company claims. Design enhancements facilitate mounting and dismounting and improve condition monitoring and operation. This allows the housing and bearing to be used in a particularly flexible and cost-effective manner, while significantly reducing lifecycle costs. The housing can be installed as a one-to-one replacement for existing housings. A wide range of different seals makes operation possible in harsh conditions, such as in the extraction and processing of raw materials. The housing is manufactured from high-quality spheroidal graphite cast iron as standard. Rolling bearings of several different diameters and widths can be installed. These are movable and thus function as non-locating bearings. Schaeffler Online Reader Inquiry No. 320

tions. The heater measures 10 in. high by 10 in. wide and weighs 3.2 kg (7 lb). Cone Mounter Online Reader Inquiry No. 504

Bearing helps in reliable pumping of light hydrocarbon fluids

Self-lubricating, non-galling Graphalloy bearings and wear rings from Graphite Metallizing solve pumping problems caused by low viscosity, and light hydrocarbon liquids such as Natural Gas Liquids (NGL), LNGs and CO2. The bearings are used in horizontal and vertical

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Online Reader Inquiry No. 134

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Bearing products are designed to reduce friction in various industries

Schaeffler has introduced the INA radial insert ball bearing, which is f itted with a non-contact BRS seal, for reducing friction in textile machinery. Also, the company is expanding its range of large-size bearings in X-life quality. Two- and four-row tapered roller bearings with ODs of 320 mm to 625 mm and cylindrical roller bearings with ODs of 320 mm to 1,600 mm will be available as X-life products subject to customer request. Schaeffler

pumps for low-viscosity service to help eliminate operational problems due to the poor lubricity of these liquids. They allow pumps to continue working even when experiencing run-dry, flashing or cavitation. Using these bearings and wear rings allows tighter clearances, improving reliability, lowering vibration and increasing efficiency in vertical and horizontal pumps. Graphalloy materials are self-lubricating, impervious to temperature extremes from minus 240°C to plus 400°C (minus 400°F to plus 750°F) and thrive in harsh environments. Graphite Metallizing Corporation

Wind power station bearings increase general component durability

ContiTech Vibration Control has introduced a generator bearing and a gearbox bearing for wind power stations that can help to increase the service life of all components in the drivetrain. The generator bearing, which can be moved both vertically and horizontally, enables the generator to be aligned correctly during assembly. Because of this adjustability, the location of the entire drivetrain can be set exactly, and the load can be reduced to a minimum. The gearbox bearing’s two half shells fit tightly into each other, ensuring an even load distribution within the cylindrical bushing and providing long service life.

Double row ball bearing suits agricultural applications

SKF has developed a costeffective double row ang ular contact ball bearing suitable in trucks and agricultural applications, ranging from pulleys, fan hubs and seeding planters to disc harrows and other attachments. Available in the 32 and 33 series in the range from 20-mm to 50-mm bore diameter, the CE bearings are equipped with low-friction and low-noise glass-fibre reinforced polyamide cages as standard. They are optionally available with stamped steel cages. They are offered open or capped with either seals or shields, and both are dimensionally interchangeable and have the same high load-carrying capability. The open and sealed CE bearings are available in Normal (CN) axial clearance class. Sealed and shielded bearings are available with greater than Normal (C3) clearance class. SKF Canada

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KSB Pumps Inc. has expanded its service facilities to provide you with a full range of service repair options for your pumps, regardless of the manufacturer. Hard-to-find spare parts? No problem, we have the resources to locate or re-manufacture everything you need.

Online Reader Inquiry No. 417

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KSB Service skills you can count on

ContiTech Vibration Control GmbH

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Online Reader Inquiry No. 326

Plane bearing insert facilitates greaseless running of mounted bearings

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The Grooved Roller Bearing line has been introduced by Creative Motion Control. The bearing’s design is said to considerably increase the load capacity – and therefore the life expectancy – of comparably sized bearings. This is accomplished by using grooved rollers that create many more contact points in the same physical space. This provides either for significant reduction in the replacement cost and downtime for an exact replacement, or for a much smaller and lighter envelope for the same load capacity. Available in thrust, radial or combination configurations, the bearing is suited for roller screw or ball screw linear motion applications. It can handle extremely high speeds. Also, the alloy steel construction and the combo load capability offer protection from catastrophic failure due to impact loads or unexpected radial loads. RGW Sales Canada

Plummer block housing increases working life of bearings

Online Reader Inquiry No. 323

MRO

Obtain free additional information about any of these items by using our online reader reply card at www.mromagazine.com/rsc.

14-04-09 2:18 PM

P R O D U C T

N E W S

April 2014

Machinery & Equipment MRO

What’s new in personal protective equipment (PPE) ▼

Dual-purpose gloves eliminate need for multiple pairs for multiple tasks

Lincoln Electric has introduced Roll Cage welding and rigging gloves, which deliver complete hand protection for both welding and rigging, eliminating the need for a separate pair of gloves for each task. These rugged, dualpurpose gloves also are suitable for cutting and grinding. Designed to withstand tough environments, the gloves are constructed with durable, fire-resistant cowhide and sewn with Kevlar thread, then enhanced with segmented, high-temperature-resistant silicon pads for knuckle protection. The finger-structure design enhances grip and durability. The numerous safety features include a protective overlay on the palm that reinforces high-wear areas, an inside lining that helps protect against cuts, and a long cuff that guards wrists and forearms against heat and sparks. Fire-resistant Velcro wrist guards secure the gloves, while allowing for quick removal. Lincoln Electric Online Reader Inquiry No. 336

Work glove provides strong grip, prevents fatigue

3M has introduced work gloves made with 3M gripping material that deliver greater productivity and performance with less effort for anyone from construction and industrial workers to weekend warriors who need a better grip, especially in wet or oily conditions. Work gloves made with this material can provide up to a 270% improvement in friction when used as a two-part system. Comprising thousands of micro fingers, the material is incorporated into the work gloves, enhancing traction and hold, on tools and equipment. The gloves can be used alone, or as a two-part system, which mates the gloves with tools or pieces of equipment wrapped with 3M gripping material tape. In addition, the work gloves are resistant to abrasion and punctures. 3M Canada Online Reader Inquiry No. 337

Fall protection system allows users to work with confidence

The T-Line fall protection safety system from PeakWorks gives the wearer the ability to move both horizontally and vertically in the work space. Self-retracting and self-tensioning, this cost-effective system prevents the pendulum effect in the event of a fall and features an integrated rescue winch. It can be mounted with each end at different heights. After a fall the system can be serviced and reused. It is certified to EN 360 and ANSI Z359.1 and meets or exceeds CSA Z259.2.2. Two models are available, one that will span up to 12 m (40 ft.) and the XL version which will span up to 24 m (80 ft.) in a single span. The sys-

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Boot/shoe line comes in wide range for comfort and durability

tem is well suited to applications in many industries, such as transport, construction, maintenance, manufacturing, aeronautical, telecommunications and more. PeakWorks Online Reader Inquiry No. 340

Reflective band on helmet assures high visibility indoors or out

Lynn Valley Manufacturing offers a stretchy, reflective band that adheres to any protective head gear by friction alone and provides high-visibility fluorescence in the day and intense reflection for low light conditions. Whether inside or outside, on the road, in the bush or underground, this additional level of visibility helps to prevent accidents. The ultra-thin, 38-mm (1.5-in.) tape, which comes in orange and yellow-green, fits most hardhats and helmets. Quick and easy to attach and detach, it stays in position until removed. Custom printing is available. Lynn Valley Manufacturing

Keen carries a wide variety of footwear and clothing for men, women and children. The footwear line includes everything from heavy-duty industrial utility boots to casual shoes and sandals. Each Keen shoe comes with Hybrid.ology, a feature that ensures a comfortable fit and long-lasting performance; Keen.Dry, a waterproof, breathable membrane that lets vapour out without letting water in; Keen.Warm, a lightweight, antimicrobial insulation and Keen. Protect toe protection, where the outsoles wrap up over the toes for increased protection. The utility work boots meet CSA Z195-09 Grade 1 Standards. Some of the utility work line also has Keen.Grip – oil- and slip-resistant outsoles that meet or exceed ASTM F1677-96 MARK II non-slip testing standards. Also offered are a left and right asymmetrical steel toe design, which provides a roomier toe box and still meets ASTM F2412-11 and F2413-11 I/75 and C/75 standards. Product test: Reviewer Katie Roebuck notes Keen offers utility work boots designed specifically for women. “My purchase was the Keen Hoodoo II winter boots with Keen.Dry, Keen.Warm and Keen.Protect features. The boots look heavy-duty but are actually quite light. They keep out snow and slush and provide suitable traction and ankle support when walking on uneven surfaces, but do not limit movement with other activities such as driving. And while the rest of my extremities would start to feel frozen in Calgary’s -35°C weather, my feet remained toasty warm with only a light pair of socks between my skin and my Keens.” Keen Online Reader Inquiry No. 339

Online Reader Inquiry No. 380

Sealed eyewear protects workers in extreme work environments

Uvex Livewire sealed eyewear for extreme, high-particulate environments has been introduced by Honeywell. Features include a precision-engineered frame that ensures a gap-free fit and Uvextreme Plus coating for good anti-fog protection and scratch resistance. This sealed eyewear can be worn with easy-

to-exchange temples or a headband. Its streamlined, wraparound design enhances line of sight and accommodates respirators and other PPE, while its lowprofile temples fit comfortably with earmuffs. Nine specialized lens tints are offered – clear, amber, espresso, gray, SCTReflect 50, SCT-gray, SCT-low IR, Shade 3.0 and Shade 5.0. Frame options include matte black and silver. The eyewear meets the ANSI Z87.1-2010 standard as well as the CSA Z94.3 standard, and its lenses provide 99.99% UV protection. Honeywell Safety Products Online Reader Inquiry No. 338

ContiTech Belts — Now available for all your industrial applications. ContiTech has been a leader in automotive belts for years. Now you can have the same quality under your roof as you do under the hood.

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A full line of Industrial synchronous belts • CONTI® SYNCHROCHAIN (8M & 14M), the perfect replacement for Gates Poly Chain • Metric HTD (5mm, 8mm, and 14mm), standard and high performance • Timing Belts (XL, L, H, XH) • Urethane (T & AT series)

Single-use black nitrile glove line fits all hand sizes comfortably

The Clean Hand powder-free black nitrile glove from Safety Today is a single-use, non-sterile glove for applications where dirt, grime, inks and other materials accumulate. This economical, latex-free glove offers a sleek appearance, and good dexterity, comfort and protection. The glove is 3.5 mm in thickness and provides good puncture and chemical resistance. Available in small through extra-large sizes, the glove finds application in industrial premises and maintenance departments. Safety Today Online Reader Inquiry No. 335

What do the Ford F-150 and your industrial equipment have in common?

MRO

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ContiTech’s NAFTA market partner.

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Online Reader Inquiry No. 135

14-04-09 2:18 PM

P R O D U C T

N E W S

Machinery & Equipment MRO

April 2014

What’s new in seals Sealed linear stages withstand harsh operating environments

A line of ballscrew- and linearmotor-driven sealed motion stages has been developed by Bell-Everman. SLS sealed linear stages feature a lip seal design that keeps debris, particulate and liquid contaminants from gumming up the internal drive and bearing components. Made from a ruggedized polyurethane elastomer, the seal integrates seamlessly with the stage’s anodized aluminum housing. Polyurethane is resistant to chemical exposures, temperature extremes and mechanical wear. The seal’s design allows it to be field replaceable in minutes without disassembling the stage.

Applications include laser machining, welding, semiconductor, machining and many other contaminationsensitive precision motion jobs. Bell-Everman Online Reader Inquiry No. 334

Seal withstands high pressures, temperatures in fluid power applications

Trelleborg Sealing Solutions has created the Zurcon Z13 Glyd Ring D seal in a material engineered for applications that are subject to increasingly higher pressures and temperatures. The Zurcon polyurethane material, offering good mechanical and elastic properties, withstands pressures up to 500 bar (7,250 psi) at both

Radial-shaft seal protects large bearings from contaminants

SKF has introduced HSS radial-shaft seals for critical steel mill and metals industry assets. The all-rubber, reinforced sealing solutions provide metal rolling mills with high-performance and easy-to-install solutions to protect large-size bearings from the ingress of potentially harmful contaminants. They can serve in such demanding applications as mill stand chocks and ultimately can help upgrade asset performance, boost overall mill productivity from increased uptime and contribute associated cost savings. Manufactured from nitrile rubber, SKF Duratemp (HNBR) and SKF Duralife (FKM), the seals are available in a wide range of metric or inch sizes. Optional rear grease ports can be integrated to enable easy regreasing between the sealing lips for those applications involving back-to-back or tandem installations of two HSS seals. SKF Canada Online Reader Inquiry No. 330

sides and at temperatures up to 120°C (248°F). Features include good resilience, friction and wear-resistance properties, compatibility with hydraulic fluids, 60 Shore D hardness, tolerance against lower-quality mating surfaces, good extru-

sion properties, and hydrolysis resistance. Applications include construction machinery, earthmoving equipment, mobile cranes, forklift trucks and any other solutions involving mobile hydraulics. Trelleborg Sealing Solutions Online Reader Inquiry No. 332

Bearing seal helps keep costs down, extends service life

Schaeffler’s sealed FAG E1 X-life spherical roller bearing features a seal concept that allows the egress of grease to be minimized and eliminates the need for relubrication, while maintaining the same high dynamic and static load rating. The compact bearing, which has the same outside dimensions as the non-sealed standard bearings, is almost maintenance-free and is also protected against contamination. The standard version of the 240/241 series features a highperformance elastomer that is suitable for use up to 200°C. Together with a high-temperature lubricant, this allows reliable sealing even at high temperatures and thus extends the service life of the bearing. Cost-effectiveness is boosted by the reduced costs for grease consumption and disposal. The bearings are particularly suitable for use in continuous casting plants of steelworks. Schaeffler Online Reader Inquiry No. 321

Metal-detectable and x-rayinspectable seals offer protection

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As elastomers degrade, there is a high risk of rubber fragments breaking off, resulting in product contamination, product recall, lost product and downtime. Due to its low conductivity, elastomeric material is often missed by even the strongest detection systems. Daemar has manufactured a standard elastomer with a metal-impregnated compound, allowing fragments as small as 1 mm of displaced rubber material to be located by an in-line metal detector. This enables systems to instantly reject contaminated product. X-ray-inspectable and metal-de-

At Veyance Technologies, we created REAL RESULTS – an interactive end-user web site designed to drive preference for valueadded services and our premium belts and drive components. By highlighting case studies of successful results delivered with Goodyear Engineered Products, REAL RESULTS can empower you toward greater belt drive efficiencies – and grow your sales, too.

See for yourself at www.realPTPresults.com The GOODYEAR (and Winged Foot Design) trademark is used by Veyance Technologies, Inc. under license from The Goodyear Tire & Rubber Company. Goodyear Engineered Products are manufactured and sourced exclusively by Veyance Technologies, Inc. or its affiliates. ©2013 Veyance Technologies, Inc. All Rights Reserved.

tectable seals provide confidence to food, dairy and pharmaceutical manufacturers. Detectable seals are available in standard elastomers, including buna, silicone, FKM fluoroelastomer and EPDM. Daemar Online Reader Inquiry No. 136

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Online Reader Inquiry No. 462

MRO

14-04-09 2:18 PM

L I T E R A T U R E

Advertising Feature

MACHINERY AND EQUIPMENT

G U I D E

Free MRO Product

Literature Guide HARTING — DEVICE CONNECTIVITY – PUSHPULL HARTING’s PushPull connectors are designed for transmitting optical and electrical communications as well as signals and power. With their robust housing and compact size, high contact density, high bandwidth and outstanding signal integrity, they are ideal for device connectivity in harsh conditions. The user-configurable PushPull boasts a latch-free, self-locking mechanism that secures tightly with a single click for easy handling in the field. HARTING, INC. OF NORTH AMERICA Online Reader Inquiry No. 271

BEARING SOLUTIONS AND SERVICES FOR DRILLING RIGS Rolling bearings utilized in the drilling sector have to operate under some of the harshest conditions on (and under) the earth. Because this unforgiving operating environment subjects the drilling equipment to so much stress, extremely robust and reliable bearings are required for this industry. SCHAEFFLER TECHNOLOGIES GMBH & CO. KG Online Reader Inquiry No. 274

THE MOST COMPREHENSIVE CATALOG IN THE TIMING BELT INDUSTRY BRECOflex, Co., L.L.C., is proud to offer its B212 polyurethane timing belt catalog. This catalog focuses on the wide range of belting products and gives detailed, technical information including full-scale belt drawings for confirming tooth shape. Also included is a preview of available belt backings, weld-on profiles, pulleys and accessories. BRECOflex is your single-source manufacturer with unmatched quality and lead times for standard and custom products. For a FREE copy, samples and technical support, visit our website at www. brecoflex.com or call 732-460-9500.

When your business depends on productivity, when you need to meet a deadline, when the work is tough and the specs are demanding, you have to be able to trust your tools to help you get the job done. And you have to trust the company that makes those tools. The Snap-on Industrial Brands have earned your trust, each with a long tradition of quality workmanship, superior performance and constant innovation. The bottom line? Productivity.

CHP hard chrome plated pins, with exceptional pin-surface wear resistance, help reduce chain elongation and can increase wear-life up to three times over conventional premium chain - with no reduction in working loads or operating speeds. CHP chain is ideal for applications that cannot be lubricated and operate in dry or abrasive environments - like timber, paper, gypsum and food – and is directly interchangeable with ANSI standard chain. TIMKEN DRIVES Online Reader Inquiry No. 273

BRECOFLEX Online Reader Inquiry No. 272 SKF RELIABILITY MAINTENANCE INSTITUTE – GET THE 2013 TRAINING CATALOGUE The best way to increase productivity is to invest in training. If we put equal amounts of extra cash into more equipment, increasing hours worked, or into training – the biggest return is from training. SKF RMI provides training courses designed to help increase equipment reliability and reduce wastes. Equip yourself and your team with Knowledge! SKF Online Reader Inquiry No. 275

A TRADITION OF TRUST

TIMKEN-DRIVES – EXTENDED LIFE CHP® CHAIN:

HIGH LOADS. HIGH SPEED. HIGH SATISFACTION. NSK High Performance Series (HPS™) Spherical Roller Bearings offer higher speed and load capacities for a wide variety of industrial applications. Increase operating life, reduce maintenance costs and optimize performance with innovative bearing design only from NSK. Learn more at thinknsk.ca NSK CANADA Online Reader Inquiry No. 278

SNAP-ON TOOLS Online Reader Inquiry No. 277

MOTOVARIO WORM GEAR REDUCER GUIDE Product and technical information for Motovario NEMA and IEC worm gear reducers including the new Power Series. Detailed information on models, available ratios, input/output ratings, mounting positions, key dimensions and accessories. Stocked in Canada by RotoPrecision. Helical Bevel and InLine Helical reducers also available. Contact Application Support for more information. Phone: 1-800-232-1985 Website: www.rotoprecision.ca/ downloads Email: applsupport@rotoprecision.ca ROTOPRECISION INC.. Online Reader Inquiry No. 276 KOYO CANADA DEVELOPS METRIC NEEDLE ROLLER BEARING INTERCHANGE GUIDE Did you know along with being the world’s largest supplier of inch based needle bearings, Koyo offers a broad line of metric needle bearings? With over 1,000 price listed metric needle bearings Koyo can meet your metric needle bearing requirements no matter the application. To help customers choose the right bearing for their application, Koyo is pleased to release a new metric needle roller bearing interchange guide. Contact your local authorized Koyo distributor or Koyo Canada for more information at 1-800-263-5163, www.koyo.ca. KOYO Online Reader Inquiry No. 279

WALTER'S XCAVATOR DELIVERS A HEAVY-DUTY PERFORMANCE Introducing XCAVATOR, the newest and most powerful member of Walter's innovative family of ultrahigh removal grinding wheels. The XCAVATOR delivers heavy-duty performance, the highest level of removal rate in steel and stainless steel and can confront some of the industry's toughest metals, from tungsten carbide to quenched and tempered steel. WALTER Online Reader Inquiry No. 280

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BROCHURE DESCRIBES PUMP SERVICES KSB Pumps Inc. offers a comprehensive range of services for industrial pumps valves from all manufacturers. These include hands-on training and support services for installation and maintenance activities at the customer’s location, plus repair/ overhaul services performed onsite or in KSB’s fully equipped Mississauga facility. KSB’s worldwide support network can help source out-of-production or hard-to-find components.

NEW WEG E-CATALOG This application will allow WEG Electric Motor customers in NEMA markets to search an electronic catalog for motors and produce data sheets and technical drawings. The application will also allow the user to download or email PDF data sheets and drawings. The app is available for iOS, Blackberry, Android. Go to www.pamensky. com/downloads VJ PAMENSKY Circle Reply Card No. 282

KSB PUMPS Online Reader Inquiry No. 281

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M R O

O N

T H E

R O A D April 2014

Manufacturing technologies bolstered at Fabtech event

Photos by Bill Roebuck

Machinery & Equipment MRO

BY BILL ROEBUCK

Toronto – Manufacturing has come a long way from past images, transforming it into what is today a high-tech, leading-edge industry with plenty of job opportunities. That was a key message from the organizers of Fabtech Canada, a metalforming, fabricating, welding, stamping, coating and finishing event, which took place in March at the Toronto Congress Centre. The final verified statistics from the event show a total attendance of 6,489, which is an 11% increase over the launch event in 2012. The buyer attendance of 4,355 visited almost 300 exhibitors’ displays spread across 73,630 sq. ft. at the Toronto Congress Centre. “Young people would be wise to look to manufacturing as a sound career choice, with its current skilled workforce shortage and wide range of financial and growth opportunities,” said Janine Saperson, event manager of SME, one of the organizers of the show. “The industry has become increasingly attractive to up-and-comers who recognize that manufacturing is a dynamic field that is constantly producing cutting-edge technologies,” she added. Take welding for example. Once conjuring up images of “greasy, heavy equipment, sparks and dirty fingernails,” Saperson said Fabtech Canada displayed the latest in welding equipment, including the world’s first battery-powered portable welding unit by exhibitor Fronius Canada. With a shoulder strap for easy transport, the miniature unit is ideal for use in remote locations, at high-altitudes or in difficult environments. Saperson pointed to other groundbreaking innovations seen at the show too, including the latest in robotics technology – in which robots are being used for everything from welding and assembly to cleaning – to apparatus that uses a strong stream of water instead of a knife for cutting. These products were among the hundreds of exhibits featured at Fabtech Canada, which also included a comprehensive conference. With targeted technical, operational and managerial sessions, the educational program covered such topics as new manufacturing workforce solu8

tions, best practices, industry trends and advances, the future of welding, and new applications, among many others. Karin Lindner, author of the recentlyreleased book, How Can We Make Manufacturing Sexy? was among the event speakers. In her book, Lindner emphasizes that now more than ever, it’s time to rethink, redefine and rediscover the sexiness of the manufacturing industry. Up until now, “rather than being viewed as an important cornerstone to our wealth and prosperity, a career in manufacturing was looked upon as a possible option for those who are not smart enough to go to university,” she added. “This may have been true in the past, but it no longer applies today because skilled trades truly are excellent career options.” Lindner said that parents, young adults, educators and guidance counsellors must be made aware of the incredible opportunities that exist in the manufacturing industry, and promote technical trade school and STEM (science, technology, engineering and mathematics) education. Gail Smyth, executive director of Skills Canada – Ontario, and a speaker at Fabtech Canada, emphasized that it’s particularly important for young women to be encouraged to pursue careers in the skilled trades and technologies. Explaining that Skills Canada – Ontario starts educating girls about technical career opportunities as early as grade four, Smyth shared her organization’s innovative initiatives in a Women in Manufacturing panel discussion. “There are many myths out there about the industry – from it being dirty and low paying, to lacking in opportunities – yet these ideas couldn’t be farther from the truth,” she said. “Young people, from elementary to high school and beyond, are encouraged and actually excited once these myths are dispelled and they learn about the many possibilities available to them.” Fabtech Canada was hosted by SME, The Fabricators & Manufacturers Association, Int’l (FMA), The American Welding Society (AWS), The Precision Metalforming Association (PMA), and the Chemical Coaters Association International (CCAI). MRO

1. Eyal Geiger of Proto3000 3D Engineering Solutions demonstrates 3D laser scanning equipment, ideal for reverse-engineering parts. 2. Two weeks into a new position at Walter, Jean-François Dubois shows the Xcavator disc for ultra-high removal grinding, which he was responsible for when working in research and development for the company. 3. Derek Coughlin and Jenniufer Kriticos of Superior Glove Works Ltd. 4. Tim Phillips of the Swagelock Central Ontario division was on hand to exhibit various fluid system solutions, including valves, fittings, regulators, tubing, gauges and filters. 5. Charles Moreau, grandson of the founder of International Sew-Right, enthused about the company’s customized safety apparel. 6. 3M Canada Inc. presented a full line of engineered abrasives, adhesives and tapes. 7. Julian Disabatino of Pruftechnik Maintenance Technology Service Inc. displayed the company’s alignment and condition monitoring systems. 8. Scott Ledrew of Walter Surface Technologies demonstrates the Surfox electrochemical weld-cleaning system. 9. Karl Elliott of Tsubaki of Canada Ltd. shows the company’s KabelSchlepp cable and hose carrier systems.

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Online Reader Inquiry No. 138

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