Machinery & Equipment MRO April 2015 by Annex Business Media

How repair methods extend the life of bearings

MACHINERY AND EQUIPMENT

Can industrial connectors outperform hardwiring?

Vol. 31, No. 2

Learning about Focused Improvement

APRIL 2015

REMOTE MONITORING Getting data from a distance

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WHATâ&#x20AC;&#x2122;S NEW | BEARINGS | BELT & CHAIN DRIVES | SAFETY | ELECTRICAL

P R O D U C T

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Machinery & Equipment MRO

Sturdy, low-profile caster handles up to 20 tons

Hamilton’s low-profile Enhanced MaxiDuty (EMD2) caster series features dual forged-steel wheels for heavy manufacturers who need to boost load capacities without increasing overall height. The wheels are precision CNC-machined with a slight crown, then clear-coated. A hybrid of the company’s Maxi-Duty and Ultra Maxi-Duty lines, this rugged series packs a small mounting plate paired with a massive swivel construction. The mounting plate is 5/8 in. thick, joined with a 1-in.-thick swivel base, and the 3/4

in.-thick legs are welded continuously inside and outside the base. The main load bearing is a 7-in.-diameter thrust ball bearing, while the secondary load bearing is a 1-1/4-in. precision tapered roller bearing to counteract radial thrust. The series is offered in wheel diameters starting from dual 8-in.-by-3-in. wheels rated at 28,000 lb up to dual 12-in.-by-4-in. wheels rated at 40,000 lb. Hamilton Caster & Mfg. Co. http://bit.ly/MRO696Apr15

Rib-cooled motor line now fits more applications

ABB’s expanded line of type NXR high-voltage, rib-cooled motors from Baldor Electric is available with higher power ranges and optional increased ingress protection. Based on the HXR range, the motor platform is available in frame sizes 355 to 450 and in the

April 2015

power range of 100 kW to 1,250 kW. The entire power range is enhanced with optional increased protection ratings up to IP66. Size, shape and positioning of the cooling ribs have been optimized, and pre-engineered fixing points are provided on the sides for accessories. Maintainability is enhanced by features such as easy access to check the coil ends and bearings, which can be inspected with an endoscope without the need to remove the end shields. The wide range of standardized accessories includes ABB MACHsense-P and ABB MACHsense-R condition monitoring systems. The motor line is particularly suitable for applications where dust is present, such as in the mining and cement industries. The enclosure is completely dust tight and withstands powerful water jets. Baldor http://bit.ly/MRO697Apr15

Keeping Industry Up and Rolling

Toolbox blends traditional look with modern features

The Pro+ line of tool storage solutions, combining a classic look with modern features, comprises 17 products, including top chests and roller cabinets in 28in. and 42-in. widths, side riders and utility carts that provide additional tool storage options. A wide variety of drawer configurations is available to accommodate bulky hand and power tools. Some standard features include 100-lb-capacity ball bearing sides on all drawers, up to 14% more storage capacity than previous models, premium 5-in.-by-2-in. casters with rear 360° brake, a robust tubular lock system and a redesigned all-steel double-hook engagement mechanism. Spare keys, replacement drawers and other parts also are available. Gray Tools Canada http://bit.ly/MRO698Apr15

Steel levelling feet have non-skid pad options

Winco’s GN 440.1 steel levelling feet have a fixing lug and are available in inch and metric sizes. The RoHS-compliant units feature a base and tapped socket of zinc-plated and blue passivated steel (the base is stainless steel for the rubberpad type). The assembly screw is of stainless steel, lactated into stud. Three types are offered, one with a base cap of black elastomer (TPE) plastic, 73 Shore, one with a vulcanized non-skid pad of black nitrile butadiene rubber, 70±5 Shore, and one plain. The feet will accommodate static loads ranging from 8 kN to 16 kN (1,800 lbf to 3,600 lbf) and are available in a large range of base diameters and thread sizes. J.W. Winco Canada http://bit.ly/MRO699Apr15

Thermal camera has compact design, radiometric imagery 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

• Unmatched Quality • Superior Reliability • Energy Efficient • Stock and Custom Orders

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The Flir C2 full-featured, pocket-sized thermal camera is designed to help professionals, including electricians, see hidden heat patterns that can reveal sources of energy loss, signs of structural defects and plumbing issues in buildings. Features of this compact device include a brilliant, simple-to-use touch screen with auto orientation and a rugged casing. The camera captures and displays subtle thermal patterns and small temperature differences using 4,800 pixels of resolution. The wide-angle fixed-focus lens and built-in work light and flash make it particularly suitable for use in large and dark areas typically found in building inspections. With quick point-and-shoot operation, the camera stores radiometric thermal and visible jpeg images with the push of a button. The images can be downloaded with Flir Tools, free software that allows users to adjust thermal image levels, isolate and add temperature measurements, change colour palettes and create reports. Flir Systems http://bit.ly/MRO700Apr15

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April 2015

in this issue p10

departments

Vancouver is venue for big MRO trade show / 26

1,900 visitors saw 277 booths at The Works show.

Editor’s Notebook / 6 Industry Newswatch / 8

p26

Business Briefs / 9 Mr. O, The Practical Problem Solver / 9 Maintenance 101 / 20 Product News Product Spotlight / 2 Focus on Belt &

Plant tour highlights EASA Ontario meeting / 26

A half-day seminar on rotor balancing is provided by S.A. Armstrong Ltd. Getting data from a distance / 10

The more valuable and inaccessible a motor or gearbox, the more sense remote condition monitoring makes. Here is what three suppliers have to offer.

columns Mr. O, the Practical Problem Solver / 9

Avoiding premature bearing failure.

Extending the life of bearings / 12

Don’t discard those worn bearings. You can use bearing repair to save up to 60% on the cost of installing new ones. Here is how to decide.

p12

Learning about Focused Improvement / 20

Maintenance 101: How to improve activities that maximize the overall effectiveness of equipment through the elimination of losses. MRO On The Road / 26 We visit a big MRO and safety show in Vancouver — The Works — organized by industrial distributor Acklands-Grainger. And we report on the annual general meeting of the Ontario Chapter of the Electrical Apparatus Service Association (EASA).

p20

Chain Drives / 21 Focus on Bearings / 22 Focus on Electrical Components / 23 Focus on Safety / 24

editor’s selections

‘When you can correlate

real-time oil sensing and real-time vibration analysis, you have the complete story of what’s going on inside the drive train.’ Mike Grunow / 10

‘Advancements in bearing design, steel cleanliness, and maintenance and repair methods have greatly improved the effectiveness of repairs extending bearing life. A common question is whether a repaired bearing will last as long as a new one. Independent studies have shown that a properly repaired bearing will run a second service cycle comparable to the first.’ Jay Alexander / 12

Can connectors outperform hardwiring? / 18

When you compare the cost of using industrial connectors against hardwiring, connectors can be more economical and practical for machinery OEMs as well as for in-plant installation and maintenance.

p26

‘Recent innovations in connectors like quick-lock termination, click-and-mate assembly and twist-top locking make installation and maintenance faster and simpler than ever.’ Harting / 18

‘Organizations often struggle to effectively identify and address recurring problems that cause waste, poor performance and ultimately, low staff morale.’

p18

Peter Phillips / 20

Cover Toby Smith

‘Strategic, operational, product and safety support helps customers save time and money.’ Dean Johnson / 26

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April 2015

Counting the costs of effective solutions T

here are a few common topics that prove popular issue after issue, year after year, and we’re always looking for new ways to cover them. Top-rated among them are condition monitoring and extending the life of bearings, and we’re tackling both with a fresh view in this issue. First, we’ve talked to three expert companies in the condition monitoring business to get their take on the advantages of remote monitoring, a technology that’s especially useful for hard-to-access equipment and components. From wind turbines to factory gearboxes, this technology can not only monitor, but provide a diagnosis and even offer the capability

to remotely correct certain problems. It’s not cheap to install, but I’m sure you can imagine the trouble, time and cost to repair equipment that’s difficult to get at. For such equipment, the expense of remote monitoring is sure to be far less than the cost of downtime caused by an unexpected breakdown. Moving over to the subject of bearings, you probably expect a certain amount of longevity from every bearing in your facility. But as Jay Alexander points out, you need have to rebuild a bearing once, twice or as many as three times to get every ounce out of a bearing’s potential life. Importantly, he reports, independent studies show that a

repaired bearing can run a second service cycle that’s as long as the first one – and that’s at a significantly lower cost than replacing an old bearing with a new one. Another story in this issue, which also compares the cost of one method over another, discusses the use of industrial connectors versus hardwiring in factory equipment and systems. Although the initial cost for using connectors can appear higher, they can offer a lower total cost of ownership over the service life of a machine so equipped. The cost of labour involved with hardwiring is a significant factor in this calculation. One study found the cost for hardwiring a pair of connection points on a complex piece of equipment was about $80 when done inhouse, but that it costs 30% more to do the same connection in the field, as part of re-wiring during installation or for when repairs are needed. That kind of thinking also applies to

the concept of Focused Improvement, a TPM technique explained by Peter Phillips in our Maintenance 101 column. The method concentrates improvement efforts on areas with the greatest leverage to achieve real breakthroughs. With this issue, we’d also like to introduce a new version of MRO in the French language. Our first issue of Maintenance, Réparation et Opération is being distributed to about 5,000 readers throughout Quebec, so we hope to hear some constructive feedback about it. We already plan to produce another French edition in December. Throughout the year, we’ll continue to provide relevant content to our audience across Canada and to develop new ventures like our French edition where we see a need. If you have a suggestion about something we should be writing about, please don’t hesitate to get in touch. Bill Roebuck, Editor & Associate Publisher

MACHINERY AND EQUIPMENT

MAINTENANCE, REPAIR AND OPERATIONS

APRIL 2015 Volume 31, No. 2

Established 1985 www.mromagazine.com www.twitter.com/mromagazine EDITORIAL Bill Roebuck, Editor & Associate Publisher 416-510-6749 broebuck@mromagazine.com Mark Ryan, Art Director Contributing Editors Carroll McCormick, Peter Phillips 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 Tim Dimopoulos, Vice-President Annex Business Media East 416-510-5100 tdimopoulos@canadianmanufacturing.com Mike Fredericks, President & CEO mfredericks@annexweb.com Machinery & Equipment MRO is published by Annex Publishing & Printing Inc., 80 Valleybrook Dr., Toronto, ON Canada M3B 2S9; tel. 416-442-5600, fax 416-510-5140. Toll-free: 1-800-268-7742 in Canada, 1-800-387-0273 in the USA. AWARD-WINNING MAGAZINE

Subscription rates. Canada: 1 year AW ARD-W I N N$58.95, I N G 2Myears A G A$94.95. Z I N E 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, 80 Valleybrook Dr., Toronto, ON Canada M3B 2S9. © 2015. 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. 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 Dr., Toronto, ON Canada M3B 2S9. MRO, USPS 012-846 is published six times per year. 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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April 2015

Toronto – The Ontario government brought together workers, employers and experts from a wide range of sectors at a Summit on Work-Related Traumatic Mental Stress on March 5, 2015. More than 150 participants from the policing, fire services, emergency medical services, corrections, health care, transit and social services sectors shared their experiences and workplace best practices in dealing with traumatic mental stress. The summit opened with a keynote address by humanitarian and decorated Lieutenant-General, the Honourable Roméo Dallaire (ret’d), who drew on his insights and experiences to highlight the importance of dealing effectively with work-related traumatic mental stress and psychological health. “The goals of this Summit were to elevate the conversation around work-related traumatic mental stress and take the next step toward helping those who suffer and those at risk, and I believe we accomplished that today,” said Ontario Labour Minister Kevin Flynn. The Canadian Mental Health Commission has reported that, in any given year, one in five people in Canada experience a mental health illness, with a cost to the economy of more than $50 billion.

PTDA CANADIAN CONFERENCE SET FOR VANCOUVER IN EARLY JUNE Vancouver, BC – Registration is now open for the PTDA 2015 Canadian Conference, to be held June 4-5, 2015, at the Four Seasons Vancouver, Vancouver, BC. For the fourteenth year, decision makers in the Canadian power transmission/motion control (PT/MC) industry will gather for business networking, market-driven education, a manufacturer industry showcase and more. The line-up of business speakers at the conference includes Jock Finlayson, executive vice-president and chief policy officer, Business Council of British Columbia; Ron Monk, M.Eng, P.Eng, district energy system practice leader of hydro-consultancy Kerr Wood Leidal; and Todd Snelgrove, an expert on total cost of ownership selling solutions. Others will deliver market updates on the mining and manufacturing industries. “It is essential to gather market facts and have an intense understanding of the pain points felt by end users in order to be of the most service possible in this industry, said Tom Dielschneider, PTDA 2015 Canadian Conference Planning Committee co-chair and vice-president, supply chain, Motion Industries Inc. “We worked diligently in planning this event to deliver the means by which Canadian distributors and manufacturers can gather this type of information during the conference so they can use it to map out their business strategy for the next few quarters.” According to David Heal, business development manager, NSK Canada Inc. and also co-chair of the Canadian Conference Planning Committee, “When preparing for our next business launch, we seek out Canadian economic insight based on facts, figures, data and solid information. This is what we will get from this line-up. These are experts who really ‘get’ our industry.” In addition to Canadian business topics, participants will be served up a bit of entertainment and fun, a key goal of the president of PTDA’s 2015 board of directors, Ajay Bajaj of Woodbridge, ON-based Rotator Products Ltd. Toronto-born comedian Arthur Black will endeavour to deliver belly laughs for the closing event. For more information, visit www.ptda. org/CanadianConference or call 312-5162100.

INJURIES AT CONVEYOR BELT PLANT RESULT IN $80,000 FINE Whitby, ON – Veyance Technologies Canada Inc. has pleaded guilty and has been fined $80,000 after two workers suffered

hand injuries in separate incidents. The company’s plant at 45 Raynes Ave. in Bowmanville, ON, processes and manufactures conveyor belts and employs about 130 employees. In the first incident, which took place February 20, 2013, a worker was moving a boom into position to lift it with a 50ton overhead crane. The worker was moving a steel cable belt roll weighing over 72,000 lb with the aid of a ‘keeper bar’ attached to the belt roll. The boom was being moved to the keeper bar when one of the worker’s fingers became pinched between the boom and keeper bar; a finger was partly amputated. This occurred contrary to Section 45(a) of Regulation 851, which governs industrial establishments in Ontario. It states that anything required to be lifted, carried or moved should be done in such a way that does not endanger the safety of a worker. In the second incident, which took place December 18, 2013, another worker was using a knife to cut frayed threads that had been accumulating on a roller. While cutting off the threads, the worker’s glove on one hand got caught in an in-running nip hazard created by the brake and rollers. The nip hazard pulled the hand between the rollers and resulted in the amputation of two fingers. This occurred contrary to Section 25 of Regulation 851, which requires that

Photo: Andrew Lever, Thinkstock

Steps taken to reduce impact of work-related mental stress

WORKPLACE SAFETY PLANS ON TRACK AT BC SAWMILLS Ontario wants to help workers suffering from work-related traumatic mental stress.

an in-running nip hazard on a machine that may endanger the safety of any worker must be equipped with and guarded by a guard or other device that prevents access to the pinch point. The company was fined $30,000 on the first incident and $50,000 on the second.

NOMINATIONS SOUGHT FOR WOMAN IN PT/MC INDUSTRY Chicago, IL – To honour the memory of Wendy B. McDonald, one of the power transmission/motion control industry’s true pioneers, the Power Transmission Distributors Association’s PTDA Foundation last year established the Wendy B. McDonald Award. The award acknowledges 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. A trailblazing woman 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. The inaugural recipient of the Wendy B. McDonald Award in 2014 was Pat Wheeler of Motion Industries (Canada). When merited, the Wendy B. McDonald Award will be presented annually during the PTDA Industry Summit. Nominations are now being accepted

Victoria – Sawmill operators in British Columbia have committed to a safety plan since two separate explosions killed four workers and injured 40 others in 2012, says a special advisor appointed by the provincial government. Gord Macatee took on the task last July to review safety operations at the province’s sawmills. His mission also involved overhauling investigation and inspection methods at WorkSafeBC after flawed techniques were cited by the Crown for its decision not to lay criminal charges in both cases. The threat of combustible sawdust at mills was highlighted as a safety issue that required constant vigilance. “I see evidence of a serious commitment to managing this risk on an ongoing basis,” Macatee said. “All of that leads me to say, hopefully, it’s much safer than it’s ever been in the past and it will stay that way.” He said sawmills have committed to a daily inspection routine and reporting weekly to WorkSafeBC, which would also conduct regular on-site inspections. “It’s an example of where the industry has really taken responsibility for getting on top of this risk and ensuring that not only are they compliant on a day the inspector shows up, but that they are compliant every day,” Macatee said. Macatee’s report made 43 recommendations, which the government said it would implement. He said 23 of the recommendations are already in place, eight are on track for completion and new legislation covers the 12 that reMRO main. The Canadian Press The BionicOpter can fly in all directions and execute complicated flight manoeuvres.

FLYING ROBOTS DEMONSTRATED BY AUTOMATION FIRM Mississauga, ON – As part of the 40th anniversary celebrations of Mississauga, ON-based Festo Canada, the German company Festo, a producer of automation technology, held demonstrations of four members of its Bionic Learning Network. These bionic robots fly by applying some of the principles that nature has perfected over millions of years. The flying bionics, as well as other members of Festo’s Bionic Learning Network, like the bionic kangaroo, provide inspiration to encourage engineers and scientists to imagine how concepts in nature can be applied in industry. They are learning projects for developing prototypes of breakthrough products that could improve industrial automation in particular. The four models demonstrated were: • SmartBird, which is modelled after the herring gull. Festo engineers have succeeded in deciphering the flight of

through May 31, 2015, and will be judged by the following criteria: • Nominees must be female and employed by a PTDA member company within the calendar year for which the nomination is being made. There are no criteria with respect to title, position in 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. The criteria and nomination form can be downloaded at: www.ptda.org/WBMcDonaldAward.

birds. It can start, fly and land autonomously – with no additional drive mechanism. • BionicOpter – Festo technically mastered the highly complex flight characteristics of the dragonfly. This ultra-light flying object can fly in all directions, hover in mid-air and glide without beating its wings.

• AirJelly – Modelled after jellyfish, this flying robot moves gracefully through the sea of air thanks to the movement allowed by the Fin Ray effect. • AirPenguin is an autonomously flying robotic penguin. Links to videos showing the models operating are in the article at http://bit .ly/1EGayb9.

Photo: Festo

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April 2015

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Business Briefs

Mr.0 The Practical Problem Solver

News and views about companies, people, product lines and more. • Wayne, PA – Affiliated Distributors (AD), an industrial products wholesale buying/ marketing group, has announced the first wave of Charter Members in its newly formed Bill Childers Bearings & Power Transmission (PT) division. “Our Bearings & Power Transmission membership is full of companies who are looking to achieve profitable, above-market growth. This is a strong team that will only get stronger in the years ahead,” said Bill Childers, AD’s vice-president and managing director of Bearings & Power Transmission. All Charter Members are US-based, although Childers told MRO Magazine he is currently working to include distributors based in Canada. For more information, visit www.adhq.com/join-AD.

program in Canton, OH, and will start working in his territory in June. • Montreal, QC – Canada’s Top 100 Employers has selected Walter Surface Technologies as one of Canada’s Top Small and Medium Employers for 2015. The official award presentation for the program was in March in Toronto, where Claude Vandemeulebroocke, general manager for Walter Canada, accepted the award. To view the Reasons for Selection explaining why Walter was chosen, visit www.eluta.ca.

Tim Breen

Problem: Every bearing becomes unserviceable in the course of time, even if it is installed correctly and operated properly, due to fatigue. That’s because raceway surfaces and rolling contact surfaces are repeatedly subjected to compressive loads and the surfaces eventually flake. Solution: Don’t encourage premature bearing failure through improper selection or handling, or lack of maintenance. Unlike bearing fatigue, these kinds of problems are avoidable. The fact is, breakdowns due to improper application, bearing design and maintenance are more frequent than flaking due to rolling fatigue in the field. Inspect bearings during operation to see if problems are developing. Check the bearing temperature, noise and vibration, and examine the properties of the lubricant. Specific care and maintenance guidelines can be found in publications and online from all major bearing manufacturers, so take advantage of this free advice. For our 30th anniversary, we are highlighting some of the most popular tips from the past. This one first appeared in September 2004. 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 address, telephone number, print complete details and, if possible, add a sketch to help explain your tip. Send your tips to Mr. O, Machinery & Equipment MRO, 80 Valleybrook Drive, Toronto, ON M3B 2S9.

Bill Stevens

• Birmingham, AL – After 37 years at Motion Industries, a distributor of industrial replacement parts, chairman Bill Stevens retired on March 1. Tim Breen, the previous president and chief executive officer, succeeds him. • Peterborough, ON – TransCanada Corp. has awarded GE Canada’s Peterborough motors facility a contract to build customized electrical motors for the company’s Energy East pipeline project. The contract is expected to create 250 jobs within GE and GE’s local supply

• Mississauga, ON – Timken Canada has hired Michael Bernstein as a technical sales representative for northern Ontario. He will be based in Sudbury, Michael Bernstein ON. He is currently going through Timken’s formal training

Avoiding premature bearing failure

chain over a two-year period. Over the past five years, GE has invested about C$65 million, with support of the Government of Ontario, to modernize its Peterborough plant. • North Canton, OH – The Timken Company has been recognized for the fifth time by the Ethisphere Institute as being among the world’s most ethical companies. It is among more than 130 organizations selected as a 2015 World’s Most Ethical Company. The designation recognizes organizations that foster a

culture of ethics and transparency at every level of the company. • Helsinki, Finland – Metso Corporation has acquired from the US-based company Rexnord Industries LLC certain intellectual property rights related to Rexnord’s Falk Mill Products business. The acquisition allows Metso to provide replacement gears and pinions for its customers, using OEM drawings and specifications for mills and kilns purchased through Metso and certain other end users. MRO

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D ATA FROM A DISTANCE T he more valuable and inaccessible the motor or gearbox, the more sense remote monitoring makes. BY CARROLL MCCORMICK

Siemens monitors over 8,000 wind turbines globally from its remote monitoring centre in Brande, Denmark.

Photo: Siemens

y the end of 2015, 137 new wind turbines are scheduled to come on line at the Armow Wind and Cedar Point II projects in Ontario. Siemens, which won the contract to supply, install and commission the 2.3-MW units last year, will remotely monitor them from its new diagnostic centre, which it opened last year in Brande, Denmark. Siemens monitors over 8,000 wind turbines worldwide on a 24/7 basis, including more than 700 in Canada. Its task is to detect operating anomalies and react to correct them, either remotely or with up-tower service and maintenance, before they turn into major issues. Variables it monitors include temperature and vibration on the main bearings and generator bearings, and temperature, vibration, oil temperature, oil pressure and optionally, the particle count in the gearbox oil. “In regards to vibration diagnostics, Siemens monitors 17 bearings and nine gear wheels inside each wind turbine gearbox, plus the main bearing and the bearings in the generator,” says an expert in the Brande diagnostics centre. “We have approximately 90 different measurements being taken on the drive train in order to detect damage. On top of

that we apply advanced diagnostic models on the data. This makes it possible to detect very small anomalies in the data that can lead to damage.” The response time to an alarm is about 10 minutes and 99% of all alarm messages are handled within an hour, according to Siemens. “In 85% of the cases, the monitoring team can actually solve the issue and restart the turbine remotely.” Remote monitoring, diagnosis and even the ability to remotely correct some problems is an investment for high-value and hard-to-access equipment. “This is all about preventive, versus reactive maintenance,” says Mike Grunow, vice-president, sales and marketing, North America, Moventas. “We have expert analysts who spend 24 hours a day, seven days a week looking at data coming in from thousands of wind turbines.” Dealing with a problem early, say, a gear with a chipped tooth, might be a $20,000 to $50,000 up-tower repair job, says Grunow. “But if [a gearbox] runs to failure, [it] can cost anywhere from $300,000 to $450,000 to fix. Our technicians can roll to the site and fix the turbine in one day of downtime – and every day of downtime is lost revenue.” With early warning, what could have been weeks or months out of service instead

becomes a one-day, up-tower repair. Grunow describes how correlating real-time oil particle counting and realtime vibration analysis – two critical variables that speak volumes when their data is correlated – backed by software to interpret the sensor data, reveal what is happening in a gearbox. “Imagine there are 10 gears of different sizes, spinning at different frequencies and speed. You pick up an odd vibration. With vibration analysis, you should be able to tell which two gears are interacting. We know the frequency of each gear and expect a knocking tooth every X seconds. An unexpected vibration signal is not always problematic or telling. However, such a signal meaning is clarified when real time oil analysis shows a spike in ferrous particulates. If you see both, it [usually] proves that there is an issue that needs to be inspected. “When you can correlate real-time oil sensing and real-time vibration analysis, you have the complete story of what’s going on inside the drive train.” The wind turbine industry, because of the very high cost of the machinery perched hundreds of feet off the ground in the nacelles, and the remote locations of many wind farms, is an enthusiastic user of remote monitoring services. So is the

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velopment manager for online systems, SKF. “The software can alert someone to look at that data and review the trend. You are in control of how often you sample data and its resolution.” WMx is for equipment that warrants monitoring, even if it is not that dynamic; that is, it does not operate in varying environmental conditions, or is not critical to production. Further up the sophistication ladder are systems like SKF’s IMx on-line monitoring systems. They send data more frequently and a lot more of it. Data can be sent to the SKF Cloud if remote hosting better suits a company’s level of in-house expertise, or to a local database. “I see more and more the trend where people do not have the vibration expertise,” Ziegler observes. “Some plants may have the vibration expertise, but not the IT expertise. [In this case] we collect the data, but the plant vibration analysis expert logs onto our server and can manage the data if he chooses to do that. We are just hosting the data for them.” The system software can be programmed with industry standards to determine whether the numbers — for example, vibration and temperature — are moving outside of normal operating ranges. Or, companies like SKF can initially set and tune the database to set alarms. “SKF also can provide some basic machinery templates that can later be customized to that particular site or equipment,” Ziegler says. “One of our software packages has tools called diagnosis rules. It can diagnose bearing faults, looseness, misalignment, etcetera. It does this by analyzing the frequency content and understand-

There’s no subsTiTuTe for hard work...

ing the mechanical components and the fault frequencies that it would generate,” Ziegler adds. Remote condition monitoring systems can take into account the dynamic nature of some equipment. For example, what might be seen as a too-hot operating temperature in the winter might be normal in the summer. “Some peoA ruggedized industrial accelerometer and cable is measuring ple do not take into acthe health of a critical roll in a paper machine. An SKF IMX data count the dynamic naacquisition machine is used for the monitoring. ture of some machines,” Ziegler says. planned shutdowns, with early ordering Remote condition monitoring systems of parts. can also function as a protection system Should a company want to explore the for critical process equipment. “A protection system should be able to shut down benefits of remote condition monitoring, [equipment] in milliseconds — for examexpert assistance in determining ROI is ple, if a turbine blade breaks off. There available. “A client-needs analysis is fairare redundancies such as the power suply simple.” Ziegler says, “We have a tool ply, to make the platform bomb-proof,” where we can enter downtime and reZiegler explains. pairs, and we can provide numbers that Remote monitoring can help in dealshow ROI.” MRO ing with what are commonly known as ‘bad actors’. “Maybe a company knows it Montreal-based Carroll McCormick is the is rebuilding the same motors over and senior contributing editor for Machinery over each year. We can begin to under& Equipment MRO. stand bad actors, and understand what the ROI of [using remote monitoring] Get more details might be,” Ziegler reports. For more information, Monitoring can typically reduce shutuse these direct links: down time by giving maintenance teams Siemens: http://bit.ly/MRO702Apr15 advance notice of equipment that is beSKF: http://bit.ly/MRO703Apr15 ginning to operate abnormally. This Moventas: http://bit.ly/MRO704Apr15 helps them organize well-prepared, well-

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oil and gas industry. But remote monitoring is a technology that any maintenance team might want to consider. “It is all about transitioning from unplanned to planned maintenance,” Grunow explains. It is also about moving from time-based to condition-based monitoring. Will remote monitoring give a company an acceptable return on investment? Grunow answers, “The primary consideration is the frequency and severity of failure. How often does the system fail? What is the cost impact of the failure?” The sensing equipment can be retrofitted to existing equipment, so a company can make the decision anytime to begin remote monitoring. The equipment and software can be purchased outright and managed in-house. Or, they, as well as the monitoring and data analysis service, can be bought as a package — the data hosted and monitored remotely — and can be paid for by the month or year. An installed monitoring system for a wind turbine can cost between $5,000 and $10,000. On the other hand, a service agreement that covers a couple of variables can cost as little as $100 a month. One engineer put it like this, Grunow says. “We can take this whole remote management hardware system and bolt it onto the engine and transmission of a Chevy.” A fairly simple remote monitoring system works like a data collector that someone manually walks around with, except that it is hands-off and transmits data wirelessly, “Our Multilog On-line System WMx sleeps and wakes up on a schedule, and collects and sends dynamic data to a database,” says Greg Ziegler, business de-

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Technician re-installs rollers.

EXTENDING THE LIFE OF Don’t discard those worn bearings. Use bearing repair to save up to 60% on the cost of installing new ones. BY JAY ALEXANDER

bearing showing signs of wear after extended operation in a heavy industrial application is not necessarily destined for the scrap heap. Instead, that bearing can often be repaired – typically multiple times – enabling it to serve additional service life cycles. Too often, a bearing is discarded without the user realizing there’s an economical option to extend its life. By using bearing repair services, plant managers and technicians can greatly enhance the bearing’s life while saving up to 60% of the cost of a new bearing. Bearing repair services can also return a bearing to like-new specifications in about one-third of the time it would take to procure a new

bearing, depending on the required level of service. Furthermore, a successfully repaired bearing can frequently realize two or more subsequent life cycles that are comparable to its first life cycle. With bearing repair service programs offering significant value in both time and cost compared to replacing bearings, let’s review how to determine whether repair services are right for your operations. Why repair instead of replace? A wide variety of factors – load, inadequate lubrication, contamination, temperature, maintenance intervals, installation errors and more – contribute to premature wear that causes less than 10% of bearings used in heavy industrial

Cleanliness is critical when reassembling bearings.

applications to reach their theoretical L10 life. Theoretical life, or L10 life, is the length of time at which 10% of bearings for a particular application are expected to fail due to fatigue. Despite this tendency for premature failure, a bearing that has made it through its initial ‘wearing in’ period and reached its first service life cycle is primed for continued reliable operation if a qualified provider repairs the bearing. Advancements in bearing design, steel cleanliness, and maintenance and repair methods have greatly improved the effectiveness of repairs extending bearing life. A common question is whether a repaired bearing will last as long as a new one. Independent studies have shown that a properly repaired bearing will run a second service cycle comparable to the first. It’s often possible to realize up to two additional comparable service cycles before the bearing reaches its theoretical life. Therefore, those users not taking advantage of bearing repair services are likely missing out on years of extended operation, as well as the up-to-60% cost savings that bearing repair services offer. A high-quality bearing repair program can help determine if and when a bearing can be repaired. It may also offer a warranty on the service. In addition, the program will use replacement parts featuring the same materials and toler-

Bearing rollers get a visual inspection.

ances specified by the OEM, as they have already proven reliable in the application. Bearing repair eligibility Bearing repair is an option for heavyduty applications in all industrial markets, including metals, cement, oil and gas, mining, power generation, pulp and paper, aggregates and more. All types of bearings, including tapered, spherical and cylindrical roller bearings, ball bearings, thrust bearings and cross roller bearings, are eligible for repair regardless of the original manufacturer. However, repair is not always the best option for a damaged bearing. A reliable bearing repair service provider can help organizations make the sometimes difficult decision as to whether repair is an option, as well as which repair option is the most economical and long-term decision. For example, if a bearing is too worn, it’s not a good candidate for repair, as it won’t be able to be restored to like-new condition. In addition, bearings can also become worked into an out-of-round condition based on the roundness of the shaft or housing that supports it. Depending on the amount of this out-of-round condition, the bearing may not be considered for repair. To help service providers assess bearing repair eligibility, it’s critical for organizations to engage in regular monitorcontinued on page 14

Photos: Timken

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Some telltale signs that repair needs are imminent include: • The bearing nearing or exceeding its suggested life expectancy • Operating temperatures exceeding 200°F • Exposure to excessive vibration • Sudden changes in lubrication and temperatures • Excessive audible sounds during operation • Loss of bearing seal integrity.

Damage was repaired on the outer race of this spherical bearing.

Photos: Timken

ing and inspection activities. Properly trained and experienced personnel involved in routine inspections serve as the first line of defence. Early detection of a problem through routine checks, preventive and predictive maintenance, and vibration analysis can reduce unnecessary downtime and expense and help to maximize the benefits of bearing repair.

The repair process Products returned to a bearing repair service centre undergo a detailed, documented process, from cleaning to final inspection and packaging. First, the bearing is thoroughly cleaned. Next, it’s disassembled, during which repair technicians record bearing information and internal clearances, tagging each component with unique identifiers.

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A detailed inspection of all bearing components follows to determine what’s required to return them to like-new condition. The inspection looks for major problems or damage, such as fractures, major spalling or bluing due to heat damage, as these issues indicate the bearing may not be eligible for repair. In addition, technicians measure the bearing’s bore and outside diameter (O.D.), as well as the roundness of major race components to determine whether repairs are feasible and, if so, the appropriate method of repair. Bearing repair methods fall into three general service levels based on the extent of damage: • Type 1 – Recertification: During recertification, bearing assemblies are cleaned, examined, measured for verification of internal clearances, and preserved and packaged for long-term storage and transportation. This process is often performed on unused products with outdated shelf lives so they are again available for use. • Type 2 – Reconditioning: During reconditioning, bearing assemblies are cleaned, examined, polished, measured, preserved and packaged. • Type 3 – Remanufacturing: During remanufacturing, bearing assemblies are cleaned and examined, raceways and ribs are reground, new rollers and other components are manufactured as required, and internal clearances are reset before the product is preserved and packaged. Often, the regrinding of raceways will require the manufacture of oversized rollers to maintain bearing geometry and clearance in bearings where radial internal clearance is critically held. In cases where lateral clearance is held, oversized rollers, new spacers or additional shims would be provided. The above levels of repair are traditionally suited for bearings with a 12-in. inside diameter (I.D.) and larger. However, another service option – reclamation – exists for bearings as small as 3 in. in I.D., enabling smaller bearings that would typically be discarded to be returned to service. When handled in large quantities, bearings from 3-8 in. can be reclaimed at a fraction of the cost of purchasing new bearings. During reclamation, components are polished using a proprietary vibratory process that returns the used bearings to like-new condition. Additionally, end users may use the repair process to modify existing bearing assemblies. Modification services can add special features that enhance performance, facilitate retrofits for special applications and enable upgrades to current product designs. The goal for a bearing repair service provider is to turn around a quote and initial inspection report as soon as possible, but this is typically a one- to two-week process. Turnaround time on reconditioning can be as short as two to four weeks, depending on the need, complexity and size of the product, as well as the level of damage. The typical turnaround time for reclaiming smaller bearings is four to six weeks depending on the size of the order. The typical process time for remanufacturing is in the eight- to 14-week range based on the scope of work required. Depending on the facility capabilities and level of damage, some repairs can be performed on-site using existing personnel or a bearing manufacturer’s service personnel. In general, on-site programs are suited for recertification or reconditioning processes, not for remanufacturing. continued on page 16

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• Heat damage: Discoloration or checks • Electrical damage: Burns, fluting or pitting • Mechanical damage: Fatigue flaking, cracks, spalling, fractures, nicks, peeling or smearing, brinelling, indentation, scoring, abrasive wear, installation damage, misalignment or lubrication failure.

Types of damage The types of damage discovered during bearing repair vary significantly. Damage may be evident in the form of visible corrosion, scuffs, stains and dents. Or, it may be barely noticeable, such as fine cracks or fractures that indicate the potential for more serious damage to occur. Typical bearing damage falls into the following categories: • Chemical damage: Etching, stains, corrosion pitting, rust or fretting corrosion

Most resource manuals describe the types of damage and offer methods to help eliminate their causes. However, resource manuals often fail to mention that, with the exceptions of torch heat damage, extreme spalling, fractures and heavy etching, most damage conditions are repairable. Therefore, it’s recommended to contact a bearing service technician to provide a damage assessment and determine the feasibility of a repair. Repair limitations Although bearing repair has proven to be

Thrust rollers undergo reconditioning.

a cost-effective solution, like any service, it’s subject to limitations. Bearings can be repaired, often more than once, but not indefinitely. A rule of thumb is to not regrind bearings more than three times. Regrinding removes surface material, so it’s best to minimize the amount removed to reduce risks associated with altering the design integrity of the bearing. The Timken Company’s standards suggest a maximum stock removal on any race of 0.025 in. of the diameter, as well as not having roller sizes exceed 0.015 in. in diameter from the original equipment manufacturer’s standard size.

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continued from page 14 The equipment, tooling and knowledge to remanufacture bearings require substantial investment and commitment. A qualified bearing repair provider will perform significant repairs and manufacture replacement parts on the same types of equipment that would be used to manufacture new bearings.

When fully restored, repaired bearings offer like-new performance. However, not every repair option addresses every damage type. For example, polishing is not effective for removing debris indentations or wear. If such damage is not repaired, a polished bearing will not deliver like-new performance. Determining the cause, extent and suggested repair of the damage is best handled by consulting with a bearing manufacturer representative and/or application engineer. It’s also important to have any bearing repair performed by properly trained and experienced personnel, as unnecessary, or inadequate repairs can lead to additional damage and limited bearing life. In addition, proper equipment is required to ensure damage has been reviewed and properly removed. Maximizing value To maximize the value of repairs, consider using the bearing repair process as a troubleshooting tool to minimize future bearing damage. Taking corrective actions may improve the likelihood of getting closer to the bearing’s L10 life. Planning when to remove bearings from service for reconditioning can greatly enhance the total life cycle value of bearings. If removed from service too early, the bearings aren’t being used to their full potential. Leaving bearings in operation for too long increases the risk that they will surpass the point of economical repair. Operating somewhere between these two conditions can optimize cost savings. A good bearing inspection report is a smart first step in trying to solve performance issues. For example, if the report details black staining and rust on raceways, the likely cause is water ingress. If the raceways show abrasive wear, foreign material has probably entered the bearing. In either case, the bearings’ seals are likely the root cause of the problem. The corrective action is to investigate the seals and improve their maintenance and/or redesign them to minimize bearing contamination. Choosing bearing repair When a bearing is damaged, the entire operation will suffer, resulting in additional costs, lengthened maintenance work schedules, unnecessary downtime and extended delivery times to final customers. To reduce these undesirable circumstances, bearing repair offers a fast and economical option to extend the life of a bearing further along its theoretical life line. A quality bearing repair program can result in significant time and cost savings compared to discarding worn bearings and purchasing new ones. MRO Jay Alexander is general manager for Timken Industrial Bearing Services – North America. For more information, use the link below. http://bit.ly/MRO701Apr15.

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CAN CONNECTORS

Today’s modular connectors offer many benefits over hardwired connections.

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any thousands of equipment manufacturers have switched from point-to-point (hard) wiring to connector-based cable assemblies in factory and process automation and control systems. Adopting progressive connectivity solutions has improved their unit costs and productivity. It allows them to turn around orders and complete installations much faster. With margins under increasing pressure, many OEMs have come to regard

these benefits as a must-have. For end users, the principal argument for connector-based wiring over hardwiring – a lower total cost of ownership over the service life of the machine – is equally compelling. Today’s connector lineup includes more user-friendly and application-specific choices that can further enhance reliability and convenience. Connectors offer excellent mechanical stability and are available with high ingress, temperature and vibration resistance, harsh weather durability and multiple termination options.

In a plant layout, connectors can distribute power and signals to motors as drops off a main cable.

Modular connectors can be used in a wide variety of applications.

Most rectangular connectors are modular and user-configurable. Using different inserts, each can be configured for different voltages – for example, signal and power, or combinations of different transmission media: power, signal, fibre optic, coax, D-Sub and pneumatic. Recent innovations like quick-lock termination, click-and-mate assembly and twist-top locking make installation and maintenance faster and simpler than ever. Most industrial equipment, for indoor or outdoor use, contains extensive electrical wiring between its components and subsystems. When the equipment is manufactured, the machine builder typically assembles and tests it at the plant, disassembles it for shipping and reassembles it at the customer’s location. With hardwiring, this means each connection – often there are hundreds – has to be individually unmade for shipping and then remade when setting up at the customer. That’s labour intensive. If wiring errors are made during this final setup, and it happens frequently, they can cause equipment damage upon start-up or, at a minimum, further delays and considerable additional expense to diagnose and correct. Using connectors makes the wiring for the same machine a pre-engineered job that can be designed, assembled and tested as a harness and then quickly integrated into a machine or system as it takes shape. Some time is invested in

Photos: Harting Inc.

Industrial connectors or hardwiring? More and more machine builders comparing the cost of using both wiring approaches in their operations find connectors more economical and practical.

assembling the harness, but then installation only takes a fraction of the time hardwiring requires. The risk of wiring errors is virtually eliminated. That’s why hardwiring has a dwindling appeal, increasingly limited to production where substantially all connections are made just once, at the factory, with little or no field assembly required. Even in those circumstances, connectors make a strong business case. Connector-based wiring provides advantages over hardwiring at every stage of the product life cycle. Connectorized wiring is almost perfectly complementary with the continuing shift to modular machine design. Modularization, where machines and plant systems comprise inter-related functional modules, offers significant efficiencies and economies over the traditional unitary design approach. Standard components such as control panels, motor assemblies and power distribution boxes can be pre-built, pre-tested then plugged together in final assembly with connectors. In a connectorized plant layout, most plant engineers are well-versed about using a communication bus with drops coming off a main trunk cable. Power and control signals for motors can be distributed the same way using connectors. Installing or replacing a motor becomes a plug-and-play operation, with little downtime or risk of wiring errors.

For example … Here is what some North American companies found in switching to connectors. • A producer of conveyor systems for the food and beverage sector needed to design an IP67-compliant product that could withstand harsh conditions like immersion in washdown situations. Adopting a connector-based assembly with Han-Yellock modular connectors in place of hardwiring allowed it to reduce install time and maintenance downtime and increase the throughput of the conveyor by 15%, with cost savings going directly to its bottom line. • The manufacturer of large material handling cranes takes each one apart for shipment to the customer, where it is reassembled. Transitioning from hardwiring to hybrid connectors cut field installation time from weeks to a mere three to four hours. Through the initial setup in the field, the manufacturer calculated its all-in cost using connectors was, on average, $622 less ($12,540 for connector-based wiring, $13,162 for hardwiring). However, when hardwiring errors happened during installation, the cost doubled to $26,325, for total savings using connectors of about $13,000. • A builder of large, automated, precision-welding machines was hardwiring over 300 contacts per unit. It took a week to build and test one, then several days to dismantle it and another week to re-assemble it at the customer’s location. Switching to pluggable connectors cut wiring time dramatically, saving extensively on labour cost. Now, each step that used to take a full week is being done in less than a day. Online Reader Inquiry No. 127

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Savings on the production floor Pre-making connectorized wiring assemblies allows for precise, repeatable measurement of cable lengths. Connector-based wiring harnesses can be assembled by lower paid staff or a contractor rather than by an electrician for additional cost savings. With installation, they require little if any of the rigid or semi-rigid conduits that protect pointto-point wiring from damage that would require extensive re-wiring. Since power and signal needs often vary within a machine, a single connector can be configured to accommodate different DC voltages or both AC and DC power. The alternatives, like mounting multiple terminal blocks inside a control cabinet, require additional labour and materials and take up more space. Another example of labour-saving possibilities is the Harting Han-Yellock connector, which requires only male crimp contacts. The electrical feed per wire can supply up to five contacts by using a multiplier insert inside the connector. This enables the connector to perform the multiplier function previously done by terminal blocks inside the machine. The connector’s housing can be populated from either side, so the entire connector interface – hood and housing – can be mounted from the outside once the machine is fully built, again, a job for an installer rather than an electrician. With modular design and connectorbased wiring, the machine can be shipped to the customer in smaller pieces, reducing transportation costs and the risk of damage. Faster field assembly with much less risk of wiring errors translates into major cost savings for the OEM. Troubleshooting and maintenance are similarly accelerated. During the warranty period, that’s a cost benefit to the OEM and a benefit to the end user in the form of reduced downtime during scheduled and unscheduled maintenance. After the warranty period, the entire benefit accrues to the end user, the major reason why connectors assure a lower total cost of ownership than hardwiring. Many progressive machine builders see that lower lifetime cost as a unique selling point to differentiate themselves from competitors and maintain customer satisfaction (and loyalty) over the years.

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tion points on a complex piece of equipment was about $80 when done in-house. Experience shows there is about a 30% premium on doing the same hardwired connection in the field, whether part of installation or for warranty service and repairs. The right connector for each budget Today’s connector portfolio offers users unrivalled flexibility. Connectors are available in different sizes, made from a range of coated and uncoated metals and plastics, and with different cable entry angles and termination technologies. There are models created for specific design objectives, such as slim models to fit compact units or tight spaces. Many rectangular connectors offer simple termination options that can be per-

formed quickly, easily and safely by installers rather than electricians, using common tools like a screwdriver. Usually, there are multiple suitable options for each job, allowing the OEM to determine the appropriate combination of capability, convenience and price – even aesthetics. For example, Harting invented and popularized the rectangular connector in the 1950s. Rectangular and square connectors are more readily scalable, configurable and customizable than round ones. More and more connectors are being designed for special situations. These are based on standard connector products, optimized for particular demanding operating conditions or requirements, harsh weather, extreme heat or corrosive environments, high load appli-

cations or where high electromagnetic protection is required. There are models enhanced for high mating cycles in prototyping and testing scenarios, as well as stainless steel ones for hygienic applications like food or pharmaceutical production. These and other specialty versions come in standard sizes, and can generally replace standard connectors without modifications to the design of the machine. Choosing the right connector solution for the job will optimize the benefits of connectorization while giving end users the lowest possible cost of ownership and greater peace of mind. MRO This article was provided by Harting Inc. of North America, Elgin, IL. http://bit.ly/MRO705Apr15

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Hardwiring: the cost myth Given these advantages, why do some OEMs still hardwire? For some, the thought of making a significant change in their manufacturing processes is daunting. Others may not fully appreciate the cost of assembling a hardwired system in the field. They say connectors are an additional item on the bill of materials and their customers buy solely on the basis of the lowest sticker price. Yet most OEMs that compare their use of hardwiring and connectors find connectors save them time and money, particularly when the full cost of making hardwired connections is recognized. Unlike connector-based wiring where most of the attributable costs are incurred once, up front, the costs associated with hardwiring are recurrent and often unpredictable because of the possibility of wiring errors. Each manufacturer has different labour and overhead costs, but a time study by one found the fully allocated cost for hardwiring one pair of connec-

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Learning about Focused Improvement Focused Improvement includes all activities that maximize the overall effectiveness of equipment through the elimination of losses in order to improve performance. BY PETER PHILLIPS

This issue’s column continues an ongoing discussion of a current project aimed at improving maintenance operations at an Ontario food plant. n our previous article, we outlined more opportunities for improvement at this food processing plant. They included increasing the number of tool time hours for the maintenance crew, and improving its planning and scheduling of work orders. We will work with the crew on these items over the coming months. During our visit in February, we started the plant off on a new process that will help increase reliability of its troublesome equipment. Specific pieces of equipment within the plant have a lessthan-reliable track record and account for the majority of downtime and lost productivity. We helped the crew lay out a systematic plan of Focused Improvement. Focused Improvement is the part of TPM – Total Productive Maintenance. Focused Improvement includes all activities that maximize the overall effectiveness of equipment through the elimination of losses in order to improve performance. It is implemented systematically by a plant team that follows a series of steps that will improve asset availability and reduce waste. Organizations often struggle to effectively identify and address recurring problems that cause waste, poor performance and ultimately, low staff morale. Furthermore the attempts to rectify the problems are regularly disjointed due to a lack of structured meetings and because some people take ownership of equipment. The plant’s standard reports also fail

to provide users with the opportunity to delve into the data for detailed analytical purposes. Implementing a system and practices for structured and focussed improvement activities thereby addresses asset-related problems and performance gaps within the organization. Focused Improvement concentrates improvement efforts on the areas with the greatest leverage to achieve real breakthrough improvements. Meetings are established and people are provided with the skills to do effective problem solving. This combination ensures successful and sustained performance improvement. The results stemming from Focused Improvement are quick, tangible and visible. Projects are aimed at improving the optimal performance of assets and achieving constant reliability. Asset owners gain control and gain the ability to manage maintenance and operational costs through increased performance. Quick wins help overcome initial internal resistance to change and build momentum for the improvement process for larger projects. Problem solving becomes intrinsic to the organization, resulting in a culture of continuous and sustainable improvement as staff are trained and enabled to effectively drive Focused Improvement. Communication channels among different departments involved with Focused Improvement are established and cooperation greatly improves, which helps in all day-to-day communications. Following is a summary of the Focused Improvement steps we outlined for the plant. The document is intended as an outline. The seven key headings are

the tasks the crew must undertake to investigate and develop improvement activities. The points under each main heading are meant as a guide for the team to follow, although we want it to develop its own list of items to review. The Focused Improvement steps are as follows. 1) Pick a machine: The chosen equipment should have reliability or waste issues. 2) Select a team: The team must include a variety of departments to broaden the knowledge base. The team leader must have knowledge of the Focused Improvement process. Take picture of the team and post it on the plant’s activity board. 3) Create a clear vision: Outline the goals of the process. Post the vision on the activity board for all employees to see. Here’s an example. ‘The vision of this process is to reduce equipment downtime and reduce waste due to equipment breakdowns, lack of PMs, lack of SOPs and documentation, raw material issues, lack of spare parts and spare parts organization, setup/ changeover time, SOP not followed or insufficient training, quality issues or housekeeping. 4) Create a list of items that affect equipment performance and reliability: Examine PMs, lubrication, parts, setup, SOPs for operators, housekeeping, QA (quality assurance), material/storage, training and planned modifications. 5) Create a detailed plan and include the following items: • Equipment ledger. Get drawings of ma-

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chines. ID subassemblies/components that require PMs. Review all PMs including OEM-recommended ones for accuracy and details. Determine who is responsible to complete the PMs. • Lubrication identified in PMs. Who is responsible? Complete a lubrication map with the types and amount of lubrication to be applied. • ID wear parts and what is required to stock. Organize parts into identifiable locations and label them. Determine reorder points. Enter the data into the maintenance software. Plan to maintain the correct parts and amounts. • Set up requirements for equipment after changeovers and start-up. What is required? Who is responsible? Is the proper documentation available? • SOPs (Standard Operating Procedures). Are SOPs available? Are they correct and up to date? • Housekeeping. The equipment and area must be kept clean in order to maintain it. Who is responsible? Is cleaning documentation available? • Quality Assurance (QA). Review responsibilities and documentation. • Materials — maintenance and production. Storage — is there rotation of stock? • Training materials. Are they accurate and specific? • Planned modifications. Are there any planned improvements or modifications that will be affected by this project? 6) Measure progress: Start reporting repairs, breakdowns and waste immediately to capture accurate, equipment-specific information. Set a team meeting date and time. Assign members activities with deadlines. Determine what to measure for displaying improvements. 7) Update the activity board: Mount it where it is visible to all employees. Display pictures (before and after). Record completed tasks from the action plan. Display graphs and reports to show trends and improvements. Use graph results for next actions. Use Root Cause Analysis to solve problems. This is the first Focused Improvement exercise for this plant. The results will surely encourage them to continue with the next improvement project. Along with increased equipment reliability and waste reduction, personnel will develop bonds among departments that will improve overall communications. The ultimate result is that every person will think about how to improve equipment and processes. MRO Peter Phillips of Trailwalk Holdings, a Nova Scotia-based maintenance consulting and training company, can be reached at 902-798-3601 or by e-mail at peter@ trailwalk.ca.

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April 2015

Machinery & Equipment MRO

What’s new in belt and chain drives Chain monitoring system keeps equipment up and running

The CCM (Chain Condition Monitoring) system from Iwis continuously measures the wear elongation of chains in use and warns maintenance personnel if the chain needs to be replaced or preventive maintenance is required. The contactless system can be quickly and easily integrated in numerous chain applications and retrofitted in existing plants and machines without the need for special addon components for the chain. Operating state and wear status are indicated by LEDs and readings can be transmitted to a computer, where they can be viewed. The system can be used independently of chain speed. Depending on the chain

posite links and are engineered specifically to replace rubber V-belts. Features include high resistance to extreme temperatures and abrasive materials, high resistance to water, steam, oil and most chemicals, and long belt life in harsh operating conditions. The belts run on standard pulley grooves and are designed in particular for power transmission and HVAC applications. Fenner Drives http://bit.ly/MRO606Apr15

Motor base’s quick-release makes for safe belt changes

Browning has expanded the range of sizes for its self-tensioning, energysaving Tenso-set motor base to include up to NEMA 447 and equivalent IEC motor frame sizes. Product enhancements include features that improve the speed and safety of belt changes. A quick-release option, available for NEMA frame sizes up to 286, enables belt changes on a 20-hp motor in about a minute, around one-sixth the normal time. This is a drop-in replacement for most standard motor bases and uses the same jackscrew design to adjust and hold tension on the belt. A coil spring inside the screw housing pushes against the carriage to maintain tension as the belt naturally breaks in and seats itself

further into the sheave groove due to loss of mass. This helps eliminate the need for frequent belt re-tensioning, including during the first 24 hours of run time, which reduces the need for service calls. Browning/Emerson Industrial Automation http://bit.ly/MRO670Apr15

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size, possible chain speeds range from 0.02 m/s to over 15 m/s. The device has protection class IP67 and can be used under normal environmental conditions and at temperatures from 0°C to 60°C. Iwis Drive Systems http://bit.ly/MRO671Apr15

Drive belts are ecologically-friendly

ContiTech has broadened its range of ecofriendly drive belts marketed under the BlueConcept label. The Conti Synchrobelt Pioneer contains no carbon black and is free of allergens, while the Conti Poly-

QUALITY MEANS TO US:

TO PROVIDE PREMIER ALIGNMENT AND CONDITION MONITORING SOLUTIONS. rope, certified according to the 95/16/EC Lifts Directive, features an abrasion-resistant coating, is resistant to hydrolysis and has good traction characteristics. Reliable power transmission is ensured even at maximum load. The Polyrope is available in widths of 25 mm and 50 mm with both a flat and a ribbed rear side. The company states that a timing belt will be available in the future for project business. ContiTech Division/Continental http://bit.ly/MRO672Apr15

Narrow-wedge belts built for long life in hostile areas

Fenner Drives has introduced two belt profiles, 3V and 5V narrow-wedge belts. An addition to the SuperTLink family of products, the HPC Link belts are made of individual polyurethane/polyester com-

With sales and services, support and training, we serve Canada‘s maintenance professionals with innovative technology for plant reliability. • Laser shaft and geometric alignment • Portable vibration analysis and balancing • Continuous online monitoring • Training and Machinery Services PROVEN QUALITY

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PRÜFTECHNIK Inc. 4406, rue Louis-B.-Mayer Laval, QC H7P 0G1 Tel.: 1-877-778-3832 info@pruftechnik.ca www.pruftechnik.ca

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Machinery & Equipment MRO

April 2015

What’s new in bearings Robust ball bearing, guideway needs little maintenance

Dry-running bearing made to withstand high temperatures

Schaeffler’s Kuve four-row linear recirculating ball bearing and guidance system features X-life technology for superfinished raceway surfaces that ensure smooth, uniform running characteristics, as well as maximum load-carrying

Metallized Carbon’s Metcar bearings for dry running in high-temperature applications are designed for use at temperatures ranging from 350°F to 1,000°F in oxidizing atmospheres, and from 350°F to 6,000°F in non-oxidizing atmospheres. These dimensionally stable carbongraphite bearings are not subject to melting, softening or deformation. Applications include continuous dryers, kiln cars, and high-temperature conveyors and ventilation dampers, in addition to continuous bakery ovens, screw conveyors, valves and paint dryers. Bearings can be provided to customer prints or custom-designed for specific application capacity and superior rigidity. The system features an integrated lubrication channel in the carriage’s load zone, so grease is stored where it is needed and

Durable coating protects rubber-metal components in corrosive environments

grease breakdown is minimized, enabling extra-long lubrication intervals. Schaeffler Canada

Surface coatings for bearing elements from ContiTech protect Schwingmetall and Megi rubber-metal parts in highly corrosive applications, such as vibration elements in construction machinery and rolling stock. These electroplated coatings were used in over 1,000 test hours of standardized salt spray testing without red rust appearing, according to the company. Metal ions settle on the vibration elements and thus prevent the corrosion process, after which the rubber-metal element can be given an additional protective coat. The durable coatings protect components against corrosion without affecting their function and strength. ContiTech Division/Continental Corp.

http://bit.ly/Apr2015-678

http://bit.ly/MRO674Apr15

dimensions and tolerances. Standard pillow blocks and flange blocks with Metcar bearing inserts are available with cast iron, stamped steel or stamped stainless steel housings. Bearings also are available shrink-fitted into metal housings or metal retaining rings. Metallized Carbon http://bit.ly/MRO673Apr15

Bearing is designed for continuous caster operations in steel mills

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SKF caster bearings are engineered for support rollers in continuous caster applications at steel mills. Spherical roller and Carb toroidal bearings can withstand the axial expansion and contraction of rolls associated with induced axial loads and temperature fluctuations. In addition, they can eliminate induced axial loads, reduce risk of roll seizure, promote enhanced bearing reliability and service life, and increase caster productivity. All SKF caster bearings are available in a wide range of sizes and can be specified with specialized seals and otherwise customized to meet the most demanding application requirements. SKF Canada http://bit.ly/MRO675Apr15

Thin-section bearing catalogue packed with information

The latest edition of Kaydon’s Reali-Slim thin-section bearings catalogue features more than 400 new part numbers and an expanded line of stainless steel thin-section bearings. Other additions include ISO radial ratings and a user’s guide to the company’s Reali-Design software for bearing analysis and selection. The 136-page Catalogue 300 features dimensions and capacities for the full range of the company’s standard thin-section bearings. This edition adds easy-to-read colour cross-sections and illustrations and includes an easy-to-use Request For Proposal form for standard or custom bearings. Kaydon Bearings http://bit.ly/MRO676Apr15

Corrosion-resistant mounted units suit washdowns

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- REPRESENTATIVES IN CANADA Southern Alberta, Saskatchewan & Manitoba: Robin Tetrault / Summit Agencies Ltd. / 403-236-8655 / robin@summitagencies.ca Northern Alberta and Saskatchewan: Peter Liston / Summit Agencies Ltd. / 780-406-7462 / peter@summitagencies.ca British Columbia: Brian Weihs / Summit Agencies Ltd. / 604-329-7848 / brian@summitagencies.ca Southeastern Ontario: Mechanical Sales Co. / 2199 Dunwin Dr. / Mississauga, ON L5L 1X2 / 800-263-7226 Southwestern Ontario: RJ (Richard) Seguin / Mechanical Sales Co. / 800-263-7226 / rjs@mesaco.com Northern Ontario: Gord Jopling / Mechanical Sales Co. / 800-263-7226 / gordj@mesaco.com Quebec and the Maritimes: Lydia Oosterbaan / Mechanical Sales Co. / 800-263-7226 / lydiao@mesaco.com

Online Reader Inquiry No. 131

ReliaMark corrosionresistant mounted units from Kaman are available with stainless steel and thermoplastic housings with set screw or eccentric collar stainless steel inserts in pillow block, two- and four-bolt flange, three-bolt flanged bracket, tapped base and take-up unit styles. The units are available with standard stainless steel bearing inserts featuring shaft sizes ranging from 3/4 in. to 2 in. Most housing styles are available in both set-screw and eccentric locking collar mounts. Reliamark/Kaman Industrial Technologies http://bit.ly/MRO677Apr15

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P R O D U C T April 2015

Machinery & Equipment MRO

What’s new in electrical components Digital temperature switch protected by enclosure

The series TSW digital temperature switch combines the TS family of temperature controls and an installationfriendly weatherproof enclosure. By using the same programming parameters as the series TS2 and TSS2, set up can be quickly completed using the front keypad or by using the TS2-K configuration key. Features include a parameter lock physical jumper, software passcode security, and a bright, easy-to-read LED display showing the current output status and temperature measurement. The multiple conduit knockouts give flexibility to the installer to determine the best location for the conduit entry. Also featured is the ability to quickly jumper the line voltage to the common of the output relay using fast tabs. Dwyer Instruments http://bit.ly/Apr2015-680

Connector set made for explosive environments

The Harting Han Ex industrial connector portfolio for explosion-proof applications comes in a series of five size 3A sets, each comprising a hood, housing and high pin count insert. The series is for use exclusively in intrinsically safe circuits of categories ‘ia’, ‘ib’ and ‘ic’ of explosion protection method ‘Ex i’, and is suitable for Zones 0, 1 and 2 for gas and Zones 20, 21 and 22 for dust. The housing’s blue colour indicates that an intrinsically safe circuit is present. Sets are available with four, seven, eight or 12

Power transducer produces analogue signal proportional to real power used

NK Technologies’ APT series power transducers measures three phases of current and voltage and produces an industry-standard analogue signal directly proportional to the wattage used. The monitor uses current transformers to measure the amperes, and the line voltage connects directly to the transducer, up to 600 VAC. The device can be configured to accept 5-A secondary current transformers, or the company’s ProteCT low-voltage output sensors. For use in such applications as plant energy management, conveyors and

N E W S

Power supply module puts safety first

Polytron Devices’ UI10 series of 10-W, single- and dual-output AC/ DC power supply modules deliver 75% power supply efficiency in 2.5-in.-by-1.75-in.-by-0.75-in. fully encapsulated plastic cases. These universal input devices feature short circuit, overload and overvoltage protection for automatic re-

contacts, and there are three variants with crimp termination and two with Han-Quick Lock termination technology. The portfolio is suitable for a wide range of applications where the substance being processed or transported is potentially explosive or combustible. These include gases, liquids and solids in the chemical and mining industries, grains and sugars in the food sector, alcohol and dust in pharmaceuticals, fermentation gases in waste management, thermal fuels in power generation and biogas plants on farms. Harting Canada

http://bit.ly/MRO682Apr15

Overload relay’s modular design offers easy installation

The Allen-Bradley E300 overload relay comes in a modular design. Consisting of sensing, control and communication modules, the modularity provides users the flexibility to tailor the relay to meet their particular needs. The device’s native dual-port EtherNet/IP option simplifies network wiring by allowing relays to be daisy-chained and by eliminating the need for an Ethernet switch. Also, the device easily integrates into the Rockwell Software Studio 5000 control environment via an add-on profile. A variety of digital and analogue expansion I/O modules is included, all within a single network node, providing four inputs and two relay outputs. Allen-Bradley/Rockwell Automation http://bit.ly/Apr2015-684

Analogue output module transmits intrinsically safe signals in hazardous areas

Wago’s two-channel analogue output module carries Ex (ia) safety approvals. The intrinsically safe 750-586 module provides a signal current of 4-20 mA, linking the company’s Ethernet controllers with actuators in hazardous location Zones 0, 1 and 2. ATEX and IECEx certified, the module galvanically isolates field and system levels while providing short-circuit-resistant outputs, bolsterpump monitoring, it can measure the power usage of a single piece of equipment, an area of a plant or the entire facility, and can detect conveyor jams and overloads, and check that belts are loaded properly. The transducers are externally powered and offer 4-20 mA, 0-5 VDC or 0-10 VDC output. They are housed in a compact DINmounted case with a low profile, while their finger-safe terminals are clearly labelled for quick installation. NK Technologies http://bit.ly/Apr2015-681

covery and include an internal input filter to minimize electromagnetic interference. The series is ROHS compliant and has both UL and CE Certifications, while CSA certification is available upon

ing safety in atmospheres, such as those in mining, where gas and dust accumulate, or in hazardous-location applications such as oil and gas. It resides within standard Wago-I/O-System nodes. Intrinsically and non-intrinsically safe sections within one node are separated, providing hazardous-location applications with fieldbus-independence and economical sensor/actuator connections. Wago Corp.

request. Typical applications include industrial control machines, amplifiers, ultrasonic welders, meter control boards, and power and telecom equipment. The company can customize the module by adjusting electrical specifications and pin configurations to meet individual application requirements. Polytron Devices www.polytrondevices.com

drop lights and portable spotlights where operators need to simply pull a long cord behind them. It can be used in applications where operators wish to use their portable Golights, Magnalight HML12/24 or PML-LED spotlights, or other similar equipment that requires 12-VDC current, but which does not have a suitable 12-volt power source available. Larson Electronics www.magnalight.com

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www.wago.us

Units broaden line of hazardous location enclosures

Pentair Technical Products has expanded its line of Hoffman brand Zonex hinge-cover and screw-cover, IECEXand ATEX-certified enclosures. Included are inch-based offerings in an extended range of sizes. In addition, all models are now offered with enhanced customization options, including material changes, size changes, paint options, holes and cutouts, population of any ATEX-certified terminal block, stopping plug or drain, mounting bracket changes and more. New inchdimensioned hinge-cover enclosures are available in 16 standard sizes from 12x12x6 in. to 36x24x8 in., while screwcover enclosures are available in five sizes ranging from 4x4x3 in. to 10x10x5 in. The enclosure family now features European ATEX and global IECEX certifications on all products, as well as American AEXe certification on the hinge-cover products. Pentair Technical Products

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Compact waterproof power supply includes accessory power switch

The Magnalight DCP-11-DP-SW waterproof power supply converts standard 120/240-VAC power to 11-amp, 12-VDC output for powering lights and equipment requiring 12-volt direct current. It is fitted with an inline switch, allowing operators to control the on/off operation of equipment. Designed for durability and resistance to wet or damp conditions, the small unit consists of a power converter, heavy-duty on/off switch, straight blade plug, and a two-prong Deutsch connector on the output end, all mounted to a heavy gauge strip-type mounting platform. The converter measures 8.7 in. long by 2.5 in. wide by 1.5 in. deep and weighs less than 1 lb, making it suited for inline use with

Online Reader Inquiry No. 132

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Machinery & Equipment MRO

What’s new in safety

April 2015

Emergency shower washes away hazardous chemicals

eye/face wash for immediate drenching of personnel that have been exposed to hazardous chemicals. In addition, it is equipped with frosted front strip curtains, interior grab bars, raised deck grating, and bottom or rear drain outlet. Hemco

Hemco emergency shower/decontamination booths are fully assembled and ready for installation to water supply and waste systems. Moulded in a one-piece, seamless, chemical-resistant glass fibre, the shower is equipped with a pull-rodactivated shower and push-handle

www.hemcocorp.com

accommodates other forms of PPE. The toricshaped lens affords workers a wide field of unobstructed peripheral vision, while the Uvextra anti-fog lens coating, coupled with an indirect ventilation system, minimizes fogging and provides a clear view. A temple clip allows the adjustable, latex-free, neo-

Goggle has splash protection plus comfortable fit

The Uvex Entity safety goggle is designed to protect workers from impact, dust and chemical splash hazards while delivering a secure, gap-free fit. Its flexible, lightweight PVC body easily conforms to the face and the compact design

prene headband to swivel 360 degrees. The goggle is available in translucent blue with a clear lens for multi-purpose use or matte black with shade 3.0 and shade 5.0 lens options for welding applications. The style meets both ANSI Z87.1-2010 and CSA Z94.3 standards. Honeywell/Uvex www.uvex.us

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Upgraded pneumatic barrier features improved safety

The Vertiguard automated barrier panel, a bottom-up pneumatic panel that provides physical separation between machine operators and manufacturing processes, has been upgraded. The standard size has been increased to 110 in. wide and 96 in. tall. Other upgrades include an improved finger guard using a 40-oz FR vinyl sewn-in loop design to eliminate the pinch point, new brand cylinder and flange mount with centre support, and an improved sliding panel design. More options include eliminating the toe gap to allow for lower stored panel heights, improved interlock switch brackets and additional switch options, galvanized steel back panel and cylinder cover, availability of 3D modelling for easy insertion into project drawings, improved pneumatic hose and fitting quality, and a photo-eye strip option to prevent door movement when obstructions are sensed. Rite-Hite Machine Guarding www.ritehite.com

Rugged safety boot protects foot from falling debris

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Blundstone’s UTE 165 CSA Met Guard safety boot features flexible and comfortable Poron XRD foot-top met guards, steel toes, protected side elastics with leather covers, bullet-proof Kevlar stitching and shock-proof soles. This fast-on, fast-off, laceless and durable boot delivers all-day comfort, even on concrete, and stands up easily to Canada’s rugged climate. Tin Shack www.tinshack.ca/blundstone.html

Online Reader Inquiry No. 133

Online Reader Inquiry No. 134

Extracted key adaptor restricts access to moving hazardous machinery

Adhere and remove from your walkways with ease Brady SPC’s Adhesive Mat is a great addition to your absorbent program. The tacky underside adheres to any surface, keeping the absorbent in place to greatly reduce the likelihood of slips, trips and falls.

Multiple Functions �

All-purpose mat designed for general industrial applications

�

Perfect for tool cribs, while adhesive rolls provide walkway protection

�

Grey colour masks drips and spills, encouraging longer use

Catalogue #

Type

Adhesive Mat Pads AD1524 Heavy Wt. Pad Adhesive Mat Rolls AD15100 Heavy Wt. Roll AD30100 Heavy Wt. Roll

Size

Perfed

Absorb. Absorb. Shipping Pallet Qty. Factor (gl/gs) Cap. (gal) Wt. (lbs) Qty.

15” x 24”

6.75

25/case

15” x 100’ 30” x 100’

No No

8 8

11 21

15 29

30 12

1/case 1/case

For more information, visit: www.BradyCanada.ca/SPC Online Reader Inquiry No. 135

Fortress Interlocks has added the E1 Extracted Key Adaptor to its amGard range of modular safety gate switch interlocks. The E1 ensures that the door to hazardous machinery cannot be opened without removing the safety key, and the machinery cannot then be restarted until the key is returned. The mechanism is designed to trap an actuator in the head unit until the key is removed, which then allows the gate to swing over the keyhole. While the actuator remains out of the head, the gate remains over the keyhole, preventing the key being returned to the lock. The device ensures a specific sequence of operation and can be stacked or combined with other adaptors; up to five key adaptors can be used in one configuration. It works with access key and safety key adaptors, Fortress amGard LOK or Stop bodies, and is suitable for either hinged or sliding door applications. Fortress Interlocks http://bit.ly/MRO693Apr15

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P R O D U C T

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April 2015

Machinery & Equipment MRO

What’s new for mining, oil & gas MRO Bolt-on pump package withstands rigours of offshore applications

BBA Pumps’ bolt-on pump package caters to the offshore industry, where there is no need for a complete skid and/ or canopy. The package features a highefficiency BA-C pump coupled to a diesel engine, including the control panel, and mounted on a high-quality, galvanized sub-frame, which can be custom-

Brochure features robust electrical products for metals and mining industry

Thomas & Betts’ brochure, Electrical Solutions for the Metals and Mining Industry, outlines the company’s electrical systems solutions for vehicles, machinery and processing plants in the mining and metallurgy industries. The brochure is organized around product groupings that provide solutions to specific challenges, as well as indicating which product lines, services and training programs are designed to address each of these challenges. Products are included for continuous operation and sustainability, corrosion and harsh environment protection, liquid ingress protection, safety and contamination, extreme temperature protection, hazardous location protection, efficiency and reliability, and grounding and bonding. Thomas & Betts http://bit.ly/MRO639Apr15

ized with lifting bales, protection bars, etc. These auto-prime pumps have a capacity of 100 cu m/hour to a maximum of 1,750 cu m/hour (7,700 gpm) and a head up to a maximum of 250 mwc (800 ft). The units can be bolted on to any object or structure, and only need a fuel tank to be connected to be operational. Optional pump wet-ends in Duplex stain-

Large-capacity water pump built for oilsands megaproject

KSB has been contracted by Fort Hills Energy (a consortium with Suncor Energy, Total E&P Canada and Teck Resources) to supply large RDLO water transport pumps for its oil sands project north of Fort McMurray, AB, estimated to be worth $13.5 billion. The order is for 12 pump sets for use in the process water recycling system. Current plans call for first oil from the project in 2017, with production ramping up to 180,000 barrels of liquefied bitumen per day. The pumps are of a double-volute design and will be built to deliver flows between 4,250 cm/h and 6,125 mwc per hour, at heads of up to 128 m. Pumps and motors will be mounted on API 610 standard baseplates. Full instrumentation, including temperature and vibration sensors, will be installed in Canada by KSB Pumps, and a major service centre, located in Fort McMurray and operated by KSB-subsidiary GIW Industries, has been developed. KSB Pumps http://bit.ly/MRO638Apr15

Versatile flange alignment tools put emphasis on safety Large-bore sight tube meets need for pipeline inspection

Precision Electronic Glass has fabricated a large-bore borosilicate sight tube for viewing the contents of an oil pipeline in the field. The specifications for the sight tube called for shrinking the tube to a 9-3/4-in. bore. This required a heavier wall or cross section of the borosilicate glass tube to withstand the pressure, and the cross section of the tube needed to be greater than 1 in. To fabricate the cross section needed, the company used a laminating process, which involved fitting a smaller borosilicate glass tube inside a larger tube and fixturing them over tooling to fuse them together. Repeating the process several times results in several layers of borosilicate tubing to be fused together to achieve the desired thickness. The company offers glass lathe fabrication, glass-to-glass or glass-to-metal graded sealing, and cutting and special end finishing. All glass and quartz fabrications are produced in facilities certified to ISO 9001:2008 standards. Precision Electronic Glass www.pegglass.com/

The ATM-2, 4 and 9 series flange alignment tools from Enerpac are designed for use by a single operator and do not require an external power source, chains, slings or lifting gear. Also, they will not damage bolt holes. The ATM-2 and ATM-4 mechanical models are compact, durable, yet lightweight, self-contained solutions for easy transport to remote locations. The ATM-2 has a maximum lifting force of 10 kN, handles bolt holes as small as 16 mm, and weighs 1.6 kg. The ATM-4 can apply 40 kN of force, is designed for bolt holes as small as 24 mm, and weighs 8.6 kg. The ATM-9 features hydraulic alignment for tougher applications demanding up to 90 kN. With its larger capacity, it is suitable for bolt holes down to 31.5 mm diameter, and weighs

ring, ultra-high-pressure brass valves is designed with heavy-gauge forgings and internal parts to deliver industrialstrength performance during the most critical applications in breathing air cascade systems, safety and mining applications. The valves are available in many configurations for CGA valve outlets, as well as most international outlets. Common cylinder inlets such as 3/4-in. NGT, and 3/4-in. 24OS and 25E for UN ISO are available. Harrison Valve www.harrisonvalve.com/

Mobile electric oven made for long, hard, continuous use

less steel enable the pumps to handle tough jobs in severe environments. BBA Pumps www.bbapumps.com/en/

14.5 kg. A kit version includes an Enerpac P-142 two-speed hand pump, and a 1.8-m hydraulic hose. Suggested uses include oil and gas, mining, energy, construction, infrastructure, manufacturing, process engineering, water and waste water industrial applications. Enerpac http://bit.ly/MRO641Apr15

High-pressure valve is for industrial gas markets

A line of robust industrial gas valves for high-pressure DOT and UN ISO cylinders from 4,500-psi to 6,000-psi service pressure has been introduced by Harrison Valve. Used in applications that demand extremely low leak rates for the most demanding high-pressure environments, the VH series of double-O-

MACHINERY AND EQUIPMENT

Grieve has introduced the No. 882 500°F electric top-loading oven, currently in use for testing downhole oil field equipment. Measuring 300 in. by 12 in. by 18 in., the workspace is heated by 34.8-kW installed-in Nichrome wire elements, while a 600-cfm horizontal front-to-rear airflow is provided by two 3-hp recirculating blowers. The unit features an aluminized steel interior and exterior with 4-in.-thick insulated walls, a reinforced 1/4-in. steel plate workspace floor to hold a 5,000-lb distributed load, a motor-operated rearhinged door and a front flush-mounted control panel. The oven is supported on eight swivel casters with swivel locks and brakes for mobility. Grieve www.grievecorp.com/

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Literature Guide HARTING - M8, M12 AND 7/8” CONNECTORS – YOUR ONE STOP SOLUTION. · M8, M12 and 7/8” Sizes · Single and double ended as· Robust IP67 Cordsets semblies available in straight, · A, B and D Coding Types angled, male and female · 3, 4, 5, 8 and 12 pole options · PVC and PUR cable jackets The comprehensive HARTING Selection offers you information on everything you need: HTTP://WWW.HARTING-USA.COM/INDUSTRIAL-CONNECTORS/HARTING-USACOM/ COMMUNICATION-SOLUTIONS/HARTING-USACOM/ THE MOST COMPREHENSIVE CATALOG IN THE TIMING BELT INDUSTRY BRECOflex, CO., L.L.C., is proud to offer its 184 page, 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 YOUR FREE COPY, SAMPLES AND TECHNICAL SUPPORT, VISIT OUR WEBSITE AT WWW.BRECOFLEX.COM OR CALL 732-460-9500 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 In-Line Helical reducers also available. CONTACT APPLICATION SUPPORT FOR MORE INFORMATION. ROTOPRECISION INC., 1-800-232-1985, APPLSUPPORT@ROTOPRECISION.CA, WWW.ROTOPRECISION.CA/ DOWNLOADS.

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Machinery & Equipment MRO

April 2015

Vancouver is venue for MRO trade show Vancouver, BC — Acklands-Grainger, a distributor of industrial, safety and fastener products, hosted ‘The Works’, Canada’s largest maintenance repair and operations (MRO) and safety show, at the Vancouver Convention Centre in February. Now in its ninth year, the trade show saw 1,900 of the distributor’s customers view products at 277 booths and attend seminars to learn about strategies for effectively managing MRO costs, creating a world-class safety culture and driving business performance through sustainability efforts. “Acklands-Grainger partners with customers to provide strategic, operational, product and safety support that helps them save time and money,” said Dean Johnson, president of AcklandsGrainger, which is based in Richmond Hill, ON. A highlight of this year’s show was a 9,000 sq ft factory-themed pavilion that showcased nearly 500 different products and illustrated how businesses across the country can leverage eCommerce capabilities and inventory management solutions to save time and money in buying and managing their MRO purchases. Floor space for all of the exhibits totalled 125,000 sq ft.

The Works show in Vancouver had 277 exhibitor booths.

Mark Sceeles and Wayne King of CRC Industries Inc.

Mike Michalichyn and Barry Woods of Continental (formerly Veyance Technologies). Pat Sheehan of Simple Green.

Molly McDowell of NilfiskAdvance Inc. David Street of the Industrial Channel/ Power Tool division at Robert Bosch Inc.

Plant tour highlights EASA meeting BY BILL ROEBUCK

Toronto – The Ontario Chapter of the Electrical Apparatus Service Association (EASA) — one of three EASA chapters in Canada — held its 2015 annual general meeting in Toronto in January, with exhibitors and attendees coming from across Canada and the US. The event included a tabletop trade show featuring exhibitors who service the motor repair and sales industry. This year’s technical course was presented at the S.A. Armstrong pump facility, where attendees had the chance to tour the plant, discuss pumps and their applications, and attend a half-day seminar on rotor balancing. During the meeting, Sid Seymour moved into the role of past president as he passed on the duties of president to Jason McGruthers. Scott Cotterill stepped into the post of vice-president and Christopher Culver is the group’s secretary for the next year. The Ontario Chapter’s Spring Meeting will take place at the Best Western Plus Leamington & Conference Centre in Leamington, ON, May 1-2, 2015. For more information, visit www.easaontario.ca. To view photos from this meeting, go to http://bit.ly/EASA_Apr15.

Dean Johnston, P.Eng, president of AcklandsGrainger.

Acklands-Grainger vicepresident Sandro Verrelli describes the features of the factory-themed pavilion at the show.

Photos: Jay Armstrong, MRO Magazine

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