MRO December 2020

MACHINERY AND EQUIPMENT

Vol. 36, No. 6

December 2020

MAINTENANCE IN THE

FUTURE MRO QUIZ MAINTENANCE 101 WHAT’S UP DOUG NEW PRODUCTS MR. O

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Improves productivity

Eliminates unplanned stops

Increases employee safety

— Condition monitoring For mechanical components

The ABB AbilityTM Smart Sensor for mechanical products is an easy-to-use, wireless sensor which monitors the health of mounted bearings and gear reducers. The sensor provides warnings when health status declines, reducing the risk of unplanned downtime.

In addition, connectivity and trend data allow maintenance to be planned proactively instead of reactively, and remote monitoring capabilities keep employees away from areas that are difficult or dangerous to access.

Operate safely. Reduce downtime. Improve reliability.

new.abb.com

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C O N T E N T S Machinery and Equipment MRO

December 2020

in this issue

Departments Editor’s Notebook / 3

Industry Newswatch / 6 Product News / 29 Mr. O / 30

Events Second Annual German Technology Day Goes Online / 7

Maintenance in the Future / 8

What's Up Doug / 10

Maintenance: what does the future hold.

The challenge of outer ring rotation.

CanREA Renewable Energy Forum / 7

Social Media

:@mro_maintenance : @mromagazine : linkedin.com/company/mro-magazine : @MROMagazine

Cover Photo: ipopba / Getty Images

Maintenance 101 / 12

Dust Collector Systems / 14

Adapting to maintenance technology.

Benefits of dust collector pulse valves.

Main Electrical Substation Upgrades / 22 Part 2 – project planning, construction, and commissioning.

No More Firefighting / 26 MRO Quiz / 16

Future of Maintenance / 18

Electric motor troubleshooting using vibration analysis.

Is IIoT the future of maintenance?

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Imagine an industrial site or manufacturing facility that actually accomplished the mission of every maintenance and reliability professional.

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SKF TOOLS HELP KEEP YOUR MACHINES RUNNING Improve your efficiency with solutions from SKF » SKF EasyPull mechanical puller TMMA series The patented SKF EasyPull is one of the most user-friendly and safe tools on the market. The series is equipped with spring-operated arms and a solid design.

Avoid damaging the shaft with improper removal techniques, the TMMA series will assist you in the secure way to remove your bearings.

https://bit.ly/3kDQTCx

»

By applying the right maintenance practices and using the correct tools in all stages of the bearing life cycle, you can considerably extend your bearing’s service life and thereby increase plant productivity and efficiency.

More at: https://bit.ly/2KduY8B

»

SKF Portable Induction Heater TWIM series

The TWIM 15 features glass-fiber, high-temperatureresistant plastic construction that allows a low temperature difference between the inner and outer rings of the bearing. It is compact, lightweight, contains automatic temperature monitoring, and detects bearing size to heat appropriately for easy use.

Bearing fitting kits TMFT Series

Poor fitting, usually using brute force, accounts for 16% of premature bearing failures. SKF’s TMFT Bearing Fitting Tool Kits are designed for quick and precise mounting of bearings, while minimising the risk of bearing damage.

https://bit.ly/3lFCzuy

https://bit.ly/36GMcmx

»

Shaft Alignment Tool TKSA Series

The TKSA Series are easy to use laser alignment solutions for achieving accurate shaft alignments. With two wireless measurement units, large sized detectors and powerful lasers, the instrument performs in even the most challenging conditions.

https://bit.ly/2IIwIGc

» SKF SYSTEM 24 Single Point Automatic Lubrication Continuously delivers precisely measured amounts of lubricant to desired points via a gasdriven pump.

It is ideal for lubrication points difficult or unsafe to reach manually, or where there are a large number of lubrication points where manual greasing would be less effective.

Smartphone based solution

Industrial touch screen display unit (included)

Tablet based solution

https://bit.ly/36Cl6N6

Talk to your SKF Authorized Distributor for more details and pricing.

SKF.CA MRO_SKF_Dec20.indd MRO_Dec_2020_MAR.indd 1 4

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E D I T O R ’ S

MACHINERY AND EQUIPMENT

DECEMBER 2020

Vol. 36, No. 6 Established 1985 Reader Service Print and digital subscription inquires or changes, please contact Beata Olechnowicz, Audience Development Manager Tel: (416) 510-5183 Fax: (416) 510-6875 Email: bolechnowicz@annexbusinessmedia.com Mail: 111 Gordon Baker Rd., Suite 400, Toronto, ON M2H 3R1

es

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use.

www.mromagazine.com Twitter: @mro_maintenance Instagram: @mromagazine Facebook: @MROMagazine linkedin.com/company/mro-magazine Mario Cywinski, Editor 226-931-4194 mcywinski@annexbusinessmedia.com Contributors Richard Beer, Philip Chow, L. Tex Leugner, Justin Lesley, Douglas Martin, Peter Phillips, Bavan Poologarajah, James Reyes-Picknell, Michael Russo Paul Burton, Senior Publisher 416-510-6756 pburton@annexbusinessmedia.com Jason Bauer, Media Sales Manager 416-510-6797 jbauer@annexbusinessmedia.com

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Ilana Fawcett, National Account Manager 416-829-1221 ifawcett@annexbusinessmedia.com Mark Ryan, Media Designer Catherine Giles, Account Co-ordinator 416-510-5232 cgiles@annexbusinessmedia.com Scott Jamieson, COO sjamieson@annexbusinessmedia.com Mike Fredericks, President & CEO Machinery and Equipment MRO is published by Annex Business Media, 111 Gordon Baker Rd., Suite 400, Toronto ON M2H 3R1; Tel. 416-442-5600, Fax 416-510-5140. Toll-free: 1-800-268-7742 in Canada, 1-800-387-0273 in the USA. Printed in Canada ISSN 0831-8603 (print); ISSN 1923-3698 (digital) PUBLICATION MAIL AGREEMENT #40065710 Subscription rates. Canada: 1 year $65, 2 years $110. United States: 1 year $110. Elsewhere: 1 year $126. 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 our circulation department in any of the four ways listed above.

5

N O T E B O O K

Machinery and Equipment MRO

2020: The Year Like No Other

T

his year started as any other, with MRO planning to have an in-person expo, a large selection of in-person events to visit (conferences, trade shows, seminars, and more), and in-person interviews for editorial on these pages. Well, as many other companies, our plans from early this year had to be thrown out, and new plans had to be drawn to adapt to the new normal of life in a pandemic.

Early on during the pandemic we held a Maintenance Management Amid Covid-19 webinar, led by Susan Lubell, President, PEMAC Asset Management Association of Canada, that walked attendees through maintenance and staffing needs.

Further, as we were not able to have in person events, we held MRO's first ever virtual event in August. Maintenance and Reliability in a Changed World Virtual Summit brought together professionals from across the MRO world. We had Suzane Greeman and James Reyes-Picknell lead learning sessions that had attendees engaged. While our open discussion allowed attendees, speakers, and sponsor representatives to have a lively discussion. Session can still be viewed at mromagazine.com/virtual-events/maintenance-and-reliability-in-a-changed-world-virtual-summit/.

After getting our feet wet with the virtual summit, for 2021, we will be launching our MRO Expo, this time in partnership with Design Engineering magazine, and its DEX Expo. The event will take place February 18, digitally. For more information, visit: mroexpo.ca.

In an effort to increase Mr. O's profile, we created In Conversation with Mr. O podcast, which allowed us to have great conversations with maintenance, reliability, and operations experts. Our guests in 2020 included: Shawn Casemore who spoke about Engaging Your Employees in a Safety Culture; James Reyes-Picknell, in a two part series, spoke about Managing Maintenance and Reliability; Doc Palmer, explained the Focus on Scheduling and Planning of Maintenance; and most recently, Scott MacKenzie discussed Maintenance at TMMC Plants with a Focus on the Environment. For those who missed these episodes, they can be heard anytime at mromagazine.com/podcasts/.

Our number one goal for 2020, during the COVID-19 pandemic, was to keep our readers informed as to what is going on in the MRO world, but also to keep offering our readers timely and informed articles to help them navigate their maintenance needs. I believe in that regard, we have succeeded.

Expect to see even more from MRO in 2021.

To all our readers, Happy Holidays and a Happy New Year, hopefully 2021 is a better year than this one was.

Annex Privacy Officer Privacy@annexbusinessmedia.com, 1-800-668-2374 No part of the editorial content of this publication may be reprinted without the publisher’s written permission © 2020 Annex Publishing & Printing Inc. All rights reserved. Opinions expressed in this magazine are not necessarily those of the editor or the publisher. No liability is assumed for errors or omissions.

Mario Cywinski Editor

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I N D U S T R Y

N E W S W A T C H

Machinery and Equipment MRO

December 2020

CpK R&D Invents Anti-Viral Plastics to Eliminate COVID-19

C

pK Interior Products Inc. has developed a line of patent pending anti-viral plastics, which can eliminate COVID-19 on material surfaces in under an hour.

CpK was able to invent, test, and apply for a patent within 90 days of the project kickoff. Led by Dr. Gregory Farrar, Head of R&D, CpK, the team was tasked to create

For more industry news and events, visit www.mromagazine.com/news

material for car interiors that showed anti-viral activity. CpK invented cast skin materials for Dodge Challenger and Dodge Charger.

Anti-viral testing was another challenge, but CpK was able to contract the ImPaKT facility at Western University’s Schulich School of Medicine & Dentistry, to collaborate and perform testing. MRO

ABB Names President Ringball Appointed of Mechanical Power Canadian Master Transmission Division Distributor

A

BB has named Roger Costa as President of its global Mechanical Power Transmission division (The Dodge Business). He will be based in Greenville, South Carolina.

Costa has been with ABB for over 17 years, and has held executive roles in Canada and the US. While at ABB, Costa has gained knowledge of the company’s operations, from mechanical to motors and robotics.

Costa has a bachelor’s degree in electro-mechanical engineering from Humber College and an advanced university program in business management at the University of Toronto-Roman School of Management. MRO

Production Coming Back to GM’s Oshawa Plant

G

eneral Motors Canada and Unifor have reached an agreement, which has been ratified, that will see truck production back at Oshawa Assembly Plant in January 2022.

The agreement will also see St. Catharines Propulsion Plant and Woodstock Parts Distribution Centre seeing investment.

GM will build a new body shop and flexible assembly module, which will allow for building of pick-up trucks.

GM was the third of the domestic three brands to reach an agreement with Unifor. MRO

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N

adella Group of Companies appointed Ringball Corporation as the Canadian Master Distributor for its full line of linear motion products.

The agreement also includes Ringball distribution of Durbal, Husillos Ipiranga and Shuton ball screw product lines. The partnership provides local inventory, lower shipping costs, faster shipping times, and invoicing in Canadian currency. MRO

PEMAC Collaborates on Global Certification Scheme

P

EMAC Asset Management Association of Canada, in collaboration with members of the World Partners in Asset Management (WPiAM), launched the Global Certification Scheme (GCS).

WPiAM are seeking to align worldwide efforts to develop, assess and recognize competence in asset management, and establish a system of assurance of quality, while respecting needs for variation of application according to the history and culture of each region.

The scheme provides a laddered career path for asset management professionals who are looking to advance their skills and improve their ability to contribute to the success of the organizations they serve. The competency-based scheme provides a common base for organizations, ensuring that the individuals they hire anywhere in the world have the knowledge, skills, and experience to apply asset management principles in various contexts.

GCS provides a three-level designation framework that has been shaped around the key asset management roles.

Level 1: Certified Senior Principal in Asset Management (CSAM).

Level 2: Certified Practitioner in Asset Management (CPAM).

Level 3: C ertified Technical Specialist in Asset

Management (CTAM).

For more information, visit: www.pemac.org/recognition/certification/gcs

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E V E N T S Machinery and Equipment MRO

7 December 2020

Second Annual German Technology Day Goes Online

BY MARIO CYWINSKI

T

he inaugural German Technology Day was held in Kitchener and Mississauga, Ontario, as an in person event in 2019, it moved online for its 2020 version. As with many events so far this year, in person events are a no-go.

However, the German Technology Day Digital Online Trade Show was able to incorporate many aspects that made the 2019 show successful into the new format.

The event, which attracted nearly 500 registrations, began with an introductory session that introduced attendees to each company and what they do. Companies involved in the day were: Rittal Canada, Murrelektronik, Bosch Rexroth, Pilz Canada, EPLAN Canada, and WAGO Canada Inc. A lobby was the home base for the event, from here attendees could visit all the aspects that were available. A virtual exhibit hall allowed for attendees to visit each company’s virtual booth, and speak with representatives, visit microsites, download PDF material, connect to their social media accounts, and watch videos.

Additionally, a media room had links to participating media; a virtual contest, allowed for attendees to answer questions for a chance at a prize; and a chat function allowed for attendees to communicate with each other during the event.

The main part of the German Technology Day took place in the Auditorium. This is where the sessions were taking place. EPLAN Canada’s Roland Younk, President, opened the individual company sessions by speaking about “Connected Manufacturing: Design to Delivery.” Production 4.0 was discussed, how to reduce production time, as well as how to handle machining, assembly, and wire processing, automatically in a digital environment.

Next up was Andre Bousette, Regional Director – Eastern Canada, Rittal, who spoke about the “Connected World of Rittal: From IT to Industry.” The presentation focused on IT, and showed how automated solutions are created by having IIoT applications and software working together.

Dave Hinder, Product Manager for Electric Drives and Controls, Bosch Rexroth discussed “The ‘Smart Phone’ of Automation.” Hinder spoke about the Bosch Rexroth’s new ctrlX AUTOMATION platform.

Colin Cartwright, System Sales Manager, Murrelektronik, presented “Connectivity and Collaboration Simplified.” He spoke about the benefits of collaborating with the company, as well as providing an example of how connectivity and collaboration strategies can help OEMs and machine builders.

Jon Pysanczyn, Senior Technical Sales Manager, PILZ explained “Machinery Safety and Industrial Security in a Connected Automation World.” Pysanczyn spoke about door interlocks specifically, and industrial security generally.

Tyrone Visser, Regional Sales Manager, WAGO Canada spoke to “Demystifying IIoT for Manufacturing.” Here Visser looked at what Industry 4.0 and IIoT is, why IIoT, which innovations make IIoT feasible, how to use IIoT, how to develop and deploy IIoT, and a WAGO IIoT example. MRO

CanREA Renewable Energy Forum

Bottom Photo: CanREA

O

ver 400 participants attended the Canadian Renewable Energy Association (CanREA) Forum, for the first time virtually.

CanREA had Sophie Brochu, President and CEO, Hydro-Québec; Michael Law, President and CEO, Alberta Electric System Operator; Mike Marsh, President and CEO, SaskPower; and Terry Young, Interim President and CEO, Independent Electricity System Operator; for a discussion on innovation and collaboration opportunities engendered by the changes in technologies, policies, and customer preferences that are disrupting the electricity sector.

The Honourable Seamus O’Regan, Canada’s Minister of Natural Resources participated in a live discussion about the role of wind energy, solar energy, and energy storage in Canada’s future energy mix.

The program also included panels on Canada’s energy transi-

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tion, where CanREA Board Chair Michelle Chislett, Managing Director, Canada and US Development, Northland Power, spoke with industry leaders and on Canada’s energy future.

Attendees were able to connect with one another though chat and video conferencing tools, and four daily networking sessions, and peruse a virtual showcase of renewable energy exhibitors. MRO

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Machinery and Equipment MRO

December 2020

MAINTENANCE: WHAT DOES THE FUTURE HOLD?

BY MARIO CYWINSKI

PEMAC Asset Management Association of Canada Asset management will focus on development of new assets, use and upgrading of existing assets (including 100+ years old infrastructure assets) to

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minimize operations and maintenance, lifecycle costs, improve operating performance through better design, asset selection and optimization, and construction. The result will be more effective operations, reduced maintenance requirements, and focus on effective proactive maintenance tasks to reduce failure consequences, and reduce lower value reactive maintenance.

Technology will continue its accelerating changes, and our new generation of maintainers will be expecting and embracing it. The current world of “drowning in data and starving for useable information� will continue to evolve. Real-time connectivity and other data gathering systems will increase the incoming data flow. Machine learning, analytics, AI, and other technologies promise relief to allow better, more timely decisions.

With the rate of change continuously accelerating, life-long learning will be

the norm. In addition to understanding of the assets and how they operate, operators and maintainers will need to understand the operating technology (OT) used to the extent required to operate and maintain the assets, and understand what the real-world impact of the information provided by the OT. Given current scarcity of skilled maintainers, and the increased understanding required, it will be an interesting future.

Nigel D’Souza, Simcoe Muskoka Catholic District School Board Data collection in many organisations has been occurring for quite some time manually and through automation; IIoT and predictive tools available today are amazing and establishing industry 4.0.

The future maintenance focus will be integrated information, processes with solutions to support asset management, and business decision making for total enterprise portfolios. With this will

Photos: Getty Images / nanostock

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echnology moves at a fast pace, and companies need to adapt quickly if they want to stay competitive in the new marketplace. Maintenance is no exception. What was once an industry that saw maintenance professionals using mental tools and wearing a hardhat, are now more likely to use a tablet to check on their assets.

MRO reached out to a cross section of the maintenance industry to get their views on what they see the future of maintenance looking like. They included industry experts, associations, and companies.

Without further ado, here is what they see the future of maintenance looking like.

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hand, management will lag behind in updating their hiring and training strategies in trying to save money by cutting back on wages and training. This opposite strategy will devastate some companies and lead to more outsourcing of maintenance (a core competency) with mixed results.

Martha Myers, MaRTHA Myers Consulting Services Maintenance will be thought of as an investment, not a necessary evil. When equipment breaks down unplanned (which will rarely happen because of the preventative and predictive tasks being done), management will ask “why” instead of “when will it be back up.” Maintenance plans will be in place before new equipment is put in service, and all industries will be sharing information to prevent recurrences of incidents. No longer will we see headlines that say, “due to maintenance.” Call me a dreamer, but that is what I believe can happen.

Richard Beer, TRO Maintenance Solutions come new risks, and an increased focus on the alignment of information technology (IT) infrastructure reliability, and cybersecurity as part of maintenance planning.

Due to the change in how information is collected, collated, and used; roles within maintenance operations and its leadership are poised to require more analytical and interpretive skills related to data science. With this will come the need to better understand IT systems as integral to the overall business operation and maintenance strategies employed, while processes will be more interdependent requiring emphasis on understanding design and measures for decision making.

Doc Palmer, Richard Palmer and Associates The future of maintenance will have more technologically complicated assets and will require more attention to hiring and training of crafts persons. The level of our crafts is going more toward being a professional, like a doctor who opens up the patient, and may or may not follow an established procedure to accomplish a certain operation. The patient came in a for a single bypass; it is okay for the doctor to deviate from the plan and perform a double bypass?

We should invite crafts persons to exercise their judgment. On the other

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With the rise of the Internet, mobile technology, AI, and IIOT, it’s no secret that maintenance management is changing.

When I first started as a planner the focus was on preventative maintenance, both time and usage based. Over time the focus has evolved to predictive maintenance. Technology is now and will be moving us forward to a concept of prescriptive maintenance. Not only will the technology predict the onset of failure it will tell us the root cause and action required. Every industry and every professional from maintenance technicians to maintenance supervisors, planners and schedulers, are affected.

Chris Beaton, eMotors Direct There's no question - the industry has changed over time. However, we expect a period of rapid change in the next five years, triggered by the normalization of automation. Large corporations have already adopted automation in maintenance, but as more SMB's adopt the technology, there will be a shift in the industry. The relative cost of real-time data capture and analysis will decrease as it becomes commonplace. Proactive maintenance costs will decrease, empowered by low-cost sensors and Wi-Fi data transmission. Data collection will be automated, and algorithms will flag abnormalities months before a human could. Equipment will be monitored at

all times of the day, sending data to the cloud to be measured and interpreted by algorithms.

Most importantly, people will work in safer environments, with better-maintained machines. Maintenance will become more accurate, proactive, and cost-effective. Ultimately, we'll see less downtime as a result of the normalization of automation in maintenance.

Hugues Therrien, ABB A 2019 MRO survey found that downtime is what the majority of maintenance professionals want to reduce (and ideally eliminate). And 28 per cent of respondents said they did not know how the IIoT could help improve maintenance. The purpose of digitalization and using sensors is to prevent and predict failures. Digitalization helps better manage shutdowns and failures; the goal is to adjust your maintenance and increase the performance of your assets.

As an example, if you know your drive or motor is working at 80 per cent, you know you can extend its life; if it’s working at 125 cent, you know it may shorten its life, and you’ll need to replace or repair it sooner. This is planning to prevent unnecessary shutdowns.

Safety is another important aspect of digitalization. When some of your equipment is in hard(er) to reach locations, being able to see how it is performing on your phone or computer will prevent unnecessary maintenance.

Ashley M. Larrimore, Eruditio, LLC. Advanced technologies, a heavier focus on reliability practices, and a resilient workforce are a few things that come to mind when considering the future of maintenance. 2020 has proven that regardless of what the world may throw at us that maintenance and reliability teams across the world will continue to adapt and keep manufacturing facilities open. Training people on how to use these advanced practices, how to read data collected, and what to do with the data will be critical. MRO Mario Cywinski is the Editor of Machinery and Equipment MRO magazine and Food and Beverage magazine, a member of the Automobile Journalists Association of Canada, and a judge for Canadian Truck King Challenge. He has over 12 years of editorial experience; over two years of maintenance, reliability, and operations experience; over 16 years of automobile industry experience, as well as small business industry experience.

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W H A T ’ S

Machinery and Equipment MRO

THE CHALLENGE OF OUTER RING ROTATION

BY DOUGLAS MARTIN

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t first glance, one may not think that a rolling element bearing with an inner ring (shaft) rotation or an outer ring rotation, really aren’t much different in terms of bearing performance. To give some perspective, most bearing applications are inner ring rotating (over 95 per cent).

As such, the focus of standard bearing design is for inner ring rotating applications. Most may not think that inner ring or outer ring rotation matters, but, outer ring rotating bearings are typically less reliable than inner ring rotating bearings. Following are cases and the associated issues.

Triple Race Bearings An applications that I have been involved with for years is the triple race bearing, which was used in some specially designed newsprint paper mill rolls, that had three rings and two sets of rollers. The inner roller set has a rotating outer ring and the outer roller set has an inner ring

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December 2020

that rotates. Having watched a video in the late 1980s of the lubrication flows through the inner ring set in a laboratory. It was part of an investigation of the problems with the inner bearing set that was an issue of many users.

The video showed the effectiveness of oil flow into the bearing, which had additional lubrication inlets into the inner ring of the bearing. At that time, all the main bearing manufacturers where working on solutions to the problem. One solution was to increase the oil flow to the problem roller set (which the video was demonstrating). This was to address what the typical failure mode diagnosis of inadequate lubrication, which was typical of what was observed.

Another solution to this problem was the change in design of the inner bearing set, to a narrower bearing that had smaller rollers. Although this solution did not intuitively address the believed failure mode, it did address a subtler issue, which was roller skidding. This issue is related to the way a spherical roller “rolls” when the outer ring is rotating about the rollers and stationary inner ring and more importantly, when this outer ring rotation is coupled with angular misalignment.

What occurs is that the direction of the roller movement begins to deviate from the rolling direction as the inner and outer ring become more misaligned.

Experiencing this with a paper mill, who used the same triple race bearing in two different machines, and their reliability in one application was worse than the other application. When investigating the applications, the roll with the poorer reliability had greater suction, which would have caused greater bending in the shaft which supported the inner ring of the innermost stationary ring. This difference in alignment of the innermost

Photos: Getty Images / nantonov / Douglas Martin (Bottom)

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ring, that was related to the poorer reliability, which was due to the difference in the rolling direction and rolling path differed.

As an visualization, watch the rear wheels of an 18-wheeler trailer as it goes around a corner. The tire is rotating, but its vector direction is at an angle to the rolling direction, and as a result, it scuffs over the road. This is essentially what was happening to the rollers in the outer ring rotating spherical roller bearing. By using a less massive roller, the effect of a roller sliding across a race is lowered and, it is lowered to the point that the sliding motion does not result in surface adhesion, which is what was the root cause of the problem.

Sealed Bearings In the above example, the problem was thought to be lubrication and it wasn’t, it does not mean lubrication and specifically grease lubrication is not affected. With outer ring rotation, the grease is always flung to the outer race of the bearing, and even when it is not being rolled over in the contact zone, it is being acted on by the centripetal force of the rotation.

As opposed to when the inner ring is rotating, grease sitting on the outer race shoulders has only the force of gravity acting on it.

The centripetal force on the grease will tend to draw the oil out of the grease. Outer ring rotation causes the grease to be constantly centrifuged. If there is no seal or means of retention, the grease itself will flow out of the bearing. Even with

a seal, the separated oil may work its way through the seal, as typical seals integrated into a bearing are not designed to seal at the outer ring interface, they are designed to seal at the inner ring interface, and under the pressure of the centripetal force, it is likely that the separated oil will seep through the seal/outer ring interface.

Therefore, there are two applications in newsprint mills in which this is a problematic application, rope sheaves and spreader rolls. Both have outer ring rotation, and both have low reliability. The ball bearings in rope sheaves may last two years, whereas the same bearing in an electric motor may last 10 years.

The other application, a spreader roll, stretches the sheet of paper to prevent wrinkles. Although the bearing needs more grease to lubricate the outer ring rotating bearings, the users are reluctant to add extra grease, as when they do, it is driven out of the bearing and onto the finished sheet of paper, making it scrap.

The rotating ring of a bearing plays a significant role in the performance of the bearing. Applications with outer ring rotation should be given special attention in terms of re-lubrication frequencies and accuracy of alignment. One cannot just assume that the bearing will operate with the same reliability as other applications using the same bearing. MRO Douglas Martin is a heavy-duty machinery engineer based in Vancouver.

He specializes in the design of rotating equipment, failure analysis, and lubrication. Reach him by email at mro.whats.up.doug@gmail.com.

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Machinery and Equipment MRO

ADAPTING TO MAINTENANCE TECHNOLOGY This year it seems like we are on the front steps of maintenance technology.

Manufactures are talking about new advanced maintenance tools, and many are moving toward implementing technological applications to be used by plant engineers and tradespeople.

BY PETER PHILLIPS

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ith technological developments such as additive layer manufacturing (ALM), Industry 4.0 and IoT, there is a paradigm shift in our ability to better repair or replace individual components, better understand the health of equipment, and plan maintenance based on the availability of significantly large volume of data provided through technology.

Let’s look at a few of the maintenance applications available to help analyze equipment health. Also, how this paradigm shift affects the culture within the maintenance department.

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December 2020

New tools and applications Over the past several months I’ve implemented maintenance tablets with CertainTeed Gypsum.

First, we needed a device that can house all applications, and provide a connection for external testing devices. Android Tablets that allow the maintenance staff to remotely connect to the new applications, were chosen. Armed with Wi-Fi connectivity, the tablets communicate directly with the software applications, and store data on the company’s network.

Initially, the push was to get the work order system mobile.

While working through the implementation, maintenance managers began to ask what other apps could be added to the tablet that would give the techs more tools to help maintain the equipment. The plants created a list of apps they would like, and explained how they would benefit the maintenance department.

Mobile applications that were asked for FLIR ONE - a lightweight accessory that transforms the Android device into a powerful thermal infrared camera. FLIR ONE displays live thermal infrared imagery using the FLIR ONE app, so you can see the world from a thermal perspective.

Proaxion and SKF Condition Based Monitoring - applications that use sensors to monitor equipment health in real time. With 24 and 7 remote monitoring, maintenance staff receive emails and SMS text alerts in advance of equipment failure. This apps also provide graphical data to provide measurement trends over time.

Yammer - helps with communication between shifts and facilitate communication with supervisors and troubleshooters.

The Yammer mobile app allows maintenance personnel stay connected from anywhere. Yammer provides a connection with leaders and peers to share, and discover knowledge and

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engage in remote troubleshooting.

The Gates Design Flex Pro - a belt design and tensioning application. Maintenance people work with many belt drives and need belt tensioning calculations and specifications.

Gensuite - a safety application. Gensuite provides a quick review and update of critical information like assigning corrective actions and inspections, regulatory citations, safety data sheets (SDS), LOTO procedures, and more.

Fast Fields - allows build your own custom mobile forms using their form's builder. The app will automatically distribute data and reports (PDF, Excel, Word, Json, XML, CSV,) according to your business workflow.

Data can also be streamed from other sources, such as a machine’s programmable logic controller (PLC), MES, CMMS, or ERP system. Other apps can access equipment historians and machine learning software.

These are only a few applications we have been looking at, there will be more to come as we progress through the mobile device implementation.

The answer to the question of whether this technology will improve reliability, maintenance productivity, and a safer workplace, is yes. Plants with the condition based monitoring remote applications have seen a quick return on investment.

Technicians receive alerting of impending failures, and take appropriate actions to avoid downtime.

One thing to keep in my mind is that technology will not replace fundamental maintenance practices. With available technology there will still be a need for basic equipment maintenance. Regular visual inspections and lubrication will need to be done by the professional maintenance staff, maintenance that cannot be measured with technology.

As these tools move further into the mainstream, they may no longer require advanced knowledge to use, putting them within reach of many organizations that may not have had the expertise or resources to leverage them in the past.

Remember, using advanced technology is a cultural shift.

For years, we have been dependent upon maintenance staff to perform routine inspection and part replacements using their years of training and experience.

Any program that affects the way people have done their

jobs the same way for years needs to have a cultural change management plan. When new devices, applications and tools are introduced into the maintenance culture, time must be taken to explain the reason for the technology, to include the maintenance staff in decision making in the implementation and training of new technology. Where maintenance managers are looking at the big picture of improved reliability and reduced cost, the equipment maintainers need to know how can this help me and what is in it for me.

Older staff especially need to be coached and encouraged to use the new devices, apps, and tools. Some of the best troubleshooters are getting older, and may not understand the latest technology. Both young and old need special attention to help them adapt to the new world of maintenance technology. MRO Peter Phillips is the owner of Trailwalk Holdings Ltd., a Nova Scotia-based maintenance consulting and training company. Peter has over 40 years of industrial maintenance experience. He travels throughout North America working with maintenance departments and speaking at conferences. Reach him at 902-798-3601 or peter@trailwalk.ca.

She ran 147K straight.

Without a single break.

Photo: Getty Images / Metamorworks

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BENEFITS OF DUST COLLECTOR PULSE VALVES

S Y S T E M S December 2020

Pulse valves are often used in dust collector systems for the grain, agriculture, and feed production industries.

Dust collector systems, like every product, have gone through technological upgrades and innovative changes to make them more valuable to the customer, by eliminating more dust and particulates from the air.

BY MICHAEL RUSSO

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usty environments in industries such as concrete, met- thereby lowering the cost of system operation. alworking, mining, steel mills, grain, agriculture, and Ideally, pulse valves should provide a high peak pressure feed are particularly susceptible to costly damage and blast of air, not only to achieve more effective dust collection downtime, due to particulates getting into machines. Dusty filter bag cleaning, but also to extend filter life. Insufficient air is a hazard to workers’ health; particularly in the food and peak pressure and slow valve response time result in poor filbeverage industries, where humans or animals must fight ter cleaning and wasted compressed air, an expensive consumpowder dust in the air. able, and a key element in market differentiation.

Many of these industries use specific equipment for handling, storage, and drying operations. Cereal, protein powder, Pulse valve design and starch product industries are increasingly incorporating When considering pulse valve characteristics, key attributes aggressive anti-bacterial chemicals meant to help eliminate sought by OEMs, engineers, purchasing managers, and end-usthe risk of contamination of food that is in contact with these ers alike include robust performance, reliability and ease of machines — but these chemicals may also be damaging to use. Today’s more popular pulse valves offer users a simplified equipment over time. design that helps to maximize valve performance, translating It is easy to see why the industries meninto longer system uptimes. tioned above would use a dust collector sysThese valves are specifically developed for tem. However, consider other industries that filter cleaning of dust collectors and baghousmay not have much powder in the air, but es in reverse pulse jet systems. Those appliproduce a large volume of particulates, such cations require high peak pressure, high flow as automotive factories, chemical producers, rates, long life and extremely fast valve openand power plants. Frequently removing dust ing and closing for effective filter cleaning and particulates from the air of these autowhile minimizing compressed air waste. Some mated applications requires the use of specifpulse valves are specified to provide a long opic equipment that is resistant to a variety of erating life with over one million cycles. materials including aggressive agents.

For the functional design of a pulse valve, It is imperative that companies incorpothere are multiple connection options, includrate highly efficient dust collector systems ing threaded, dresser and even a quick-mount to eliminate or reduce as many maintenance option that enables faster, easier, and more concerns as possible. Pulse valves are used secure installation. This is a major benefit to clean bag-type or cartridge-type filters in for initial installation and replacement situations. Further, it helps if the pulse valve can a dust collector system. These valves send a be mounted in any position without affecting high-energy pulse of air through the blow operation. Options for built-in silencers to retube creating a shock wave down the filters duce noise and prevent foreign particles from to remove dust. Higher air acceleration and Pulse valves are used to clean quicker valve response time helps clean filter bag-type or cartridge-type filters entering the valve are also important. bags better and consume less compressed air, in a dust collector system.

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Pulse Valve Innovations As with any technology, the ability to hold tighter tolerances for each component has driven performance and life expectancy forward. Plants must operate safely in hazardous or explosive environments and must comply with strict safety regulations.

Pulse valves need to meet global approvals, including UL, CSA, RoHS, ATEX, CE, and other certifications suitable for worldwide use. Be sure that you’re working with a company that provides a range of optional waterproof and explosion-proof solenoids for use in potentially explosive atmospheres, and one that offers extended ambient temperature ranges.

Solution-solving Capabilities

SWITC E H T E H AK

Mining is another key industry that relies on dust collector systems.

OEMs. Same-day shipping with ensured availability is ideal and can be an important factor in avoiding extra downtime in the plant. MRO Michael Russo has been with Emerson since 2007 and is the Product Marketing Manager, Dust Collector Systems. In this role, he leads ASCO’s industrial marketing direction and strategic vision for dust collector systems. He has been involved in new product development efforts and has been aligned with customer needs and requirements. He was previously Senior Key Accounts Specialist. He holds a Bachelor of Science Degree in Marketing from Monmouth University. He can be reached at: Michael.Russo@Emerson.com.

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When working with a valve company, the ability to provide quick delivery and outstanding technical support can help ensure smooth operations for your facility. Be sure you can get the components you need when you need them. Long lead times can slow down or shut down your processes. When talking with your supplier, be sure to ask if they offer an express shipment program to ensure the quick delivery of products. Long lead times can cause a lot of trouble, especially for

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ELECTRIC MOTOR TROUBLESHOOTING USING VIBRATION ANALYSIS Vibration is technically defined as the oscillation of an object about its position of rest.

BY L. (TEX) LEUGNER

Frequency - refers to “how many” oscillations in a given length of time (e.g., one minute), measured in cycles per minute (CPM), or cycles per second (hertz) Hz, related to 1X shaft turning speed.

Displacement - refers to “how much” the object is vibrating measured in Mils (1/1000 inch) peak-to-peak. Displacement (distance or movement) is generally the best parameter to use for frequency measurements up to 600 CPM. Velocity - indicates “how fast” the object is vibrating measured in inches/second or mm/second peak. Velocity is frequently used for machinery vibration analysis where important frequencies lie in the 600 to 60,000 CPM range.

Acceleration - of the object that is vibrating is related to the forces that are causing the vibration measured in “gs” (1 g = 32 ft/sec2 or 9.8 m/sec2) and is reported or shown as root mean squared (RMS). Acceleration (force) is best measured when all the troublesome vibrations occur at frequencies above 60,000 CPM. 1. How does your facility determine the correct selection and application of transducers?

Logic: the quality of data gathered by vibration analysis is dependent upon proper selection and mounting of transducers. If possible, vibration readings should be taken with the transducer

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mounted perpendicular to the surface in the horizontal, vertical and axial directions. Vibration signals containing “high frequencies” must be taken with an accelerometer tightly screwed, or glued to the surface, since hand held pressure alone cannot hold it tightly enough to the surface to follow high frequency motion. Displacement non-contact proximeters are used to look directly at the rotating shafts of machinery and the frequencies obtained will be quite low. A velocity transducer’s sensitivity drops off dramatically at speeds below about 600 RPM. Accelerometers have the advantage of having adequate sensitivity over a wide range of frequencies.

The low end is typically one to three Hz, while the upper range can be as high as 20 kHz. For this reason, accelerometers are the preferred device to use.

2. Can your analysts determine the causes of vibration problems in electric motors?

Logic: motors use electromagnetic forces in addition to mechanical forces and exhibit some characteristics that differ from purely mechanical rotating machinery. For example, a motor shaft may “bow” or “bend” due to excessive localized heating from shorted laminations. The spectrum of this condition will appear as unbalance, but balancing the shaft and attached components will not solve the problem. Unlike a purely mechanical machine, a motor has a multitude of frequencies generated by the electromagnetic forces inherent in the machine.

The magnetic flux produced by conductors in AC machines alternates at line frequency and all AC motors produce a

2 X line frequency vibration. In systems that operate at 60Hz, the vibration frequency is 120Hz. In an induction motor, the poles in the stator winding produce a rotating magnetic force that acts across the air gap between stator and rotor. This produces a 120Hz vibration of the stator and the number of poles in the winding determines the mode shape of this vibration.

The number of poles and line frequency also determines the synchronous speed of the rotating magnetic field and running speed of the motor. The difference is referred to as “slip”. The number of rotor bars x rotor speed in RPM, and harmonics of the rotor bar passing frequency may indicate a problem.

3. Can your vibration analysts determine the potential causes of electric motor unbalance?

Logic: AC motors may have unequal magnetic forces causing unbalance that may be caused by variations in the current in the stator or rotor, or air gap variations between the rotor and stator, or a combination of these conditions. These variations in AC current may be caused by weak or loose stator support, shorted or loose stator laminations, shorted or open windings, electrical unbalance between two consecutive conductor

Photo: Getty Images / sarinyapinngam

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efore discussing the technology as a troubleshooting tool, a review of terminology is important.

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coils, or unbalanced resistance between any of the three current phases. These variations will affect the vibration spectra whether or not the motor is loaded.

Any or all of these defects will appear on the spectrum analyzer as a high amplitude peak at 2 X line frequency with the absence of side bands around the 7,200 CPM frequency.

Broken, loose wires, or poor connectors may be seen as sidebands at ⅓X line frequency on each side of the 7,200 CPM peak. Electromagnetic force unbalance due to variations in rotor current is commonly caused by broken or cracked rotor bars, broken, cracked or poorly brazed end ring joints, high resistance end ring joints, or shorted or loose rotor laminations. These conditions will most often occur on the spectrum analyzer when the motor is under load.

This frequency may occur at 1X RPM and may be mistaken for unbalance.

When pole passing frequency side bands are present at three or four x running speed harmonics with amplitudes higher than .0125 to .0150 inches per second peak, there is uneven motor heating that can cause the rotor shaft to overheat and bend. This condition will cause the electro-magnetic unbalance to increase, generating even more heat. When this condition is suspected, confirm the mo-

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tor’s phase with a stroboscope. Any rotor flexing will cause temperature increases that will show phase changes. This is unlike misalignment, because vibration amplitude at 1X RPM and phase will stabilize at a particular RPM if there is a misaligned condition. The condition may increase to a point where the bowed rotor will contact the stator causing catastrophic failure.

4. Do your analysts understand faults caused by internal motor problems?

Logic: air gap between rotor and stator affects induced rotor current. The air gap should be less than five per cent of the total radial air gap between stator and rotor, and can be measured with a feeler gauge. Static eccentricity is a condition where the minimum air gap is fixed at one condition. This is commonly caused by such conditions as soft foot distortion, distorted stator core, worn sleeve bearings (where used), or non-concentric rolling element bearing housings in the motor end bells. This condition shows up as a high amplitude peak at 2 X line frequency of 7,200 CPM, with harmonics, but no side bands.

Dynamic eccentricity is a condition where the minimum air gap “moves around” the stator bore as the rotor turns caused by an eccentric rotor, bent shaft,

a rotor running at resonant speed, misaligned coupling or an unbalanced overhung fan. The vibration spectrum may show high amplitude at 1X RPM and may have pole passing frequency side bands.

These problems occur when the motor is partially loaded. If the stator and rotor slot teeth are not equidistant, there will be reluctance variations in magnetic forces, causing motor torque variations.

Torque pulses may excite loose or broken rotor bars or end rings, loose windings, laminations or supports in the stator. This will be indicated by 2 X line frequency (7,200) with harmonics and will appear as a mechanical looseness condition if multiples of the 2 X line frequency appear in the spectrum. Loose stator coils in synchronous motors will generate fairly high vibration at coil pass frequency (CPF) that equals the number of coils x RPM (#coils X poles X # coils/ pole). The CPF will be surrounded by 1X RPM sidebands.

High amplitude peaks at 60,000 to 90,000 CPM accompanied by 2 X line frequency sidebands may indicate synchronous motor problems. Analysts should obtain at least one spectrum up to 90,000 CPM at each motor bearing housing. Loose or open rotor bars in AC induction motors are indicated by a 2 X line frequency sidebands surrounding rotor bar pass frequency and/or its harmonics (rotor bar pass frequency = number of bars X RPM), often will cause high levels at 2 X RBPF, with only a small amplitude at 1X RBPF. Electrically induced arcing between loose rotor bars and end rings will often show high levels at 2X RBPF (with 2 FL sidebands), but little or no increase in amplitudes at 1X RBPF. Electrical fault frequencies, including cracked or broken rotor bars, loose rotors, loose transformer laminations and eccentric stators or rotors are all non-synchronous.

In addition to vibration analysis, electrical equipment might include magnetic flux, motor current and circuit analysis that will prove highly beneficial in making the correct diagnosis. MRO L. (Tex) Leugner, the author of Practical Handbook of Machinery Lubrication, is a 15year veteran of the Royal Canadian Electrical Mechanical Engineers, where he served as a technical specialist. He was the founder and operations manager of Maintenance Technology International Inc. for 30 years. Tex holds an STLE lubricant specialist certification and is a millwright and heavy-duty mechanic. He can be reached at texleug@shaw.ca.

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IS IIOT THE FUTURE OF MAINTENANCE?

BY JAMES REYES-PICKNELL

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lant and equipment monitoring is very basic to most maintenance programs, even if it is not done by maintainers. Condition monitoring (CM), as it is known, can account for a third or more of your maintenance program budget, if you are taking full advantage of it. You can do it with various hand-held or permanently installed technologies, or with the human senses. Often it is operators who apply their senses doing rounds, and noticing when things are not quite right. They may not know what is wrong, but they know something is amiss. They contact maintenance, who typically responds with a technician and some hand held monitoring tools. When you’ve “diagnosed” the problem, you can plan a course of action – job plan, arrange parts and other resources, and schedule the downtime when it convenient.

It’s that ability to act in our own time, not when the machine breaks down under load, that gives us value from CM.

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Waiting for breakdowns is expensive and risky. Acting proactively eliminates much of the risk and enables us to avoid major business losses.

The “new game” in town is the Industrial Internet of Things (IIoT), which is already making big splashes in the world of CM. Here’s a look at the impact it will have on maintenance in the not too distant future.

For a long time, we have had sensors for motion, ultrasound, light, temperature, vibration and more. Some are installed in or on equipment, and wired to monitoring analyzers, while others are carried around, and moved from machine to machine. For decades, these have been helping companies to detect failures in early stages, so that they take action to minimize the consequences of the failures they are detecting. Handheld stethoscopes, screwdrivers held onto bearing housings, and hands-on equipment, have been replaced with vibration sensors, temperature probes, ul-

trasonic and thermal imaging.

Some equipment comes with continuous monitoring; diesel generator sets or packaged compressor units have temperature, vibration, oil pressure, and other monitors installed, all sending signals back to a monitoring panel. Someone had to monitor the panel – often maintainers.

CM technicians can perform rounds and monitor other equipment, at least periodically. Companies will do that for you. Many of us have had a great deal of success with this – with many “saves,” but some were missed. This monitoring, if done by a contractor, is often too infrequent, but even with the misses, the saves can make it worthwhile.

CM is of great value in giving advanced warning of failures about to happen. The more frequently you monitor, the more likely you will be to catch failures. Monitoring a vibration signal once a month is not enough to catch all failures of rotating equipment that move through a period of degradation within weeks. Installing permanent sensors enables continuous monitoring, but it was very expensive. You would need to install the devices, wire them, and set up a monitoring station. The biggest cost was often the wiring. Someone needed training in the monitoring technology to interpret the signals and makes the judgement calls about what is a failure.

Companies will do continuous online monitoring for you, and tell you when a problem is detected. Using them you can have your equipment monitored from anywhere. This may be less costly than training your own technicians, but will limit the list of equipment monitored to only critical production assets.

Because of cost, these installations have been used by the largest companies. They can afford the contract monitoring or train their own technicians.

Smaller operations with thinner margins could not. They lived with (and live with) the risk of surprise failures and consequences of failures. They can’t afford those failures, and a big one could put them out of business, but they really had no option that they deemed viable.

Smaller organizations often lacked technical expertise to examine these options.

Now IIoT has changed that. It is removing much of the cost barrier to companies that couldn’t afford the permanently installed hardware, wiring, software, and training of their technicians. It is also opening up more than just critical major machinery to continuous monitoring.

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IIoT is an electronic industrial network of connected devices monitoring your equipment, processes, and systems. Some devices talk to analyzing equipment, while others talk to each other. Most of them are wireless. Transmitting signals via Bluetooth, LTE, or local area Wi-Fi networks. Many machine mounted devices also have the ability to monitor more than one signal (vibration, temperature, and sound levels). Many have some computational capability and machine learning built in. They “learn” what normal is for their application and use it as a benchmark for comparison, monitoring continuously. Once installed and activated, they spend time monitoring and learning what a normal signal should be, and are then ready to detect when abnormal signals occur.

That onboard computational capability is known as “edge computing.” It removes a lot of load from the available bandwidth on networks. They monitor continuously and send data only when there is an abnormal condition. Without that capability, Bluetooth, LTE and Wi-Fi networks would be overwhelmed by the steady stream of data from a large and likely growing population of devices, each one monitoring some important parameter. It’s really only the anomalies that we are interested in though, so why monitor the monitor? Let it tell us when there is a problem, and then investigate with more analyzer capability or even visits to the field to see what is happening. Our brains are reserved for the tough problems, the machines do the rest.

While the sensors themselves must still be installed, the wiring for them does not. LTE and Wi-fi may already exist in the field and if not, are easily installed. Bluetooth can be monitored by mobile monitors, handheld tablets carried by plant operators or maintainers.

One day, perhaps even drones programmed to fly through the plants can be used to carry out “rounds.” The days of the clipboard are almost over, perhaps even the rounds person won’t be needed soon.

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Behind the scenes we don’t really need to monitor all the signals all the time.

Edge computing does that, but someone must receive and act on the warnings generated by abnormal signals. Those abnormalities might be device faults, network faults, or machinery defects that are being detected.

When we get those alarms, we must act – if not, we won’t realize the benefits.

For the vast majority of defects, we know we will be stripping equipment apart and replacing parts, then putting it back together. For many cases, we don’t need in-depth analysis of what is wrong. A simple field visit by a technician might be enough to tell us what repair job we need to prepare for.

In other cases we might be monitoring major equipment that has the potential to take our operations down. Downtime to repair may be long, so we need to know more about the nature of the failure. Once an abnormality triggers an alarm, the devices can send a complete stream of signal output to a monitor that is being operated by a technician or engineer, who views the live stream of data, performs analysis, and pinpoints the source of the problem. Parts can be ordered, job plans prepared, and crews readied for the work, so downtime is minimized.

Some equipment might be remote or difficult to access for a human technicians. The IIoT devices allow for monitoring without human visitation. This can be a big benefit in cooling towers, oil

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or water fields, remote pumping stations, wind turbines, and other unmanned operating locations.

There are several advantages to IIoT over older CM methods. The cost to install is much lower, and can be installed anywhere that has network coverage.

The cost of devices is coming down. As more devices are sold and manufactured, their costs and pricing goes down too. What would cost millions to monitor in the not too distant past, can be monitored now for thousands.

With continuous monitoring of various signals a wide range of potential problems are picked up early. With machine learning, devices’ “signatures” are known and with AI, abnormalities in those signals can reveal specific problems. As companies permit sharing of their monitoring signal data, the ability of machine learning to expand and apply AI on problems. Data gathered from equipment in many locations can all be used to help solve problems. Until then however, we need a few humans.

Human monitoring of these signals is reduced only to the most complex and likely unusual problems. As this capability expands, the cost of monitoring will also come down. The location of the technicians doing the monitoring can be anywhere, not necessarily in your own head office, own country or even continent.

IIoT enables us to take full advantage of our connected world, to use talent and

capabilities that exist elsewhere to solve real-time problems, here and now. Furthermore, it allows us to do all that a fraction of the costs incurred for this kind of attentiveness just a few years ago.

Monitoring of equipment can expand.

As prices come down and the benefits amass, we can monitor a broader range of equipment. Where it wasn’t “worth it” in the past, it becomes more viable.

Maintenance programs become more biased towards CM. Reliance on preventive replacements and “inspect then repair as required” will be reduced. We shift further into the proactive realm and further away from “break then fix.”

As that expands and device pricing goes down, its capability is going up. A broader range of smaller companies with smaller margins can now afford it. As they become part of the IIoT market they benefit from being more proactive and less vulnerable to impacts of those big unexpected failures. Their business becomes more stable and more profitable.

Maintainers themselves are freed from mundane monitoring and inspecting tasks and freed up to what they really trained for and love doing. Fewer are needed for the CM. With fewer of the really bad breakdowns there will be less of the more difficult and riskier repair work. The work we have can be planned and scheduled. Safety performance of maintainers can increase. Productivity increases and makes it easier to maintain with the fewer technicians we have today. For operations in remote locations that probably means fewer people on-site and traveling back and forth. It’s a good fit with the practices were seeing to ensure healthy working conditions as highlighted by the 2020 COVID-19 crisis.

The CM industry will also shift. It will still exist and move to monitoring online with staffs of technicians, rather than selling devices to end-user technicians in the field. Contract monitoring services will likely shift off-shore to locations with well-educated yet less-expensive work forces.

IIoT is a game changer that will have a big impact, one device at a time. MRO James Reyes-Picknell, PEng is Principal Consultant of Conscious Asset, providing business consulting and training services in Physical Asset / Maintenance Management and Reliability. He is author of several books, including Reliability Centered Maintenance – Reengineered in 2017 and Uptime – Strategies for Excellence in Maintenance Management, 2015.

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Civil work for the temporary substation is being completed in the background. Sunnybrook remained powered from its existing substation in the foreground.

Part 2 – Project Phasing, Construction and Commissioning

BY PHILIP CHOW AND BAVAN POOLOGARAJAH

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n part one (February 2020 issue) we discussed design considerations, planning and equipment selection decisions for upgrading the main outdoor electrical substation at Sunnybrook Health Sciences Centre. With an equipment package consisting of 38 kV class gas-insulated switchgear housed in customized E-Houses, four new 7.5/10 MVA KNAN/KNAF transformers, and an intelligent control and monitoring system pre-selected, the next challenge was developing a detailed project phasing strategy, which coordinated utility upgrades to the site, demolition and construction of a new substation, while maintaining a reliable power distribution system to the site, and implementing the phasing strategy over a two and half year construction schedule.

“Sunnybrook’s main outdoor electrical substation is critical in providing reliable power throughout the entire campus,” said Michael McRitchie, Director of Plant

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Operations, Maintenance and Biomedical Engineering, Sunnybrook. “Minimizing power interruptions during construction was a key priority for the team.”

The temporary substation is nearly complete, with equipment landed and 5 kV feeders being installed to the hospital’s main 4.16kV distribution switchgear.

Photos: Philip Chow

MAIN ELECTRICAL SUBSTATION UPGRADES

At the onset of the project, coordination with the local electrical utility was an essential part of the planning process.

Not only would Sunnybrook’s new main outdoor electrical substation provide critical power throughout the hospital, but it would interface with Toronto Hydro’s distribution system, which supplies power to the City of Toronto. Coordination on various design features, operational aspects and construction work was essential to ensuring a successful outcome.

Frequent design, planning and construction meetings were held between the utility, project engineers and hospital staff, throughout the project. In addition to replacing end of life equipment at Sunnybrook’s existing substation, the project would incorporate a new utility circuit

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from the local transmission station to site, replacement of existing utility feeders on the Sunnybrook campus and the installation of new SCADA controlled pad-mounted switchgear in the substation. A detailed phasing plan, with 14 major phases of construction was developed by the project engineers, which allowed both the project contractor and electrical utility to complete the work required to build the new substation, and connect it to an upgraded electrical service, while minimizing disruption to a fully operational hospital.

With a pre-selected equipment package and detailed phasing plan in place, the project was tendered to a group of pre-qualified electrical contractors, and awarded to Ontario Electrical Construction Company Ltd. Construction on the project started immediately after the project was awarded. First phase of the project involved constructing a temporary substation, which would allow for Sunnybrook’s existing substation to be decommissioned and demolished. Given the various construction parties involved with the work, including the hospital contractor, utility, and utility contractor, the project engineers needed to take a hand’s on project management approach to coordinate work between the various parties, and chaired numerous construction meetings over the course of the project.

When the civil work was complete for the temporary substation, newly manufactured equipment (for the permanent substation) was installed in the temporary substation, and one of the incoming 27.6 kV utility circuits was routed to it. The temporary substation and temporary utility feed had to be strategically located, such that they would not be affected by future demolition work, and future construction of the permanent substation.

While the temporary substation was being commissioned and subsequently energized from one utility circuit, the hospital remained supported by the second utility circuit, thereby avoiding any utility power interruptions associated with temporary construction.

Once the newly constructed temporary substation was energized, each of the four new 7.5 MVA transformers were connected to part of Sunnybrook’s 4.16 kV distribution network, until the entire hospital was powered from the temporary substation. The cutover process was completed over four weekends, minimizing power interruptions to parts of the hospital during each cutover. Demolition of the existing substation started immediate-

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Once Sunnybrook was supported from the temporary substation, the existing substation was demolished and civil work for the new permanent substation started.

ly after the last cutover was completed.

Existing overhead distribution and pole mounted switches were removed by the electrical utility and existing switchgear and transformers were removed by the project contractor.

Civil work on the new permanent substation followed demolition work, with excavation and foundation work for a network of below grade service trenches. The new gas-insulated switchgear only accepts incoming and outgoing feeds via bottom entry connections, so below grade cable chambers and service trenches were required to connect the new upstream load break switches, and new downstream power transformers to the GIS. Important design parameters were incorporated into the below grade service spaces, including: need for multiple access points; ability to house multiple levels of cable tray, and associated support structure, that facilitates future installation of new 27.6 kV campus circuits; maintaining cable bending radii for connections to equipment; concrete sloping and drainage, ensuring water penetration into the space would be routed to a sump pit and pumped away to the site’s drainage system.

When the civil work for the new permanent substation was complete, the loadbreak switch and E-House with integral GIS line-up, which were not in use, were installed in their permanent location.

The incoming utility circuit, not in use

during construction of the permanent substation, was connected to the switch, and the second gas insulated switchgear line-up was energized.

As initial electrical connections were being completed in the new permanent substation, the entire hospital remained supported from the temporary substation. Given the increased capacity of the new transformers, the hospital’s load could be fully supported off of three of the new transformers, while maintaining an N+1 redundancy in available capacity to support the electrical load. One of the four transformers was disconnected from the temporary substation, craned to the permanent substation, connected and energized. Once this transformer was online and serving hospital load, the process was repeated until three transformers were relocated to the permanent substation, and Sunnybrook’s entire load was being supplied from the permanent substation, in a temporary configuration.

At this point, the remaining equipment (the second E-House, a load-break switch, and the fourth transformer) in the temporary substation was relocated to its permanent position. The second utility circuit was connected to the second line-up of GIS, and two of the four transformers were subsequently connected. A tie connection between the two line-ups of GIS was installed, along with control/alarm wiring interconnections, and redundant pathways for the controls network. As the remaining electrical in-

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When civil work was finished in the new permanent substation, equipment was craned into place and energized in a phased approach. Both the temporary substation and permanent substation were operational for a period of time, to minimize disruption to the hospital.

stallation was being completed, the foundations for the temporary substation were being demolished and the parking lot was remediated.

Throughout the project, a detailed commissioning plan was developed by the project engineers to test equipment, both in temporary and in permanent configurations. A test script was created for all of the new equipment, and commissioning was split in two groups: standalone tests

and dynamic tests.

Standalone testing included: site acceptance tests for cable insulation and transformers; detailed site verification of protective relays, with functional verification of differential protection systems, for gas-insulated switchgear and transformers; and monitoring and control systems, including the transformer dissolved gas analysis (DGA) monitoring systems, which were networked to Sunnybrook’s

Once the new permanent substation was operational (foreground), the temporary substation was demolished and the parking lot was remediated and returned to use.

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alarming and data logging server.

Field service representatives from the various equipment suppliers would often have to be on-site at the same time, for joint commissioning efforts, which required additional coordination efforts.

Once standalone testing was completed, final dynamic testing of the new automatic transfer system for incoming 27.6 kV utility circuits was scheduled with the hospital and utility. Various scenarios of utility power outages, including single circuit outages and coincident outages of both incoming circuits, were tested by opening and closing main load-break switches in the substation.

With the 27.6 kV automatic transfer system fully commissioned, Sunnybrook was left with the ability to transfer between utility circuits, in the event of a prolonged utility outage. One of the main challenges during the commissioning period was the onset of the COVID-19 pandemic, before the final dynamic tests were scheduled to occur in April 2020.

Recognizing the importance of having the new substation fully commissioned, Sunnybrook undertook a significant effort to organize internal services to ensure disruptions associated with testing were minimized. Additional precautions were taken by the parties on-site, such as daily screenings before entering the job site, maintaining two-metre social distancing, wearing masks on-site, and minimizing the number of people in enclosed spaces, during testing.

Replacing a main outdoor electrical substation can seem like a formidable challenge. By developing a detailed design, a phasing strategy, which minimized the impacts of construction, and maintaining a coordinated approach to construction management, Sunnybrook Health Sciences successfully upgraded their substation.

Similar to the equipment selection process, a number of innovative features were incorporated into constructing the new permanent substation. Removable, composite panels were used throughout the substation, to provide access to below grade service trenches and cable chambers, for the installation of future circuits. Medium voltage armoured cables were used as feeders and colour-coded based on voltage class, to help distinguish 5 kV and 35 kV circuits.

Free-standing, fire rated walls were installed between transformers to provide an improved level of protection, in the event of an unexpected transformer failure. New fencing, flood lighting, and

Photos: Philip Chow

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The gas-insulated switchgear (left photo) and 27.6 kV automatic transfer system (right photo) were dynamically tested at the end of the project.

Photos: Philip Chow

security cameras were installed, along with a ground grid spanning the entire substation area and complete with ground rod inspection boxes, for future maintenance and testing.

“The project was a success,” said McRitchie. “Sunnybrook will have an intelligent substation that will support future campus development and power the hospital’s distribution network for many years to come.” MRO Philip Chow, P.Eng., P.E., was the lead engineer on the project and is a senior project manager at H.H. Angus & Associates Ltd. He specializes in electrical projects and construction in critical facilities and can be reached at Philip.Chow@hhangus.com.

Bavan Poologarajah, P.Eng., was the senior electrical designer on the project. He has worked on a number of electrical projects in critical facilities and can be reached at Bavan.

Poologarajah@hhangus.com.

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Machinery and Equipment MRO

December 2020

NO MORE FIREFIGHTING Imagine an industrial site or manufacturing facility that actually accomplished the mission of every maintenance and reliability professional – zero per cent unplanned downtime.

BY JUSTIN LESLEY

T

hat nirvana seems so distant to most of us, that we don’t even consider it a real possibility. As farfetched as it may seem, let’s indulge ourselves and think of what it would take to realize our dreams and master our equipment. Theoretically, accomplishing zero per cent unplanned downtime is dependent on management’s

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ability to meet two criteria: 1) to properly plan maintenance activities during scheduled downtime; and, 2) having the proper resources (parts, people, and know-how) to execute those jobs.

Can we ever get there? Can we ever convince company leaders to approve funding for the tools we need to revolu-

tionize our operations and improve reliability metrics to approach perfection?

The only hope for success and funding is a relentless commitment to data.

What does it mean to be committed to data and why is data so integral to planning and executing maintenance efforts? Being committed to data means that we must leverage modern tools to record all maintenance tasks, to collect machine performance data, to track spare parts inventory, and to assign dollar figures to breakdowns and events that interrupt production.

That last part is an area where maintenance and reliability professionals rarely shine; generally, because we are too busy fixing broken equipment that is costing a lot every second it’s out of service. We can all relate to the madness of being called out to investigate a catastrophic failure on a production line in the middle of a shift, or worse, a component within the facilities infrastructure that affects the entire plant.

Photo: Motion Industries.

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In the best-case scenario during a breakdown, you and your team can identify the problem and have the tools and parts required to repair it, but that’s not always the case. For example, if a storeroom doesn’t have a spare pillow block bearing to replace the one that (hypothetically) seized, and even if the part is available at the distribution centre across town, the waiting game for spare parts can get expensive quickly. The cost of downtime could be in the thousands or tens of thousands of dollars per hour, depending on the industry and particular asset that is down. Such costly interruptions can unfortunately happen all too often. Do you know the value of production time in your facility? Do you know what it is per department or even per line?

Every business management decision must equate to financial drivers, which is why it is imperative to track the cost of downtime. Maintenance and reliability professionals have to clearly understand the financial implications of lost production, and use data to put ourselves in a position to succeed. In practice, being in position to succeed means having the right resources to do jobs effectively: technology, people, and support from leadership to plan downtime, prioritize repairs, and make upgrades.

Here are two technology resources that maintenance and reliability teams should be using to enhance their effectiveness. management • Maintenance software – If you are still using paper work orders and/or simple spreadsheets to manually track maintenance activities, you are robbing yourself of the ability to track critical metrics. Modern maintenance management software simplifies records, and integrates with ERP systems to capture the cost of maintenance including labor/time and materials/inventory.

• Predictive maintenance (PdM)/ condition monitoring (CM) solutions – Transitioning from time-based to condition-based maintenance (CBM) is key to efficiently managing resources. PdM solutions enable your team to detect failure trends of degrading equipment, allowing

you to prioritize and schedule downtime before catastrophic failures interrupt production.

Maintenance management software and CM solutions have been around for decades, and they have been continuously improving in both functionality and accessibility as new providers vie for market share. This is a wonderful trend for users, as modern technology tools now have more functionality; they are more user-friendly and are more cost-effective.

The “Industrial Internet of Things” (IIoT), and Industry 4.0 have produced a wave of demand for sophisticated

PdM solutions, which has created a race among incumbent industrial providers as well as new technology players. Each of these solution providers must compete in the marketplace based on cost, functionality, ease of use, field support, and interoperability with existing technology infrastructure.

With regard to CM solutions, wireless communication has drastically reduced the cost of installation and enabled seamless scalability. Additionally, sensor technology has been enhanced and machine learning algorithms have been incorporated into solutions to automat-

Grasp your Industrial performance

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Machinery and Equipment MRO

ically detect and interpret trends in performance metrics.

If you haven’t had experience with modern CM solutions, you may be wondering how they will complement your team of mechanics, electricians, engineers, and technicians who currently bear the burden of ensuring your facility runs smoothly. The basic idea is that leveraging these tools puts your team in a position to work smarter. They will be able to target problematic equipment before it fails, skip the guessing game of diagnostic inspections, prioritize work based on remaining equipment life data, and ensure appropriate spare parts are in inventory ahead of shutdowns.

Along with the technology trend, there is a more alarming trend in progress related to maintenance and reliability human resources. Industrial and manufacturing environments are becoming more automated, meaning there is more machinery to maintain. At the same time, fewer young people are entering maintenance-related fields of study or directly entering the workplace. The resulting reality is that we must maintain more motors, pumps, fans, gearboxes, bearings, compressors, and the rest of the equipment within plants with less people. The only way we can accomplish that task is to leverage technology to work smarter

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December 2020

and use maintenance management software to rationalize our planned downtime practices.

Though PdM solutions can become indispensable tools in your overall reliability strategy, implementing them can be a significant challenge. Solution providers have been through generations of development with a significant design focus on ease of use. Even so, not all sensor solutions are compatible with certain environments or applications.

When investigating PdM solutions, some of the features to evaluate are battery life, wireless communication range, IP and hazardous area ratings, alert/notification functionality, sensor size (for confined space areas), sensor temperature ratings, installation method, commissioning and setup process, scalability, and on.

The good news is that the market for PdM solutions is expanding, and providers are focusing on specific applications and/or equipment types in order to meet the needs of the market. As the offerings continue to expand and diversify, training and system integration could become significant factors to consider before implementation. A professional evaluation of your facility and a review of applicable PdM solutions to address specific needs may be the best place to start the journey into the future of maintenance where

downtime is always planned.

Two modern technology tools – maintenance management software and PdM/ CM solutions – can drastically improve maintenance and reliability efforts when used properly. Therefore, a company’s culture could have more to do with its success than any sensor or software solution. A cultural commitment must be made to fully leverage the functionality of maintenance and reliability systems, in order to generate and analyze asset management data.

That means believing in the value of data analytics, and training people to trust the results when trends are detected. Additionally, make sure to be grounded in the reality that virtually no process can run continuously without being maintained. A cultural commitment to reliability means building space in the schedule to take equipment offline for maintenance, and the only way to accurately plan downtime efforts is with a relentless commitment to data. MRO Justin Lesley, Industry 4.0 Innovation Manager at Motion Industries, directs IIoT strategy and partnerships related to the MRO industry. His career centres on operational efficiency supported by his Lean Manufacturing and Six Sigma certifications combined with his engineering credentials.

Photo: NanoStockk / Getty Images

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December 2020

WHAT’S NEW IN PRODUCTS ABB SafetyInsight ABB Ability SafetyInsight digital software applications support companies through the lifecycle of process safety management. The software digitalizes early engineering technology (ET) data to create a process safety digital twin, using this data to give context to data generated through IT and operational technology

(OT) systems.

SafetyInsight enables engineering data to be digitalized, and accessible by operation and maintenance teams.

The addition of IT/OT data provides near real-time updates. The suite has process safety dashboards to provide the information. www.abb.com

Endress+Hauser platform Endress+Hauser platform approach for real time monitoring of critical parameters and collection of true representative samples for lab testing.

With Promag flow measurement, the monitoring solution based on Liquiline platform provides risk mitigation to avoid incurring violations and pen A complete platform includes four Memosens sensors (for pH, turbidity, spectral absorption coefficient for organics and dissolved oxygen) connected to a Liquiline CM44x series

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For more product news, visit www.mromagazine.com/products

Schneider Electric TeSys island Schneider Electric TeSys island is a digital load management system, that digitally integrates multifunction motor starters into machine control panels. TeSys island features a catalog of TeSys avatars that act like a digital twin on top of the physical device.

In operation with EcoStruxure Machine solution, TeSys island minimizes machine stoppages by providing access and diagnostic data by generating pre-alarms when unusual electrical load behaviour is detected. Information can be accessed remotely. TeSys island provides device health, load level energy consumption, and application-specific protection data.

The system manages motors and other electrical loads up to 80A, and electrical and mechanical configurations can be updated throughout a machine’s life cycle. www.se.com

transmitter, with Liquistation CSF48 and CSF34 monitoring stations, and CA80 series colourmetric analyzers for phosphorus and ammonia. www.ca.endress.com

OZ Lifting Stainless Steel Trolley

Festo VTSA-F-CB Festo VTSA-F-CB, with serial communications added to existing parallel communications capability.

VTSA-F-CB’s internal bus system allows users to actuate up to 96 valve addresses, in four zones, on one valve terminal and one fieldbus node. VTSAF-CB can mix 18 mm and 26 mm valves on the same manifold, reducing size and cost of the manifold.

VTSA-F-CB features four CPX/ pneumatic interfaces: basic interface when safety control is not required, two integrated PROFIsafe versions, and a version that makes it possible for an external safety fieldbus module to

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directly control three pneumatic safety zones.

VTSA-F-CB configuration options include a pilot air switching valve, and a safety soft start/quick exhaust valve.

New vacuum generator VTSA-F-CB has an air saving feature with ejector pulse. www.festo.com

OZ Lifting Products LLC stainless steel push beam trolley, available in one or two ton capacities. The push beam trolleys fit most common I-, S- and W-beams. It is adjusted using supplied, in addition to an owner’s manual and test certificate.

The trolley does not require maintaining beyond that of a traditional steel product. Additional features include individual test certificate and serial number; stainless steel identity tag; antidrop plate; and precision ball bearing trolley wheels. The trolley is designed for use in corrosive environments. www.OZLiftingProducts.com

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The Podcast for MRO Professionals

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he podcast features conversations with industry experts about maintenance, reliability, and operations. Topics that are of utmost importance to MRO readers.

Previous guests and topics have included: Doc Palmer – Focus on Scheduling and Planning of Maintenance; James Reyes-Picknell – Managing Maintenance and Reliability; and Shawn Casemore – Engaging Your Employees in a Safety Culture. MRO

Mr. 0, The Practical Problem Solver

Having worked with maintenance and HSSE professionals for over 25 years, we see the struggles organizations have with data qualities. Inaccurate data causes a number of problems that range from safety to unnecessary downtime. Therefore, it is vital for any organizations to manage their maintenance data properly.

In this connected age, where technology advancements seem to always be at the forefront, it can be easy to lose sight of what business need underlies these innovations. What can be even worse is that managers and executives lose control of what really drives business – information. In its simplest form information leads to sufficient knowledge and ultimately drives decisions, and then actions, at all levels of any organization.

Decision making in asset management is driven in part by key performance measurements that are derived from transactional data through the work management processes. Underlying this data is the master data that exists for

every asset. It is well established that inaccurate master data can be the source of a broad range of problems including health, safety, and environment risks,

LISTEN HERE: www.mromagazine.com/podcasts/

regulatory compliance and reduced uptime. MRO - Richard Beer, TRO Maintenance Solutions

Photo: bernie_photo / Getty Images (Top) sesame / Getty Images (bottom)

Asset Information Management

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