Plant West March/April 20122012

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Volume 7, No. 01 >> Supplement, PLANT >> March/April 2012

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Energizing KEYSTONE Opportunities for

Canadian manufacturers

HIGHLIGHTS CBM goes wireless R&D boosts solar power PKL seeks fugitive emissions Software automates piping design

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Editorial

Finding energy consensus 6

A

lberta premier Alison Redford would like the other provinces to get together on a national energy strategy. That is, a provincially driven plan, not one imposed by Ottawa (the province is still peeved by the national energy program introduced by the Trudeau government in 1980 and cancelled six years later).

She contends the provinces need to find common ground concerning infrastructure objectives, targets and goals for greenhouse gas reductions and environmental standards.

It’s a good idea that could help to invigorate manufacturing, but it’s off to a rocky start.

Ontario premier Dalton McGuinty has telegraphed his enthusiasm for the idea by uttering the heresy that a strong oil sands means a high dollar, which hurts Ontario’s manufacturing and export sectors; ergo, he’d prefer a lower dollar to a growing oil and gas industry in the west.

Redford wasn’t pleased with McGuinty who has since tried to tap dance away from his buzz killing remarks, but the surly attitude is not making friends among the other resource-rich provinces.

You have to sympathize with poor old, have-not Ontario, reeling from the deterioration of its manufacturing base because of the stronger loonie, competition from abroad and tepid business conditions in the US, it’s primary market. And McGuinty is a bit cranky because the province is sporting an annual $16 billion-plus deficit that can only be tamed by making a lot of potentially unpopular cuts. No wonder he’s looking at the west’s energy bonanza as a welcome target to deflect attention away from the tight spot his big-spending Liberal government finds itself in back home.

Looking at on the ground conditions, the prognosis doesn’t appear to be all that promising for manufacturing, but to paraphrase Monty Python, it’s “not dead yet.”

Yes, there are formidable challenges. The sector has lost 500,000 jobs over the past decade, many of them in Ontario and it’s not creating a lot of new ones in line with increasing output.

But the energy economy presents opportunities for several provinces, especially Ontario.

The Canadian Energy Research Institute (CERI) notes in a report that Ontario enjoys the biggest share of oil sands benefits after Alberta – $63 billion in economic spinoffs and 65,000 new jobs over 25 years. Over the same period, the Canadian economy will tally $1.7 trillion worth of economic benefits.

Canadian Manufacturers & Exporters calls the energy resource sector a valuable source of new demand. Manufacturers may have to reorient their business models to poke their way into the global supply chains that serve energy developers, but the opportunities are there for those who succeed. And the rapid growth of the sector suggests there will be much reliance on North American suppliers who have built-in logistics advantage.

The challenge for companies, especially those serving other markets, is to get through the door but help is available at the annual National Buyer Seller Forum (www.nationalbuyersellerforum.ca). The event, to be held in Edmonton Oct. 2-4, brings potential suppliers together to form supply chain collaborations and learn from procurement specialists what it takes to win contracts. McGuinty is a supporter. The Ontario government sends a delegation every year consisting of politicos and company executives.

Instability in the Middle East and rising demand for energy as developing economies grow makes the development of Canada’s unconventional oil and gas resources a strategic imperative. Those resources will have to cross provincial and national boundaries to get to North American and Asian markets. By recognizing their common cause, Canada’s provinces will help ensure the rapid pace of energy development will also address concerns about environmental impact and lead to new and better ways to extract the resources. It’s all good – even for Ontario.

Joe Terrett, Editor Comments? E-mail jterrett@plant.ca.

Vol. 7, No. 01, March/April 2012 A supplement to PLANT Executive Publisher: Tim Dimopoulos 416-510-5100 tdimopoulos@bizinfogroup.ca Publisher: Michael King 416-510-5107 mking@plant.ca, mking@cienmagazine.com

District Sales Managers: Amanda Bottomley 416-859-4527 abottomley@canadianmanufacturing.com Catherine Martineau (Quebec) 647-988-5559 cmartineau@bizinfogroup.ca Deborah St. Lawrence 416-510-6844 dstLawrence@canadianmanufacturing.com Derek Morrison 416-510-5224 dmorrison@canadianmanufacturing.com Ilana Fawcett 416-510-5202 ifawcett@canadianmanufacturing.com

Group Editorial Director: Lisa Wichmann 416-510-5101 lwichmann@canadianmanufacturing.com

Market Production: Barb Vowles 416-510-5103 vowlesb@bizinfogroup.ca

Editor: Joe Terrett 416-442-5600 ext. 3219 jterrett@plant.ca

Circulation Manager: Diane Rakoff 416-510-5216 drakoff@bizinfogroup.ca

Assistant Editor: Matt Powell 416-510-5145 mpowell@plant.ca

Editorial Advisory Board: Robert Hattin, Hattin Holdings • Ron Harper, Cogent Power • Greg MacDonald, Wentworth International Services • Roy Verstraete, Anchor Danly

Contributing Editors: Ron Richardson, Steve Gahbauer Art Director: Kathy Smith 416-442-5600 ext. 3215 ksmith@plant.ca

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9 Features

>> TRENDS 6

ENERGY Manufacturing stands to benefit from Keystone and other energy projects.

>> INNOVATIONS 8

SAFETY PKL Technologies’ digital sensor package fine-tunes gas detection and monitoring.

>> SUSTAINABILITY 9

SOLAR CELLS University of Saskatchewan R&D focuses on strengthening the solar capture capabilities of photovoltaic cells.

>> OPERATIONS

10 MAINTENANCE Scanmetrics takes CBM wireless with a system that monitors equipment and component health.

>> TECHNOLOGY

11 PLANT DESIGN LICAD software allows planning and design of a pipe support system within minutes.

PLANTWARE Switches for harsh conditions from Wago.

12 PRODUCTS AND EQUIPMENT What’s new in industrial products, machinery and equipment.

Departments 4 4 5 14

PLANT Pulse Careers Events Postscript

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Departments

>> Industry View

>> PLANT PULSE West to lead GDP for two years The West continues to grow, despite economic uncertainty, according to the Conference Board of Canada’s Provincial Outlook-Winter 2012.

The report shows the four provinces are a attracting new arrivals and strong commodity prices will boost their economies over the next two years.

“The recent economic slowdown is now barely noticeable in Western Canada,” said MarieChristine Bernard, associate director responsible for the report from the Ottawa-based research firm. “Despite concerns over global growth and the lasting fiscal problems in Europe, growth in the Western Canadian provinces is expected to be a full percentage point stronger than in the rest of the country this year and next.”

The Canadian economy is to post GDP of 2.1% this year. The western provinces will meet or exceed that rate, while the other six will not top 1.9%.

Alberta will lead all provinces with growth of 3.3% this year and 4% in 2013. Global oil prices are expected to remain high, boosting construction and expansion of oil sands projects. By next year, the unemployment rate will drop to 4.5%.

Mining and manufacturing are strong in Saskatchewan, which is looking at matching Alberta’s unemployment rate. Growth will be 2.6% this year and 3.5% next year.

Manitoba’s agriculture, manufacturing and utilities sectors are expected to perform well in 2012, growing by 2.7% this year and by 2.6% in 2013.

Modest improvement in US housing will generate some gains for BC’s forestry industry but restrained public sector spending will dampen construction so the province can look forward to 2.1% growth this year and 3.6% in 2013.

Productivity up, GDP Growth down Canadian businesses improved their productivity faster than their counterparts in the US last year for the first time in nearly 10 years, according to Statistics Canada.

They posted a 0.7% gain in the fourth quarter of 2011 to end the year with 0.8% overall. That’s down from 1.5% in 2010.

In the US, productivity grew by 0.2% in the fourth quarter for a yearly total of 0.2%, down from 4% in 2010.

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Westport to develop NA truck engine

Investing $12M in HPDI project with unidentified partner VANCOUVER: Westport Innovations Inc. has signed an agreement with a global engine manufacturer to develop a heavy duty truck engine for the North American market featuring Westport’s high– pressure direct injection (HPDI) technology.

The Vancouver-based manufacturer of components that allow engines to burn compressed or liquefied natural gas withheld product details and the name of the engine maker. However, each partner will contribute to the Westport-led project. The company said it expects to invest US$12 million with the product launch set for 2014.

Westport has signed a supply agreement with engine-maker Cummins Inc. that will allow manufacturing of the Westport HD 15-litre engine at a Cummins manufacturing facility in Jamestown, NY. The term is for three years.

Westport and Cummins have also amended their joint venture agreement.

Cummins Westport Inc. had exclusive global rights to design, engineer and market mid-range natural gas engines based on Cummins diesel engines.

The new agreement will focus on North American markets for the 5.9- to 12-litre engines made at domestic Cummins plants.

Westport has also acquired Advanced Engine Components Ltd. in

Westport technology will go into heavy duty trucks for the North American market.

PHOTO: WESTPORT

Perth, Western Australia, for US$1.6 million.

AEC specializes in research, development and production of patented electronic fuel injection and engine management technologies for natural gas engines.

Our tax system is way ahead of G8 Empire wins $30M ‘attraction’ deal Canada places in top 15 of global rankings

WINNIPEG: Empire Industries Ltd. has announced its dynamic structures business unit has won a contract to design, engineer and manufacture the mechanical and structural systems for a mediabased attraction.

The $30 million-plus project is to be completed over the next two years.

Empire manufactures specialized engineered products and provides steel fabrication and installation services to the industrial and infrastructure markets in western Canada.

It has sold its KWH Constructors and Somerset Engineering business units for $1.4 million dollars. Empire said investment in domestic steel fabrication and erection outside of Alberta is being reduced to expand the engineered products businesses.

PwC study places Canada at 39 out of 183 economies.

PHOTO: THINKSTOCK

TORONTO: Canadian manufacturers are paying corporate taxes at a lower rate than much of the G8 and BRIC countries, according to a joint study by consulting firm PwC, the World Bank and the International Finance Corporation (IFC).

Paying Taxes 2012 places Canada with a business tax rate reduced to a low of 28.8% at 39 out of the 183 economies.

Canada’s rate is significantly lower than the US rate of 46.7%, which ranks our neighbour at 131. The global average is 44.8%.

The study measures the ease of paying taxes for a hypothetical small to medium-sized domestic business by assessing three indicators: number of tax payments per year; time taken to compile returns and submit tax payments; and by calculating companies’ total tax liability as a percentage of pre-tax profits.

Canada’s rank for the ease factor is 11th, which puts it at the top of the countries in the G8 based on the number of tax payments, the time it takes to comply and the total tax rate.

This also puts us ahead of the BRIC economies, where Russia and China rank at 102 and 121 respectively.

The study ranks Brazil the lowest for time taken to comply, placing it at 183 with 2,600 hours, compared to Canada’s ranking at 37 with 131 hours.

Canada is ranked eighth for number of tax payments (global average 28.5) and it takes 131 hours to comply with tax affairs here. The world average is more than double at 277 hours.

Another PwC study of CEOs worldwide reinforces just how important tax policy is when it comes to investing. Its 15th Annual Global CEO Survey of more than 1,200 business leaders in 60 countries shows 44% of them see it as a significant factor in site decisions compared to 17% who cited immigration policy.

>> Careers Logan International Inc. has named Robert Russell president of its Canadian operations in Calgary. The company manufactures tools for the energy industry. Russell, previously COO of Trinidad Drilling Ltd., will be responsible for Logan businesses that include Xtend Energy Services, Scope Production Development and Logan Completion Systems.

Marvin Romanow left his post as CEO at oil and gas producer Nexen Inc. in Calgary and Gary Nieuwenburg stepped down as the executive vice-president of the company's Canadian operations in a management shake-up. CFO Kevin Reinhart was appointed as interim president and CEO while the company searches for a permanent replacement for Romanow.

President and company director Brian Doherty has resigned from Carmen Energy Inc. in Calgary to pursue other interests. Tyler Rice was appointed interim president while the oil and gas exploration company searches for a permanent replacement for Doherty.

Connacher Oil and Gas Ltd. has appointed Peter Sametz, former president and COO, interim CEO. Gregory Boland has joined the Calgary energy company’s board. He’s the president, CEO and co-chief investment officer of West Face Capital Inc., an 11.7% shareholder of Connacher.

TriOil Resources Ltd., an energy exploration outfit in Calgary, has added Robert Herdman to its board of directors. He was a partner of PricewaterhouseCoopers in Calgary for 21 years and retired in 2010.

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Industry View << Departments

T-rex to prowl Alberta, on three wheels

>> Events

Roadsters get clearance for provincial roads

BOUCHERVILLE, Que: A Quebec manufacturer of a unique three-wheel motorcycle will finally see its products licensed to hit the road in Alberta.

The trikes retail – top end – at just under $63,000 and have met Transport Canada’s safety requirements since 2006, but Campagna Motors says it has taken until now to change the province’s legislation to allow them on the road.

These sleek roadsters powered by name-brand motorT-Rex RR ready to ride in Alberta.

PHOTO: CAMPAGNA cycle engines come in three models – the T-REX R ($56,499), T-REX RR ($62,850) and Vi3R ($51,499) – and are based on a threewheel reverse trike architecture with side-by-side cockpits.

“We can now fast track our business development in the central and western Canadian provinces,” said Michel Paquette, sales and marketing manager for Campagna Motors.

The trikes are manufactured in Boucherville.

$2B cold Lake expansion CALGARY: Imperial Oil Ltd. has approved a $2 billion expansion of the company’s Cold Lake operation in northeastern Alberta.

The Calgary-based petroleum company said the Nabiye expansion will add bitumen production of more than 40,000 barrels per day at Cold Lake.

The project will access 280 million barrels of recoverable reserves and is to start-up by yearend 2014.

The expansion will include development of a new steam generation and bitumen-processing plant, field production pads and associated facilities.

Imperial received regulatory approvals for Nabiye in 2004 and amended regulatory approvals were obtained in 2010 to improve the project’s environmental performance.

Improvements include a 170-megawatt cogeneration facility to enhance the plant’s energy efficiency and a reduced land footprint for field production pads.

The company describes the Cold Lake facility as the largest and longest-running in situ oil sands operation in Canada that includes four steam generation and bitumen production plants. The operation produced an average of 160,000 barrels of bitumen per day in 2011.

Titan Ligox automates aviation refuelling EDMONTON: Titan Logix Corp.’s Av-Stik level gauging and overfill prevention system automates aviation refuelling.

Av-Stick, the Edmonton company’s most recent addition to its Radar-Stik product line, delivers digital guided wave radar technology, an advanced controller using Organic LED (OLED) display technology, and plug and play wiring.

“The Av-Stik, with its CAN Bus based communication and Bluetooth capabilities will enable the aviation refuelling industry to more fully automate and integrate their refuelling processes,” said Titan Logix CEO Greg McGillis.

Titan Logix specializes in R&D and manufacturing of advanced fluid management technologies.

NPE 2012 SPi April 1-5, orlando Society of the Plastics Industry presents an International Plastics Showcase with technical presentations, keynotes, workshops and sustainability sessions. Visit http://www.npe.org.

LEAN 101 cME – innovation insights April 3, Prince Edward, Ont., May 3, Brampton, Ont. The 5 steps to lean thinking, how to use value stream mapping, takt time and visual factory, hosted by Creative Education April 3. Hosted by Taro Pharmaceuticals Inc. May 3. Visit www.innovationinsights.com.

MMTS SME May 14-16, Montreal Society of Manufacturing Engineers (SME) presents the Montreal Manufacturing Technology Show (MMTS). Visit www.mmts.ca. ultrasound World viii uE Systems May 14-17, Clearwater Beach, Fla. The Ultrasound World technology forum features presentations and short courses by users of ultrasound technology. Visit http://209.200.118.95/resources/ultrasound-world-viii-conference.aspx.

2012 cME National Lean conference cME June 4-7, Winnipeg Thought leaders and practitioners share their insights and perspectives on continuous improvement, hosted by Canadian Manufacturers & Exporters (CME). Download the details at http://mb.cme-mec.ca, Upcoming Events.

PTDA canadian conference PTDA June 7-9, victoria, Bc Power Transmission Distributors Association (PTDA) hosts this Canadian event featuring education sessions, an industry showcase and networking.

Visit www.ptda.org/CanadianConference.

AME chicago 2012 AME oct. 15-19, chicago The Association for Manufacturing Excellence (AME) presents this international lean conference featuring best practices from the best lean practitioners. Visit www.ameconference.org.

P2 Solar scores Bulgarian deal SURREY, BC: P2 Solar Inc. will develop a 4.95-megawatt solar power farm in Bulgaria with a potential 20-year gross revenue of $40.7 million.

The Surrey, BC solar power developer said the 15.1-hectare project has also signed a 20-year government power purchase agreement (PPA) and all the required approvals for grid connection.

It said Bulgaria has emerged as one of Europe’s most lucrative solar energy markets because of the country’s strong solar irradiation and its government feed-in-tariff program.

P2 Solar is focusing its development efforts on focus India, Europe and Canada.

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charging and more.

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Trends

>> Energy

Keystone What’s in it for us

Manufacturing stands to benefit from this and other energy projects.

BY: Matt Powell, Assistant Editor

T

ransCanada may have to drop the “XL” from its proposed $7.6 billion Keystone pipeline project.

After the proposed line that would carry more than 500,000 barrels of Canadian crude from Hardisty, Alta. to the US Gulf Coast was rejected by the Obama administration, the Calgarybased pipeline company has returned to the drawing board.

Now, it’s splitting up the nearly-3,500 kilometre super pipeline into two separate projects and going forward with permit applications to build a 902 kilometre line from Cushing, Okla. to the US Gulf Coast to relieve shortages of crude oil supply at refineries. The shorter pipeline is expected to carry a price tag of $2.3 billion.

“We are working with the US Army Core of Engineers to acquire the require permits to build that section of pipe,” says TransCanada spokesman Terry

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Cunha. “We will be pulling out a section of pipe from Cushing to the US Gulf Coast and are proceeding with the shorter pipeline as a separate project,” The company expects Keystone’s little brother to be operational by 2013.

Because of ongoing issues with the US government over the proposed route through Nebraska’s environmentally sensitive Sandhills region, the company has pushed the expected service date of the big pipeline to the back-end of 2015.

The project has also ensnared US President Barack Obama into a bit of a catch-22. He promised to alleviate US dependence on foreign oil while placing a massive emphasis on creating jobs, the latter of which would be accomplished should Keystone become reality. But now that his administration has rejected it, he is on the defensive as Republicans vehemently support the pipeline.

TransCanada, however, is so optimistic it will win Keystone approval that Cunha confirmed the company will re-apply

If it’s built, the Keystone XL pipeline would carry more than 500,000 barrels of oil sands crude a day to the US Gulf Coast.

PHOTO: TRANSCANADA CORP.

with a new route to ensure the other part of the $7.6 billion project gets built.

This means crude exports from the Alberta oil sands to the Gulf Coast refineries are still at least three years away. The pipeline will not only move half a million barrels of Canadian crude a day across the 49th parallel, it will also relieve US dependence on oil from Mexico, Venezuela and the Middle East.

Indeed, the pipeline project could turn into a white knight for another sector, struggling in both the US and Canada: manufacturing.

Getting it built The Canadian economy is driven by its resources, especially the massive oil and gas and energy investment in Alberta’s oil sands. A new report by Canadian Manufacturers & Exporters (CME) estimates energy and resources companies invested more than $85 billion in major capital projects in 2011. And there’s billions more on the way.

One potential spin-off of those investments would be to give Canada’s floundering manufacturing sector a much needed boost thanks to a potentially massive demand for fabricated products.

“The US understands that manufacturing should be the cornerstone of its economic development strategy to create high paying, high quality jobs,” says Jean-

Michel Laurin, CME’s vice-president of global business policy. “Canada’s sector needs to realize the opportunities the oil sands present. Manufacturers looking to expand need to have the energy sector at the top of their lists because of these massive investments.”

TransCanada says about 90% of the goods it needs to build the pipeline will be made by North American companies. It has already purchased finished pipe worth more than $800 million from US and Canadian manufacturers, estimating it will use 660,000 tons of steel for the 2,100 kilometre US portion of the pipeline.

The company says about 25% of the

>> Keystone job prospects There are 2,100 kilometres (1,300 miles) of pipeline to build in 17 segments. Workers will be needed for the following: • 500 construction workers per segment = 8,500 • 30 pump stations (100 workers per) = 3,000 • Workers for camp and storage tank construction = 600 • Management and inspection jobs = 1,000 TOTAL: 13,000

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finished pipe will come from Canadian suppliers; about 156,000 tons.

The Regina-division of Russia-based Evraz, one of the world’s largest vertically integrated steel and mining producers, has acquired contracts for the Canadianmade finished pipe.

But there’s still the 35,000 tons of unsourced steel that would make up other pipeline components such as valves, fittings, sheet steel for storage tanks, pumps and motors, all of which present major opportunities for struggling Canadian manufacturers.

Those opportunities translate into jobs, directly or indirectly. Numbers in the tens of thousands have been tossed around in all the Keystone hoopla, but TransCanada expects about 4,000 will be necessary to build the shorter pipeline.

Cunha says some of those jobs will come from TransCanada – positions such as project managers and engineers – but the majority will be hired on through local contractors and labourers. Not all of them will come from the US, though.

“Without a doubt, we want to ensure we’re building this project safely and effectively, so we’ll bring the most qualified people in to do the job, no matter where they’re from,” he says.

TransCanada doesn’t foresee any major regulatory resistance hampering the smaller project. The shorter line, Cunha adds, will help fill a shortage of crude supply to refineries already running under capacity because of constraints at the Cushing storage facility.

“We’re not an oil company, we’re a pipeline company and now we’re trying to do what our customers have asked us to do,” he says. “We’re building a pipeline to bring crude that doesn’t have a market to go to and bring it to the Gulf.”

Who wants it?

Meanwhile, Canada is sorting out regulatory issues related to Enbridge’s Northern Gateway pipeline. Very much like Keystone, the project has been fiercely denounced by environmental and social groups who foresee damaging effects of the nearly-1,200 kilometre twin pipelines from Bruderheim, Alta. to Kitimat, BC. One pipeline would bring 525,000 barrels of Alberta crude daily to tankers on the Pacific shore for export to China, the other would carry natural gas condensate in the opposite direction as a diluent in oil refining to reduce the viscosity of oil sands heavy crude coming in.

While not directly competitive, both Northern Gateway and Keystone XL offer export and economic rewards for Canada, but to objectors, they represent environmental and economic ruin.

Some argue the pipeline projects will boost oil prices to a point where they reduce purchasing power, while the undervalued loonie continues to impede manufacturing sales.

Alberta’s finance minister, Ron Liepert, says the Northern Gateway project will reveal who truly wants Canadian oil, and those customers exist across the Pacific Ocean.

“Quite frankly, we need to start paying

>> Sourcing pipes Keystone says 75% of the steel pipe will come from North America, with 660,000 tons needed to build US portion of the line.

• 50% of it will come from US-based Welspun (332,800 tons) • 24% of it will come from Regina’s Evraz (186,266 tons) • 16% from Italy’s ILVA (103,147 tons) • 10% from Welspun’s India subsidiary (69,457 tons) • Unsourced steel: 35,000 tons, $29 million TOTAL VALUE: $800 million

TransCanada says it has yet to secure contracts for pipeline components such as valves, pumps and motors.

PHOTO: TRANSCANADA CORP.

closer attention to who else wants it,” he told The Canadian Press. “No market is more important these days than Asia. Diversifying our markets to Asia is fundamental to our country’s national interest.”

But to whose benefit? A report by the Canadian Energy Research Institute (CERI) estimates Ontario will be the biggest winner outside Alberta, but that will amount to just 3.8% of additional economic activity and 10% of the direct and indirect jobs. The US states would capture four times the benefit of nonAlberta provinces.

Liepert has gone on record to suggest that 23% of all oil sands related jobs will exist outside Alberta, representing massive opportunities for companies across the country. “[Canadians] need to be thankful that we have all this investment going into resource development, because its great news when it comes to rebuilding the Canadian manufacturing sector,” says Laurin. “We have an opportunity to capitalize and to create high paying, sustainable jobs and also to work with the education system to develop young people’s interest in manufacturing and the energy sector, where there’s currently a huge skills gap.”

Ontario premier Dalton McGuinty recently laid some of the blame for his province’s diminished manufacturing sector on a high-value loonie fuelled by the west’s booming energy sector. He said he would rather have a lower loonie than a growing oil and gas industry in the west.

McGuinty has since been reminded by Alberta premier Alison Redford that of all the other provinces, Ontario is benefiting the most from oil sands development. There are currently 350 companies plugged into the Alberta’s resource sector.

The Keystone projects and the Northern Gateway offer additional opportunities. The message for manufacturers looking to diversify and grow their businesses is clear. Go west.

Change

Air…

PLANT WEST is evolving with a new look and enhanced editorial.

PLANT WEST and the CIEN technology section provide you with more comprehensive coverage of what’s new in technology, products and equipment.

Powered by CIEN, which has been providing product news to Canadian industry since 1940, this exclusive New Technology section features product news, application stories and case histories that will improve the production efficiency and competitiveness of Canada’s manufacturing and process industries.

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Comments? E-mail mpowell@plant.ca.

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Innovations

>> Safety

PKL Technologies in Edmonton beats an “open-path” toward environmental and safety applications with TDLAS.

One-man manufacturer: Perry Kain assembling his PKL TDLAS gas detectors in Edmonton.

PHOTO: FLAKSTAD

By Nordahl Flakstad

P

KL Technologies Inc. is a modest Edmonton manufacturer, but founder Perry Kain sees opportunities in the air for the Spectra-1 digital gas detector and monitor, the company’s main product.

The “open-path” device, employing tunable diode laser absorption spectroscopy (TDLAS), is already being deployed for environmental and safety monitoring to detect fugitive emissions and other gas releases.

Though he founded PKL in 2005, Kain has only focused full-time on the company since 2010. That’s when he secured space in the Edmonton Research Park (ERP), where the Advance Technology Centre offers technology start-up firms various supports, including space at below market costs. (See Innovation incubator.)

Apart from outsourcing some work to a computer programmer, Kain remains a one-man show. Credits would list him as CEO, designer and shop-floor assembler of the sturdy and compact instrument package that’s a bit larger than a shoebox.

It houses what Kain terms the “core” of the device – namely, a tunable laser diode spectrometer that uses an industrial embedded computer, along with a custom low-noise, laser diode driver circuit.

“Boutique” manufacturing suitably describes PKL’s operation. It could be seen as a throwback to days when meticulous watchmakers crafted timepieces one at a time in their workshops. Or maybe PKL is pointing toward a future where one-person manufacturing is feasible.

Compare boutique manufacturing to the transformation brought about by personal computers that have allowed many to run home-based businesses.

Kain concedes turning out a high-tech product as he does on his own would not have been feasible a few decades ago.

Then, almost invariably, manufacturing meant investing in design and machine tools to turn out products.

With a sales price of $24,000 – or about half that of earlier-generation analogue gas detectors – much of the PKL sensor’s value lies in its software, which can be readily installed by one person in a small production space.

Gas detectors have been around for years. In fact, Kain previously worked in Edmonton for a manufacturer of analogue gas analysers. While there, the University of Lethbridge physics grad sensed that, just as digitization had allowed for smaller phones, comparable advances could permit lighter (at 8.5 pounds, about half the weight of its analogue predecessor) gas detectors. More importantly, adapting digital process techniques to absorption spectroscopy – using light to determine the chemical composition of a substance by spectral lines emitted by elements – allowed for

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Fugitive

emissions

Digital sensors fine-tune gas

detection and monitoring refinement and updates to the sensor through programming rather than from changing hardware.

“In an analogue device, you have to make changes to resistors, capacitors and other components – something we don’t have to do,” Kain explains. “When you’re making changes in a digital device, you’re making changes in software, digital filters and the like. You re-program and it’s done. That makes development a lot easier.”

Keeping it simple Rather than make physical prototypes, as he did for analogue sensors, Kain uses 3D CAD design software SolidWorks – a faster and, over time, less-costly develop-

ment tool.

“My design philosophy is to keep it simple,” say Kain. “With the optical design and when you’re dealing with spectroscopy, by minimizing components, the less noise sources you have, the better the instrument performs and less it costs to make.”

Kain designs and then assembles the devices using off-the-shelf computer, power supply and other components, which are integrated with elements, notably the laser circuits that he solders.

“If you make 40 or 50 units a year, it would make more sense to outsource the boards, but I’m not there yet. If you’re doing 20 or less, it’s more cost-effective to spend the time and do it yourself.”

Although they could be moved,

historically gas detection devices, were designed to detect and analyze gas levels right at a monitor’s location. Traditionally sensors “sniffed” the targeted gases.

In contrast, PKL’s analyzers “see” the gas across an open path. A laser beam is tuned to reflect off a target up to a kilometre away and then bounces back to the main instrument for analysis. It can detect the presence of the targeted gas over a much wider area than a sitespecific sensor.

While Kain believes he has led the way, others are developing similar products, although he suspects “there are many engineers and people in industry who have no idea that you can monitor gas over long distances in this way.”

Existing Fourier transform infrared (FTIR) spectrometers assess numerous gases at once. But Kain notes the accuracy of these devices is limited. Furthermore, his gas-specific sensor does not generate false alarms and performs reliably even when unattended.

The parts on all PKL TDLAS units are identical except for the laser diodes, the critical gas-specific component, which Kain designs and installs to sense a particular gas (although a single laser diode handles carbon dioxide, carbon monoxide and hydrogen sulphide). PKL currently offers sensors for detection of about a dozen gases, including ammonia, methane,

Digitization makes PKL’s gas detectors lighter (8.5 lb.) and easy for single-person use.

PHOTO: FLAKSTAD

Innovation incubator

Edmonton Research Park supports tech start-ups

A

part from two lots still awaiting groundbreaking in the near future, the 87-acre Edmonton Research Park (ERP) is now fully developed.

However, an additional parcel of land (between the existing campus and the recently completed Anthony Henday Drive) is earmarked for future expansion.

The current campus includes three incubator properties managed

by Edmonton Economic Development Corp. (EEDC). The buildings are Research Centre One, the Advance Technology Centre and the Biotechnology Business Development Centre, (the current home of PKL Technologies Inc.). Together they accommodate about 40 start-up firms focusing on IT, clean tech, oil and gas and life science technologies.

The buildings incorporate office, research/laboratory and production space as well as meeting areas that tenants access to differing degrees depending on where they are on the start-up curve.

Through EEDC, the City of Edmonton subsidizes rents at 15% to 20%

below market prices for comparable facilities elsewhere in the city.

ERP also serves 14 larger organizations, such as Syncrude Canada and Schlumberger, with R&D activities in dedicated buildings.

Candace Brinsmead, EEDC vice-president of innovation and technology advancement, notes ERP provides much more than a roof overhead for start-ups. “Our slogan is ‘We’re More than Just Space,’ we are able to offer a lot of other services.”

Among those she lists are access within the incubator complex to AVAC, a provincial funding agency; the federal NRC-Industrial Research Assistance Program, and the Greater Edmonton Regional Alliance.

The latter, with Brinsmead as chair, consolidates a number of agencies that deliver various facets of start-up support.

The alliance links start-ups and larger firms with a view to forming alliances that may evolve into lasting business partnerships. www.edmonton.com/edmonton-research-park

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hydrogen fluoride, acetylene and ethane.

Different industries and environmental observers are potentially interested in different gases. For instance, aluminium producers might want a device to monitor hydrogen fluoride. Fertilizer firms and agricultural researchers may want to check ammonia levels.

“With ours being a laser-based instrument, we can set up a reflector 500 metres or a kilometre away, allowing monitoring of gas concentrations over huge areas,” Kain says.

Off to market Science and engineering is the easy part for Kain but he admits to being a reticent marketer. Despite this, he has generated sales to the likes of Agriculture Canada, which sees potential for the PKL system in detecting ammonia and methane in pig barns and bio-digesters.

A distributor in Italy contacted Kain and he has been dealing with another distributor in China without a formal arrangement: that's not a well-defined distribution network.

A TDLAS monitor is not something everyone “must” have and sales likely will remain confined to a pretty limited market. Kain foresees doubling his annual sale in each of the next few years.

“I’ve entertained the idea of finding the right business collaborator, someone with sales offices and the like, who might take some of the marketing burden off me,” he says.

Growth would likely mean emerging from the sparse basement quarters of the Edmonton Research Park’s Biotech Business Development Centre, where PKL moved in mid-2011 from the adjoining Advance Technology Centre incubator. Certainly being a tenant in the research park, which comes under the umbrella of the Edmonton Economic Development Corp., can facilitate networking and marketing. For instance, a PKL sensor has been used to monitor greenhouses gases at the state-of-the-art Edmonton Waste Management Centre, where landfill gases produce electricity fed into the energy grid.

As greenhouse-gas-reduction credits become more negotiable, it will be important to establish baselines and to quantify emissions over time. Through several major energy projects, Alberta has made a $2-billion commitment to carbon capture and storage (CCS). Again, Kain sees potential applications for his sensors in connection with CCS. While carbon capture proponents insist the CO2 injected into the ground will stay sequestered, opponents have claimed it may surface somewhere nearby. Using PKL equipment to watch for CO2 releases could provide the basis for a more measured argument.

Stepped up monitoring of injection sites would benefit PKL. Certainly Perry Kain won’t object to another open path – in this case toward more regulation.

Nordahl Flakstad is an Edmonton-based freelance writer. Contact him at nordahl@flakstad.edmonton.ab.ca.

Comments? E-mail jterrett@plant.ca.

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Energized,

Solar Cells << Sustainability

one cell at a time R&D focuses on strengthening solar-capture capabilities A University of Saskatchewan research team hopes to maximize dye-sensitive solar cells to near 50% efficiency.

By Matt Powell, Assistant Editor

A

team of researchers at the University of Saskatchewan are trying to improve the efficiency of solar cells, and after years of R&D to prove their theory, they’ve now got $492,000 to bring the idea to life.

Ron Steer, a physical chemist in molecular spectroscopy, and his team are trying to prove a process called photon upconversion will improve the energy-grabbing capabilities of the modern-day solar cell by Photon upconversion energizes low-energy infrared light, improving solar cell efficiency. making use of often wasted infra-red light.

PHOTO: THINKSTOCK “The idea is based on 30 years of fundais not an idea that’s over our heads – it’s completely feasible.” mental research by professor Steer,” says Ian Burgess, a chemAnd once it is, the technology could be in high demand. istry professor at University of Saskatchewan and member of According to Natural Resources Canada, 70% of Ontario’s Steer’s team. “That research led to a novel means in which we energy grid will need to be refurbished by 2030. The province’s can take light and turn it into electrical energy.” green energy incentives have also attracted billions of dollars in The team, which also includes University of Saskatchewan foreign investment and major manufacturing partnerships for researchers Tim Kelly, Matt Paige and Rob Scott, is working to companies such as Celestica and Enbridge. make organic photovoltaics, also known as dye-sensitized solar The technology could also have an impact on the amount of cells, stronger. land necessary to create the massive solar farms because if the Dye-sensitized cells are notoriously brittle, but by incorporattechnology works, individual cells will transmit more energy. ing a tougher material known as carbon nanotubes, the team Solar may be the fastest growing industry in the world, but hopes to develop an organic solar cell that’s not only stronger, it still produces less than 1% of the electricity generated. High but will transmit more energy than traditional, more expensive total system costs likely have a good deal to do with the slow photovoltaics. rate of adoption.

Research such as the University of Saskatchewan’s photon Energizing infrared upconversion investigations will improve solar cell efficiency Burgess says the crux of the research is taking infrared light and bring costs down, which will increase adoption rates. and turning it into something useful.

“Near infra-red light is too low in energy for eyes to see – we Comments? E-mail mpowell@plant.ca. feel it as heat,” he says. “It’s that light you can’t see that we’re looking to capitalize on. There’s a huge abundance of it.”

Even the best solar cells today – such as those used in spacecraft – are only about 40% efficient, while energy capture in consumer level photovoltaics is only about 12%. Both are also currently far too expensive to make a major market impact.

Tim Kelly says the team hopes to eventually maximize the Wind energy grows by 21% dye-sensitive cells to near 50% efficiency. espite an uncertain global economy, the world’s wind energy “In the summer, you put sunscreen on to protect yourself industry continues to boom. In 2011, global wind power capacity from ultra-violet light–that light with the most energy,” he says. grew by 21%, according to statistics by the Global Wind Energy Coun“But down on the other end of the spectrum you have infrared cil (GWEC), a global trade association based in Belgium. light – which your body senses as heat – that’s what we’re going A record 41,000 megawatts of wind power was installed in 2011, after. The question is: can we actually make it work?” bringing the total global capacity to more than 238,000 megawatts.

Thanks to the Natural Sciences and Engineering Research About 75 countries have commercial wind power installations, 22 of Council (NSERC), the team will have the opportunity to answer them more than one gigawatt. that question and become one of the 70 university teams across Canada’s sixth-place ranking comes from installations of more than the country that have been granted more than $30 million to1,260 megawatts added to provincial grids – an investment of $3.1 bilwards solar research. lion and the creation of more than 13,000 person-years of employment.

Steer and his team have been granted almost $500,000.

By the end of 2011, Canada had 5,265 megawatts of installed capac“The money is going to fund a three-year project to develop a ity, ranking it ninth for cumulative capacity. proof of concept photovoltaic device that uses the photon upconMore than 5,000 megawatts of wind energy projects are currently version technology to improve the efficiency of the traditional contracted for completion over the next five years. solar module,” he says. “Commercializing this idea in three years

>> Power

D

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Operations

>> Maintenance

CBM goes wireless Scanimetrics’ system monitors equipment and component health It measures strain, bolt tension, crack propagation, pipe integrity, fatigue and vibration.

By Steve Gahbauer

C

ondition-based maintenance (CBM) is all about machine health.

What affects machine health most are loading, stress, strain and fatigue.

These parameters need to be monitored because CBM relies on accurate failure predictions.

Still, many “solutions” don’t reliably predict when a machine will fail because monitoring produces high volumes of data, often collected in an unreliable way – information that needs to be under-

stood and then managed. There are also physical issues. There’s a wire connection between sensors and data collection units in current CBM monitoring systems that corrodes, breaks or gets ripped off many equipment types.

Scanimetrics offers a better way to monitor machine health through a series of wireless products that measure and monitor such important machine health parameters as strain, bolt tension, crack propagation, pipe integrity, fatigue and vibration. The key word here is “wireless.”

The company has developed a standalone, add-on wireless system for measuring the parameters in heavy equipment and components. This data can trigger maintenance events. The system, already used in mining and power generation equipment, consists of a portable display and control unit and a software

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The Edmonton-based company believes advanced technology drives change. It developed its small, standalone systems based on studies carried out at the University of Alberta and with financial support from Alberta Innovates Technology Futures.

The hardware includes a sealed sensor module that attaches to any: strain, vibration or crack propagation gauge; ultrasonic thickness, temperature, thermocouple, accelerometer or pressure sensors; and a master data capture unit connected to a computer. The modules operate as a mesh network relaying data between the master and its units, which are not directly reachable by the master. A 900 MHz RF frequency for the modules does not interfere with Wi-Fi 2.4 GHz signals.

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The system, sealed in an air vacuum epoxy compound, is built to IP67 standards and is intrinsically safe for explosive and harsh environments. The battery powered units operate within a - 40 to 50 degrees C temperature range and accommodate three channels with four megabytes of flash memory storage at 10 samples per second. Data is transmitted daily. The sensor pods are mounted to a surface either with spot welds or attached with epoxy. Once the sensor pod has been activated, it can be configured to provide one full year of operation.

Data is gathered wirelessly from the sensors and instantly processed by a user-friendly interface with real-time graphic data viewing. The software performs data translation and analysis and has an option for live data display or unattended logging.

The wireless strain gauge system – which will also accommodate crack sensors and vibration sensors – is fast and easy to install, non-intrusive and requires

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Scanimetrics systems are at work in mining and power generation operations.

walter.com

www.cienmagazine.com/rsc 103

PHOTO: THINKSTOCK

no operator intervention. Applications include monitoring of strain vectors and torque on rotating shafts, as well as metal fatigue and developing cracks in gear teeth and wind turbine blades.

The smart bolt and bolt tension system monitors all critical bolts continuously and takes precise tightness readings.

Applications include vibrating equipment, turbines and power-generating equipment, heavy mobile units, fans and other rotating machinery and flanges on pipelines.

The wireless crack propagation system detects micro-cracks in metallic objects and measures their expansion, which eliminates the need for visual inspections. It allows real-time monitoring of cracks and the evaluation of structural integrity of industrial equipment, bridges, roads, rails and buildings.

The wireless pipe integrity monitoring system measures and monitors the thickness and/or strain on permanently mounted pipes and takes pipe rotation angle measurements. It has a built-in signal conditioning for strain gauges and a temperature sensor for compensation. There’s also on-board storage for data back-up. Pipe intervals are optimized, pipeline life is extended and field failures as well as production losses are reduced.

Manufacturers are turning away from reactive and time-based preventive maintenance. Wireless sensing and data collection offers an alternative that will maintain machine performance and give them a competitive edge.

Visit www.scanimetrics.com for more information.

Steve Gahbauer, an engineer and Toronto-based freelance writer, is the former engineering editor of PLANT. E-mail gahbauer@rogers.com.

Comments? E-mail jterrett@plant.ca.

March/April 2012

12-03-19 2:13 PM

Plant Design << Technology

COMPLEX

piping supports AUTOMATING THE DESIGN PROCESS KEEPS IT SIMPLE LICAD software plans and maps out a pipe support system within minutes.

E

xtensive pipe systems that run through industry rely on complex support chains that ensure system functionality, safety and longevity.

Whether for refinery, petrochemical, power generation, emission reduction or other processing applications, these support systems protect pipelines from the stresses of seismic activities, wind loads and internal pressures such as thermal expansion.

Choosing and designing the right pipe supports can be challenging. Many systems include an array of products, ranging from hangers and supports to bearings, structural steel elements and attachments. LICAD, an advanced design program from Lisega Inc. USA, a Kodak, Tenn. manufacturer of support systems for piping, simplifies the entire process.

As a rule, the planning and design of complex pipe systems runs through numerous iterations. Inevitably, the design of pipe supports takes place at the end of the planning chain, even though they’re needed on site prior to the installation of the piping. This often puts a squeeze on support designers, and heightens the likelihood of orders being placed too late to meet delivery requirements.

Late or last minute pipe deliveries add pressure to the design and specification process, delay piping and equipment installation, and increase the risk of project cost overruns.

Sourcing pipe supports from catalogues is often tedious work that involves engineering expertise that may not be readily available. CAD software from pipe support suppliers would help, yet many programs involve a time-consuming design process that requires selecting various pipe support component parts, then copying

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and pasting them to design the support chain. 3D modelling of components is also labourious, involving the use of graphics software and conversion of illustrative elements.

The next generation of CAD software for pipe supports and load chains makes it much simpler to electronically design, spec and order the needed products all at one time.

Time savings The LICAD program automates the entire process. It provides a comprehensive design, ordering and pipe support tracking system for engineers, but can be used by architects, construction contractors and users who are not necessarily pipe support specialists.

The program references LISEGA’s 10,000 standard pipe support components to design standard pipe support configurations, and it creates customized products for special applications.

There are time savings on the logistics process side. For example, support data can be sent directly to the supplier’s computer system for order processing on the same day. This fits in well with tight Continued on page 12

CAD software makes it easier to design, spec and order pipe supports and load chains.

PHOTO: THINKSTOCK

>> Plantware SWiTchES hANdLE hArSh coNdiTioNS WAGO Corp.’s 852 ethernet switches operate between -40 to 70 degrees C in harsh process, energy, transportation and automation environments.

The 852-103 has a redundant power supply and a 9- to 48-V range. A top-mounted DIP switch sets an alarm relay to monitor loss of 24 VDC or port status. There are eight 100BASE-TX ports for copper connections, plus two 100BASE-FX SFP ports for fibre optic cables.

The seven-port 852-104 features Xpress Ring, which enables networks to recover from link failure within 50 ms.

Jet Ring provides redundant data-transmission routes during link failure/damage, with recovery occurring in less than 300 ms. Web-based management, port configuration, data packet prioritization, IGMP snooping and management access (security) are also available.

Both models are made with a robust, IP30 metal housing with anti-shock/vibration proprieties and overvoltage/ polarity protection. Approvals include CE, UL and UL 508.

WAGO, based in Germantown, Wis., is a manufacturer of spring-pressure connection technology. www.wago.us Wide temperature range.

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CIEN

Pipe support for upgrades Continued from page 11

order schedules. Time savings also allow for quality assurance and even revisions of the pipe support chain design in minutes.

The automated program is useful for replacing worn-out pipe supports or providing retrofits, especially when an upgrade makes more sense than replacing a failed support with a like-for-like or a component. When a refinery or petrochemical plant is upgraded with a new system, the program quickly identifies the necessary pipe support.

An automated design program should be compatible with associated software.

LICAD can be exported into popular 2D programs such as AutoCAD and 3D programs from software development companies such as Intergraph, AVEVA, Bentley and Navisworks.

The relevant data for individual support points is entered using a menu driven program control. Only six parameters are required to find the optimum solution: pipe diameter, pipe temperature, operating load, travel, installation height and support configuration.

From this input, the appropriate load chains are created automatically in fractions of a second. The program makes the optimum selection of supports – such as variable spring and constant hangers – simultaneously.

Economical solution Specific customer requirements, such as travel and load reserves in accordance with ASME, B 31.3, VGB or other codes, are taken into account and provided for by the corresponding input in a special menu. The program also ensures the most economical solution will be selected from the possible options.

The program generates true-to-scale drawings of the support chains, which are saved as complete assemblies and can be printed or plotted as a drawing at any time. The data also includes relevant details, including parts lists with weights and material, and if required, pricing and location plan.

The modular design system matches components by load bearing requirements, allowing an engineer or architect to design the pipe support system so the entire chain of products match the loadbearing requirements and are all compatible with each other. A broad range of operating loads and temperatures are covered within these product groups.

For more information visit www. lisega.com.

Digital pressure switches and transmitters.

Switch on ProSense ProSense digital pressure switches and transmitters from AutomationDirect handle air, non-corrosive gas and nonflammable gas applications.

The precision digital devices are fitted with a two-metre cable and include a three-colour LCD display, two digital outputs, an analogue output and a lockable keypad that permits three operation modes and six pressure unit conversions.

The switch/transmitters are also equipped with two vacuum-to-pressure ranges (-14.5 to 14.5 psi and -14.5 psi to 14.5 psi), selectable response times that eliminate chattering, and a fast zero reset.

AutomationDirect is a supplier of automation products based in Cumming, Ga. www.automationdirect.com

Comments? E-mail jterrett@plant.ca.

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Har-Flex PCB connectors.

Board bridging

Accelerometers can be submerged.

Keeps bearings rolling Bearings will run more smoothly with the Wilcoxon Research 712F-M4 and 997M4 high-frequency accelerometers from Meggitt Sensing Systems.

The side exit accelerometers are capable of continuous submersion and high frequency monitoring in low clearance areas with metric mounting.

A captive screw design with a safety wire hole adds protection in underwater applications.

More compact and lighter than general purpose or low-frequency accelerometers, they’re usable on smaller, lighter structures without mass loading, ensuring the sensor will not alter the vibration of the structure.

A glass to metal seal ensures true hermetic sealing at 100 psi.

The 712F-M4 houses a general purpose 100 mV/g vibration sensor with ±10% sensitivity, and operates from 3 Hz to 25 kHz. The 997-M4 comes with 10 mV/g output with ±5% sensitivity and a frequency range from 0.5 Hz. Meggitt Sensing Systems designs and manufactures the Wilcoxon Research line of vibration sensors at its facility in Germantown, Md. www.wilcoxon.com www.cienmagazine.com/rsc 3

Rockwell Automation’s latest version of RSLogix 5000 software delivers a singlecontrol infrastructure that scales to match the application needs of manufacturers and machine builders.

A key feature is its integrated motion

supply and other circuits in a single load.

With a width of only 12.5 mm, the 12-V models snap onto symmetrical DINrails for easy installation. There are also cross-connection busbars and an integral multi-colour LED status indicator.

Weidmuller, a manufacturer of circuit protection products, is based in Richmond, Va. www.weidmuller.com www.cienmagazine.com/rsc 6

Avoid motor overheating.

Voltage sensing

www.cienmagazine.com/rsc 2

Smaller single control This article is an edited version of a longer piece written on behalf of Lisega Inc. by Ed Sullivan, a Hermosa Beach, Calif. business writer.

on the EtherNet/IP network to the AllenBradley CompactLogix controller family.

RSLogix 5000 v20 used in combination with scalable, right-sized control system components scales from 200 to 10,000 I/O points using a single control platform and common user experience.

Rockwell, an industrial automation provider based in Milwaukee, Wis., says the software provides a single-development environment for its integrated architecture system, including: CompactLogix 5370 programmable automation controllers (PACs); Allen-Bradley ControlLogix and Allen-Bradley GuardLogix 5570 PACs; Allen-Bradley Kinetix 350 servo drive on EtherNet/IP; and Bulletin 1734 POINT Guard I/O Analog Input Module. www.rockwellautomation.com

Get connected with space-saving HarFlex PCB connectors from the Harting Technology Group.

Board-to-board and board-to-cable applications include insulation displacement connectors and right-angled configurations.

They’re based on a two-row, 1.27-mm grid and come in even-numbered models from six to 100 pins for optimal use of PCB real-estate.

Straight model mezzanine applications come in four different stack heights that bridge parallel PCB distances from 8 to 13.8 mm.

Harting Canada Inc. distributes the company’s industrial connection products. www.harting.ca

VTD high-performance transducers from NK Technologies sense voltage in a variety of DC powered installations, including industrial motors, battery chargers, photovoltaic arrays and wind generators.

The transducers detect below normal voltage conditions and voltage conditions that stress or damage starter components.

They’re used on circuits from 0-15 VDC to 0-600 VDC. Fully isolated and industry standard 4-20mA loop-powered outputs make use with existing controllers, data loggers and SCADA equipment easy and reliable.

NK Technologies, based in San Jose, Calif., makes current sensing, ground fault detection and power monitoring products. www.nktechnologies.com www.cienmagazine.com/rsc 7

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Breaker protection Weidmuller’s ESX10-T electronic circuit breakers, approved for use in Zone 2 hazardous areas, ensure selective disconnection of 12-VDC load systems in both factory and process control applications.

They also protect a For disconnecting wider range of systems 12-VDC load systems including battery-supplied circuits. Typical process applications are with remote, unmanned equipment where lightning or other transient voltage surges trip protection equipment and cause downtime. A remote control functionality gets the system back into operation with minimal losses.

Active current limitation responds much faster to overload or short circuit conditions than the switch-mode power supply.

The precise and fast-acting tripping mechanism provides protection to the power

Control circuit breakers.

Easy transfer power Russelectric’s medium-voltage (5-15kV) circuit breaker-type transfer switches and bypass/isolation switches are UL-tested, listed, and labeled under UL 1008A for use in emergency power systems.

They transfer electrical loads between normal and emergency power sources through controlled opening and closing of circuit breakers. Switch functions are controlled by a RPTCS programmable microprocessor-based control system.

The switches bypass power from live source to load if the transfer switch becomes disabled. They also isolate and deenergize the automatic transfer breakers for maintenance, testing, and repair.

Based in Wingham, Mass., Russelectric builds power control systems and equipment for computer and communications systems. www.russelectric.com www.cienmagazine.com/rsc 8

March/April 2012

12-03-20 7:00 AM

Products and Equipment << Technology Deep hole drill

Real time power supply status.

Need to do some deep drilling? That’s just the kind of job the Walter Titex UFL HSS-E grade high-speed drill from Walter USA LLC can do.

It has a parabolic flute profile with a 50% larger web and greater chip space than conventional twist drills, and employs a helix angle of 40 degrees rather than the standard 30 degrees.

Power predictor Maintenance crews will get real time power supply status and predict the replacement and maintenance cycle of the supply, using Balluff’s IP67 Heartbeat technology, The energy efficient systems are electrically durable (power boot 150% for four seconds), have a minimum service life of 15 years, they’re IP67 rated and vibration and shock resistant.

Balluff Inc., based in Florence, Ky., is a sensor manufacturer. www.balluff.com www.cienmagazine.com/rsc 9

Boosts tool life.

The Waukesha, Wis. toolmaker says the excellent chip formation and chip evacuation deliver high reliability. The drill also reduces or eliminates the need for pecking cycles even at maximum drilling depths. In many applications, drilling to a depth of 10-12xD without pecking is possible. In comparison, standard twist drills have to withdraw much earlier in order to allow for chip removal.

Heat resistance is high because of the 5% cobalt content and the drill’s TiAIN tip coating boosts cutting parameters and tool life.

It comes in diameters of one to 12 mm. www.walter-tools.com

Additional conductors available.

copper graphite brushes with copper alloy rings for each circuit.

Assemblies with additional conductors and/or amperage up to 75 A are also available. www.hannay.com www.cienmagazine.com/rsc 13

Secure your tools Snap-on Industrial’s Level 5 KTC keyless tool control storage system fully secures tools with an electronic keypad or by scanning an ID badge to gain entry into a tool box.

www.cienmagazine.com/rsc 11

Electronic keypad and scanner.

Snap-On Industrial, a manufacturer of tools and equipment based in Kenosha, Wis., says the KTC entry panel is incorporated into the top of the tool box for easy access and is powered by six D-cell batteries, which can last up to six months, plugged into an AC outlet. www.snapon.com/industrial www.cienmagazine.com/rsc 14

Single and double disc couplings Ruland single and double disc couplings are low inertia and torsionally stiff.

Single and double disc Low inertia, couplings are available in torsionally stiff. clamp and set-screw styles with bore sizes ranging from 3- to 30-mm and are used for precise zero-backlash systems with speeds up to 10,000 rpm.

Ruland Manufacturing Co., a manufacturer of precision components based in Marlborough, Mass., says the disc couplings are comprised of two black anodized aluminum hubs and multiple flat stainless steel disc springs.

Single disc styles work for compact installation. Double disc styles add a centre spacer to increase the misalignment capabilities. www.ruland.com www.cienmagazine.com/rsc 15

Accounting for changes in machine geometry.

Maintain constant zero MAG IAS has added W/Z zero tracking to its horizontal boring mills and HMCs with the Siemens 840D control for machinists programming collinear axes.

W/Z zero tracking for up to three collinear axes retrofits to existing MAG machines with 840D controls or added to new machines.

When one of the axes in a collinear set is repositioned in the part program, the toolmaker explains W/Z tracking accounts for changes in machine geometry.

It electronically tracks each axis of the set to calculate and maintain the correct part reference coordinate when one of the axes is repositioned.

For example, the Z-axis reference point is typically the spindle gauge line, while the W-axis reference point is a surface on the workpiece. After the W/Z relationship is established through part referencing, the control tracks all Z and W axis moves, displays their relationship and moves one of the two axes to maintain the correct gap position.

W/Z tracking is especially useful when the machine operator modifies the part program at the CNC to account for interferences, resulting in better visual access to the cutting zone.

The feature is now available on MAG horizontal machines, including floor-type (FT/FTR series) and table-type (RT, PT and MC series) boring mills.

MAG-IAS has a Canadian office in Mississuaga, Ont. www.mag-ias.com www.cienmagazine.com/rsc 10

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Cheminert C72.

Eliminate dead volume VICI Valco has made the Cheminert C72 UHPLC injectors for valve and fitting systems that minimize internal volume and eliminate dead volume.

A proprietary stator coating permits pressures up to 15,000 or 20,000 psi and all models are compatible with any VICI actuation option.

A microelectric actuator determines accurate positioning without limit switches or adjustment and an RS-232 or RS-485 interface handles computer control, but it can also be done manually.

The actuator is CE-certified and includes an autosensing 110/230 VAC to 24 VDC universal power supply.

The compact, lightweight package comes in 4-, 6-, 8-, and 10-port configurations with a choice of .004-, .006- or .010-in. bore. www.vici.com www.cienmagazine.com/rsc 12

Live power cable connection Hannay’s ECR1600 power rewind cable reel offers continuous, live power cable connection for direct wiring to a collector ring assembly through payout and rewind.

The Westerlo, NY-based reel manufacturer says the ECR1600 features a 45 A 3-conductor, 600-V collector assembly with #8 gauge wiring from the collector ring to the junction box.

The standard collector assembly has www.cienmagazine.com/rsc 104

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Departments

>> Postscript

C f

Canada is the global Barney Rubble

BY TODD HIRSCH

P

op culture is full of beloved characters and compelling heroes, but common among many of them is the lowly sidekick. Batman had Robin. Archie had Jughead. Frodo had Sam. The sidekick lives in the shadows – never quite as popular, but you root for them anyway.

Economically, the US has its sidekick: Canada. For reasons having to do with our history, our congenial attitudes and our self-effacing character, we’ve contentedly lived in America’s economic and

Everyone’s watching. We’re no longer plain old vanilla. Let’s seize the “opportunity in 2012 to promote the Canadian brand to the world… ” cultural shadow. To borrow from the old cartoon, America is Fred Flintstone and Canada is Barney Rubble. The affable next-door neighbour was always a tagalong to the brasher, louder Fred.

Until now.

The global economy has been evolving in unusual ways since the downturn of 2008, and Canada has the chance to climb out of its silly sidekick role. We’ll never be a larger economy than the US, nor can we

ever de-couple from its influence, but if we work at it, we have the chance to snag a few starring roles of our own.

Consider three recent developments that give Barney Rubble some leading man potential on the global stage.

First, the Bank of Canada Governor Mark Carney has gradually become a very influential person in the world. Because of some extremely shrewd manoeuvres just prior to the 2008 collapse, Carney

is widely regarded as a monetary policy rock star. Last fall he was appointed to head up the G20 Financial Stability Board. He’s blunt, confrontational, and speaks a language that everyone can understand. Yet he’s still 100% Canadian, so no one mistakes him for American Lite. That gives Canada some credibility and recognition in global financial circles.

Wallflower Barney is finally turning heads at global financial dance parties – but his dance card is still pretty empty.

Second, the favourable business tax environment in Canada has not gone unnoticed. The venerable Forbes Magazine list of best countries for business put Canada in the No. 1 spot in 2011, up from No. 4 the previous year, mostly because of low taxes and relatively little red tape.

Of course, not everyone is so pleased with lower corporate taxes. It’s a sore spot with the Occupy movement, not to mention some opposition parties that would raise, rather than lower, corporate taxes. But now it’s up to corporate Canada to prove the naysayers wrong. Hire more people and keep employees’ wage increases commensurate with profits and executive pay. If you simply squirrel away the extra profits, you’ll only paint larger targets on your corporate rear ends.

Flipping the bird Third, Canada is rich in what the world needs: natural resources, and the engineering prowess to extract them.

Hydrocarbon resources in the oil sands have been particularly conspicuous, not only for their abundance but also for the controversy around their extraction. Barney is getting some very negative vibes from various environmental lobbies and Fred Flintstone has just body-slammed him with the denial of the Keystone XL pipeline. The Northern Gateway pipeline is Barney flipping Fred the bird.

The world is both amazed and confused with the new Barney, but if the old saying is right, there’s no such thing as bad publicity. Suddenly, Canada has a chance to improve its environmental stewardship and turn negative attention into something extremely positive.

Financial street cred, a newfound business boogie, and the opportunity to prove he really can be a sustainable energy provider – Barney has it going on!

Everyone’s watching. We’re no longer plain old vanilla. Let’s seize the opportunity in 2012 to promote the Canadian brand to the world and forge trade deals with friends other than America. It’s up to us to show the world what we already know: that there’s so much more to Canada than being America’s goofy neighbour.

Todd Hirsch is senior economist with ATB Financial in Edmonton and Alberta business columnist with Calgary-based Troy Media. Visit www.troymedia.com.

Comments? E-mail jterrett@plant.ca.

14 PLANT WEST

March/April 2012

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B

C M

T

o G

T e h p o c o t o c

W t g n o h v b p

S n c c a q t m s t n

A i e

CCEMC provides clean tech funding to smaller businesses ment would be the best place for CCEMC to focus. We also confirmed that a relatively small investment could make a significant difference for these organizations.

Last year we announced plans to make $10 million available to organizations with less than 250 employees and in December we released our shortlist of 31 innovators. They’re diverse, and run the gamut from low-cost carbon capBY ERIC NEWELL ture, to high efficiency engines to CHAIR, CLIMATE CHANGE AND EMISSIONS MANAGEMENT CORPORATION cost-effective net zero home dehe CCEMC hosted the GHG sign that could be used in mainReduction Summit in Ed- stream housing production. monton last year to identify The CCEMC investment will be a opportunities to strengthen the maximum of $500,000 per project.

GHG management system.

We know SME’s have lots of great The Summit targeted three key ar- ideas to help reduce Canada’s eas: technology and innovation, greenhouse gas emissions. Our human and financial capital and shortlist of 31 projects was culled public policy. It included a series from 85 proposals – representing of breakout sessions to encourage a total combined project value of constructive discussion about how more than $205 million. organizations can help Alberta The CCEMC will announce which transition to a lower carbon econSME projects it will support with omy. [You can access the report on funding later this year, but each of ccemc.ca.] these projects has tremendous poWhile many of the recommenda- tential. tions from the Summit were for The shortlist of SMEs who have government, industry and the fibeen invited to submit full pronancial community, we identified posals to CCEMC is available on one area where CCEMC could ccemc.ca. have an impact in the near term: investing in clean tech projects lead Since 2007, Alberta companies by small and medium-sized enter- that annually produce more than 100,000 tonnes of greenhouse gas prises, or SMEs. emissions are legally required to SMEs who focus on clean tech- reduce their greenhouse gas intennology aren’t always able to ac- sity by 12 per cent. One complicess the necessary capital. Larger ance option is to pay into the Clicorporations have deeper pockets mate Change and Emissions Manand can generally finance the re- agement Fund at $15/tonne. quired research behind the innovation. It made sense for CCEMC to The CCEMC is a not-for-profit make some funds available just for organization whose mandate is to smaller organizations and support establish or participate in funding for initiatives that reduce greentheir efforts to develop clean techhouse gas emissions and support nology projects. adaptation. The CCEMC invests in After talking to stakeholders we discovery, development, and operidentified that SMEs who were in ational deployment of clean techearliest stages of project develop- nologies.

THERE’S A CLIMATE FOR CHANGE

T

The Climate Change and Emissions Management (CCEMC) Corporation is committed to investing in bold ideas that support Alberta’s transition to a lower carbon future.

We reinvest funding into innovative projects that advance clean technology, support energy conservation and efficiency, and assist carbon capture and storage.

The CCEMC is an Alberta based independent not-for-profit organization.

Learn more at ccemc.ca.

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THE WAY CAM WORKS:

KEEP THE THIRST TO BUILD, CREATE AND MAKE.

CAM MARSHALL President and CEO, Global Flow Inc.

BUSINESS BANKING IS ABOUT A SHARED PERSPECTIVE. At Canadian Western Bank, we see the world the same way as our customers.

As a result, we take the time to understand your business and provide banking solutions suited to your business needs. Discover insights and learn more at theworkingbank.ca. www.cienmagazine.com/rsc 107

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