MRO November 2018

MAINTENANCE CHALLENGES IN THE OIL SANDS ORE PREP PIT INTELLIGENT NETWORK SURVEILLANCE USE IN MINING IS CRITICAL FOR SAFETY AND PRODUCTION BENEFITS OF BEARING REMANUFACTURING Vol. 34, No. 5

November 2018

PEMAC HOSTS MAINTRAIN CONFERENCE IN OTTAWA

MISSION CRITICAL

Emergency Power Upgrades Completed

WHAT’S NEW SWITCHES MONITORS INDEXERS MOTORS LUBRICATION IIOT

3 Machinery and Equipment MRO

MAINTENANCE, REPAIR AND OPERATIONS

NOVEMBER 2018

Vol. 34, No. 5 Established 1985 www.mromagazine.com www.twitter.com/mromagazine Mario Cywinski, Editor 226-931-4194 mcywinski@annexbusinessmedia.com Contributors Mark Campbell, Philip Chow, Keith D'Sa, L. Tex Leugner, Douglas Martin, Ian Miller, Peter Phillips, Brooke Smith Michael King, Publisher 416-510-5107 mking@annexbusinessmedia.com Mark Ryan, Art Director Barb Vowles, Account Co-ordinator 416-510-5103 bvowles@annexbusinessmedia.com Beata Olechnowicz, Circulation Manager 416-442-5600 x3543 bolechnowicz@annexbusinessmedia.com Tim Dimopoulos, Vice-President tdimopoulos@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 CIRCULATION email: blao@annexbizmedia.com Tel: 416.442.5600 ext 3552 Fax: 416-510-6875 or 416-442-2191 Mail: 111 Gordon Baker Rd., Suite 400, Toronto ON M2H 3R1 Subscription rates.

Canada: 1 year $63.50, 2 years $101 United States: 1 year $108 Elsewhere: 1 year $123.50 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.

Annex Privacy Officer Privacy@annexbusinessmedia.com, 800-668-2374 No part of the editorial content of this publication may be reprinted without the publisher’s written permission © 2018 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.

PEMAC

Industry events alive and well

R

ecently, the Plant Engineering and Maintenance Association of Canada (PEMAC) held its annual conference, MainTrain, at the Brookstreet Hotel in Ottawa. This was my first time being a part of the conference, and it was definitely time well spent. Being able to network with those in the industry was invaluable. Learning from experts at the workshops and sessions, as well as speaking to companies and maintenance professionals, helped me to learn a lot about the MRO world. Our full recap of MainTrain is on page 8.

Thank you to all those who attended the MRO roundtable and to the facilitators that helped to make it happen. We’ll have an article on the roundtable in our December issue.

Another show we cover in this issue (page 6) is the International Manufacturing Technology Show (IMTS), which was held at McCormick Place in Chicago. I’ve been to many trade shows, conferences and symposiums, but this had to be the biggest in terms of scale. In all, more than 2,500 companies exhibited at the show, with almost 130,000 registered attendees. For those who wanted to show their products to a large group of people, this was definitely the show to do it.

Our cover story on page 26 looks at how TELUS completed a new standby generation plant at its mission-critical network facility in Vancouver. Three authors cover the process of the project: Philip Chow, Peter Formosi and Matthew Walker.

As the November issue focuses on the resource sector, we cover a cross-section of relevant topics. First, Douglas Martin looks at Mining–Conveyor Pulley Bearing Sealing, and how to best keep a belt conveyor running without issue (page 16).

Next, Ian Miller looks at the maintenance challenges within the oil sands ore prep pit on page 18. Canadian oil sands definitely have unique challenges when it comes to maintenance, and ensuring everything runs smoothly is always top of mind.

On page 32, Mark S. Campbell looks at the benefits of remanufacturing bearings instead of replacing them with new ones. And Keith D’Sa takes a look at how intelligent network surveillance (INS) is critical for safety and production in the mining industry. To find out how INS can help, read our story on page 22.

In this issue, we also cover learning management systems (LMS), which allow training and resource documents to be maintained electronically. Peter Phillips breaks down what you need to know about LMS on page 12 in his Maintenance 101 column.

As always, we also have our Industry Newswatch, Product News, MRO Quiz, Spare Parts and more.

If you have any questions or comments, please don’t hesitate to contact me at mcywinski@mromagazine.com. MRO

Good day,

Mario Cywinski Editor

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.

goo.gl/BL26Qo

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: goo.gl/o2cwdF

»» SKF Portable Induction Heater TIH series The TIH series combines high heating capacity with portability. Heat is used to expand the bearings inner ring before placing on the shaft, as the bearing cools a stronger interference fit is the result.

»» 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.

goo.gl/WrkTMQ

goo.gl/TOSupQ

»» SKF SYSTEM 24 Single Point

»» 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.

goo.gl/zw7223

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

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

SKF.CA

goo.gl/1gpzZZ

5

5

C O N T E N T S

Machinery and Equipment MRO

November 2018

in this issue

Departments

Cover Story

Editor’s Notebook / 3 Industry Newswatch / 6 Business Briefs / 11 Maintenance 101 – Learning Management Systems / 12 What’s Up Doug? – Mining - Conveyor Pulley Bearing Sealing / 16 MRO Quiz – Biodegradable Lubricants / 20

26

Spare Parts / 38

Mission Critical Emergency Power Upgrades

TELUS completes integrated project to build a new standby generation plant.

Product News What’s new in products / 36

PEMAC Hosts MainTrain Conference / 8

Maintenance Challenges / 18

Plant Engineering and Maintenance Association of Canada recently held its MainTrain conference in Ottawa.

Ian Miller speaks to maintenance challenges in the oil sands ore prep pit.

Intelligent Network Surveillance / 22

Benefits of Bearing Remanufacturing / 32

INS use in mining is critical for safety and production.

Mark Campbell looks at when it makes sense to remanufacture bearings.

Cover Photo by Philip Chow.

6

6

I N D U S T R Y

N E W S W A T C H

Machinery and Equipment MRO

November 2018

IMTS 2018 BREAKS RECORDS

BY MARIO CYWINSKI

T

he 32nd annual International Manufacturing Technology Show (IMTS) 2018, put on by The Association For Manufacturing Technology (AMT), was a record setter.

For 2018, IMTS had 129,415 people registered, offered 1,424,232 square/feet of exhibit space, and included 2,123 booths and 2,563 exhibiting companies.

IMTS allowed those in the industry to network with exhibitors, find out about new products, and see where manufacturing technology is heading. Using all four buildings of McCormick Place in Chicago, the show truly had something for everyone in the industry.

“Connectivity, the digital transformation of manufacturing, automation, additive manufacturing and a strong

economy drove record numbers at IMTS 2018,” said Peter R. Eelman, Vice President – Exhibitions and Business Development, AMT. “Digitization collided with a robust manufacturing industry to create our most dynamic show ever.”

HANNOVER MESSE USA (with four co-located shows: Integrated Automation, Motion & Drives USA; Surface Technology USA; ComVac USA; and Industrial Supply USA) had 510 exhibitors, as well as a Solutions Theater, that hosted 60 learning sessions.

“HANNOVER MESSE USA and IMTS bridge the gap between Silicon Valley technology and main street manufacturing. People find technologies here that change the spaces we work in,” said Douglas K. Woods, President, AMT.

IMTS also featured a conference component that offered many sessions presented by industry experts and attended by 2,500 visitors.

Further, a Smartforce Student Summit had 23,000 registrants and gave students the chance to experience different jobs available in manufacturing.

“The national conversation around STEM education has had a positive influence on our ability to attract more schools to the Student Summit,” said Greg Jones, Vice President of Smartforce Development, AMT. “Students engage with the people who are in those manufacturing jobs right now, as well as see the technology and equipment they would use on the job. Technology is making manufacturing careers cool again.”

EXXONMOBIL HOSTS PANEL FEATURING TONY STEWART AT IMTS 2018 ExxonMobil held “The Winning Advantage: Lessons from the Stewart-Haas Racing CNC Shop” panel discussion at the International Manufacturing Technology Show (IMTS) 2018 in Chicago recently.

“Machine shop operations that support professional motorsports teams like Stewart-Haas Racing face distinct challenges – every job is unique and deadlines are set in stone – but a lot of their practices and strategies can be applied by other professional shops,” said Alan Suan, North America Commercial Lubricants Advisor, ExxonMobil.

The panel discussion featured NASCAR champion Tony Stewart; Ray Salazar, Equipment Builder Engineer, ExxonMobil; and Brad Harris, Director, SHR CNC Operations. It was moderated by Derek Korn, Executive Editor, Modern Machine Shop.

“We’re excited to partner with Stewart-Haas Racing – one of the most successful teams in NASCAR – to provide machine shop operators from around the country with a forum to hear from the team’s CNC experts so they can identify winning advantages for their own

businesses,” said Suan.

The discussion looked at best practices and challenges that machine shops face, and allowed attendees to have insights into how to develop winning equipment and shop management strategies, as well as cultivate partnerships with suppliers that enhance success.

The discussion was followed by a Q&A session as well as an autograph session with Stewart.

Photo credit: Mario Cywinski

BY MARIO CYWINSKI

I N D U S T R Y

N E W S W A T C H

Machinery and Equipment MRO

7 November 2018

NTN Celebrates Centennial

BY MARIO CYWINSKI NTN held a gala celebration recently at the Omni King Edward hotel in Toronto to celebrate its centennial, as well as 50 years of operations in Canada.

“We are so proud of this milestone,” said Paul Meo, CEO and President, NTN Bearing Corporation of Canada. “NTN has achieved 50 years of steady growth in the Canadian market and 10 decades of global innovation. Our longevity is a credit to our employees, whose dedication and commitment are key to our competitiveness.”

Special guests in attendance included Hazel McCallion, former mayor of Mississauga; Takako Ito, Consul-General of Japan in Toronto; Hiroshi Ohkubo, President, NTN Corp.; and Paul Meo. Also on hand was the Right Honourable Justin Trudeau, Prime Minister of Canada.

“NTN is a leading example of a long-standing Japanese manufacturer in Mississauga that continues to introduce new innovative products to Canada,” said McCallion, adding that “the 100th anniversary of NTN’s founding is a tremendous milestone achieved in the competitive world of global business.”

NTN was established in Canada in 1968 to help support local sales and manufacturing of NTN bearings in the Canadian market. NTN is the world third largest bearing manufacturing and has over 68 plants globally.

“Motion Canada is all about partnership – with our employees, customers, communities and our suppliers,” said Dermot Strong, President, Motion Industries (Canada) Inc. “We consider NTN a world-class partner for a number of reasons, but in particular, their program execution drives mutual growth and profitability like no other supplier we work with. That’s why we’ve enjoyed such a long and prosperous relationship with NTN, and that’s why we’ll continue to partner with NTN well into the future.”

Special guests were on hand at the celebration.

Prime Minister Justin Trudeau.

NTN has a range of bearings, constant velocity joints, and other precision industrial and automotive equipment. It provides bearing services, which include technical support, maintenance and reliability services, engineering consulting and training.

“NTN’s impressive history of building strong industry relationships has contributed to the success of many companies worldwide, including Wajax,” said Justin Warren, Vice President, Marketing, Wajax. “We congratulate NTN for their 50 years of service to Canadian industries and for reaching the impressive milestone of 100 years in operation.”

EMC Hosts Woodland Classic

BY MARIO CYWINSKI Excellence in Manufacturing Consortium (EMC) held its 16th annual Woodland Classic golf tournament at Rebel Creek Golf Club in Petersburg, Ont. “Thanks to everyone who participated in EMC’s 16th Annual Woodland Classic where we brought together over 100 manufacturers and industry experts to share best practices, attend plant tours, network and connect with their manufacturing peers from across Canada,” said Shawn Casemore, President, EMC. Hands-on plant tours were available in the morning for those attendees who wished to participate. Two plants were visited: Ontario Drive and Gear Ltd. in New Hamburg, Ont., and Chrima Metal Fabrication in Stratford, Ont. Over 100 people played 18 holes of scram-

Carts were ready to go for the EMC Woodland Classic. (Insert) Shawn Casemore, President, EMC, speaks to the crowd.

ble best ball, and took in lunch and a buffet dinner in the afternoon. With a score of 15 under par, the winning team was George McCarter, David Lang, and Adam Borisko and John Atherton from Apri Insurance Solutions.

EMC also announced its Advantage Through Excellence Conference, which will take place from October 8 to 10, 2019, in Vaughan, Ont.

8

8

I N D U S T R Y

N E W S W A T C H

Machinery and Equipment MRO

November 2018

PEMAC Hosts MainTrain Conference in Ottawa

BY MARIO CYWINSKI

EXHIBITOR SHOWCASE Part of the conference was an exhibitor showcase, which featured a wide variety of sponsors and exhibitors that are of importance to the industry. It was opened with a networking reception that allowed delegates to interact with exhibitors, sponsors and other delegates. Vend-

er bingo gave each delegate a bingo card to have each exhibitor sign and have a chance to win a prize. Finally, the Author’s Corner allowed delegates to speak one on one with select authors. They included James R. Picknell with Jesus Sifonte, Suzane Greeman, and Susan Lubell.

KEYNOTES. SESSIONS AND WORKSHOPS Each day of MainTrain featured a welcome from a sponsor as well as a morning keynote. Keynote speakers were Susan Lubell, National President, PEMAC (presented the opening keynote); Michael Rosenberg, President, WPV Corp. (presented Redefining Maintenance – A Flexible Thinker's Approach); Marc Rene de Cotret, Director of Service Transfor-

Several awards were presented at the dinner.

mation, City of Ottawa (presented The Role of Digital in an Innovative City); and Mike Crowell, Director of Maintenance Pulp and Paper Division, Irving Pulp and Paper Ltd. (presented Accelerating Management Talent in Partnership with PEMAC).

Sessions and workshops were the bulk of MainTrain; it allowed attendees to gain knowledge on a variety of topics that were offered, and were led by industry experts.

AWARDS As part of MainTrain, PEMAC held an awards dinner at the Canadian War Museum in Ottawa. The first-ever PEMAC Maintenance Team of the Year – Large Organization award was presented to

Keynote speaker Michael Rosenberg, WPV Corp.

Keynote speaker Marc Rene de Cotret, City of Ottawa.

Photo credit: Mario Cywinski (Top image: PEMAC)

P

lant Engineering and Maintenance Association of Canada (PEMAC) recently held its MainTrain conference at the Brookstreet Hotel in Ottawa, Ontario.

The theme for 2018 was Connect, Learn, Contribute. The event hosted nearly 200 attendees with 37 total presentations, 33 exhibitors (including sponsors) and an awards gala.

I N D U S T R Y

9

N E W S W A T C H

Machinery and Equipment MRO

Cameco Port Hope Conversion Facility. The Sergio Guy Memorial award was presented to Dick Olver. Also presented were the 2018 Capstone Awards. John Colwell, Maintenance Supervisor, Molson Coors, won the Best Maintenance Management Professional (MMP) Capstone Project: Technical Focus Award.

“This capstone project was comprehensive and well prepared. John’s commitment and attention to the course content and subsequent application of the material was impressive,” said Brian Malloch, MMP instructor and nominator of this capstone project.

The 2018 Best MMP Capstone Project: Business Technical Focus was awarded to Sameh Abadir, Maintenance and Reliability Engineer, Skjodt Barrett Foods.

“In my current position, I have been able to apply learnings from the MMP program, including RCM, RCA, work management and financial analysis, in order to improve asset reliability and performance within my organization.

"The skills and relationships I have built because of the program have enabled me not only to advance in my career, but also to directly apply the learnings within my organization. I am honoured to receive this award and look forward to upholding the excellent perception and reputation of the profession,” said Abadir.

The 2018 Best Asset Management Professional (AMP) Capstone Project was won by Tonnie Trim, Asset Data Supervisor for Maintenance Management and Systems Group, at Enbridge.

“This capstone demonstrated a complete and comprehensive Holistic Asset Management approach to delivering value to the organization. Tonnie’s capstone project related to an Amine Filtration System and described how it was clearly in support of, and critical to, more than one strategic objectives,” said Cliff Williams, Maintenance Manager, ERCO Worldwide, and AMP instructor.

November 2018

The exhibitor showcase allowed those in attendance to network and get information they need.

INTRODUCING THE NEW

® touch OPTALIGN THE LASER ALIGNMENT GAME CHANGER

Optimize the speed, ease and precision of all your daily alignment jobs with PRUFTECHNIK’s OPTALIGN® touch Notable features include: 5-axis measurement system with sensALIGN 5 laser/sensor technology Simultaneous Live Move for real-time horizontal & vertical corrections Pass Mode for uncoupled shafts that cannot be stopped at definite positions ... and many more

www.optalign-touch.com PRUFTECHNIK Inc. | Philadelphia | Montreal | 1-877-778-3832 | info.na@pruftechnik.com

MRO_Sept_Pruftechnik.indd 1

2018-08-30 11:54 AM

10

10

I N D U S T R Y

N E W S W A T C H

Machinery and Equipment MRO

Emerson to Acquire Intelligent Platforms Emerson has agreed to acquire Intelligent Platforms, a division of General Electric (GE). Intelligent Platforms’ programmable logic controller (PLC) technologies help Emerson to provide its customers broader control and management of their operations. Terms of the deal were not disclosed.

The acquisition expands opportunities for Emerson in machine control and discrete applications across process industries and target hybrid markets, such as metals and mining, life sciences, food & beverage and packaging. By interfacing Intelligent Platforms’ PLC technology with Emerson’s leading distributed control systems, customers will be able to connect “islands of automation” within the plant to further enhance operational performance, safety and reliability.

Both Emerson and Intelligent Platforms are focused on leveraging automation technologies to drive digital transformation in their end markets. Intelligent Platforms recently developed a new family of cloud-connected controllers and devices to enable smarter plants, a strong complement to Emerson’s focus on digital transformation and the Industrial Internet of Things through its Plantweb digital ecosystem.

The acquisition is expected to close in the first half of fiscal 2019, subject to regulatory approvals, GE’s consultation with employee representatives where required and other customary closing conditions.

CONSULTING ENGINEERS OF ONTARIO NAMES NEW BOARD Consulting Engineers of Ontario (CEO) announced a new board of directors at its annual general meeting (AGM) at Blue Springs Golf Club.

For 2018–19, the Board of Directors are as follows: Directors Officers • Jeremy Carkner, Morrison Hershfield • Steve Dyck, SNC-Lavalin Inc. Vice PresiPrincipal & Director – Chair dent Ontario, Government Relations • Christine Hill, Cole Engineering Group • Khaled El-Dalati, HDR Inc. Vice President Ltd. Business Development, Leader, • Karen Freund, Jacobs Vice President • Don Holland, Stantec Consulting Ltd. Vice Water Practice – Chair Elect • Bill Allison, Dillon Consulting Ltd. President, Water Partner – Governance Chair • Steve Pilgrim, McIntosh Perry Assistant • Joe Sframeli, WSP Canada Inc. ExecVice President, Transportation utive Vice President, Infrastructure – • Tom Richardson, R.V. Anderson AssociTreasurer ates Ltd. Chief Structural Engineer • Rex Meadley, C.C. Tatham & Associates • Brian Ruck, GHD Group Ltd. Principal, Ltd. President & Chief Engineer – Past Vice President, Transportation Chair • Ron Scheckenberger, Wood Principal, • Bruce Matthews, CEO Chief Executive Senior Water Resources Engineer Officer – Corporate Secretary The AGM was followed by CEO’s annual golf tournament.

Beckhoff Automation Opens Office in Laval Beckhoff Automation Ltd., has opened a new office in the Greater Montreal area, in Laval, Que. This is the second Beckhoff Automation office in Canada, and is a 2,223-sq-ft facility that allows for Beckhoff to supply and support manufacturers, machine builders and tech companies throughout the region.

The facility offers collaborative space for Beckhoff customers and employees to develop innovative automation and control projects. A dedicated training room is available for customers to increase their engineering knowledge of Beckhoff PC-based control solutions and to enhance programming expertise in areas such as PLC, motion control, safety technology, IoT connectivity and more. Beckhoff Automation’s Canadian headquarters are located in Mississauga, Ont.

November 2018

OMRON CANADA MAKES APPOINTMENTS Omron Canada Inc. has announced new appointments.

Michael Joaquin has been named Safety Services Specialist. Joaquin will be responsible for Omron’s strategic and tactical actions to increase sales within all of the company’s key industries, including automotive, food, beverage, packaging, pharmaceutical and infrastructure and government. He will report to Brett Lupton, Sales Manager, Advanced Sensing and Safety.

He is a professional engineer with more than 17 years of career experience, most recently as a consultant with a practice focused on pre-start health and safety reviews, HAZOP, hazard and risk assessment, design and implementation of safeguards, and arc flash assessment.

Joaquin has held in-house engineering, project management and engineering management roles in the automotive manufacturing sector. He was also a member of the technical committee for CSA Z432-16 “Safeguarding of Machinery.”

Joaquin holds a Bachelor of Engineering in Electrical Engineering from Ryerson University.

Bashar Abuhamdan has been named Account Manager, Southern Alberta. He will report to Josh Yates, Regional Sales Manager – Western Canada, and be responsible for managing Omron’s end users, EPCs, system integrators and OEMs. He has more than 22 years of experience in sales and marketing with multinational organizations, including 3M, Schneider Electric, Honeywell and Lloyd’s Register. He has held senior roles in various sectors (e.g. electrical, construction, engineering consulting services, channel partner management and oil and gas). Abuhamdan holds a Bachelor of Science in Electrical Engineering and MBA from University of Leicester, U.K. Sean Garrity has been named Territory Account Manager – British Columbia. Garrity will be responsible for building relationships and exploring opportunities to collaborate on projects with end users, EPCs, system integrators and OEMs. He will be reporting to Josh Yates, Regional Sales Manager – Western Canada.

Garrity has a background in consulting, having worked for more than five years as a consulting engineer specializing in controls for power generation, public safety systems and bulk material handling.

He has experience in design, pre-operational verification, commissioning and troubleshooting at facilities across Canada.

He holds a Bachelor of Electrical Engineering from the British Columbia Institute of Technology, where he graduated as class valedictorian.

Garrity is also Chair for the IEEE Canada Young Professionals committee and sits on the steering committee for the BCBC NEXT Leaders program.

I N D U S T R Y

N E W S W A T C H

Machinery and Equipment MRO

November 2018

Business Briefs News and views about companies, people, product lines and more.

• Michael Faulkner has been named as President at Garlock, an EnPro Industries company. He takes over for Eric Vaillancourt, who has been named President of STEMCO, a sister EnPro company.

Faulkner will be responsible for establishing the strategic direction for the company and will oversee global operations, and enable customer-driven product innovation. He will also be responsible for ongoing implementation of EnPro’s dual bottom line approach that places financial performance of the organization and human development of all employees on an equal footing.

Faulkner has been with the company for 13 years, most recently as Vice President and General Manager of GPT (a member of the Garlock family of companies). He has a Bachelor of Science from the Rochester Institute of Technology and an MBA from the William E. Simon School at the University of Rochester.

• Tim Dunphy has been named Marketing Director of Underground Technologies at RIDGID. Dunphy will now manage new product development, partner relations and new business opportunities for the RIDGID line of diagnostics, inspection, locating and drain cleaning products.

Dunphy has global expertise in market and brand strategy, new product development, omni-channel marketing communications, and market research.

He has more than 20 years of experience in consumer-packaged goods and durables marketing.

Dunphy has a Bachelor of Science in Marketing from the University of Florida.

• Motion Industries, Inc. announced

11

the passing of its President and CEO, Tim Breen.

Breen began his career with Berry Bearing Company in 1982 and served there as a Sales Representative, Branch Manager, Regional Manager and Corporate Accounts Manager. His responsibilities continued to grow after Berry Bearing and Motion Industries joined forces in 1993.

His leadership as both a Division Officer and Group Officer distinguished his record, and he assumed responsibility of all the U.S. locations in 2011 as Executive Vice President and Chief Operating Officer. Breen was promoted to Motion Industries President and Chief Operating Officer in 2013, before his promotion in November 2014 to President and CEO. With Breen at the helm, Motion Industries attained its record $5-billion sales goal at the end of 2017.

• Finning International Inc. announced it will expand its dealer relationship with Weiler, Inc. after Caterpillar Inc. announced it has entered into a preliminary agreement to sell its Cat purpose-built forestry business to Weiler.

Founded in 2000, Weiler has a long-standing history of successfully manufacturing purpose-built equipment distributed through the Cat dealer network. Finning will work to distribute Weiler’s purpose-built forestry machines, including wheel skidders, track feller bunchers, wheel feller bunchers and knuckleboom loaders while continuing to provide Cat’s forestry excavators designed for log loading, processing and other forestry applications. Weiler’s product offering is complementary to other specialty forestry lines already offered through Finning.

• ATS Automation Tooling Systems Inc. announced the election of directors. The vote was conducted by show of hands at the annual meeting of shareholders, which took place on Aug. 16, 2018, in Toronto.

Directors elected were Neil D. Arnold, Joanne S. Ferstman, Andrew P. Hider, Kirsten Lange, Michael E. Martino, David L. McAusland, Philip Whitehead, and Daryl C.F. Wilson.

The total percentage of ATS common shares represented at the meeting was 87.65 per cent.

• KP Tissue Inc. and Kruger Products L.P. announced their plan for a capital investment of $575 million in the Brompton area of Sherbrooke, Que., to build a new state-of-the-art tissue plant featuring Canada’s largest and most modern through-air-dry machine. The project will create more than 180 new jobs in the region.

The new plant, which will be adjacent to an existing facility of the Kruger Group, will produce, at maturity, approximately 70,000 metric tonnes per annum of bathroom tissue and paper towels, which will enable Kruger Products to increase its offering of ultra-premium and innovative tissue products under the Cashmere, SpongeTowels and Purex brands.

The project is supported by the Government of Québec through Investissement Quebec), which has agreed to invest $105 million by way of a convertible debenture. The remaining financing for the project is currently being finalized.

Construction of the project is expected to begin in early 2019, and the plant is slated to commence production in early 2021. The project will generate major benefits, including more than $250 million in direct expenses in Quebec and one million person-hours for the construction of the new plant.

• Pamela Sims has been named Vice President of Marketing at Motion Industries, Inc. Sims has been with Motion Industries since 2004 in market research she and has been the Director of Marketing since 2013.

Sims has developed and implemented marketing plans to position Motion Industries as a leading industrial distributor. She also developed relationships with the company’s top strategic supplier partners, working to implement Motion Industries’ extensive co-op advertising program. She is a graduate of the University of Alabama at Birmingham.

Motion Industries is a wholly owned subsidiary of Genuine Parts Company.

12

12

R E S O U R C E

S E C T O R

Machinery and Equipment MRO

November 2018

Learning Management Systems –

LMS is software that allows maintaining of training and resource documents on an electronic platform.

BY PETER PHILLIPS

T

his issue of MRO is dedicated to the resource sector and how it services needs in facilities, industries and factories.

When thinking of resources in manufacturing and industrial facilities, what comes to mind? We think about the services and parts needed to maintain buildings and equipment. We need contractor services and vendor parts to keep equipment reliable and buildings and grounds in good condition. We determine exactly

what internal and external services are needed to make this happen.

This month, let's look at the service and maintenance of employees and contractors. Exactly what does this mean?

In order for employees and contractors to work safely and effectively, they need to have a certain level of knowledge. They need training and information readily available to perform their jobs. What type of resources need to be given, so they have the credentials

to do the work we ask them to do?

First, a certain level of safety awareness and training to conduct themselves in a safe manner at a plant is needed.

For example, new employees and contractors need safety orientation for specific facilities.

Second, generic training to comply with safety policies– such as WHMIS, lock and tag, confined space entry, ladder safety– is needed.

Third, they need to have specialized training and information available to perform the work assigned, like special forms for hot work and permits for confined space. They often need to use spe-

Photo credit: Unsplash.com

RESOURCES FOR OUR RESOURCES

R E S O U R C E Machinery and Equipment MRO

S E C T O R

13 November 2018

cific checklists for risk assessments and 10 things that an LMS eliminates: 9. Manually updating course material. other checklists to perform jobs safely.

1. Time taken to organize, deliver and re- 10. Doing this over and over again year Where does this information and cord employee and contractor training. after year. training normally come from? Current- 2.

Cost to print handbooks, textbooks Employee and contractor training ly, in most facilities, it comes from cerand resource documents. results and schedules are totally digitification and training courses provided 3. Storage of training materials. tized. Training courses can be taken on at work sites. We organize the trainer, 4.

Files of employee and contractor the LMS at the employee’s convenience trainees, locations and course materials, training records. without the need for a trainer, training release people to attend the training and 5.

Time people need to be away from location or printed materials. have them sign attendance sheets and their jobs attending training.

An LMS can also eliminate paper keep the test results in their personnel 6.

Time it takes to mark, test, and checklists that are used on the job site. file to record their training in case it is produce a certificate.

Pre-job safety checklists, risk assessneeded for safety audits and to prove 7. Cost of trainers and their expenses. ments, working at heights, hot work perdue diligence to regulatory agencies.

8.

Deciding who needs what course mits and many more are all at the fingerAnyone who has been responsible to and when. tips of the contractor or employee. These organize training knows it is very time-consuming to say the least and it has been this way for decades. In our facilities, we use technology in maintenance activities to help keep up buildings and equipment. We use computerized maintenance software to track maintenance, laser alignment tools, oil analysis, thermal graphics and other tools to keep assets working smoothly.

Here’s the question. How can we use technology to help maintain our employees and contractors?

Enter the LMS (learning management system). An LMS is essentially software that allows us to maintain all training and important resource documents on an electronic platform that is easy to access and manage. Every conceivable training course whether it is safety, technical or HR-related can be mounted on a company server or cloud-based application ready to be taken at a moment’s notice. Results are recorded and stored for easy access whenever it is needed. An LMS provides interactive training programs that keep participants engaged in the training.

Quizzes and tests are designed to ensure students understand the material and are asked to review sections they answered With an online catalogue of over 10,000 products from 16 major brands incorrectly.

We have what you are looking for.

Training can be taken most anywhere on most any device, workstation, tablet or phone.

Training is truly available anytime and anywhere, and personnel in the field can access train1.800.890.7593 customerservice@eMotorsDirect.ca ing and important documents in real time.

MRO_Nov_EMotors.indd 1

2018-10-23 2:21 PM

14

14

R E S O U R C E

S E C T O R

Machinery and Equipment MRO

November 2018

A POWERFUL COMBINATION OF

RELIABILITY, DURABILITY AND PERFORMANCE Sullair LS Series Air Compressors

forms can be filled out using the LMS phone app or on a tablet right at the point of execution of the work. The completed forms can be immediately sent to the safety co-ordinator or the person responsible for the job safety via email, and/or stored in Google Sheets for easy access.

Think of the daily mobile equipment pre-operation checklists that are usually handwritten at the beginning of a shift on forklifts, loaders and farm equipment. These checklists can be filled out electronically and stored on the LMS software ready for review at a second's notice anywhere and anytime. Training records and government-regulated forms are safe and secure.

No more searching for records in file cabinets and file folders.

ONE HARDWORKING PACKAGE RELIABILITY including the full-color, easy-access Sullair Touch Screen controller DURABILITY including the patent-pending, new generation Sullair air end PERFORMANCE including highly efficient Electronic Spiral Valve technology Find your local authorized Sullair distributor today at

SULLAIR.COM

© 2018 Sullair, LLC. All rights reserved.

Where else can we use the LMS? A company in Nova Scotia provides me with an LMS for training and important documents my people need in the field. It also provides other resources needed to run my business. Call it an MRS (maintenance resource system). For example, all of us have issues hiring good people. Although applicants may have a great-looking resume and interview well, that doesn’t guarantee a good employee.

Atlantic Webfitters along with all the LMS resources, also provides pre-screening of job applicants. We simply provide the potential employee with our MRS website address, user name and password. From there they go through a series of exercises that tells us if they are worthy of further consideration and a traditional interview. Our hiring process has become much more streamlined and has helped hire people with the right skills, knowledge and attitude.

If you’d like to visit their introductory website to learn more, go to www.mylms.ca. They have worked with us all the way along our LMS/MRS journey and have customized our digitized world. They have helped get what we need; give what we need to our employees, contractors and clients all with a simple business application.

We so often overlook our most precious resource, our people, but they need care and attention just like equipment and facilities. Now more than ever we rely on resources and have people working through our facilities moving from location to location within plant and in the field away from our facility. It might be time to join the LMS/MRS world to give your people the resources they need wherever they're working. MRO Peter Phillips of Trailwalk Holdings, a Nova Scotia-based maintenance consulting and training company, can be reached at 902-798-3601 or by email at peter@trailwalk.ca.

Photo cfredit: Unsplash.com

EXPERIENCE THE SULLAIR DIFFERENCE IN

16

16

W H A T ’ S

U P

D O U G ?

Machinery and Equipment MRO

November 2018

MINING, MINING – CONVEYOR CONVEYOR PULLEY PULLEY BEARING BEARING SEALING SEALING O

ne of the most common pieces of equipment on a mine site is a belt conveyor. No matter what mineral is being extracted, this piece of equipment generally will be present in some form. Depending on the complexity and length of the belt conveyor, there will be at least two pulleys–one at either end of the belt (head and tail pulleys). Most belt conveyors will have additional pulleys for tensioning the belt in some form, and, depending on the mechanism and design of the tensioning system, there could be multiple pulleys.

A pulley is essentially a drum with a shaft that is then supported by two bearings. Those two bearings are typically spherical roller bearings in split pillow block (plummer block) housings. This type of bearing allows for the assembly to be easily mounted on the conveyor frame with a minimal amount of alignment between the foot of the housing and the pulley shaft as a spherical roller bearing can tolerate up to three degrees of angular misalignment.

The original seals in pillow block housings were either strips of felt or metal labyrinth rings (triple ring seals), which are non-contact and depend upon sufficient grease being added to the pillow

block to fill and purge this labyrinth. In most general industrial applications this type of seal was adequate.

However, in mining applications, this seal did not do a great job, and in such mines that extracted abrasive materials such as iron ore (taconite), the users were not satisfied with the performance of the seals and bearings. The users at these “taconite” mines developed a more robust seal that was more complex and included direct grease feed to the seal to purge the contamination. This type of seal has come to be known as a “taconite" and is essentially the standard seal for mining applications. However, the only “standard” feature is that it is a grease-purgeable seal, and there are many different variants on the market today. This is unfortunate as a user may specify a “taconite” seal, and, hoping to get the best performing design, they get the least expensive design.

As the reliability engineers in mining companies have tried to improve their performance of their pulleys, some, specifically oil sands mining companies, have invested in more and more complex taconite-like seals. Some of these seals feature external shrouds, lip seals, V-ring seals and more complex labyrinths all to make it more difficult for

the external contamination to enter the bearing cavity. Although taconite seals have improved the performance of pulley bearings, they are not infallible. A mining company in Australia studied the performance of sealing and found that the iron ore dust still was able to work its way through the taconite seals and into the bearing cavity. It was even observed that the iron ore made its way through to the other side of the bearing.

Based on observations at a Canadian iron ore mine, it appears that the contamination makes its way along the areas of highest shearing of the grease, specifically along the interface of the shaft and the grease pack in the housing. The key observation was that when looking at the degree of contamination in a housing, the contamination was concentrated nearest to the shaft and grease at the inner surfaces of housing (cap and base) farthest away from the shaft had the cleanest grease. (This makes sense, as anyone who makes pancakes on Sunday morning knows that to get the flour blended into the batter, you should scrape down the sides of the bowl; otherwise, it just stays there unblended.)

The latest solution for pulleys, which is more commonly available these days,

Photo credit: Getty Images

BY DOUGLAS MARTIN

W H A T ’ S

U P

17

D O U G ?

Machinery and Equipment MRO

November 2018

Acoustic Lubrication Workshop

Grease Bearings Right

is a “sealed spherical roller bearing” in which a rubber lip seal is integrated into the spherical roller bearing. This is not new technology and sealed ball bearings have been commonly available for years.

It is simply that this proven technology is being made more available in spherical roller bearings.

Since this lip seal is inside a “sealed” cavity, it does not have to deal with gross particles, spray from pressure washing, rain; it just needs to provide a barrier between the grease churning at the shaft/ grease interface. And, this area of grease is the highly sheared zone, which is most likely contaminated.

However, we do know of an overall issue with seals of all types. They do not like angular misalignment. With labyrinth seals, the seal designer must open up the spaces between the labyrinths to allow for misalignment, making more access to the contamination.

As the more complex taconite seals were developed and lip and V-ring seals were added, they were made more sensitive to angular misalignment, which opens the lip-contacting area.

For the external seals to be most effective, they need to be far more accurately aligned than the open spherical roller bearing.

SRB – 3.0 degrees STD housing seal (LER) – 0.5 degrees

Taconite seal – 0.5 degrees

Integral bearing seal – 0.5 degrees As can be seen, we have added layers of protection to the bearing, and have created greater demands for alignment. This is not to say that if you have misalignment your bearing will quickly fail (such as with tapered roller bearings and cylindrical roller bearings); rather, as the misalignment increases, the less effective the sealing is. Therefore, the bearing will still operate; it will just have a shorter service life, as more contaminants will be allowed to enter as the amount of angular misalignment increases.

From field experience, the best performance has been achieved using sealed spherical roller bearings with taconite seals and accurate housing to shaft alignment (achieved by laser alignment practices). It is a given that taconite seals must also be greased and constantly purged. 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.

New Dates Accross Canada

FREE Registration

sdtultrasound.com/1dayworkshops 1-800-667-5325 info@sdthearmore.com

R E S O U R C E

S E C T O R

Machinery and Equipment MRO

November 2018

MAINTENANCE

CHALLENGES Within the oil sands ore prep pit.

BY IAN MILLER

F

ew industrial environments have as many challenges as those faced in the Canadian oil sands.

Harsh and unforgiving weather combined with demanding schedules, abrasive ore and a very remote location all culminate into the absolute necessity for a robust maintenance program.

When you consider the sheer scale of the equipment in use, it is easy to see that regular maintenance is just a bare minimum requirement. In fact, most well-run sites have invested heavily in both preventative maintenance and a robust reliability department.

These challenges can be even further amplified on the front end of this mining process. For those unfamiliar with the conventional mode of mining in the oil sands, it all starts in what is referred to as ore prep. This is the first step in the extraction process and is an area that offers many unique challenges. The raw ore is deposited (usually by truck) into a primary crusher. Once sized, the ore is then transported via conveyor to the surge bin, which, as the name implies, is a large storage bin. This storage is needed to ensure a constant flow of uninterrupted ore to the next stage, slurry prep.

The surge bin can also act as an intermediate between trains. If the crusher on

one train is down, the ore from another train (usually the adjacent one) can often be diverted at the surge bin. From here, the ore then travels via conveyor to slurry prep.

At slurry prep the ore is again resized via a “sizer� (a type of secondary and often also tertiary crusher) and then mixed with water and caustic before transferring into a pump box where it is then transported via large pipes to the next stage. Again, the sheer scale of this process can’t be understated; the hydro transport pump used to feed this next stage is often in excess of 2,000 horsepower.

Out of all the challenges that apply to both open-pit mining and a northern Canada location, the single largest challenge for maintenance in this area is still friction. This is the normal friction that comes with any application of this magnitude, but also amplified by the egress of contamination and inclement weather.

When you consider that the composition of this mined ore is crude oil mixed with sand, you can imagine the challenges this has on the large rotating equipment used in this area of the mine.

Components like the crusher main bearings/shafts, apron feeder bearings/ shafts (apron feeders are another style of conveyor that use steel plates attached to dozer chains and are used both to feed the crushers and to empty the surge

bins), head, tail, bend and drive conveyor pulleys and the sizer shafts/bearings.

Now these are certainly not the only things affected by this issue but they are all major components whose premature/ unscheduled failure has major implications on downtime and repair costs. The logistics of removing/replacing and repairing any one of these components is hard to describe in a few short sentences but it is something to behold.

Given the criticality of these components and the implications of unplanned maintenance, the reliability departments typically use remote monitoring to help predict and plan for these failures. The most common modes of remote monitoring are vibration and thermal. These means of prediction can assist maintenance by allowing them to change out a piece of equipment before a failure occurs or, at a minimum, will give indication that a catastrophic failure is imminent.

What is the primary strategy used by these companies to mitigate against such difficult and challenging conditions? It might surprise you to know that it is the same basic and well-tested approach as any well-run facility. In conjunction with good system design principles, they also utilize a well thought out preventative maintenance schedule, fact/evidence based equipment life prediction, founded on information gleaned from failure analysis, and a rigorous and thoroughly researched lubrication regiment. Almost all of these sites also take advantage of automated lubrication systems and prophylactic seal greasing used to minimize the impact of contamination egress. This strategy might sound familiar to you, especially if you are involved in any type of industrial maintenance.

One of the truths that I have recognized throughout my career is: there is no substitute or magic bullet as effective as adhering to tried-and-true maintenance principles. MRO Ian Miller is Branch Manager at Motion Canada Calgary Service Center and Alberta-based Tech Group. He has more than a decade of hydraulic and electrical experience in the field, including system design, troubleshooting, onsite installations, and technical training/support.

Photo credit: Motion Industries, Inc.

18

18

TORONTO | MONTREAL | VANCOUVER | EDMONTON | CHICAGO | DALLAS AMCAN was founded in 1998 and is currently celebrating its 20th year in business, and we would like to thank our valued customers for this achievement. AMCAN is a leading supplier of ball and roller bearing products catering to distributors & OEMS. The company’s inventory is comprised of over 22,000 different bearing and PT related product part numbers

Amcan Bearing is proud to announce an exclusive deal to represent D&D Belting in Canada, with a full range of Belting to better serve our customers.

KYK: KYK is Amcan’s line of Electric Motor Quality Bearings (EMQ) for bearings 60mm ABEC 3 & higher, with Z3V3 noise and vibration ratings. For bearings 60mm inner diameter: Abec3, with Z2V2 noise and vibration Ratings. Both are packed with industry standard grease for electric motor applications. Stock with shields and seals in C3.

SWC: Amcan is SWC exclusive supplier in North America. SWC was founded in 1994 specializing in High-Temp Deep Groove Bearings, and Radial Insert Ball Bearings filled with special grease, giving them a range up to 350C available in open 2ZR and Viton Seals. SWC is a ISO 9001:2008 company since 2005.

FSQ: FSQ is a major Taiwanese supplier of Pillow Blocks, Plummer Blocks (split pillow blocks) Adapter Sleeves, and Seals, Amcan is their authorized dealer in North America.

We have a highly competent and professional customer service team available 24/7 that provide tailor-made solutions to specific requirements of our customers for their bearing and power transmission product needs.

• Toronto 1-877-275-6304

• Edmonton 1-877-454-6203

• Montreal 1-866-349-6304

• Chicago 1-866-625-6203

• Vancouver 1-866-941-6203

• Dallas 1-888-477-6203

Website: www.amcanbearing.com

MRO_SEPT18_AMCAN_LAZ.indd 1

E-mail: info@amcanbearing.com

2018-11-09 12:52 PM

M R O

Q U I Z

Machinery and Equipment MRO

November 2018

BIODEGRADABLE LUBRICANTS– SELECTION, APPLICATION AND MAINTENANCE

T

he description of the two primary classes of biodegradable lubricants, vegetable oil and synthetic categories, have been well documented when compared with traditional mineral oil base lubricants.

However, very little information has been provided by major oil companies or the manufacturers of these biodegradable products with regard to application guidelines and the maintenance of these products once they are in use as machine lubricants.

Industrial users of these products must be prepared to treat biodegradable lubricants somewhat differently than standard mineral base oils. In order to understand these application and maintenance requirements, it is first necessary to review the various types of biodegradable lubricants to point out their advantages and disadvantages.

Vegetable base oils include corn, soybean, canola, sunflower, peanut and olive oils. In their natural form, these oils consist primarily of triglyceride molecular structures and, as such, they have performance limitations; most notably, poor thermal, hydrolytic and oxidation stability.

For example, most natural vegetable oils cannot withstand reservoir temperatures over 80°C (176°F). In addition, water, even in very small amounts of a few hundred parts per million, is the natural enemy of vegetable oils and can cause serious foaming and degradation problems. In general, these oils also exhibit low cold flow abilities.

On the other hand, most of these nat-

ural oils have good lubricating qualities due to their polar nature. This provides good metal wetting attraction and also makes them good solvents to keep dirt and debris off metal surfaces. Their molecular structure provides for a natural high viscosity and viscosity index. Genetic modifications have also overcome much of the thermal and oxidative stability problems, particularly with soybean and canola oils.

The use of biodegradable lubricants is desirable for equipment used in certain resource industries, such as forestry, mining, certain oil and gas production, or wherever the lubricants themselves might come into contact with the environment. For example, a perfect application of biodegradable vegetable oil is sawmill chain drive, saw guide and saw blade lubricant, where the oil is “once through” and enters the environment immediately after use. It is also well suited for use in low to medium pressure hydraulic systems or lightly loaded gear drives where operating temperatures do not exceed 71°C (140°F) and where there is little chance of water ingress or high contamination.

Application considerations include the following. Biodegradable lubricants may be very different in their characteristics, and the conversion necessary for their effective use is not quite as simple as draining the used mineral oil and dumping in the new biodegradable lubricant. Before converting to a biodegradable lubricant, consider the lubrication system’s operating and design characteristics, such as operating temperature, pressures and flow rates, types

Biodegradable lubricants have become extremely important to support the demands of environmental protection.

BY TEX LEUGNER

of sealing or hose materials used, potential for contamination such as water or dust and dirt, and whether or not the quality of the existing filtration system is sufficient for the new fluid.

A most important consideration is whether or not the new biodegradable fluid is compatible with mineral oil. If it is not, serious problems may result if all of the old mineral oil is not thoroughly flushed from the system before the new fluid is installed. Some of the resulting symptoms of a poor or incomplete conversion to biodegradable fluids are severe foaming, leaking seals (particularly if the seals are of neoprene or nitrile), plugged filters, higher than normal wear on some components (such as the hydraulic pump), and increased operating temperatures.

The next group of biodegradable lubricants includes synthetic types, specifically polyalphaolefins (PAOs), diesters and polyglycols. PAOs are finding increased use as hydraulic and engine oils, particularly in cold climate applications and where hydraulic pressures are increasing, in certain cases up to 7,000 PSI and higher. These oils are also finding selected use as gear lubricants because of their ability to operate over a wide range of temperatures due to their high viscosity index and lower coefficient of friction, both of which help to reduce wear.

These products are generally compatible with mineral oils and, as a result, there is no requirement for extensive flushing before conversion unless required by the manufacturer. PAOs have a negative effect on certain sealing materials

Photo credit: Getty Images

20

20

M R O

Q U I Z

Machinery and Equipment MRO

causing shrinkage, so initial leakage may be a problem.

Diester biodegradable fluids are excellent lubricants for compressors and turbines. Diester fluids may have a negative effect on certain varnish or paint surfaces because of their exceptional solvency and detergency, so it would be wise to remove the paint from any internal contact surfaces such as the reservoir, as well as thoroughly flush the entire system before conversion.

Polyglycols (PAGs) are often recommended as fire retardant lubricants in addition to their biodegradability, are not compatible with mineral oils, and have some negative effects on certain seal and paint materials. As a result, thorough flushing of the system should be carried out before the conversion.

These products are water soluble, which helps to provide biodegradability but also creates a disadvantage in lubricant applications, because free water contamination tends to occur very quickly. Since these fluids contain water, they have a greater tendency to hold contaminants in suspension, and, as a result, the filtration systems should be improved in order to ensure bearing surfaces are not unduly introduced to dirt, which has been suspended in the fluid.

Three-micron filters can be used successfully in these systems and are recommended for hydraulic system and pressurized gear reducer applications.

Operating temperatures must be controlled in order to avoid excessive and unnecessary evaporation of these aqueous fluids, and the recommended operat-

21 November 2018

ing temperature should be kept within a range of about 50°C (122°F) to 60°C (140°F).

Another consideration when using biodegradable water-soluble fluids in a hydraulic application is to pay attention to the pressure relief valves that may be required to remain in the discharge or open position for long periods. This condition can cause cavitation erosion of the valve seat and cause premature failure of the valve, so proper valve selection before conversion should be considered.

Monitoring the condition of biodegradable fluids in service is not any different from that called for with mineral-based hydraulic oil. The most important tests recommended are those that monitor contamination levels by ISO cleanliness standards, water contamination, viscosity changes and total acid number (TAN).

Specifically, the guidelines for these tests are as follows: 1. Contamination testing should be carried out through the use of electronic particle counts that measure the quantity of four, six and 14 micrometer particles in the fluid, respectively, and report the level of contamination by the ISO 4406 cleanliness code.

For example, Vickers hydraulics specifies that in its systems, lubricant cleanliness levels should not exceed 16/13/12, meaning that the level of contaminants of sizes four, six and 14 microns are at an acceptable level. If these levels exceed 16/13/12, the fluid contamination levels are becoming unacceptable.

Water is a natural enemy of all types of lubricants, but biodegradable fluids

with a base of vegetable oil are extremely susceptible to degradation caused by water. Moisture and condensation levels should never exceed 500 PPM if long service life is to be achieved. Even small quantities of water can cause foaming of the fluid and seriously degrade its quality. Water content must be accurately monitored using the Karl Fischer test technique.

2. The acidity increase should not exceed an AN level of 1.5 mg KOH/gm, depending upon the AN of the new fluid.

3. The viscosity changes (whether an increase or a decrease) should not exceed 10 per cent of the original fluid's viscosity specification. In addition, viscosity should be measured at both 40°C and 100°C, in order to monitor the viscosity shear rates.

Note: It is important to remember that these standard tests should be carried out on a regularly scheduled basis for any lubricant, whether the fluid is biodegradable, mineral base or synthetic. Most maintenance-oriented users of lubricants monitor their systems at recommended intervals of 350 to 500 hours of operation and, this is sound practice. MRO L. (Tex) Leugner, the author of Practical Handbook of Machinery Lubrication, is a 15year veteran of 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. Leugner holds an STLE lubricant specialist certification and is a millwright and heavy-duty mechanic. He can be reached at texleug@shaw.ca

22

22

R E S O U R C E

S E C T O R

Machinery and Equipment MRO

November 2018

INTELLIGENT NETWORK SURVEILLANCE Used in mining is critical for safety and production.

W

ith intelligent surveillance, mining companies now have the ability to be more productive. Going beyond video streams, upgrades in surveillance technology can now collect data and analytics, providing operators with more information to run their sites both safely and efficiently.

Mining is a complex industry that's now facing new challenges as digital transformation changes the way mines operate. Driverless tech, automated drilling, Internet-connected sensors, and more staff now operating the technology and

robots instead of doing the physical work themselves. The industry is becoming more technologically adept, where connectivity and network are an integral part of everyday operations that demand more surveillance and intelligent equipment and solutions to support production and provide insight on efficient practices.

Companies now leverage new opportunities created by emerging technology so that intelligent surveillance systems not only protect an organization’s physical premises and equipment, but also create a safer environment for its em-

Photos credit: Axis Communications.

BY KEITH D’SA

FOR UNSURPASSED QUALITY, PERFORMANCE AND VARIETY IN GEAR OILS....

LOOK TO LUBRIPLATE®

GEAR OILS

Lubriplate’s complete line of premium-quality gear oils has been formulated to deliver unsurpassed performance in a wide range of gear reducers. They meet and exceed the performance specifications of most gearbox manufacturers and interchange directly with most OEM oils. Available products include...

SYN LUBE SERIES 150 - 1000

100% SYNTHETIC PAO-BASED GEAR OILS

• High-performance, 100% synthetic, polyalphaolefin (PAO)-based gear oils.

• Compatible with petroleum-based oils and most seals for easy conversion.

• Available in ISO viscosity grades 150, 220, 320, 460, 680 and 1000.

SYN LUBE HD SERIES

HEAVY-DUTY, EXTREME PRESSURE (EP) 100% SYNTHETIC, PAO-BASED OILS

• Super heavy-duty, polyalphaolefin (PAO)-based synthetic gear lubricants.

• Formulated to meet AGMA EP (Extreme Pressure) requirements.

• For Heavy-duty, high load applications where an EP oil is required.

SPO SERIES

HIGH-PERFORMANCE, ANTI-WEAR FORTIFIED, PETROLEUM OIL-BASED, INDUSTRIAL GEAR OILS

• Petroleum oil-based anti-wear, rust & oxidation inhibited (R&O) gear oils.

• Can be used with silver alloy, copper, and copper alloy bearings.

• Premium quality, high-performance, petroleum oil-based gear oils.

SFGO ULTRA SERIES

NSF H1 REGISTERED FOOD GRADE 100% SYNTHETIC, PAO-BASED GEAR OILS

• NSF H1 registered and NSF ISO 21469 certified - food machinery grade.

• 100% synthetic, PAO-based fluids for food processing and bottling plants.

• Available in ISO viscosity grades 150, 220, 320, 460, 680 and 1000.

• Fortified with Lubriplate’s proprietary anti-wear additive .

PGO & PGO-FGL SERIES

ADVANCED 100% SYNTHETIC PAG-BASED GEAR OILS

• Ultra High-Performance, Polyalkylene Glycol (PAG)-Based, Gear Lubricants.

• ECO-friendly- Inherently biodegradable, provides long service life, energy conserving.

• PGO-FGL Series is NSF H1 registered and NSF/ISO 21469 certified food grade.

SYNTHETIC WORM GEAR LUBRICANT • 100% Synthetic, ISO 460 grade, polyalphaolefin (PAO)-based worm gear oil.

• Formulated especially for worm gear applications.

• Provides excellent lubricity and oxidation resistance.

APG SERIES

HEAVY-DUTY PETROLEUM OIL-BASED EXTREME PRESSURE (EP) GEAR OILS

• High-quality, petroleum-oil based, extreme pressure (EP) gear oils.

• Meets military specification MIL-PRF-2105E and MIL-L-2105D. • Conforms to API categories GL-3, GL-4, GL-5, MT-1.

KLING GEAR OILS

HEAVY-DUTY, TACKY RED, PETROLEUM OIL-BASED EXTREME PRESSURE (EP) GEAR OILS

• Heavy-duty, tacky, red, extreme pressure (EP) petroleum-based gear oils.

• These tacky, adhesive, extreme pressure oils cling tenaciously to gear teeth.

• Formulated for heavy equipment and heavy service industrial applications.

• Meets military specification MIL-PRF-2105E and API classification GL-5.

Newark, NJ 07105 USA / Toledo, OH 43605 USA / Tel: +973-465-5700 www.lubriplate.com / LubeXpert@lubriplate.com

- REPRESENTATIVES IN CANADA Southern Alberta, Saskatchewan & Manitoba: Summit Agencies Ltd. / Calgary Office / 403-236-8655 / www.summitagencies.ca Northern Alberta and Saskatchewan: Summit Agencies Ltd. / Edmonton Office / 780-406-7462 / www.summitagencies.ca British Columbia: Summit Agencies Ltd. / Vancouver Office / 604-329-7848 / www. summitagencies.ca Ontario,Quebec and the Maritimes: Mechanical Sales Co. / 800-263-7226 / www.mesaco.com

24

24

R E S O U R C E

Machinery and Equipment MRO

S E C T O R November 2018

ployees. Surveillance also supports efficient, reliable operations with access to new data, which supplement industrial control data, and serves as a way of monitoring policy adherence, evaluating risks in real time, and improving safety and security practices. The result of a successful solution is a more secure site, uninterrupted operations and a safer, healthier workforce, along with cost savings that can be shared across an organization.

Oil and gas extraction sites face unique challenges in that they operate in vast and remote locations: the Highvale Mine in Parkland, Alta., for example, is Canada's largest surface strip coal mine, covering more than 12,600 hectares; and the Gahcho KuĂŠ diamond mine in the Northwest Territories is approximately 280 kilometres east northeast of Yellowknife with no permanent town. Workers commute to the mine from south of the territory for weeks-long shifts, and supplies can only be brought in by truck.

To ensure safe and continuous operation, the costly equipment used to mine the sites, minerals and materials they procure, perimeters of the mines and employees who work on them need to be secure and protected. Network video surveillance plays a valuable role in this process, especially in isolated locations with complex challenges.

Traditionally, mining companies used analogue systems or CCTV systems that run off a coaxial cable, limiting scalability and resolution. Today’s IP-based surveillance technology offers more flexibility on scalability and the ability to do things at the "edge" of the network, meaning near the source of the data as opposed to having it centrally managed. For example, if a threat is detected, a camera can initiate a trigger such as to play an audio warning or send an alert signal back to the central surveillance location. Blasting, explosions and fires are major concerns, especially in underground sites; new technology such as thermal sensor cameras offer companies eyes where they didn’t exist previously. They can detect a fire or heat source that is increasing rapidly and trigger an alarm so that employees on-site have time to react. Thermal sensors give companies the ability to counter threats before a bigger incident happens. Thermal imaging can detect humans or animals in dark conditions and detect differentials in heat (whether that means equipment is overheating or an actual fire is about to start), offering a more safe and secure worksite.

With edge-based technology, cameras can be used with video analytics as a system to acknowledge suspect activity before a threat or intrusion on-site. If a detection area is set up and someone were to enter without going through a specific control point, or if someone is loitering, it can trigger an alarm to sound an audio warning. Video analytics, combined with thermal cameras, provides detection accuracy even in poor lighting conditions, transmitting critical real-time information for hazard identification, allowing for immediate incident response, which can prove to be a life-saving benefit.

In mining as well as other resource sectors such as oil and gas, integrating network video with health safety and environment systems also help ensure that safety rules and processes are being followed, and that tools and equipment are managed properly.

Data and new technology increase productivity Edge computing and thermal imaging are part of bigger tech-

nology advancements in network surveillance that do more with the visuals they capture.

Instead of the traditional streaming of video content back to a server, cameras are more sophisticated and intelligent thanks to connectivity to more computing power allowing for the running of sophisticated analytics. This means that in the future, certain security decisions can be made on the field devices, rather than all footage simply being streamed to a remote server and analyzed by staff. This reduces the burden on employees and has them focused on more specialized tasks.

In manufacturing, for example, video analytics can be used to study the flow of people and product throughout the plant, highlighting areas where small changes can result in big improvements in efficiency. The same can be done with mining and oil and gas, where an IP camera system can be designed and deployed throughout a mining pit to monitor operations and identify any areas that could run more efficiently.

Stracon Mining Ltd. and Oceana New Zealand Ltd. implemented this at the Globe Progress Mine in New Zealand. The mine was operating 24/7 and employs more than 100 people.

Looking for ways to optimize the allocation of their resource and increase efficiencies, thee comapnies placed an IP camera system throughout the opencast mine. The results captured

Photo credit: Getty Images

Onsite surveillance protection and employee health and safety

R E S O U R C E

25

S E C T O R

Machinery and Equipment MRO

November 2018

be customized even in challenging resource industries, and the data collected not only provides surface-level protection and safety but also allows companies to be more productive as a mine overall.

Future-proofing mining surveillance Intelligent network surveillance goes beyond security, and industries are benefitting from the technological advancements in video surveillance beyond what was possible only a few short years ago.

The streaming of video back to a server where the content was rarely used and sometimes not even viewed, is no longer the case. Integrating sophisticated cameras with faster networks, cloud, Internet of Things and analytics provides intelligent video that can be used for applications outside of just security.

In mining, where infrastructure and production disruption can cause huge economic loss, intelligent and efficient surveillance helps companies extract greater benefit out of video surveillance, offering not only a higher return on investment from the equipment but access to more data and information to improve operation, production and safety. MRO Keith D’Sa has more than 15 years providing insight and strategy tactics around business development, solution selling and account management in the security industry. He is the National Sales Manager at Axis Communications. Keith has been involved with industry-leading associations and was featured in SP&T Magazine for the Top 10 under 40 decision-makers in the security industry in Canada. He can be reached at keith.dsa@axis.com.

allowed the companies to improve the efficiency of truck deployment within the pit, helped with planning more efficient shifts and improved communications within the workforce.

With IP-based cameras, video is scalable, meaning companies can choose where they need it the most without worrying about individual coax cabling. With an IP system, cabling is streamlined, meaning lower operation costs. As an IP system is also managed though the cloud, the bandwidth needed between sensors, devices and the data centre is notably reduced as data and video can be managed remotely.

Cameras are now equipped to help companies make decisions in the field based on their business needs; whether it is to help detect a problem or intrusion, provide analytics or reducing equipment downtime, intelligent surveillance is a tool that goes beyond providing security to increasing efficiencies and understanding how businesses best operate. By integrating intelligent video surveillance into the production system, companies can remotely monitor production efficiency and visually inspect and verify that functions and processes are running correctly. This enables managers to predict maintenance, even in areas difficult to access, and provide remote assistance with planned maintenance. Essentially, the advancements made in the hardware and software of network surveillance can

WITH THE NEW 518 PEN, YOU‘RE GOOD TO GO. New roll-on applicator makes liquid gaskets easier than ever.

Visit us, we‘ll even send a free sample to qualifying participants: www.henkel-adhesives.com/us/518sample

MRO_Nov_Henkel.indd 1

2018-10-24 9:39 AM

26

26

E L E C T R I C A L

U P G R A D E S

Machinery and Equipment MRO

November 2018

MISSION CRITICAL EMERGENCY POWER UPGRADES TELUS completes an integrated project to build a new standby generation plant at a mission critical network facility.

BY PHILIP CHOW, PETER FORMOSI AND MATTHEW WALKER

E L E C T R I C A L

U P G R A D E S

Machinery and Equipment MRO

November 2018

A

Photos credit: Philip Chow.

27

Construction on the new penthouse started with structural steel framing.

s one of Canada’s leading telecommunications companies, TELUS has a multitude of network buildings located throughout Canada. Network buildings provide a number of key telecommunications services, which include outside plant communications (telephone, data and television), mobility services, data centre services, web hosting, co-location facilities, etc. Network buildings are typically divided into areas, which contain telecommunications equipment (network spaces), building services (mechanical and electrical equipment) and office space for general corporate functions.

DC power plants, which consist of numerous strings of batteries, rectifiers, inverters and distribution equipment, and uninterruptible power supplies (UPS), provide power to network equipment. This helps ensure that any external, grid-related power interruptions do not interrupt telecommunications services. While uninterruptible power can support network equipment for up to several hours, the stored energy in battery systems will eventually be depleted, and it is not feasible to support large building cooling systems (required to prevent network equipment from overheating) with battery backup. Standby diesel generators are typically used to back up battery systems, building cooling systems and an entire facility’s electrical load, in the event of a prolonged utility power outage.

Replacing end-of-life standby generation can be a daunting task, especially when interruptions to critical network services cannot be tolerated. The challenges are further increased, when you undertake a project in a high-rise building, in a high-density urban environment and in a seismic zone.

TELUS faced these challenges when it undertook a project to a build a new standby generation plant in a network building in downtown Vancouver.

The project started with a feasibility study to review various concepts for replacing the existing standby generation plant, which consisted of five packaged generators (in prefabricated enclosures), installed on the building’s lower roof (Level 9). Given the limited space within the building, the options included installing new packaged generators on a higher roof (Level 13) or building a new floor on the higher roof, to house a new standby generation plant. The benefits, drawbacks and budgetary allowances for each option were outlined.

Given considerations for operability, reliability and maintainability, and ongoing neighbourhood development, building a new building floor and standby generation plant was selected. To accommodate future load growth for the site, an overall master plan was developed. Once the new generator plant was constructed, the existing packaged generators would be removed, existing cooling towers would be replaced and a second generator penthouse would be constructed on the lower roof. TELUS reviewed budgetary constraints and developed a spend profile for the project that would align with a phased construction approach. The first phase of the project involved constructing a new penthouse on Level 13 to house a 6MW standby diesel generator plant (a 4MW design load with N+1 redundancy).

Preplanning for the project began and H.H. Angus & Associates Ltd. was selected to provide electrical and mechanical engineering services for the project, to maintain continuity with the feasibility study. Since the project consisted of major electrical upgrades, along with mechanical infrastructure to support the new generating plant, H.H. Angus also assumed the role of the prime consultant and was responsible for co-ordinating the architectural and structural design of the new penthouse.

28

28

E L E C T R I C A L

Machinery and Equipment MRO

Equipment installation required a major road closure and set-up of a 500-ton mobile crane.

Equipment was lifted into place using the 500-ton mobile crane. Photo illustrates innovative hatches that were incorporated into the structure to facilitate the installation/removal of the new generators.

U P G R A D E S November 2018

General space planning and concept design started with layouts for the new generating plant; a new medium voltage AC power room for distribution equipment used to interface with the new plant and to feed the building’s critical loads; and a new main fuel oil room, which supplemented existing fuel oil storage tanks with approximately 50,000L of storage.

While preliminary design work was underway, engineered specifications and drawings were prepared for an equipment pre-tender package. Generator suppliers were invited to submit proposals for the supply of an integrated equipment package. The equipment supply package included four 2MW, 12.47kV diesel generators (the fourth unit was bought in anticipation of the next phase of the project); approximately 25 bays of medium voltage switchgear, complete with automatic transfer and paralleling controls; diesel emissions reduction system (DERS) modules (used to catalyze emissions and reduce pollutants); a 2MW resistive load bank and a 2.5MVA dry-type transformer for the load bank; and DC power distribution equipment to interface with the building’s 48V DC system, providing control power to switchgear controls. Multiple proposals were received and the equipment supply package was awarded to Finning CAT. With the equipment supply package awarded and equipment package in production, the design for the installation and construction of the new generator penthouse entered its final phase. A detailed set of drawings and specifications was prepared for all disciplines (architectural, electrical, mechanical and structural). The new penthouse was designed to integrate with the existing 12-storey building, and special consideration was given to both the new infrastructure requirements and aesthetics of the existing downtown Vancouver neighbourhood. Intake and exhaust plenums were designed

WHAT DO YOU NEED TO MEASURE? FLIR delivers world-class thermal cameras and test & measurement tools with the accuracy, reliability, and versatility you need to tackle your most challenging jobs.

For more information please visit: www.flir.ca/work/

1

30

30

E L E C T R I C A L

U P G R A D E S

Machinery and Equipment MRO

Equipment was lifted into place using the 500 ton mobile crane. Photo illustrates a 45,000 lb diesel generator being hoisted into place.

and co-ordinated with building structure, to ensure adequate airflow was provided for generator operation.

The exterior penthouse walls and roof were co-ordinated with plans for future building facade upgrades. The penthouse structure included innovative removable hatches to help facilitate the installation of equipment and allow for the future removal of generator sets. New service risers were created for medium voltage power cabling, low voltage cabling, control wiring, fuel oil piping and urea piping for the DERS modules. Diversified, redundant routes for new service risers were incorporated into the design, where possible, to improve reliability. The new fuel oil storage room was designed for connection to the site's existing fuel storage tanks, for future reserve capacity. A new 480V power distribution system with redundant 3000/4000 kVA, ANN/ANF, dry-type transformers was installed to provide ancillary power for the new generator plant and to facilitate future electrical load migration. Construction control drawings with site constraints, such as no onsite parking, building access requirements and available spaces for material laydown, were included to complete the design package. General contractors were invited to submit proposals for the project and after a detailed evaluation of submissions was completed, the project was awarded to PCL Constructors West Coast Inc. Construction started following contract award, with the submission of shop drawings for the numerous trades that were involved on the project, procurement of materials, and the application for municipal permitting and road closures. A tower crane was erected on the building’s lower roof (Level 9) to transport materials from street level to Level 13.

Once pre-construction activities were completed, the site had been prepped for the new build, structural steel was delivered

November 2018

Interior view of the new 6MW generator penthouse.

to the site and framing for the new penthouse was started. As construction on-site was progressing, manufacturing of the pre-tendered equipment package was nearing completion.

Given the critical nature of the facility, new electrical equipment was required to undergo rigorous off-site testing before being shipped to the site. Initial testing of the medium voltage switchgear and controls was completed at the switchgear supplier’s factory and included detailed physical inspections, operational scenarios with logic simulation, dielectric testing and primary current injection testing for protective relays. Once initial testing was completed, the medium voltage switchgear was shipped to the generator supplier’s testing facilities for complete integrated testing with the new diesel generators and an array of temporary infrastructure. Integrated factory testing focused on dynamic testing of the system as a whole and included paralleling, synchronization between units, load sharing, simulated failures and automatic transfer functionality. The overriding goal of integrated testing was to identify any major operational issues before the equipment was shipped to the site, thereby minimizing the risks associated with site testing. While off-site testing and construction of the penthouse were ongoing, the project team emphasized the importance in maintaining schedule on both fronts, such that the target date for equipment delivery to site, which required a major road shutdown, could be maintained.

At the onset of the project, booking a date for a road closure to facilitate the delivery of equipment to the site, which required the set-up of a 500-ton mobile crane, was a major project challenge. As the site was located on a major downtown street, shutdowns were limited to a few weeks each year, to avoid impact to other municipal road shutdowns and seasonal traffic requirements. Once a road closure and lift date were

E L E C T R I C A L Machinery and Equipment MRO

U P G R A D E S

31 November 2018

Interior view of the new AC Power Room with medium voltage automatic transfer switchgear and new 480V power distribution equipment.

scheduled, it was important that both the equipment and the site were ready in time. Fortunately, a realistic schedule, with detailed input for the various team members, was created and implemented.

The equipment lift was completed over the course of a weekend in early November, with two days being required for setting up/demobilizing the 500-ton crane and one whole day being dedicated to lift the equipment into place. Given the planning and co-ordination efforts by the contractor, as well as having the weather co-operate with minimal wind (despite non-stop rain), the equipment lift was a success. The equipment was set in place and the final stages of construction were completed.

New electrical and mechanical infrastructure was installed and thoroughly commissioned. The entire penthouse was tested under full design load (6MW) conditions, to ensure ventilation, fuel oil and electrical systems operated per design requirements. This process necessitated the installation of 4MW of temporary load banks on-site, with the additional 2MW being supplied by the permanent load bank. Once commissioning and site testing were successfully completed and outstanding issues were addressed, the entire building load was transferred to the new distribution system, via a phased approach. Each phase involved a detailed method of procedure process for load transfers, followed by dynamic site testing, to ensure the system would operate as expected. Load transfers were successfully completed over the course of several weeks with the new generation plant supported by the entire building load.

Building a new generator penthouse on the top storey of a high-rise building, in order to replace critical electrical infrastructure, can seem like a formidable challenge. There are

several key success factors that facility managers should undertake when considering a project of this nature. Following a detailed planning process, which starts with a feasibility study and design options, enables planning departments to develop appropriate budgets to complete infrastructure renewal.

Designating the right prime consultant (design lead) to oversee a multidisciplinary design process, helps ensure that new physical space is designed to serve the infrastructure that will be installed within. Developing a collaborative approach with major equipment suppliers and the installation contractor can help identify schedule issues, lead-time requirements and progress expectations. As demonstrated by the innovative project completed by TELUS, a mission critical facility was able to construct a 6MW generation plant on the top of a highrise building, in downtown Vancouver, in just over one and a half years. MRO Philip Chow, P.Eng., P.E., was the lead electrical engineer on the project and is a Senior Project Manager at H.H. Angus & Associates Ltd. Philip specializes in electrical infrastructure projects and construction in mission critical facilities and can be reached at philip.chow@hhangus.com.

Peter Formosi, P.Eng., was the lead mechanical engineer on the project and is a Senior Engineer at H.H. Angus & Associates Ltd. Peter specializes in mechanical infrastructure projects and fuel oil systems and can be reached at peter.formosi@hhangus.com.

Matthew Walker, P.Eng., was the project lead and is a Senior Project Manager at TELUS Communications Inc. Matthew has significant experience with infrastructure projects in mission critical facilities and can be reached at matthew.walker1@telus.com.

32

32

R E M A N U F A C T U R I N G

Machinery and Equipment MRO

November 2018

Expert bearing technicians following clearly defined procedures at dedicated remanufacturing service centres will promote successful outcomes.

Bearing Re manufacturing

When it makes sense to remanufacture bearings instead of getting them new.

BY MARK S. CAMPBELL

Photo credit: SKF Inc.

Benefits of

33

R E M A N U F A C T U R I N G Machinery and Equipment MRO

Challenge A 1,000 MW coal-fired power station identified six pulverizer roll wheel bearings that needed replacement before the pulverizer could return to service, a very real problem since the pulverizer was critical for maintaining peak power. Upon checking the lead-time for new bearings, the plant management realized that the schedule requirements could not be met. In the absence of a spare to serve as a backup, the pulverizer had to be brought back to its original specifications so the station could keep running without interruption until its next scheduled major outage.

November 2018

The process of remanufacturing a bearing can include changing or substituting damaged components to optimize assemblies.

Solution After completing inspection and failure analysis, it was determined that the bearings, although damaged, could be restored. In fact, they were remanufactured in six weeks compared to seven months of lead time that a new bearing set required. In addition to the timely return to service, remanufacturing saved the plant almost $7,500 in bearing purchases and related costs, plus five months of potential reduced power production worth more than $1.2 million in lost revenue.

As this case illustrates, remanufacturing can often serve as a timely, practical and cost-effective alternative to replacing a failing or failed bearing.

Bearings in rotating equipment primarily serve to support shaft loads, reduce friction with rolling elements, and provide shaft location and system rigidity. While bearings are engineered to operate over a calculated service life, various adverse influences can jeopardize and prematurely shorten how long a bearing actually will perform properly.

Wear, rust, solid particle contaminants and sporadic metal-to-metal contact are among the typical culprits.

Sooner or later, material fatigue can be expected to occur, resulting from shear stress cyclically appearing immediately below the load-carrying surface of a bearing’s rings and rolling elements.

Over time, these stresses cause micro cracks underneath the surface, gradually extending to the surface itself. As a bearing’s rolling elements pass over the cracks, fragments of the material break away (known as “spalling”). This is usually the beginning of the end for a bearing.

Some operating environments present especially daunting challenges, exemplified by demanding applications such as

A damaged bearing can be refurbished to meet or exceed specified standards and quickly returned to service.

34

34

R E M A N U F A C T U R I N G

Machinery and Equipment MRO

November 2018

Especially large-sized rolling bearings represent ideal candidates for costeffective remanufacturing processes.

those in the oil and gas industry. In the case of offshore drilling, for instance, moving into deeper and harsher environments exposes equipment and components to severe extremes in pressure, temperature, contamination and other especially punishing forces. As a result, bearings that ultimately bear the brunt may need to be replaced.

For whatever reason, when a bearing is on the road to failure or fails altogether, replacing the bearing is certainly an option. However, this standard approach can be an expensive proposition and may involve long, and unproductive, lead times for delivery. Instead of outright replacement, applying a controlled remanufacturing process for the bearing and then returning the bearing to full service can be the most viable approach.

Underscoring the advantages, cost-benefit analysis has shown that significant cost savings can be realized by remanufacturing a bearing, depending on its size, complexity, condition, price and application needs. Ultimately, bearing remanufacturing can contribute to reduced total life cycle costs, fully exploited service life, cost savings, improved uptime from increased ma-

chine availability, reduced environmental impact in terms of less energy and less scrap, and enhanced asset reliability.

Rolling Out the Process All rolling bearings are candidates for remanufacturing (although it may be economically unfeasible for very small sizes), and the nature and extent of remanufacturing processes will naturally depend on a particular bearing’s condition and application requirements. In general, during remanufacturing, relevant functional surfaces of the bearing will be repaired during remanufacturing, including the replacement of bearing components when necessary.

Among best practices, expert bearing analysts should always be enlisted for the job. They will be sufficiently equipped to evaluate the bearing and identify which remanufacturing approach will be the most efficient in restoring the bearing consistent with application requirements. Standard industry procedures and established criteria then will guide recommendations and remanufacturing work. Just as importantly, dedicated remanufacturing service centres represent a big plus. Some bearings may need

more work than others. As a result, different remanufacturing processes have been formalized.

Inspection is always the first step, whether for used bearings or for bearings stored over a long period, and involves comparing them with drawing and/or specification requirements. This process typically includes cleaning, degreasing, disassembling the bearing, non-destructive testing, visual/ microscopic inspection and dimensional inspection, followed by a detailed bearing analysis report offering recommendations for appropriate treatment and suitable remanufacturing attention.

The type and severity of surface damage will define which remanufacturing process has to be applied.

In cases of minor damage, remanufacturing operations such as buffing and superficial polishing of inactive and active surfaces are done and completed by demagnetization, reassembly, dynamic testing, lubrication and preservation, and packaging for return to service.

For more significant damage, remanufacturing builds on activities performed for minor damage and extends to include one or more of the following: intensive polishing and/or grinding of surfaces; replacing rolling elements if necessary with new rolling elements with a diameter equal to the diameter of the elements previously contained in the bearing or with adapted oversize rollers diameter (if clearance requirements demand it); remanufacturing the bearing’s cage for the rolling elements or replacing it with an identical cage; and/or interchanging used components (such as seals, snap rings and others).

During such remanufacturing processes, appreciable material removal takes place, which removes superficial damage and modifies the stressed material volume.

For severe damage, remanufacturing can encompass the previous operations and include installing new rings and changing or substituting components to create a different assembly identity (in effect, modifying in order to improve performance or properties).

With such clearly defined procedures, bearings returned to service can meet (or sometimes even exceed) specified standards. After work is completed, final inspection and measurements, cleaning and preservation, service reporting and archiving of documentation should be performed.

35

R E M A N U F A C T U R I N G Machinery and Equipment MRO

November 2018

Detecting Damage Early Success in remanufacturing will turn on when the bearing is flagged for the process. In some particularly critical industries, it is common practice from a safety perspective to remove rolling bearings during scheduled maintenance or overhaul of equipment, regardless of the bearing’s condition, and then perform the remanufacturing and return the bearing to service.

Since this is not necessarily the case in all industries, when does a bearing become a legitimate candidate for remanufacturing? The correct timing for bearing removal and remanufacturing can be determined to achieve the optimum balance of a long service life and low operating costs.

Predictive maintenance strategies and associated condition monitoring technologies offer a big assist in detecting early defects and damage, which can signal the early need for intervention and resolution to extend bearing service life. Other related technologies, such as traditional vibration monitoring and lubrication analysis (detecting wear particles), also can be engaged, all in an effort

Remanufacturing can include replacing damaged bearing cages and rolling elements.

to avoid catastrophic failure of a bearing and the increasingly intensive and costly remanufacturing required for totally failed bearings.

In short, bearing damage detected at the earliest possible stage can contribute

to a timely and positive remanufacturing outcome at relatively minimal cost. MRO Mark S. Campbell is Manager - Solution Factories South at SKF USA Inc. He can be reached at mark.s.campbell@skf.com.

Ď€ SHIPPING SUPPLY SPECIALISTS

HEAVY DUTY BOXES

ES Z I S OX B 0 55 CK , 1 O T R S OVE AYS IN ALW

ORDER BY 6 PM FOR SAME DAY SHIPPING

COMPLETE CATALOG

1-800-295-5510 MRO_Nov_Uline.indd 1

uline.ca 2018-10-19 3:44 PM

36

36

P R O D U C T

N E W S

Machinery and Equipment MRO

November 2018

WHAT’S NEW IN PRODUCTS Van der Graaf Unveils Intelligent Drum Motor

SKF LLT Profile Rail Guides Offer Long Service Life

The Van der Graaf Intelligent Drum Motor (IntelliDrive) is designed where the rotor is magnetically self-induced by the use of permanent magnets installed on the rotor body. It requires a vector-less sensor to operate; therefore, it must be used with the integrated VFD, which is Ethernet/IP and MODBUS compatible, enabling communication with other plant equipment. It also provides conveyor drive data feedback and control belt speed either remotely or direct at the drum motor. The Intelligent Drum Motor enables the ability to select the required belt speed without loss of torque or belt-pull. It has the electric motor, bearings and gear reducer hermetically sealed inside the drum. www.vandergraaf.com

SKF Motion Technologies, Inc., LLT guides have ball circuits placed in an X-arrangement, optimizing load sharing in all four main load directions and accommodates moment loads, while maintaining selfaligning capability. Guides are available in sizes 15 to 45 with rail sizes up to 4,000 mm in a single piece with longer lengths available as attached rails. LLT guides are available with a variety of preload and precision classes, mounting configurations and accessories. They can resist temperatures up to 100ºC and achieve speeds up to five m/s. LLT guides are supplied ready-to-mount and are factory pre-lubricated.

Carriages are equipped with end seals, side seals, inner seals and internal lubrication reservoir for extended maintenance intervals. www.skf.com

Nexen MRS Precision Rotary Indexer Nexen Group, Inc. Motor Ready Sealed (MRS) precision rotary indexer offers oneway positional accuracy up to ± 31 ArcSec and one-way repeatability up to ± 5.2 ArcSec. There is zero backlash from the motor through the driven load. Offers high speed of up to 304 rpm. Motor/gearbox is ready for fast installation. Various sizes available: 150, 250, 350 mm output bolt circle diameter, with large open centre to optimize performance in small spaces. Fully sealed and IP65 rated, and low maintenance and long life. www.nexengroup.com

Festo Motion Control Package Festo Motion Control Package (FMCP) is a motion control kit for running a Festo handling system. FMCP coordinates motion of up to six axes for pick and place and other precision Cartesian robotic applications. FMCP is available as a pre-wired and ready-toinstall control solution providing kinematics for H-portal, T-portal, 2D and 3D Festo standard gantry systems. At the PLC, OEMs configure Cartesian motion applications using the FCMP’s software function blocks. With the FMCP, OEMs have to connect power, Ethernet, IO and quick-connecting cabling to the gantry motors, then use the function block to fill in key motion parameters. Basic motion can be taught through a webserver or IOS/Android app. www.festo.com

SDT Unveils CloudConnected Condition Monitoring Solution SDT SDT340 data collector and UAS4.0 is a cloud-connected condition monitoring solution combining power of ultrasound, vibration, temperature and RPM. Ultrasound and vibration are measured using the SDT340’s focUS Mode. Long data samples can be captured with 32K, 64K, 128K or 256K resolutions. Data acquisition time is adjustable from a few seconds up to 10 minutes. STD340 has an internal storage of over 4.5gb, and a 3.5” diagonal colour display. It recalls historical measurements, and displays the time waveform and spectrum with live, scalable X-Y axis. UAS4.0 is scalable, multi-technology, multi-platform software to manage and analyze SDT340’s data. www.sdtultrasound.com

LiteSpeed Washdown High Performance Door LiteSpeed Washdown High Performance Door by Rite-Hite with curtain retention of up to 0.2 InWC. PVC vinyl curtain of the LiteSpeed Washdown operates on a stainless-steel frame without a header and motor shrouds. The design translates into smaller physical footprint and peak operating speeds of 65 inches/second with one horsepower motor. A seven-inch LCD touchscreen graphic user interface allows troubleshooting at the door opening. Available are safety presence sensors and an LED countdown, and if LiteSpeed Washdown is bumped or impacted, the TRUE Auto refeed will automatically reconfigure the door on its tracks.

Additional safety features include optional full-width vision panel, and Virtual Vision, which uses presence-sensing technology to alert workers if someone is approaching from the other side of the door. www.ritehite.com

P R O D U C T Machinery and Equipment MRO

Rush Machinery Wheel Truing and Dressing Machines Rush Machinery Model FC-350EX and FC-350W wheel truing and dressing machines are designed for truing and dressing flats, angles, radii on diamond and CBN single wheels and multiple wheel packs. FC-350EX features a full enclosure, PLC controls, oscillation, and pivoting of truing wheel axis. The FC-350W allows the user to dress the diameter and inside of the wheel without taking the wheel pack apart. Both come with RushVision software, which aids in high precision, high tolerance work and truing complex forms and radii up to two inches (50 mm). Software includes drawing templates for common wheel shapes, and allows users to import from CAD via USB port or networked PC. www.rushmachinery.com

TwinCAT IoT Communicator TwinCAT IoT Communicator allows for PLCs to communicate with mobile devices by connecting the PC-based TwinCAT controller to a messaging service through TLS encryption. TwinCAT 3 IoT Communicator exchanges data using a publish/subscribe mechanism. Information is exchanged via a message broker that uses the standardized MQTT protocol and acts as a central messaging service in a cloud or local network. High level of communication security

by TLS encryption (up to version 1.2). Transmitted process data can display on mobile devices using IoT Communicator App, available for Android and iOS. IoT Communicator App incorporates integrated QR code scanner. www.beckhoff.com

WAGO Expands Multi Connection System (MCS) WAGO MCS MAXI 832 Series is a lever-actuated PCB connector for high power applications, up to 66 A / 600 V, and up to four AWG conductors.

The MCS MAXI 832 Series extends range of wire-to-board and wireto-wire pluggable solutions at the high-power end of the range.

MCS family of pluggables, the tool-free, Push-in CAGE CLAMP 832 Series with lever operation, has high current and voltage capacity relative to its size. The MCS MAXI 832 Series’ lever operation is exclusive to WAGO in the field of power electronics interconnections, offering a completely tool-free, in-hand wiring solution for wire sizes 18 to 4 AWG. www.wago.com

PRUFTECHNIK OPTALIGN Touch System PRUFTECHNIK OPTALIGN touch system consists of a touch handheld device and the PRUFTECHNIK sensALIGN 5 sensor/laser heads. It offers all PRUFTECHNIK features necessary for everyday alignment jobs. OPTALIGN touch has full wireless connectivity via Wi-Fi connection and cloud-based file transfer. The touch screen device is made

37

N E W S

November 2018

for maximum durability, is waterproof and dust-proof according to IP65, and shockproof, oil, dirt and scratch resistant. The sensALIGN technology is based on PRUFTECHNIK single laser technology. Sensors include two HD large position sensitive detectors (PSD) and MEMS inclinometers and connect wirelessly to the device via Bluetooth. www.pruftechnik.com

Festo VTUG and CPX-E Available as a Package Festo compact VTUG plug-in valve terminal and CPX-E master/modular control system can be ordered as a package. Features include new panel mount manifolds, backpressure check valves, hot-swap module and fixed flow restrictors. New manifolds eliminate the need for actuator tubing within the cabinet.

The supplied sealing gasket offers IP69K protection. VTUG hot-swap function allows individual valves to be replaced quickly during operation without valve terminal having to be depressurized. VTUG offers up to 24 valve positions in a fixed grid and two possible functions per valve when 2x 3/2-way valves are selected. VTUG can communicate to the most common fieldbus networks. DXF contour template is available when VTUG is configured online. www.festo.com

Ameridrives and Bibby Turboflex Tri-Bushing Ameridrives and Bibby Turboflex, two Altra brands, Tri-Bushing, a flex element/ blade triangular bushing design features two straight profiles that significantly reduce and redistribute the stresses that occur around the disc pack bushings.

Tri-Bushing is available for use in all new Ameridrives, Bibby Turboflex, TB Wood’s and Lamiflex disc couplings. New disc packs with Tri-Bushing technology can also be retrofitted into existing couplings as part of repair or rebuild services. www.altramotion.com

Wieland Safety Limit Switches Wieland sensor PRO safety limit switches (series SLS) offer safe position monitoring in industrial applications. A metal actuator can be turned and swapped without tools, and switches are rated to IP66/ 67.

Actuation of switch contacts is monitored

by Wieland’s safety relays, samos PRO COMPACT safety controller, and will shut down the machine immediately.

Switches offer self-cleaning contacts, mechanical life of up to 30 million operations, maximum contact reliability of 1mA at 24VDC, robustness due to the metallic actuator and mounting bracket, and actuators that can be rotated or swapped in 45° increments by pulling the fastening clip. www.wieland-electric.ca

38

38

S P A R E

P A R T S

Machinery and Equipment MRO

November 2018

ArcelorMittal Mining Canada G.P. announced today a long-term funding programme to support mining and materials engineering R&D in the Faculty of Engineering at McGill University. The strategic partnership pledges to provide $360,000 over four years to create the ArcelorMittal Mining and Mineral Processing Fund, which will finance research projects and program development in the university's Mining Department. This joint pledge by ArcelorMittal Mining Canada and ArcelorMittal Mining R&D marks the first major financial contribution by the fund to an educational institution in Canada.

A strong research focus on mining and mineral processing is critical as the global demand for high-grade raw materials increases, compelling the mining industry to minimize waste, improve industry energy efficiency and increase overall value of products. Research projects currently underway in the Department include Stochastic Mine Planning, Geo-environmental, Mine Ventilation and Industrial Transport Processes, among others.

Photo credit: Gopesa Paquette

ArcelorMittal Mining Canada G.P. to fund major mining research collaboration at McGill University

Professor Jim Nicell, Dean of the Faculty of Engineering; Nicolas Dalmau, Head of Public Relations and Government Affairs, ArcelorMittal Mining Canada G.P.; and Professor Hani Mitri, Director of Mining Engineering, Faculty of Engineering.

"This investment from one of the world's leading mining companies is a strong vote of confidence in our program," said Professor Hani Mitri, Director of the Mining Department, at Mc-

Gill University's Faculty of Engineering.

"The department is already recognized as one of the best in the world and this support will ensure that this reputation endures."

Humber and DMG MORI Canada Partnership

SECURE ENERGY STARTS UP KERROBERT LIGHT PIPELINE SYSTEM Secure Energy Services Inc. announced that the light oil feeder pipeline system and receipt terminal in the Kindersley-Kerrobert region of Saskatchewan was completed on time and on budget and began commercial operations on Oct. 1. Secure began construction of the Kerrobert Light Pipeline System in September of 2017 as part of the corporation's growth strategy to continually expand its midstream infrastructure by adding long-term contracted transportation and commercial-related services in support of value creation for customers.

"The commissioning of the Kerrobert Light Pipeline System is an incredible milestone for Secure," said Rene Amirault, Chairman of the Board, President and Chief Executive Officer.

"We're pleased to see the successful execution of a project of this magnitude from the planning phase to final completion, and are excited for the continued growth and development of the corporation's midstream business. It is another example of how we strive to help our customers.�

Humber College and DMG MORI Canada Inc. are entering into a five-year partnership to address skills needs for advanced manufacturing tooling processes and engage in applied research. Collaboration will focus initially on industry 4.0-enabled 5 axis CNC technology, and eventually broaden to support outreach initiatives related to education in science, technology, engineering, and mathematics over the course of the agreement.

DMG MORI Canada is making significant investments in Industry 4.0 development over five years, including awards and scholarships, which will be named the DMG MORI Awards. DMG MORI will also work with the college to develop education to advance employment pathways and recruitment opportunities for Humber students and graduates.

"Our students and faculty will benefit from DMG MORI's expertise and learning on its machine tooling systems, as they prepare for the highly skilled, advanced manufacturing jobs of today and tomorrow," said Chris Whitaker, President and CEO, Humber College. "Through this and other industry and community partnerships, Humber is building a network of Centres of Innovation that are bringing together people, ideas and technology to solve real-world business challenges."

DMG MORI will now be part of the planned Industry 4.0 consortium that Humber is forming, and its equipment and technology will be featured in the Barrett Centre for Technology Innovation, the college's hub for bringing industry and education together.

Introducing the Breakthrough Asymmetric Mainshaft Bearing from Schaeffler: Engineered to convert high thrust into high performance We designed our new, state-of-the-art Asymmetric Mainshaft Support Bearing for extreme applications where a wind turbine’s mainshaft bearing is threatened by high thrust forces. By optimizing the gearbox side of the bearing with an increased contact angle, potentially damaging thrust is safely transferred through the bearing to the housing support. The result: lower torque, less friction and less heat inside the bearing. Which means less downtime for you.

And more power for your wind turbine.

www.schaeffler.ca