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Canada’s trusted journal for plant operations, engineers and maintainers
P
PLANT ENGINEERING
AND MAINTENANCE
www.pem-mag.com
VOLUME 29
ISSUE 4
SEPTEMBER 2006
A CLB MEDIA INC. PUBLICATION
2006 SALARY SURVEY
Go
West
Big money
in Alberta
ALSO:
Motor maintenance
Oil lubrication
Dust collectors (part two)
BROCHURE
WITH ISSUE!
PM # 40063602
PAP Registration # 10778
RELIABILITY FACILITIES PRODUCTION MACHINERY
PEM-Sept06-Cov-pg25-2.qxd
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Omron_PEM_Sep_06 1
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To contact this advertiser turn to page 65
Hertz_PEM_June_06.indd 1
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Table of Contents
VOLUME 29, ISSUE 4
SEPTEMBER 2006
FEATURES
West
26 Go
2006 Salary Survey: Big Money in Alberta
Maintainers, engineers and plant operations can compare their
salaries and more against industry peers.
by Robert Robertson and Allen Jones
Safe
38 Fail
Use proper maintenance to extend motor operating life
26
These tips will help you improve machinery uptime and performance.
by John Malinowski
Moves
42 Slick
Plan ahead to improve oil and lubrication reliability
Proper lubricant selection keeps motors and other equipment running.
by Peter Fretty
First
48 Safety
More about explosions and fires in dust collectors
Part two of the series shows you how to keep maintainers safe.
by Gary Berwick, P.Eng.
In the next issue of PEM:
SHUTDOWNS &
TURNAROUNDS
RELIABILITY TRENDS
Eliminate costly mistakes
with your next plant shutdown and turnaround.
Maintenance experts talk
about the latest industry
issues affecting equipment reliability.
SPECIAL: With PEM issue
Check out the expanded standalone
MOTORS PLUS
Part two of the series
showcases new motors
and drives product innovations.
P
PLANT ENGINEERING
AND MAINTENANCE
A CLB MEDIA INC. PUBLICATION
EDITOR
Robert Robertson
rrobertson@clbmedia.ca
(905) 726-4655
MRO EXPRESS
eight-page brochure for information
Safety products
Welding equipment
Parts storage
Bearings
about the MainTrain 2006 physical
asset management conference.
EDITORIAL DIRECTOR
PUBLISHER
PRODUCTION MANAGER
Todd Phillips
tphillips@clbmedia.ca
Frank Shoniker
fshoniker@clbmedia.ca
Barb Wood
bwood@clbmedia.ca
(905) 713-4383
PROD./OPERATIONS EDITOR
David Berger, P.Eng. (Alta.)
CONTRIBUTORS
Wilfred List
Ken Bannister
Terry Wireman, CPMM
John Gross, P.Eng., CPE, CQE
ASSOCIATE EDITOR
SENIOR ART DIRECTOR
Vanessa Chris
vchris@clbmedia.ca
Nicole Diemert
ndiemert@clbmedia.ca
ACCOUNT MANAGERS
Tom Reilly-Smith
treilly-smith@clbmedia.ca
(905) 713-4341
Gary Dugan
gdugan@clbmedia.ca
(905) 713-4365
CIRCULATION MANAGER/
SUBSCRIPTION INQUIRIES
James Zammit
jzammit@clbmedia.ca
MANAGER, PRODUCTION
Lisa Drummond
ldrummond@clbmedia.ca
Peter Helston
peterhelston@yahoo.com
(416) 236-7852
CREATIVE DIRECTOR
Einar Rice
erice@clbmedia.ca
VICE-PRESIDENT, HUMAN RESOURCES
DIRECTOR, FACILITY MGT & LOGISTICS
Susan Bishop
Steve Dale
VICE-PRESIDENT, IT AND OPERATIONS
DIRECTOR, HUMAN RESOURCES
Stuart Morrison
David Overall
Denise Desrosiers
VICE-PRESIDENT MEDIA, PUBLISHING
DIRECTOR, SALES & MARKETING
DIRECTOR, IT
Niel Hiscox
Frank Shoniker
Michael Cunningham
VICE-PRESIDENT FINANCE/
CORPORATE DEVELOPMENT
DIRECTOR, EDITORIAL
& PRODUCTION
MEMBER, CLB MEDIA INC.
MANAGEMENT COMMITTEE
Jackie Roth
Nigel Bishop
PRESIDENT
Kent Milford
4
PEM PLANT ENGINEERING AND MAINTENANCE
w w w. p e m - m a g . c o m
PEM Plant Engineering and Maintenance is published six
times yearly by CLB Media Inc., 240 Edward St., Aurora, ON
L4G 3S9. All rights reserved. The contents of PEM are copyright by ©2006 CLB Media Inc. and may not be reproduced in whole or part without written consent. CLB
Media Inc. disclaims any warranty as to the accuracy, completeness or currency of the contents of this publication and
disclaims all liability in respect of the results of any action
taken or not taken in reliance upon information in this publication. Issue dates are February, April, June, September,
November and December. Yearly subscription rates: Canada
$84 plus GST*; U.S. $96; Others $240. Single copy prices:
Canada $15; U.S. $20.
Canada Post – Canadian Publications Mail Product Sales
Agreement 40063602. International Standard Serial Number
(ISSN) 0710-362X. PAP Registration No. 10778.We acknowledge the financial support of the Government of Canada
through the publications Assistance Program toward our
mailing costs.
*Goods & Services Tax Registration No. R101006989.
Printed in Canada.
For information on reprints of any article that appear
in this publication, contact The Reprint Outsource at
1-877-394-7350.
c a
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EDITOR’S NOTE
Don’t have
downtime
nightmares
COLUMNS
18
Plant Safety
Plan ahead for possible emergency events
Be prepared for anything in the plant.
by Fred Matthews
20
20
Power Transmission
I
Use proper bearing fits to boost uptime
The wrong fit sacrifices bearing life.
by Galen Burdeshaw
24
Maintenance Software
Analysis and reporting tools provide edge
The right data drives CMMS systems.
by David Berger, P.Eng. (Alta.)
52
8
Asset Management
Take a close look at point-of-use spares
Make the most of your parts storage.
by John M.Gross, P.Eng. CPE, CQE
54
Materials Handling
Are your systems at a breaking point?
Ensure key DC systems are updated.
by Bill Vincent
DEPARTMENTS
6
Hands On
Industry Update
People and Companies
Ask Ken
Back to Basics
51
Plant Facilities Review
56
Marketplace
62
MRO Express
65
FYI
66
People and Productivity
56
Generating plant switches oil
to improve performance.
Industrial products and services.
PEM’s bonus showcase of the
latest product innovations.
Advertiser contact information.
Better hide the dynamite
by Wilfred List
66
w w w. p e m - m a g . c o m
n PEM’s third annual
salary survey (see pages 2637), one respondent rated
average equipment downtime
at a nightmarish 30 days per month. We know this
is an exception and not the rule. To ensure reliability and improve performance, however, companies
have to provide necessary training to maintainers
and use predictive maintenance (PdM) strategies.
Clearly, there’s a better way to manage assets and
avoid machinery failure.
If not, then the results are predictable for those
organizations stuck in the no-win world of poorly
trained maintainers and reactive maintenance.
Take for example a report issued late last year by
the U.S. Transportation Department Inspector
General, which outlined concerns about the policing
of critical airline maintenance work performed by
non-certified shops.
The report said that U.S. airlines are outsourcing
an increasing amount of repair work to independent, non-U.S. Federal Aviation Administration
(FAA)-certified contractors in foreign countries. The
report alludes to potential cut backs on maintenance
training. The downtime stakes are high, as airline
safety is of critical importance to everyone getting on
an airplane.
One airline reportedly had simply mailed a workbook to each shop and requested mechanics sign a
form saying they had read it. At another unnamed
airline, it was reported that non-certified work constituted 74 percent of critical repairs, those of which
requiring an inspection before an airplane goes back
into service. Talk about rolling the dice.
There’s also the recent shut down of BP
Exploration Alaska Inc.’s damaged pipeline. It was
reported that corrosion on the transit pipeline was
discovered after workers found a small spill of an
estimated four to five barrels of crude. When the
pipeline was initially closed, it was estimated that oil
production would be reduced to 400,000 barrels of
oil a day.
Make maintenance training a priority and be
part of the PdM movement. Don’t wait for a costly
downtime repair to happen.
Robert Robertson, Editor
PEMAC Allied Member
rrobertson@clbmedia.ca
SEPTEMBER 2006
5
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Hands On
0n
NEWS AND NOTES FOR THE PLANT PROFESSIONAL
I N D U S T RY U P D AT E
PTDA holds successful
Canadian conference
president and chief economist, Canadian
Manufacturers and Exporters (CME), the
face of Canadian manufacturing is changing.
He also said that companies have to look at
business planning differently in the future.
“Manufacturing in Canada continues to
change at a fast rate. It’s not about getting
product through the door—it’s about building customer value,” said Myers. “To remain
competitive, companies also have to adjust
their business planning. Organizations must
focus on customer and supplier success, master global supply chains, specialize products
and services, go lean and innovate, as well as
attract and retain skilled workers.”
Mary Sue Lyon, PTDA executive vice-president and Wendy McDonald, chairman, BC
Bearing Engineers Ltd., both had the attention of delegates at the conference. Lyon
talked about how the PTDA Canadian conference has grown in the five years of its existence. She also outlined progress of the PTDA
Foundation’s Industrial Careers Pathway initiative at Mohawk College in Hamilton, ON,
and BCIT in Vancouver. McDonald provided
a humorous, historic look back at how her
company has succeeded over the years.
In other news, the PTDA released the June
trend data for distributors and manufacturers
of power transmission/motion control
(PT/MC) products. Canadian distributors’
year-to-date sales of PT/MC products grew
9.9 percent compared to sales for January
through June 2005. Sales rose 0.9 percent over
the previous month and grew 14.0 percent
compared to June 2005.
From left: Larry Reynolds, SEW-Eurodrive; Harry
Whyte and Todd Ward, Rockwell Automation; Jim
Magee, Bonfiglioli; and Bob Ramsden, Rexnord.
From left: Greg Babcock, NSK Canada; Estelle
Wigg, Oilite USA; David Heal, NSK Canada; and
Paul Dent, Accurate Bushing.
PHOTOS: PETER HELSTON
OTTAWA—The Power Transmission Distributors Association (PTDA) held its fifth annual
Canadian conference recently at the Fairmont Chateau Laurier Hotel here. According
to the PTDA, the conference was the biggest
and best yet with more than 220 delegates in
attendance.
Once again, the PTDA’s Canadian conference was the place to be to learn about important economic indicators and other power
transmission (PT) industry trends. Dr. Peter
Andersen, president, Andersen Economic Research, started things off with positive news
about the current Canadian economy. At the
same time, however, he said another recession
might rear its ugly head in 2009 or 2110. As a
result, PT manufacturers and distributors will
have to adjust to the shift in the economy.
“Right now, the word is expansion for
Canada and we’re at the economic mid-way
point. I believe in cycles and this one can continue,” said Andersen. “The world economy is
also doing really well. We’ve had three very
good years with a run of five-percent growth.
The quality is better than a few years ago or in
the 1990s.
“On the horizon, there looms a possible recession and you should start to worry in 2009
and 2110. It’s important that companies reinvent themselves and have options that will
offer protection on the downside. I expect
that China will become an even bigger factor
in the automotive industry. By shipping vehicles to North America, China will put great
pressure on the Big Three automakers.”
According to Jayson Myers, senior vice-
6
PEM PLANT ENGINEERING AND MAINTENANCE
w w w. p e m - m a g . c o m
TOP: From left: Helen and Sean Hickey, Lafert
North America with Dave Rannie and Arden
Redfern, Can-Am Chains.
BOTTOM: From left: Guenther Bundels,
Optibelt Canada with Gord Duncan, Kinecor
and Ian Budziszyn, Optibelt Canada, Karl
Asendorf, Optibelt Corp.
Days sales in accounts receivables increased 0.9 percent from May 2006 and fell
2.8 percent compared to the same month last
year. Annualized sales to inventory ratio in
June was 8.6, compared to 7.9 in 2005. For
June, the confidence level of Canadian distributors increased to 7.5 from 6.8 on a 10point scale.
Canadian manufacturers’ year-to-date
sales of PT/MC products increased 2.4 percent compared to sales for January through
June in 2005. Sales were down 0.2 percent
over the previous month and gained 1.0 percent compared to June 2005. Compared to
May, sales of mounted bearings, standard industrial motors, variable-speed drives, mechanical-drive systems and other PT
products, clutches and brakes and shaft couplings increased.
Sales of unmounted bearings and positioning systems/linear-motion products decreased. Annualized sales to inventory ratio in
June was 8.3, compared to 7.9 in 2005. For
June, the confidence level of Canadian manufacturers was up 5.2 from 5.1 in May on a 10point scale.
www.ptda.org
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Tired of the same routine?
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Stop throwing your money away on electric vacuum cleaners that are sure to fail. EXAIR
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Chip Vac is powered by
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The Vac-u-Gun uses
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Three Vac-u-Gun systems are
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Untitled-4 1
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A DV E R TOR I A L
Lubricants just reduce
friction, right?
Wrong. They provide a number
of valuable benefits too.
– By Tanvi N. Bhatt
The traditional definition of a lubricant is
that it helps reduce friction, or the energy
consumed when two surfaces in contact
slide relative to each other, caused by
plowing. A traditional lubricant, like oil,
when placed between the two surfaces
helps remove wear particles and in turn,
reduces the coefficient of friction.
However, when this traditional lubricant is
combined with additive technology, it does
more than just reduce friction – the oil is
transformed from a friction reducer to a
true fully-featured lubricant with a number
of valuable properties.
Additive
Engine
Oils
ATF
Detergents
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Dispersants
Anti-Oxidants
Rust Inhibitors
Anti-Wear
But, that’s all the pancake syrup will do.
As a result, the wrench will slide slower
and need more power to start moving but
it doesn’t trap any paint or metal particles
or protect the hood against rust which can
be contaminated, increasing wear. And the
pancake syrup won’t help reduce heat if
the test is repeated at a faster pace.
So, by replacing the syrup with a proper
additive (see chart above) enriched
lubricant, we can see a number of benefits
and reduced wear characteristics, such as:
Corrosion Reduction – lubricant coating
during non-use reduces or eliminates
corrosion on metal and alloy surfaces.
Contamination Resistance – increased
resistance to particulate contamination due
to friction, i.e., these are the wear particles
that are caused by the “plowing” motion
when there is metal-to-metal contact.
AW
Hydraulic
Industrial
Gear Oil
Automotive
Gear Oil
Grease
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
HVI
Some
Some
•
•
•
•
•
•
EP Agents
VI Improvers
Pour Point
Depressants
Anti-Foam
Let’s take a real life example. If you
place a heavy metal wrench on a sloped
car hood (don’t try this at home without
parental supervision and of course proper
lubrication) and let go, the wrench will slide
down the hood, creating friction and wear
particles will scratch the hood. However, by
adding a compound that reduces friction,
let’s say a thin coating of pancake syrup,
friction between the metal hood and the
wrench is reduced or eliminated.
General
R&O Oil
Dyes
Friction Modifiers
•
•
•
Heat Reduction – reduces heat caused by
friction of moving parts especially between
highly conductive materials.
Wear Reduction During Startup – good
lubricant clings to metal parts to protect at
startup, and does not break down during
high loads or heat stress.
Protection at Temperature Extremes –
protection from high temperatures that
can cause breakdown of the components
and fluids.
Lubricants are necessary and have a
significant impact in keeping machinery
running smoothly. Let’s look at a wind
generator/turbine operation as another
example.
Wind turbines run under some extreme
conditions. With constant stopping and
starting, high temperatures and scuffing
and wear of the gear teeth, it’s essential
to use a lubricant that is robust enough
to protect against these conditions but
light enough that it doesn’t fail to provide
excellent viscosity index and low pour point.
Offshore wind turbines require additional
protection from rust and corrosion caused
•
by salt water. Accessibility to these units
can be quite challenging. Gearboxes are
located at the top of 100-metre poles and
that makes the intervals between changeouts very important.
Under such extreme conditions, operators
must select lubricants that are made up of the
purest base oils combined with an additive
package to deliver strong, long-lasting
lubricants that also protect against wear.
Today’s modern definition of a lubricant is
much more than a friction reducer. It is a
combination of base oils and additives that
protects equipment from a number of wear
characteristics.
This information was provided by Tanvi
Bhatt from Petro-Canada Lubricants.
Petro-Canada blends and packages more
than 350 different lubricants, specialty
fluids and greases that are exported to
more than 60 countries on six continents.
Products are manufactured from 99.9%
pure base oils – the purest in the world.
For more information on Petro-Canada’s
products and services,
please call 1-866-730-2045 or visit
www.petro-canada.com
To contact this advertiser turn to page 65
Untitled-1 1
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Advanced Science.
Advanced Grease Lubrication.
At Petro-Canada we designed our line of Precision* Greases to deliver 3-in-1
Protection. With Precision Greases you get longer life, less water wash-out
and better surface protection. Petro-Canada grease crafters combine our
ultra pure base oils together with other selected oils and specific performance
additives. Then we process them using the advanced science of our distinctive
two stage manufacturing process. The results speak for themselves: less
wear on equipment and improved productivity for your operation.
Put the Advanced Science of Precision to work in your plant.
Contact 1-866-335-3369 or www.petro-canada.ca
*Marque de commerce de Petro-Canada - Trademark
LUB 1989 (05.09)
To contact this advertiser turn to page 65
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Page 10
Hands On
NEWS AND NOTES FOR THE PLANT PROFESSIONAL
M AT E R I A L S H A N D L I N G
Combilift introduces new forklift trucks
PHOTO: COMBILIFT
MONAGHAN, IRELAND—Combilift recently intro-
duced new forklift trucks with more than 80 journalists from around the world in attendance here.
The range of trucks include: the TeleCombi, the
Semi-RoughTerrain C10,000L and the GT Hydrostatic Electric Sideloader. The forklifts, which are
manufactured in Ireland, will be available in both
Canada and the U.S. through Combilift dealers.
At the same time, Combilift also opened a
new 100,000 square-foot manufacturing and research and development facility located in Monaghan. Founded in 1988, Combilift developed
the world’s first engine-powered, multi-directional forklift truck. Combilift says its space-saving forklifts can eliminate the need for multiple
machines when handling long, awkward loads in
or outside a facility.
The TeleCombi is designed for extrusion
companies (i.e. PVC and aluminum) and features a boom lift that enables users to load and
off load the contents of a trailer from one side. A
moving carriage allows operators to retract a
load at specific heights, which eliminates the
need for constant height adjustment, especially
in confined spaces, says the company.
row retail and wholesale lumber yards. With
larger solid pneumatic tires, it’s especially
suited to unpaved yards and semi-rough terrain, including snow conditions and offers
added suspension for more comfortable operator materials handling, says the company.
The GT Electric Sideloader is the first hydrostatic electric-powered sideloader in the
market, says the company. It includes all the
parts that are featured with Combilift’s internal-combustion GT Sideloader. The forklift
is available with optical guidance. Optical
cameras mounted on the truck, monitor a
tape bonded in the centre of the aisle to enable automatic steering.
“These forklifts mark a milestone in Combilift’s growth,” said Tommy Cadden, Combilift USA president. “We currently export to
Combilift forklift truck handles wide materials
45 countries around the world. Where there’s
handling load in lumberyard.
materials handling and construction—
The Semi-RoughTerrain C10,000L forklift is there’s a need for Combilift.”
designed to handle long loads of lumber in nar- www.combilift.com
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Special Events:
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For more information visit www.smrp.org
or call 800.950.7354.
To contact this advertiser turn to page 65
10
SMRP_PEM_June_06.indd 1
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THERMOGRAPHY
Fluke introduces new range
of IR cameras
MISSISSAUGA, ON—Fluke Electronics Canada introduced its Ti family
ELIMINATE DUST AND
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eras feature
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temperature measurement ranges, imagebrowsing capabilities, eight-colour linear pallets, 180-degree articulating lens and on-board CompactFlash memory. Some models also
feature movable on-screen spots and boxes, 2x, 4x and 8x digital zoom,
enhanced annotation capabilities and a high-temperature (1,200 degree Celsius) option, says the company.
The Fluke Ti50 and Ti55 models offer high-resolution 320 x 240 detectors, says the company. These cameras come standard with the new
Fluke SmartView image management software, a complete suite of
analysis, management and reporting tools. “We’re excited about our
line of thermal imagers,” says David Green, director of marketing for
Fluke in Canada.“We want to make it easier for maintainers to conduct
inspections.”
www.fluke.com
Fluke’s Ti family of portable thermal imagers are available in
six camera models and offer a variety of features.
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Specialists in Dust & Fume Extraction Systems
To contact this advertiser turn to page 65
230 Don Park Road, Unit 15, Markham, ON L3R 2P7
Tel: (905) 305-0094 Fax: (905) 305-0092
www.adgastech.com sales@adgastech.com
To contact this advertiser turn to page 65
w w w. p e m - m a g . c o m
SEPTEMBER 2006
11
PHOTO: FLUKE
of portable thermal imagers. The imagers are available in six camera
models—the Ti20, Ti30, Ti40, Ti45, Ti50 and Ti55. The imagers are designed both for technicians with little or no thermography experience
and for operators with more predictive maintenance (PdM) skills.
Simple point-and-shoot and intuitive on-screen commands make
the Fluke Ti20 and Ti30 easy to use, says the company. Operators simply focus the instrument on the target and the camera automatically
adjusts the temperature range and stores images for later analysis, using
Fluke InsideIR software (included). The software also allows operators
to create inspection routes, using unique location names, measurement
set-up data and high/low temperature alarms. These routes can be uploaded to the imager for use as a routing guide, says the company.
“You don’t find things with thermography—you fix things. Today,
maintainers want to do more with thermography,” says Jonathan
Blaisdell, Fluke’s thermography product manager based in Everett,
WA. “Price points on thermal imagers have come down. As a result,
thermography is now a more attractive option for maintenance professionals.”
The Fluke Ti40, Ti45, Ti50 and Ti IR Flex Cam series infrared cam-
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Hands On
NEWS AND NOTES FOR THE PLANT PROFESSIONAL
P E O P L E A N D C O M PA N I E S
From left: Mike Blundell, national sales manager energy and industry for KSB Canada and
Morris Liu, KSB’s new business development
manager for western Canada.
Rockwell introduces monitoring tool
MILWAUKEE, WI—Drawing from more than 50
years of experience in machinery protection and
condition monitoring, Rockwell Automation fulfills
the requirements of Turbine Supervisory Instrumentation (TSI) with the addition of the new AllenBradley XM 121A Absolute Shaft and the XM 442
Voted Electronic Over-speed Detection System
(EODS) Relay Modules.
The new modules are a scalable solution that can
PHOTO: KSB PUMPS
Burlington, ON-based Invensys Process Systems announced that Neil Cooper, general
manager of its Avantis business unit is a featured speaker at the 2006 Canadian Manufacturing Week Expo and Conference this
September. Invensys also announced it introduced an enhanced version of its Condition
Monitoring (CM) 2.1 software • Electromate
Industrial Sales Ltd. of Woodbridge, ON, announced it’s successful completion of the
LEAN Process Redesign certification • Waterloo, ON-based IFS Canada announced that
QuadTech, Inc. signed a contract to implement IFS Applications7 business software •
Mississauga, ON-based KSB Pumps Inc. appointed Morris Liu business development
manager for western Canada • Goteborg,
Sweden-based SKF signed an agreement with
John Crane Safematic Oy, part of the Speciality Engineering Division of Smiths Group
plc, to acquire John Crane’s lubrication systems business. The business is headquartered
and has its manufacturing operations in
Muurame, Finland. In addition, the company has sales offices in Sweden, Germany, the
U.S. and Brazil • The U.S.-based Bearing Specialists Association (BSA) released a new Educational Services Committee (ESC) Report
that covers planetary roller screws. The report can be downloaded from the BSA’s Web
site (www.bsahome.org) • Canton, OHbased The Timken Company announced
that its aerospace aftermarket solutions subsidiary, Bearing Inspection, Inc., has been
named by Cincinnati, OH-based GE Aircraft
Engines as an approved source for the repair
of bearings for the CF34-3 aircraft engine •
Toyota recently produced its 250,000th lift
truck at its Industrial Equipment Manufacturing (TIEM) plant in Columbus, IN • Birmingham, AL-based Motion Industries Inc.
opened a new branch in Woodstock, ON.
12
PEM PLANT ENGINEERING AND MAINTENANCE
w w w. p e m - m a g . c o m
be easily integrated into a plant’s control and information system, as well as meet the needs of applications requiring absolute shaft measurements and
redundant over-speed protection, says the company.
As part of an overall machinery protection and
condition-monitoring strategy, the data collected by
the XM series modules can be used to identify and
prevent issues with equipment operation, says the
company. www.rockwellautomation.com
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THERMOGRAPHY
FLIR offers the ThermaCam P640 camera
BOSTON—FLIR Systems, Inc. introduced the
ThermaCAM P640 thermal-imaging camera.
The P640 is suited for professional thermographers, infrared consultants, those working in the
utility industry, or anyone needing to view small
or distant targets with better thermal image detail and temperature measurement accuracy.
The new high-definition 640 x
480 detector in the P640 delivers
307,200 pixels versus 76,800 in an
IR camera with a 320 x 240 detector.
This is four times better resolution
(16 times better than an infrared camera with a 160 x 120 detector), says the
The ThermaCAM P640 thermal-imaging
camera gives thermographers an edge.
S O F T WA R E
Ivara partners with
MRO Software
BURLINGTON, ON—Ivara Corp. announced
that it joined the MRO Software Complementary Solution Partner program. As a reliability
partner for MRO Software, Ivara will deliver
enhanced reliability capabilities to complement
the Maximo Enterprise Suite.
The combined offering supported by Ivara’s
reliability software, EXP, will help customers to
improve the effectiveness of their maintenance
organization, say both companies.
“The integrated Ivara-MRO Software offering delivers a complete reliability system that
optimizes both equipment and financial performance,” says Ivara’s CEO Gerry Bleau.
“We’re pleased to join with MRO Software and
look forward to supporting customers.”
www.ivara.com / www.mro.com p
To contact this advertiser turn to page 65
w w w. p e m - m a g . c o m
SEPTEMBER 2006
13
PHOTO: FLIR
company. The P640’s
image quality also allows
the professional thermographer to see much more image detail to help pinpoint or diagnose the nature of a problem.
The P640 features new interchangeable lenses
that have been developed to further enhance the
camera’s ability to capture distant targets in high
detail or view close-up targets with a wide field
of view. An eight-to-one continuous digital
zoom allows the user to take full advantage of
the camera’s high-definition image to pinpoint
problems and understand their origin, says the
company.
The new camera also includes an interchangeable 1.3-megapixel visual camera, a large,
swivel-mount, 5.6-inch colour LCD, tilt-able
viewfinder and a three-hour battery, all in a
rugged lightweight magnesium package that
weighs less than cameras with a fraction of the
resolution and performance features, says the
company.
www.flir.ca
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Hands on
NEWS AND NOTES FOR THE PLANT PROFESSIONAL
By Ken Bannister
ASK KEN
Why do CMMS/EAM projects fail?
Do you want to know how to improve
equipment uptime and reduce costs? Or maybe
you have a question about predictive maintenance (PdM) tools or how to enhance MRO performance. In each PEM issue, respected industry
practitioner Ken Bannister will provide the answers. If your question is picked, PEM will send
you a maintenance textbook for your library.
Email your questions to Ken Bannister today!
CMMS/EAM SYSTEM STRATEGIES
Failure is often a result of not defining success.
When measurable performance indicators
don’t define deliverables or goals and expectations aren’t put in place for computerized
maintenance management software (CMMS)
or enterprise asset management (EAM) system
implementations, how can you know if and
when the project is successful?
Too many CMMS/EAM systems are implemented without clear purpose and direction.
They quickly becoming onerous to use and
Frustration leads to
eventual abandonment and
replacement of the software.
users experience great difficulty in extracting true management information. Frustration leads to eventual abandonment and
replacement of the software. The mistaken
belief is that CMMS/EAM systems are solely at fault. Data from the old system is then
transferred to the new software and the
failure cycle begins to repeat itself.
The majority of successful CMMS/EAM
system projects are implemented in reverse
order. Prior to any implementation work,
the maintenance department must determine and develop a series of incremental
targets and goals for a period of three
years. Goals are then established as key
performance indicators that are tiered by
equipment, area and department.
The CMMS/EAM reporting system is
then used to provide reports, which allow
completion of the performance-indicator
calculations. Work-order design and codemanagement sets are created to provide the
required data to successfully produce required system reports.
CMMS/EAM systems using 20 percent
of their capabilities are still considered a
success when they provide needed information to manage maintenance processes.
Long-term performance involves defining
what the system must do and delivering on expectations. Everything else is meaningless, unrelated data. p
Ken Bannister of Innerkip, ON-based Engtech Industries Inc. is a production and maintenance
management specialist. You can email your questions to him at kbannister@engtechindustries.com.
A Practical Guide to Occupational Health
and Safety Compliance in Ontario,
Third Edition
Ontario Pension Law Handbook, Second
Edition
Norman A. Keith and Elizabeth Rankin
The second edition sets out recent significant
developments in pension law including the issue of
partial wind up surplus; pension plan mergers and
asset transfers; class action proceedings … and more!
This third edition includes recent Bill C-45 amendments
to the Criminal Code establishing a federal occupational
health and safety criminal offence; a detailed breakdown of toxic
substances regulations and the precautions an employer needs to
take; the right to appeal orders and decisions by the Ministry of
Labour …and more.
Susan G. Seller
Perfectbound • 326 pp. • June 2006 • $79
P/C 0830010002 • ISBN 0-88804-429-1
Perfectbound • 214 pp. • May 2006 • $69
P/C 0766010003 • ISBN 0-88804-431-3
Human Resources Guide to Workplace Investigations
Janice Rubin and Christine Thomlinson
This book discusses the "dos" and "don'ts" of conducting workplace investigations. It addresses issues such as, why conduct
a workplace investigation, who should conduct an investigation, the investigation process and the investigation report.
Perfectbound • Approx. 200 pp. • September 2006
Approx. $59 • P/C 0141010000 • ISBN 0-88804-443-7
For a 30-day, no-risk evaluation call: 1 800 263 2037 or 1 800 263 3269
www.canadalawbook.ca
Shipping & handling charges are extra (unless payment accompanies your order). Prices are subject to change without notice, and to applicable taxes.
To contact this advertiser turn to page 65
14
PEM PLANT ENGINEERING AND MAINTENANCE
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Reliability.
Durability.
Performance.
Support.
Always.
Raymond reliability.
Johnston support.
Depend on us.
You can depend on the rugged new AC-powered 8000 Series pallet trucks, part of the
full line of tough Raymond® trucks that are helping Johnston customers make their
operations more productive than ever. All 8000 Series trucks are equipped with Raymond’s
exclusive ACR SystemTM, which helps to maximize uptime and lower costs. Add Johnston
Equipment’s knowledgeable people, coast-to-coast, and our customer-driven commitment
to superior service and you have a team you can depend on. Put Raymond reliability and
Johnston support to work for you.
Contact your local Johnston office,
visit www.johnstonequipment.com
YOU’RE WHAT DRIVES US
or call 1-800-668-5586.
To contact this advertiser turn to page 65
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Hands On
NEWS AND NOTES FOR THE PLANT PROFESSIONAL
By John Lambert
BACK TO BASICS
Have more respect for V belts
In each PEM issue, top industry practitioner
John Lambert will provide you with useful tips on
maintenance fundamentals. His many years of
experience will help you get back to the basics,
which is the first step to advancing to worldclass maintenance. In this column, he talks
about V belts and the importance of avoiding
costly failures.
WORK SMARTER WITH V BELTS
I watched two tradespersons recently work on
a large belt-driven pump. They removed the
belts by simply prying them off with a bar.
They tested the motor and pried the belts
back on after finishing. This didn’t totally surprise me, however, as I have seen brand new
belts installed in a similar way. The old belts
were cut off and new ones pulled on with the
use of a hand rag. You do this by starting the
belt in the groove and placing the rag or wipe
under the belt and pull it on. This happens in
plants and I call it “reality” maintenance.
Another common belt-drive issue
is the re-tensioning of new belts.
A new belt will stretch a little and
the sides of the belt will wear.
It’s not surprising and the term fits, when
you think that some shops are still using
string to align the sheaves. Some maintainers
have the opinion that it’s only a rubber band.
It can handle misalignment, so who cares?
Well, the reality is that it can’t. And with current low-cost, laser-belt systems, there’s no
reason not to buy the right tools to do the job.
One reason for doing this is that industry
experts say you should get seven years of
operation from a belt drive. How many years
do you get from yours?
Another common belt-drive issue is the
re-tensioning of new belts. A new belt will
stretch a little and the sides of the belt will
wear. This allows the belt to sit lower in the
groove. When this happens, however, you
will lose belt tension and the belt will slip. If
you don’t re-adjust the tension, the belt will
slip and the sides of the belt will become
glazed. The slipping creates heat, which
dries out the belt and it starts to crack. It’s
basically toast.
This type of belt fails at the worst possible
time (i.e. during a plant V.I.P. tour or if it’s
outside—the scenario is a brisk February
night). With a little more respect regarding
the installation process, however, your belts
won’t fail on the job. p
John Lambert is president of Pickering, ON-based
Benchmark Maintenance Services Inc. You can
reach him by email: info@withinspec.com. For a
more detailed abstract of this column visit:
www.withinspec.com.
You can’t afford
workplace injury
Every day there
are more than
10 arc flash
incidents *
Arc flashes are a danger
to the health and safety of
service personnel working
on energized equipment.
What kind of safety
precautions have you
established within your
plant? And are they in
line with the standards
set by NFPA 70E?
Schneider Canada
Services can help you
achieve a safer and more
productive workplace.
Our highly experienced
team will assess the
potential risk, train your
employees on safety
procedures and retrofit
your equipment with new
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from trusted Schneider
brands, like Square D.
www.schneider-electric.ca/af
* North American figure
Schneider Canada Services
To contact this advertiser turn to page 65
16
PEM PLANT ENGINEERING AND MAINTENANCE
To contact this advertiser turn to page 65
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Instant gasketing
and sealing with
fingertip control.
Loctite® Silicone Power Cans....
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• Easy-to-use, ergonomic, fingertip control
• Extrudes product in a more accurate, constant, steady bead
• Silicone and dispense system in one – no caulking gun required!
• Attached nozzles – no more searching for dispensing nozzles!
• VOC-free propellants
Application expertise is available by calling your local
Loctite® distributor or Loctite® Application Engineering
Specialist. For more information, call 1-800-LOCTITE
or 1-800-263-5043 (in Canada), or visit us on the web
at www.loctite.com.
Loctite is a registered TM of Henkel Corporation, U.S.A.
® = registered in the U.S. and elsewhere. © Henkel Corporation, 2006. All rights reserved. 3730 LT-4528 (06/06)
To contact this advertiser turn to page 65
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Plant Safety
BY FRED MATTHEWS
Plan ahead for possible
emergency events
An emergency response plan is based upon
an organization’s needs and provides guidance for an
effective response to hazards, which could cause significant losses that stem from loss of life, serious injury
and property damage. Emergency response plans assign
responsibilities to specific individuals, establish procedures for effective communication and evacuation, as
well as offer resources for mitigating the impact of serious incidents. Emergency response plans are effective
when procedures are developed specifically for each
work site. This takes into account that each location is
unique and has its own hazards and challenges.
Prior to any plan-related work, you should assemble
a team that includes all of the major emergency stakeholders. Members of the planning
team should include representatives
All scenarios with high or
from human resources, operations,
workers from the plant floor, purmoderate risk ratings should chasing and risk management,
including the company’s safety, secube included in the plan.
rity and environmental professionals. Putting together a multi-disciplinary team allows for input from
experts from different areas of the company, which
could be affected by a major emergency or disaster.
Once the planning team has been created, the first
step is to perform a risk assessment to determine all of
the potential emergencies that could seriously impact
the work site. You can quickly start to identify potential
emergencies by examining the company’s loss history.
By examining incident reports and other loss data over
a specified period, you begin to get a picture of what the
company has experienced and its potential risk.
Statistical information collected by insurance actuaries
(i.e. the probability, frequency and severity of claims)
can also help with emergency planning.
Performing a risk assessment will provide you with a
list of emergencies that your facility could be exposed
to. Once you have this list, you then need to decide what
emergencies actually represent a realistic threat. To
accomplish this task, each scenario must undergo a risk
T H E C O L U M N I S T:
evaluation to determine how often the facility will be
Fred Matthews is the prairie and
exposed to the emergency, what the probability of that
northern regional health and safeexposure is and how severe the consequences would be
if the scenario was to actually occur.
ty coordinator for EdmontonRegardless of the risk matrix you use, you will have a
based Golder Associates Ltd. For
risk rating for each potential emergency. This will allow
more information call (780) 483you to determine how much effort is needed to reduce
3499 or visit www.golder-ehs.com.
the risk to an acceptable level. All scenarios with high or
18
PEM PLANT ENGINEERING AND MAINTENANCE
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moderate risk ratings should be included in the plan.
After determining what emergencies need to be
planned for, the team must analyze each scenario to
identify potential causes, impacts and problems that
may interfere with an effective response. This is where
the team asks the “what if” question. Go through each
scenario and develop a flow chart that identifies the
potential causes and bottlenecks, which may impede
emergency response teams from effectively dealing with
the emergency.
The next step is to identify any conditions in the
facility, which may exist and could interfere with an
evacuation. You want to identify primary and secondary evacuation routes and include them in your plan. By
performing this analysis, you will end up with a visual
picture of the procedures that need to be developed.
This will help you deal with each emergency scenario
that was identified during the risk-assessment process.
After completing the analysis phase of the emergency
response plan process, the team will need to begin developing generic procedures to include in the plan. These
procedures should be developed for reporting, plan activation, communication, incident-command structure,
evacuation, resource mobilization, mutual aid, site security, public communications and media relations.
These procedures should provide step-by-step
After determining what emergencies need to be
planned for, the team must analyze each scenario to
identify potential causes, impacts and problems that
may interfere with an effective response.
instructions on how to deal with each emergency scenario. They must also include the training requirements
and emergency response equipment, which will be
needed for an adequate response to the crisis. It’s
important to train front-line workers, administration
staff and all other employees on these procedures. This
is a critical point to follow.
To develop an effective emergency response plan you
must do our homework and identify those scenarios,
which are most likely to occur and cause harm. Your
goal is to be ready for emergencies, train employees and
keep people safe. p
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To contact this advertiser turn to page 65
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Power Transmission
BY GALEN BURDESHAW
Use proper bearing fits
to boost uptime
20
PEM PLANT ENGINEERING AND MAINTENANCE
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usually accomplished when the overall interference isn’t
that great, and a large mechanical press can be used to
force the two components together. A shrink fit is usually accomplished by leveraging the thermal-growth characteristics of the part. One or both parts are either heated
to a larger diameter, cooled to a smaller diameter or a
combination of the two. After the temperature of the
components has been altered, then they’re assembled
and allowed to reach ambient temperatures.
As the component temperatures neutralize, the surfaces gradually work together. The result is an interference fit. This assembly process is usually quite tedious
and errors will lead to a time-consuming correction
process. Although the assembly of interference-fitted
components is more time consuming and the preparation of the machined surfaces is more costly, the result is
a fit that’s reliable and durable.
Clearance fits for bearings are much more common
since they’re easy to assemble, mount and disassemble. A
clearance fit is when the bore is basically larger than the
OD of the mating part. For a bearing, at least one of the
raceways must be anchored. Therefore, clearance fit
inner rings are commonly held together by setscrews,
clamp collars, eccentric cams, locknuts, snap rings or
spring washers. They must use some sort of reinforcement otherwise they would move freely on the shaft.
The final type of fit is a mechanized fit, which
mimics an interference fit without the
special shaft tolerances. Mechanized
fits provide all the benefits of interference fits and also allow for easy
disassembly. These fits commonly
use a slotted-tapered adapter
sleeve that collapses down on the
shaft during installation and provides a fully concentric, high-pressure installation.
Bearings that use these types
of mechanized fits to the shaft
traditionally include adaptermounted, spherical-roller
bearings. Mounted bearing manufacturers, however, have now ex-
Time and effort spent to select and use
the right bearing fit will pay for itself in the
long run. This will result in improved equipment reliability and performance.
PHOTOS: DODGE
Bearing fits are an important factor to consider for proper bearing operation. Bearing life will be
sacrificed if the fit between the bearing and the outer
housing or the bearing and the rotating shaft aren’t correct. These fits are dependent upon the type and level of
loading subjected to the bearing.
Most mounted-bearing manufacturers offer a general
fit between their outer housing and the bearing inserts.
These fits are practical for the majority of applications,
but occasionally inherent machine-loading characteristics warrant a different type of fit. Shaft or housing wear,
bearing creep and/or thrust-load evidence can all signify
improper bearing fits for the application.
When discussing fits, it’s important to note that most
fits are defined through ISO (International Standards
Organization) standards. Definitions of these tolerances
are often available through bearing
Before selecting a bearing
manufacturer publications, standards
pamphlets, textbooks and various Web
fit, it’s best to understand
sites. Additionally, these fits can be
used for the design of mating compothe type of loading that will nents other than bearings.
The ISO fits are defined by an albe required.
phanumeric designation, starting with
a letter character and then followed by
a numeral. Tolerances on outside diameters are defined
with a lower-case letter character, while tolerances on
bore inside diameters are defined with an upper-case letter character. Examples of ISO fits on an OD might
look similar to g6, m14, or d3 whereas ISO fits on an
ID might look similar to H7, G6, or JS12.
There are three main types of fits: interference,
clearance and a mechanized fit. Interference
fits are just that—pure interference
between two surfaces. Basically, the diameter of the bore
of one part is smaller than
the outer diameter of the
mating part. The result is
high pressure in the localized area, which will keep
the static interaction beT H E C O L U M N I S T:
tween the surfaces snug
Galen Burdeshaw is customer
against each other. This requires tight tolerances on
order engineering manager for
both surfaces and a great deal
Dodge couplings and drives. For
of preparation before assembly.
more information, call (905) 792Interference between the two surfaces
1739 or visit www.dodge-pt.com.
is achieved by either a press or shrink fit. Press fits are
PEM-Sept06-Cov-pg25-2.qxd
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To contact this advertiser turn to page 65
Untitled-1 1
9/11/06 7:44:40 AM
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Power Transmission
Galen Burdeshaw is customer order
engineering manager for Dodge
couplings and drives.
panded these fits into smaller mounted ball
bearings. This is due to the advantages they
offer in customer applications beyond the
benefits of standard setscrew mounted ball
bearings.
Before selecting a bearing fit, it’s best to understand the type of loading that will be required. Fit selection is usually dependent upon
raceway point loading or raceway circumferential loading. For example, consider the loading
characteristics on an outer ring within a stationary housing when a rotating shaft (and
inner ring) is affected by a belt drive.
The load from the belt pull will result in a
single point load on the bearing outer race in
the direction of the pull. The inner ring, howev-
er, would have a circumferential load—since
for every single shaft rotation—the entire inner
ring raceway would have been exposed to the
load zone.
Let’s look at a different example where an eccentric or imbalance load is applied to a rotating shaft with a stationary housing (outer
ring). In this case, the outer ring would now
have a circumferential load whereas the inner
ring would now have a point load from the eccentricities.
The two above scenarios warrant different
housing-bearing fits, as well as different shaftbearing fits. If not, then bearing failure is likely to occur. Bearings with point-loads on the
outer ring typically require tight fits between
the shaft and inner ring, yet can tolerate loose
fits between the outer ring and outer bearing
housing.
The scenario with the imbalance load would
work best with a tighter fit between the outer
bearing housing and the outer rings, yet could
tolerate a loose fit between the shaft and bearing inner ring. Load level and bearing speeds
will provide further guidance as to how tight or
loose each fit should be. p
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22
PEM PLANT ENGINEERING AND MAINTENANCE
w w w. p e m - m a g . c o m
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4/10/06 8:46:47 AM
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Page 24
Maintenance Software
BY DAVID BERGER, P.ENG. (ALTA.)
Analysis and reporting tools
provide edge
One of the key factors affecting your ability
to get the most out of your computerized maintenance
management software (CMMS) system is how well data
is analyzed and presented to each functional group or
individual. Effective decisions have to be made quickly.
From report and graphics generators to decision-support systems (DSS) and executive-information systems
(EIS)—then on to data mining, marts and warehouses
and more recently dashboards, business intelligence and
scorecards—we’ve seen quite a progression in how
CMMS vendors allow users to extract data in a meaningful way.
The three most powerful analysis and reporting tools
(business intelligence, dashboards and scorecards) can
provide both a snapshot and trend
line for better managing each and
Try to imagine what would
every asset. In some cases, CMMS
vendors have opted to build their
be on the “dashboard” of
own engine to provide this functionality. This affords seamless integrayour CMMS application.
tion with the rest of the package, but
might not be as sophisticated. Others
encourage the user to buy specialized
and sophisticated add-on software from vendors. This
requires, however, purchasing and learning another application. Finally, some vendors supply these add-ons
through third-party license, which can be the best of
both worlds with properly integrated packages.
on the source of the problem. Action is then required to
bring the measure back in line.
Some CMMS vendors have developed a business-intelligence system that encompasses an entire hierarchy
of scorecard measures and related dashboard graphics.
They allow you to see your maintenance operations at a
glance. For example, suppose at 11:00 a.m., you notice
your overall indicator pushing 7.5 out of 10, which
causes the indicator to turn yellow and start to flash.
Your goal, however, was to maintain an overall score of
8.5 this year. You can then drill down to sub-indicators
underneath the headings (i.e. asset performance, production, inventory, human resources and financial). Of
these, perhaps all indicators are green except for asset
performance, which shows 4.3 out of 10 and is clearly
condition red.
Successive drill-downs may eventually indicate that
there’s a problem with the reliability of one of the assets.
A problem code has re-occurred at great cost for the fifth
time on several of the same production lines. As well,
there has been a serious safety problem that results in a
lost-time accident. These lower-level indicators were
both condition red and caused the higher-level variances. It’s then possible to drill-down still further and access base documents, such as work orders and cost
summaries.
BUSINESS INTELLIGENCE, DASHBOARD
AND SCORECARD DEFINED
T H E C O L U M N I S T:
David Berger, P.Eng. (Alta.) is
PEM’s production/operations editor and a principal with Western
Management Consultants. He’s
also the founding president of the
Plant Engineering and Maintenance Association of Canada
(PEMAC). For more information
call (416) 362-6863 ext. 237;
email: david@wmc.on.ca or visit
www.wmc.on.ca.
24
Think of the dashboard of your car, and then try to
imagine what would be on the “dashboard” of your
CMMS application. Imagine an on-line, “real-time”
summary of the latest scorecard results, including various ratios, forecasts, trend graphs and estimated versus
actual-cost comparisons. Picture the use of colour to denote if trending is out of range. For example, an indicator remains green if a given measure is okay; yellow if a
measure is beginning to trend outside of the acceptable
range; and red if it’s out of range.
Measures might be levels of downtime on a given
piece of equipment or number of preventive maintenance (PM) turns past due, or the level of spare-parts inventory. In terms of graphics, indicators may be in the
form of speedometers,“idiot”lights, dials, charts, graphs,
etc. Once the user is presented with a yellow or red “condition,” there’s an option with some CMMS vendors to
drill down on the indicator for more detailed reporting
PEM PLANT ENGINEERING AND MAINTENANCE
w w w. p e m - m a g . c o m
Although CMMS vendors have developed significantly
advanced analysis and reporting tools in the past few
years, there’s still a tremendous opportunity for further
improvement.
This balanced scorecard approach to monitoring your
maintenance operation is unquestionably an extremely
effective management tool. It requires a relatively sophisticated management team and user base, however, to set
up the hierarchy, measures, control limits and graphics
relevant to each user group. Furthermore, and perhaps
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Page 25
more importantly, data must be collected accurately on a timely basis.
Results must also be understood and followed up by everyone.
Although CMMS vendors have developed significantly advanced
analysis and reporting tools in the past few years, there’s still a tremendous opportunity for further improvement. It’s not fair to solely blame
the vendors for the gap, as users aren’t yet demanding sophistication in
this area. This stems from the users’ lack of readiness for computerization, which is evidenced by the still-high failure rate for CMMS system
implementations. Moreover, the average use of features and functions
of a typical system runs at about 15 to 30 percent.
BUSINESS INTELLIGENCE, DASHBOARD
AND SCORECARD APPLIED
To make the business intelligence, dashboard and scorecard features
more effective, CMMS vendors must provide a simple tool that helps
answer a key question for each user: “What’s in it for me?” The following provides a sampling of some of the many features and functions
that could provide the balance between sophistication and simplicity:
■ Work order control—Work orders are the focal point of any CMMS
system. It’s critical for users to have access to as much information as
possible when entering work-order data. Several systems provide access to parts on hand, on order, on reserve, in transit, in repair and for
quality assurance inspection. As well, a high-end CMMS system provides analysis of tradesperson utilization, work-order history, workorder and part-status statistics, asset performance and even a
troubleshooting database—right at the point of data entry. Business
intelligence can be used to assist maintenance planners to more easily
determine the appropriate action to be taken and timing required.
■ PM and predictive maintenance (PdM)—This is the most important area for many maintenance departments. Some of the more sophisticated features offered are multiple PM triggers, schedule
flexibility (i.e. seasonality, multiple formats, zoom and simulation) and
condition monitoring for user-defined data (i.e. activating a PM work
order when meter readings reach a certain value). Business intelligence
can be effective in monitoring output from PM and PdM programs to
ensure measures are trending within acceptable limits, as well as identifying what work is required when.
■ Materials management—In terms of the sophistication of this function, CMMS vendors vary widely. Some of the more advanced features
include: multiple costing methods; ABC and XYZ analysis for classifying your inventory; multi-warehouse tracking; multiple part number
cross-references; serialized-component tracking; and e-procurement
integration. Business intelligence can provide an analysis of inventory
and supplier history, including “what-if” analysis on service levels. This
allows users to fine-tune the balance between service and cost.
■ Asset management—Successful CMMS system implementations
produce savings and benefits that stem ultimately from proper asset
management. Equipment history reports on actual versus planned
labour, materials and other costs. Business intelligence can provide
more advanced features that include: tracking maintenance costs by
user-defined statistics (i.e. cost per volume produced); equipment status tracking and analysis; and complaint, cause, action and delay code
analysis. Other important features are analysis of production versus
machine downtime, mean-time-between-failure (MTBF), drill-down
capability to determine the cause of downtime on summary reports, as
well as analysis of total cost of ownership in support of repair/replace
decisions. p
Key Focus
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+EEPINGäAäPLANTäRUNNINGäATäOPTIMUMäEFFICIENCYä
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w w w. p e m - m a g . c o m
SEPTEMBER 2006
25
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PEM’s 2006 Salary Survey
GO
WEST
Big money in Alberta
Welcome to PEM’s third annual salary survey, which is a useful
snapshot of important industry trends. A comprehensive threepage questionnaire was sent by fax to a select number of readers. Based on information provided by readers, PEM continues to
develop a solid industry benchmark for maintenance, plant operations and engineering professionals. This year, it was possible
to compare certain result findings against the 2005 and 2004
surveys.
Some tables reflect multiple answers and total more than 100
percent. In other tables, categories with a low response were left
out and not factored in the overall percentage to reinforce
accuracy. There’s some duplication, but note that respondents
this year aren’t necessarily the same people who participated in
previous surveys. The large jump in overall average pay and
salary versus the 2005 and 2004 surveys is also in large part
due to those respondents working in western
Canada, specifically Alberta and its booming
petroleum industry.
By Robert Robertson and Allen Jones
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The petroleum industry
drives Canada’s economy
ake a trip to Ft. McMurray and see for yourself.
Companies can’t find enough workers, real estate is
going through the roof and Suncor Energy reported
huge second-quarter profits. As a result, it’s not surprising to
discover a pay spike in this year’s survey. To make more money
than their peers in the rest of Canada, maintainers and other
plant workers want to be Alberta bound.
The survey shows a whopping increase in the all-important
category of overall average annual pay at $75,754. This is 8.2
percent higher than the pay of $69,987 reported in 2005, and a
staggering 17.5 percent higher than the pay of $64,457 reported in 2004. In this year’s survey, respondents earned between a
low of $33,000 and a high of $200,000. The overall annual
salary is $79,603 (10.7 percent more than those in the same
category last year).
Non-union, hourly-rated employees (17 percent of this year’s
respondents) reported an overall average pay of $67,184. This is
5.0 percent more than in 2005. Unionized hourly-rated employees (11 percent of this year’s respondents) reported an overall
average pay of $63,667. This is 23 percent higher than last year.
Again, you should repeat the following mantra: go west to
earn bigger pay. As was the case in last year’s survey, the petroleum industry scored top earnings by industry sector—this
time by an even higher margin. Respondents working in the
petroleum industry earned an average of $130,000. This beats
the overall average pay ($75,754) by nearly 72 percent.
They also topped their closest rivals by nearly 35 percent
(forestry workers) who earned an average of $96,571. Even
at that, however, pay for respondents from the forestry
sector is still head and shoulders above the overall
average pay of $75,754. It seems clear that maintainers and other plant workers in these two
sectors have every reason to happy about
their lucrative jobs.
T
▲
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PEM’s 2006 Salary Survey
Salary Survey Highlights
Overall average annual pay ................................ $75,754
Stayed in same job ........................................ 11.8 years
Average annual salary ........................................ $79,603
Took skills training ............................ 52% of respondents
Average annual unionized hourly pay .................. $63,667
Employer pays for skills training ........ 87% of respondents
Average annual non-unionized hourly pay ............ $67,184
Avg. mtnce. budget ........ 20.5% of plant operating budget
Average raise in 2005 .......................................... 3.86%
Average plant employs .................................. 394 people
Received a raise .............................. 81% of respondents
Average plant size.................................... 320,248 sq. ft.
Average age ...................................................... 47 years
Average maintenance department .................... 37 people
Average experience ........................................ 22.1 years
Average equipment downtime ............ 2.2 days per month
he biggest industry sector was manufacturing. A
total of 53.2 percent of respondents reported
average wages of $71,631, which were 5.4 percent
below the overall average pay ($75,754). At the bottom of
the chart, maintenance professionals in the transportation sector reported wages of $55,625, which is more
than 26 percent below the overall average pay (Table 1).
Since the petroleum industry scored the highest overall average pay, it makes sense that, from a geographic
standpoint, Alberta would be the envy of Canada. As
Table 2 shows, maintenance workers (including other job
titles) from Alberta earned an average of $88,889. This is
17.3 percent more than the overall average pay ($75,754)
T
TABLE 1:
Average Annual Pay by Industry
Industry
% of Respondents
Petroleum
2.7%
Average Annual Pay
$130,000
Forestry
6.3%
$96,571
Mining/construction
6.3%
$90,429
Utilities/municipalities
4.5%
$85,200
Chemical
2.7%
$75,000
Manufacturing
53.2%
$71,631
Health & educational
17.1%
$65,316
3.6%
$55,625
Transportation
TABLE 2:
Average Annual Pay by Province
Province
Alberta
% of Respondents
Average Annual Pay
8.1%
$88,889
12.6%
$80,214
9.9%
$77,955
42.3%
$76,452
New Brunswick
6.3%
$75,143
Manitoba
6.3%
$69,143
Nova Scotia
4.5%
$67,000
Quebec
6.3%
$65,714
British Columbia
Saskatchewan
Ontario
28
PEM PLANT ENGINEERING AND MAINTENANCE
and 10.8 percent more than the nearest rivals in B.C.
These two provinces ranked in the same order in last
year’s survey.
It should be noted that respondents in Quebec fell to
the bottom of the heap at $65,714. This is 13.3 percent
below the overall average pay of $75,754 and 26.1 percent
below those high-earning Albertans. Quebec was listed
number three in last year’s survey results.
This year’s survey shows that raises were marginally
bigger in 2005 (3.86 percent) compared with 3.82 percent reported in 2004. Exactly the same percentage of
survey respondents (81 percent) reported they received a
raise last year and in 2004. Respondents who received a
raise ($78,436) in 2005 started from a much stronger
footing than those respondents who didn’t ($63,800).
This is a difference of nearly 23 percent.
Optimism regarding increased pay packages remained
at the same level as it was last year, when 65 percent of
respondents said they expected to receive a raise in 2005.
Those who expect to receive a raise in 2006 reported
earnings of $78,038. This is three percent higher than the
overall average pay of $75,754.
TABLE 3:
Do Respondents
Expect a Raise this Year?
NO
12.6%
Avg. annual pay:
$67,643
NOT SURE
18.9%
Avg. annual pay:
$71,762
YES
64.9%
Avg. annual pay:
$78,038
PEM-Sept06-PG26-50-2.qxd
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Page 29
respondents who answered no or not sure, and more
than the overall average pay ($75,754). Maybe these top
earners fear the good times won’t last forever or figure
they’ve priced themselves out of a job (Table 4).
Asked directly to rate their prospects for promotion,
23.4 percent of maintenance professionals and other
plant workers said good, while 36.9 percent answered fair
and 37.8 percent said poor. Those respondents who enjoy
good prospects for promotion also receive the highest
pay at $85,288. This is nearly 13 percent above the overall average pay ($75,754). Respondents with fair
prospects earn three percent less than average at $73,505,
while those with poor prospects make 5.4 percent less
than average at $71,643 (Table 5).
▲
Those who said they’re not sure about receiving a raise
(19 percent of respondents) reported earnings of $71,762
or 5.3 percent below the overall average pay ($75,754).
Those who said they don’t expect a raise in 2006 (almost
13 percent of respondents) made $67,643. Their earnings
are tracked at 10.8 percent less than the overall average
pay (Table 3).
This year’s survey shows a bit more optimism about
job security than in 2005. A total of 79 percent of respondents said they have no fear of being laid off. This compared with 74 percent in last year’s survey. Likewise, when
you turn the question inside out, only eight percent of
respondents this year fear layoffs compared with 10 percent last year.
Oddly enough, those respondents who said they were
concerned about being laid off earned more than those
TABLE 6:
TABLE 4:
Are Respondents
Concerned about Layoffs?
YES
8.1%
Avg. annual pay:
$82,222
NOT SURE
11.7%
Avg. annual pay:
$74,517
NO
79%
Avg. annual pay:
$75,398
TABLE 5:
Respondents Rate
Promotional Prospects
GOOD
23.4%
POOR
37.8%
Avg. annual pay:
$85,288
Avg. annual pay:
$71,643
FAIR
36.9%
Avg. annual pay:
$73,505
Average Pay by Job Title
Job Title
% of Respondents
Average Annual Pay
Plant engineer
5.4%
$88,000
Design engineer
2.7%
$86,000
Industrial millwright
3.6%
$83,000
Electrician
9.9%
$77,049
Maint. manager/supervisor
30.6%
$75,574
Plant manager/supervisor
17.1%
$74,625
Facility manager
14.4%
$71,842
Maint. planner/scheduler
2.7%
$67,408
Maintenance engineer
4.5%
$62,300
TABLE 7:
Age of Maintenance Workforce
Age Range
% of Respondents
Average Annual Pay
25 to 30 years
1.5%
$53,500
30 to 35 years
6.7%
$76,692
35 to 40 years
10.4%
$71,321
40 to 45 years
13.3%
$75,111
45 to 50 years
27.4%
$78,649
50 to 55 years
25.2%
$72,574
55 to 60 years
14.8%
$77,500
60 to 65 years
0.7%
$84,000
TABLE 8:
Rewards for Experience
Years in the Trade
% of Respondents
Average Annual Pay
5 to 10 years
11.3%
$76,324
10 to 15 years
10.0%
$77,148
15 to 20 years
15.3%
$61,435
20 to 25 years
15.3%
$75,935
25 to 30 years
25.3%
$81,474
30 to 35 years
16.0%
$78,083
35 to 40 years
4.0%
$85,833
w w w. p e m - m a g . c o m
S E P T E M B E R 2006
29
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PEM’s 2006 Salary Survey
TABLE 9:
How Long in the Same Job?
Years in Same Job
% of Respondents
Average Annual Pay
1 to 5 years
18.9%
$78,875
5 to 10 years
29.1%
$81,540
10 to 15 years
18.9%
$76,393
15 to 20 years
12.2%
$66,500
20 to 25 years
12.2%
$67,111
25 to 30 years
6.8%
$72,400
30 to 35 years
2.0%
$62,333
TABLE 10:
How the Maintenance Workforce is Educated
Education Level
% of Respondents
Average Annual Pay
Engineering degree
15.3%
$87,324
University degree
23.4%
$82,173
Community college
51.4%
$77,030
Industry certificate
(i.e. MMP program)
18.0%
$76,061
High school
25.2%
$67,196
From a list of 21 job titles provided in the survey questionnaire, respondents checked off titles most nearly
describing their own. Table 6 shows nine titles that are
arranged in order from the highest paid down. Job titles
not shown had too few checked off in the survey returns
to yield an accurate result.
Note that those ranked in the first half of the list
earned more than the overall average pay of $75,754,
while those in the second half earned less. Reported
earnings for plant engineers were 41 percent more than
for those who described themselves as maintenance
engineers.
The average age of survey respondents has climbed
from 42 in the first year of the survey to 46 in 2005 and
now 47 for this year. More than one-quarter of respondents fit into that average age category (between 45 and
TABLE 12:
How do Respondents Score Maintenance Efforts?
% of Respondents Today
30
Scale
% of Respondents in 5 Years
0%
1 - Poor
0%
0%
2
0%
1.8%
3
3.6%
8.1%
4
3.6%
12.6%
5
9.9%
9.9%
6
12.6%
27.9%
7
16.2%
28.8%
8
25.2%
7.2%
9
24.3%
3.6%
10 - Outstanding
PEM PLANT ENGINEERING AND MAINTENANCE
3.6%
50 years old), and earn on average $78,649. This ranks the
biggest age group slightly higher (3.8 percent) than the
overall average pay of $75,754 (Table 7).
The PEM think tank studied Table 8 at length. We
concluded that maintainers and other plant workers with
the most experience were paid the highest wages, but discerning no other logical pattern. Why did those respondents with 15 to 20 years of experience earn considerably
less than others who worked fewer years in the trade?
Using conventional wisdom, it’s difficult to explain the
dive in the middle of the table.
If you like your job well enough to stick with it for the
long term, you might want to look at Table 9. Industry
“lifers” do as well financially speaking compared with
those respondents who advance their careers from job to
job. In fact, the table shows respondents did better than
average for the first 15 years in the same job. After that,
however, their pay took a serious dive.
Average Annual Pay by
Type of Maintenance Operation
TABLE 11:
Maintains
production
equipment only
6.3%
Maintains
facility only
9.9%
Avg. annual pay:
$70,909
Avg. annual pay:
$96,071
Maintains
production
equipment & facility
82%
Avg. annual pay:
$74,838
The highest pay ($81,540), which is 7.6 percent higher
than average, was reported in the five- to 10-year range.
The lowest pay ($62,333) and 17.7 percent less than the
overall average pay ($75,754) is shown in the longestserving category, which is 30 to 35 years. Note the finding is opposite to last year’s survey results. In 2005, the
survey found the lowest pay was in the one- to five-year
range with the highest pay at the opposite end of the
scale (30 to 35 years). This is just they way you would
expect it to be.
On average, maintainers and other plant workers at
the low end of the education spectrum (25 percent of
respondents with no more than high school) earned
what would be regarded as a respectable wage. At
$67,196, however, it was the lowest-paid category and
12.7 percent lower than the overall average pay
($75,754).
Everybody else made more than average with engi-
PEM-Sept06-PG26-50-2.qxd
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PEM-Sept06-PG26-50-2.qxd
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PEM’s 2006 Salary Survey
neering degrees leading the pack at $87,324. This is 13.2
percent above the overall average pay ($75,754). Slightly
more than half of the respondents had community college diplomas. They earned $77,030, which is 1.7 percent more than the overall average pay.
Respondents who earned an industry certificate,
such as the Maintenance Management Professional
(MMP) program from the Plant Engineering and
Maintenance Association of Canada (PEMAC),
reported earnings higher than the overall average
pay ($75,754), though only by 0.4 percent. These
certificate-holders represented 18 percent of
respondents who may be from any of the other
TABLE 13:
How Has the Job Changed?
Change in Job Function over Past 3 Years
% of Respondents
Demands for higher productivity
30.6%
Technology advancements
24.3%
More emphasis on predictive maintenance
21.6%
19.8%
Downsizing or re-engineering of department
18.0%
Increased difficulty to obtain project funding
13.5%
▲
Economic restraints
education categories (Table 10).
More than half of this year’s respondents (52.3 percent) said they received training to upgrade their skills
in the past two years. Wise move it seems, as they
earned $80,509, which is 6.3 percent more than the
overall average pay of $75,754. By contrast, however,
the 45.9 percent of respondents who didn’t receive
training reported earnings of $70,455. This is seven
percent less than the overall average pay. The difference
between the two groups is 14.3 percent.
This year, 86.5 percent of respondents said they
work for employers who pay for training to upgrade
job skills. These maintainers and other plant workers
were paid $78,393, which is 3.5 percent more than the
overall average pay ($75,754). By contrast, however, the
12.6 percent of respondents who said they work for
employers who don’t pay for training earned 22.1 percent less than the overall average pay at $59,071.
Another survey anomaly involves respondents who
only maintain production equipment. They once again
reported earnings much higher than the overall average pay ($75,754). Their pay is also higher than those
respondents who maintain production equipment and
their respective facilities, as well as respondents who
maintain only their facility.
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PEM PLANT ENGINEERING AND MAINTENANCE
w w w. p e m - m a g . c o m
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From Furnace to Finishing Lines
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PEM’s 2006 Salary Survey
This year’s small group of production-equipment
maintainers (6.3 percent of respondents and virtually
the same proportion as a year ago) beat the overall average pay by some 27 percent. They reported annual
wages of $96,071. Perhaps, these select few respondents
hold executive-management positions in their organi-
TABLE 14:
Main Job Challenges
Rank
Job Challenges
1
Budget restrictions
50%
2
Health & safety
49%
3
Equipment downtime
47%
4
Management responsibilities
33%
5
Skills training
25%
6
Energy management
24%
7
Labour relations
21%
8
Inventory management
20%
9
Maintaining air quality
17%
10
Plant automation
17%
11
Promoting maintenance to management
15%
12
Facilities management
14%
13
Quality management
14%
14
Inadequate plant facilities
14%
15
Sourcing new products & technology
13%
16
Promoting maintenance projects to staff
10%
17
Materials handling
10%
18
Waste management
8%
19
Engineering trends
5%
20
Implementing software (CMMS/EAM)
4%
TABLE 15:
Facility Initiatives
Rank
Activity in the Next 2 or 3 Years
1
Implementation of new maintenance/
engineering or operations strategies
51%
2
Physical plant expansion
(interior or exterior)
44%
3
Implementation of materials handling
equipment and systems
32%
4
Use vendor-managed inventory
at the facility
24%
5
Implementation of automated robotic
manufacturing processes & equipment
23%
6
Installation of computer-controlled plant
management systems (CMMS/EAM)
16%
7
Implementation of Web-enabled operation/
engineering/maintenance practices
16%
8
Buying MRO products on the Internet
14%
9
Purchase new source of energy/power
14%
34
PEM PLANT ENGINEERING AND MAINTENANCE
% of Respondents
% of Respondents
w w w. p e m - m a g . c o m
zations, ranking high on the corporate ladder.
Meanwhile, the lowest paid group, the 9.9 percent of
respondents who maintain the facility only, reported
their overall average pay at $70,909. This is 6.4 percent
less than the overall average pay ($75,754). By far the
largest group, the 82 percent of respondents who maintain both production equipment and the facility that
houses it, reported earnings within a thousand dollars
of the overall average pay (Table 11).
Seven out of 10 respondents were able to pinpoint
the percentage of the total plant-operating budget
that was allotted to maintenance. On average, maintenance received 20.5 percent of the plant-operating
budget. This compares with 19 percent last year and
21 percent in 2004.
“
In terms of a possible trend,
the survey shows the installation
of CMMS/EAM systems in
the next two to three years ranked
at 16 percent.
”
Asked if this year’s maintenance budget increased
over the previous year, 43 percent of respondents said
yes and 57 percent answered no. Asked if this year’s
maintenance budget decreased from the previous year,
21.6 percent of respondents said yes and 78.4 percent
answered no.
This year, the survey heard from respondents working in plants that ranged from 3,000 to 3,500,000 square
feet. The average plant size was 320,248 square feet, up
substantially from last year’s figure, but nearly identical
to the average plant size reported in 2004 (318,600
square feet). Plants employed between two and 4,500
workers. The average plant employed 394 people.
Maintenance departments ranged in size from one to
1,000 people with an average of 37. If you divide that
average into the number of employees per plant, you
can see that there was one maintainer to every 10.7
plant workers. Last year, the ratio was one maintainer to
10 plant workers and one to 12 in 2004.
In terms of maintenance quality, how accountable
were respondents this year? When asked about their
role in quality management, 21.8 percent of respondents said they were fully accountable (up from 19 percent last year), 60.0 percent answered they shared
accountability (down from 69 percent in 2005) and 18.2
percent claimed no accountability (up from 11 percent
last year).
The survey asked respondents to score their maintenance performance on a scale of one to 10 (one being
PEM-Sept06-PG26-50-2.qxd
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Run Till It Hurts?
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To contact this advertiser turn to page 65
SKF_ISB_Sept_06.indd 1
9/18/06 12:26:20 PM
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PEM’s 2006 Salary Survey
the poorest rating and 10 being outstanding). They
were asked to score themselves today, and then using
the same scale to project where they expected to be in
five years. The average was 6.9 today (the same ranking
as last year) and 7.3 projected five years out compared
to 7.5 in 2005 (Table 12).
The survey asked respondents to rate their own average equipment downtime, as tracked in days per month.
Keeping in mind the survey covered a long list of industries, which use a wide variety of equipment types—
respondents said they had downtimes that ranged from
TABLE 16:
The Future of Maintenance
Rank
Where You’ll be in 5 Years
1
Larger
% of Respondents
32%
2
More autonomous
28%
3
More influential
26%
4
Smaller
18%
5
More centralized
14%
6
Less influential
12%
7
Less autonomous
10%
8
Less centralized
5%
zero to a nightmarish 30 days per month—along with
everything in between. The average score was 2.22 days
compared to 2.18 last year and 2.35 in 2004.
The survey asked respondents if their jobs have
changed in the past three years. The majority (57.8 percent) said their job functions had changed during this
time. Table 13 shows that respondents ranked the following factors affecting job changes from a list of choices: demands for higher productivity (30.6 percent),
technical advancements (24.3 percent), more emphasis
on predictive maintenance (21.6 percent), economic
restraints (19.8 percent), downsizing or department reengineering (18.0 percent) and lack of project funding
(13.5 percent).
Presented with a list of 20 possible job challenges,
respondents checked off their choices according to their
operations. This gave us an overall ranking when we tallied the votes. Table 14 shows the top five job challenges
include: budget restrictions (50 percent), health and
safety (49 percent), equipment downtime (47 percent),
management responsibilities (33 percent) and skills
training (25 percent).
These job challenges ranked the same last year with
very similar percentage votes. The remainder of the list,
however, underwent some minor changes compared
MINUTES
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36
PEM PLANT ENGINEERING AND MAINTENANCE
w w w. p e m - m a g . c o m
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Page 37
with last year’s results. One notable difference is that
implementing computerized maintenance management
software (CMMS) and enterprise management software
(EAM) systems fell to the bottom of the list at number
20 (ranked at four percent). Last year, respondents listed
this choice at number 18 (ranked at 10 percent).
Which major facility initiatives will likely be undertaken in the next two to three years? From a menu of
nine possibilities offered in the survey questionnaire,
Table 15 shows that respondents once again listed the
implementation of new maintenance/engineering or
operations strategies (51 percent), physical plant expansion (44 percent) and the implementation of materials
handling equipment and systems (32 percent) in the
top three.
In terms of a possible trend, the survey shows the
installation of CMMS/EAM systems in the next two to
three years ranked at 16 percent. This is a marked drop
from 24 percent in 2005. When you look at the results
contained in the last two tables, it could mean that current CMMS/EAM systems are performing well in the
opinion of respondents. The software market itself may
also have reached a maturity level for now.
The final section of the survey asked respondents to
look five years ahead and characterize how their main-
“
An important change shows that
32 percent of respondents said
their maintenance departments
will be larger compared with
29 percent in 2005.
”
tenance departments will operate. They selected from a
menu of eight choices provide in the survey questionnaire. This year, an important change shows that 32
percent of respondents said their maintenance departments will be larger compared with 29 percent in 2005
(Table 16).
Once again, we hope the PEM salary survey was able
to help you on the job, while serving as a tool to enhance
your career development and future success. p
Robert Robertson is PEM editor. Allen Jones is a Cambridge,
ON-based freelance writer specializing in industrial surveys
and trend analysis.
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w w w. p e m - m a g . c o m
SEPTEMBER 2006
37
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Motors &
Machinery
FailSafe
By John Malinowski
Use proper maintenance to extend motor operating life
oped over the last 25 years. It’s been reported that about 60
percent of premature motor failures involve the motor-
bearing system. A few washdown duty and most severe-duty IEEE 841
motors use a non-contact labyrinth seal to minimize contamination of
the bearings. Some manufacturers supply these seals on both the drive
and fan-end of their IEEE 841 motors.
Contact seals cause friction losses and their sealing capabilities are
reduced as wear takes place. Bearing manufacturers are also working on
non-contact and lower friction bearing seals for applications where
sealed bearings are required. Ceramic balls in anti-friction bearings may
38
PEM PLANT ENGINEERING AND MAINTENANCE
offer lower losses and reduced lubrication intervals.
Many washdown duty motors are supplied with contact seals that
provide a barrier to prevent anything from entering the bearing system. These have a lip that’s in continuous contact with the rotating
shaft. The lip can be damaged if allowed to run without lubrication.
Abrasive contaminants can also cause the lip to fail prematurely. Lip
failure leads to contaminants entering the motor and bearing failure.
There are some newer designed contact seals available that minimize
these problems.
As motor specifications are written, supplying more complete details
of application data and environmental issues will be most useful to the
motor manufacturer. Knowing pulley and belt data, special-thrust
requirements or the existence of severely contaminated environments
provides essential data. This allows motor designers to help specify the
The lifecycle cost of a motor needs to be evaluated rather
than just its purchase price. Look also for the reason why a
motor failed before replacing it.
w w w. p e m - m a g . c o m
PHOTO CREDIT: BALDOR
T
he high efficiency levels of today’s motors have been devel-
PEM-Sept06-PG26-50-2.qxd
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Page 39
best motor for the job. Smaller motors can usually handle normal belted
loads with standard ball bearings. On 100-hp motors and above, pulley
data should be supplied to evaluate bearing loads and determine if a roller
bearing may be required.
Corrosion and moisture protection
After bearings, motor corrosion is the second most frequent cause of premature motor failure. Many production processes contain highly corrosive liquids and gasses. In food-processing applications, caustic solutions
and high-water pressure are used to clean equipment. In non-food,
process-industry applications, the user should try and specify cast-iron
motor housings and TEFC (Totally-Enclosed Fan-Cooled) motors with
“severe-duty” features (IP54-IP55). Open (IP23) motors shouldn’t be
specified where corrosion or moisture is a problem. In food-processing
areas, washdown duty motors should be specified when sanitation is performed on machinery.
Most severe-duty motors are built with cast-iron housings, endplates,
fan covers and conduit boxes. These are standard construction features
for motors complying with IEEE 841, tested to ASTM B117-97. Motors
are painted inside and out with a corrosion-resistant primer and finish
paint. Rotors are also provided with a corrosion-resistant coating. If possible, any exposed or unprotected aluminum motor parts should be
avoided.
Washdown motors share these same features, but use a steel band for
the housing. Many manufacturers offer a version that has a white FDAapproved epoxy finish, as well as one that has stainless-steel components. The decision should be made based on the severity of cleaning
done in the plant.
As motor specifications are written, supplying
more complete details of application data
and environmental issues will be most useful
to the motor manufacturer.
Joints between the housing and endplate must have a rust-preventative
and conduit boxes supplied with gaskets. Many motors use lead separators as part of the gasket system between the conduit box and motor
frame. The motor’s varnish system is often upgraded by either a doubledip process or vacuum-pressure impregnation (VPI). Hardware on
severe-duty motors is plated for rust prevention. If desired, stainless hardware can be provided for extra corrosion resistance on severe-duty
motors (it’s generally standard with washdown motors).
Despite the care taken in sealing, moisture can form inside the motor
from condensation. The worse case is when moisture contains chlorine or
other highly corrosive liquids. Breather drains at the lowest point in the
motor allow the condensation to exit the motor. It’s common to use
drains made of stainless steel or composite materials rather than brass.
These may be moulded into a “T”configuration for two points of exit and
to comply with IP56 requirements.
Most washdown motors have a large condensation hole rather than a
t-drain. Condensation holes are supplied in all quadrants with the unused
holes plugged. After mounting the motor, it’s essential to make sure the
open drain hole is at the bottom. Plugs need to be removed at the bottom
and replaced at the top to correctly reseal the motor.
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drawings—without ever
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leaving the distributor’s Web site.
This includes AC motors and conFor more information visit:
trols, DC motors and controls,
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In applications where there’s a severe problem with condensation,
space heaters should also be used to keep the motor from cooling down
and drawing in outside air that can condense. Space heaters help prevent
condensation inside of the motor by elevating the temperature of the
motor above ambient.
When using a vector drive with feedback, if the motor is in a very wet
area, a magnetic-pulse generator should be specified rather than an optical encoder. Contamination may enter the encoder and obstruct the disc.
Magnetic-pulse generators are more rugged and can provide the same
type of output signal as an encoder, while maintaining relatively high
pulse counts.
Starting methods/adjustable speed drives
In the past, motors had a simple starter that started them across the line.
Larger motors might be started with part-winding start or wye-delta.
Today, we have solid-state starters that can ramp up the motor voltage,
providing a peak pulse to get the load moving—then folding the voltage
back to increase the power factor if there’s a light load. Sometimes, a
bypass is used with these solid-state starters to reduce losses.
It’s very common to use an adjustable-frequency drive or add one to an
existing motor. On some new motors that are designed specifically for use
with inverter drives, the motor design may not allow the motor to be
started across the line, as the design was optimized for adjustable-frequency use. If the motor needs to run directly from the line or with a
bypass, as well as a drive—this should be specified when ordering.
Most low-voltage motors (<600-volt) are suitable for operation
from an adjustable-speed drive for typical variable-torque applications, such as pumps and fans. Many premium efficiency and severeduty motors come standard with an insulation system, using magnet
wire that’s specifically designed to withstand the voltage spikes from
PWM drives. These motors stand up to the spikes, as defined by NEMA
MG1-2003 (Part 32.4.4.2). The best guarantee, however, of successful
motor application with an adjustable-speed drive (ASD) is consultation with the motor manufacturer.
The majority of ASD applications are for pumps and fans, presenting
the motor with a variable-torque load that reduces when the speed is lowered. If constant torque loads, such as conveyors are present, most fourand six-pole premium efficiency motors are capable of at least a 10:1 constant torque speed range (CTSR). If used over a wider speed range, totally enclosed blower-cooled (TEBC) models can provide full torque to zero
SEPTEMBER 2006
39
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Motors &
Machinery
speed when used with a flux-vector drive. The
motor manufacturer’s performance data should
be evaluated to see the motor’s speed/torque
operating envelope.
If the motor is operated from an ASD, eliminating bearing currents should be considered,
especially on larger motors or those that are
important to the process. Conductive grease,
isolated bearings and other methods don’t
work as well as shaft-grounding brushes.
Common-mode voltages, reflected voltages, filters and line reactors should be discussed with
the drive supplier. When installing the drive,
you should use the correct power cables and
grounding practices.
Motor management
Plant managers are tasked with keeping the facil-
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40
PEM PLANT ENGINEERING AND MAINTENANCE
ity running, while spending the least amount of
money. They must evaluate the motors used in
the plant and decide on how they should be
replaced at the time of failure. This will ensure
that a correct decision is made at the critical
time, rather than just selecting any motor to get
equipment running.
The lifecycle cost of a motor needs to be evaluated rather than just its purchase price.
Compared to life costs, the purchase price of a
motor can be two percent of the lifecycle cost.
Investing in a NEMA-premium efficient motor
may cost a little more for the motor, but savings
on energy will continue for many years.
An industry group called Motor Decisions
Matter (MDM) has a motor management guide
to accomplish this task. While inventorying the
motors, each should be tagged as to its replacement status. Some very old inefficient motors that
operate continuously may need to be replaced
immediately with NEMA-premium motors, even
before failure. Others can be replaced on failure
with either NEMA-premium or EPAct motors,
depending on how many hours they operate.
Other motors maybe of a special OEM design
that should be rewound upon failure.
w w w. p e m - m a g . c o m
When a motor fails, look at the reason it failed
before replacing it. If the motor failed because
water got inside and shorted the windings,
upgrade the motor enclosure to a TEFC severeduty or washdown motor. If the motor was overloaded, determine the load and upsize the
motor. If the plant survey shows the motor is
oversized, install the correct motor rating to
reduce energy costs.
Use motor failures as an opportunity to
replace the motor with one having a higher efficiency and a more robust enclosure that will
provide better equipment uptime. Open motors
must not be used in dirty areas where water is
present. Even standard TEFC motors shouldn’t
be used where high-pressure cleaning solutions
are used in food-processing areas. Washdown
and stainless motors offer extra protection features. Where chemicals that corrode regular
motors are present, cast-iron enclosed motors
with epoxy paint and bearing isolators made to
IEEE 841 standards are best for severe-process
industries. p
This article is an edited version of a Baldor
white-paper presentation. John Malinowski is
product manager, motors for Fort Smith, ARbased Baldor Electric Co. You can reach him by
email: jmalinowski@baldor.com.
PEM-Sept06-PG26-50-2.qxd
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10:15 AM
Page 41
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PEM-Sept06-PG26-50-2.qxd
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Page 42
Motors &
Machinery
SlickMoves
By Peter Fretty
Plan ahead to improve oil and lubrication reliability
E
taken for granted at times, especially when product rolls
out the door. As maintainers know, it’s important to invest
the time and resources to ensure proper reliability. This involves thor-
Avoid common errors
oughly understanding the entire oil and lubrication process.
Equipment downtime, however, is often attributed to the use of poor
oil and lubrication practices.
42
PEM PLANT ENGINEERING AND MAINTENANCE
▲
Lubricating with the right lubricant and using the right amount
and at the right frequency increases your probability of success. The
proper selection and lubricating with the correct amount in the recommended frequencies, however, are only two pieces of the puzzle.
Having a lubrication-management strategy in place also influences
machine reliability. This requires succinct planning, scheduling and
execution.
“Cables, chains, couplings, bearings, plain bearings, gearboxes and
Here are a few useful tips to help maintainers get the most out of their
oil and lubrication initiatives. The trick is not to make common
errors. Here’s what the experts say:
Lack of proper processes. Plants with thousands of moving parts
have unique lubrication requirements and schedules, which are difficult to meet and track effectively and efficiently. “As a result, it’s not
uncommon to eventually discover oversights, such as empty oil reservoirs or grease fittings that may have been overlooked due to the lack
of proper documentation,” says Dow Corning’s Grellier. “If it’s difficult to find, it will be even more difficult to repair.”
Smart maintainers apply the right lubricant at the right time.
It’s important to also implement and use a lubrication program to optimize equipment uptime performance.
w w w. p e m - m a g . c o m
PHOTOS: MOLYKOTE
quipment that runs like a well-oiled machine is often
electric motors have specific requirements according to the operating
conditions at which they operate,” says Rigoberto Moreno, division
manager of Toronto, ON-based SKF Reliability Systems Canada.
“When defining properties in the lubricating oil or grease that’s going
to be selected, you must consider factors like temperature, presence
and type of contaminants, rotational speed, lubrication method and
seal material.”
To optimize oil and lubrication programs, maintainers have to take
a serious look at what they might be ignoring. Phil Grellier, development manager for U.K.-based, Dow Corning Molykote Global
Solutions, says it has been estimated that hundreds of billions of dollars are spent every year repairing machinery, which is damaged from
wear caused by the use of poor lubrication.
“A large manufacturing plant can typically have more than 80,000
lubrication points, involving hundreds of combinations of lubricant
types, lubrication frequencies and methods of application,” says
Grellier. “The wrong lubricant or the correct lubricant applied in the
wrong manner can halt operations. With so much at stake, making
sure that the right lubricant is used at the right time is critical.”
PEM-Sept06-PG26-50-2.qxd
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10:15 AM
Page 43
To contact this advertiser turn to page 65
PEM-Sept06-PG26-50-2.qxd
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10:16 AM
Page 44
Motors &
Machinery
PHOTO: PETRO-CANADA
Lack of understanding. Lubricants
that are over- or under-engineered for
a given application can cost machine
life and maintenance dollars.
According to Tanvi Bhatt, category
manager for Mississauga, ON-based
Petro-Canada, choosing an efficient
lubricant that meets OEM recommendations should be at the top of
a maintenance department’s list.
“Effective lubrication demands
knowing the right lubricants to use at
the right time to avoid mistakes in lubricant selection and application, which can
shorten equipment life and stop production,” says Bhatt.“For example, high temperatures in air compressors accelerate
reactions between compressed oxygen
and impurities.
“This results in rapid oxidation and a
sudden increase in viscosity and lubricant failure. Mineral oils in air compressors generally last only 1,000 hours. By
comparison, synthetic compressor oil,
specially formulated for air compressors,
can last approximately 12 times as long.”
Failure to account for root causes.
To contact this advertiser turn to page 65
44
PEM PLANT ENGINEERING AND MAINTENANCE
w w w. p e m - m a g . c o m
Lubrication problems account for more
machinery downtime minutes than actually
appear in plant-based statistics. The cause is
a lack of standards and not using root-cause
failure analysis (RCFA). “Some companies
don’t have an RCFA process in place,” says
SKF’s Moreno. “Others have an informal
process followed only when a catastrophic
failure occurs.
Lubrication problems
account for more machinery
downtime minutes than
actually appear in plantbased statistics.
“A select few organizations have a standard
consistent process that’s triggered by the specific effects of the failure (i.e. financial, health
and safety, as well as quality aspects). A proper RCFA process will take you to the root
cause of a failure and incorrect lubrication is
one of them.”
Lack of environmental knowledge.
Designing solutions for the shop environment requires an understanding of the pertinent properties, including base-oil viscosity,
viscosity index, dropping point, consistency,
fire point, additives, mechanical stability and
water resistance. These properties are measured based on industrial standards established by different organizations (ASTM,
ISO, NLGI, etc.).
Lubricant manufacturers make this information available for each particular product.
This enables maintainers to compare the
requirements of the lubricant based on evaluations with the properties of current products available. Maintenance professionals
have to be aware of these properties, however, before they can determine whether or not
they fit and meet the operation’s needs.
“You need to find a supplier that not only
offers a product, but also a service. They
should have a fully trained technical and
engineering staff that can come out to your
facility to ensure the proper selection is made
based on the unique environment,” says
Darren Lesinski, technical service manager
and OEM compressor fluid development
manager for East Hanover, NJ-based,
Anderol. “If these services aren’t available, it
may be time to start looking for a new
PEM-Sept06-PG26-50-2.qxd
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10:16 AM
Page 45
The Driving Force
®
in Power Transmission
Switch today to save
TIME and MONEY.
To learn more call 519-759-4141 or visit
www.gates.com/pt
G-106-56t
To contact this advertiser turn to page 65
PEM-Sept06-PG26-50-2.qxd
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11:14 AM
Page 46
Motors &
Machinery
Lubrication by the book makes the job easier
The easiest way to head off problems is by
mended, as well as totally replacing machin-
putting a proactive plan in place, which pays
ery lubricant.
close attention to all of the critical areas within the facility. Having a plan will help improve
5
your preventive maintenance (PM) tasks and
to make an on-site or lab analysis a part of
strengthen the use of oil and lubricant prod-
the monitoring program. This type of used-oil
ucts by the maintenance team. Keep the fol-
analysis can be important to the bottom-line.
lowing factors in mind:
“You need to safeguard yourself from errors,”
1
2
Sample: Every plan should dictate the
extraction of lubricant from the machine
Assess: Look at individual needs to best
says Anderol’s Lesinski. “This type of moni-
determine the amount of resources nec-
toring helps solve these problems.”
essary to complete the tasks at hand.
Reassess and modify: All plans should
Process: Develop a time-conscious pro-
6
gram that best uses resources to
continue to adapt to the environment and
accommodate each machinery point to be
take into consideration fluctuating equipment
lubricated.
requirements.
be viewed as living documents, which
Train: The processes and technologies
“At the beginning and throughout the matu-
will not be implemented properly, if plant
rity of the plan, you need to ask common-
personnel responsible for lubrication aren’t
sense questions and find answers to ensure
properly trained.
nothing is missed,” says Timken’s Pierman.
3
4
Service: Perform all required tasks,
“You must take the time to pay attention to
including topping off reservoirs, applying
details and avoid cutting corners at all costs
grease to fittings, applying oil as recom-
with the plan.”
The Clever Way to Separate
What can our clever separation
technology solution do for you?
• Save on tramp oil disposal costs
• Extend the life of caustic wash water
provider.”
Unaware of long-term costs. When choosing the right lubricant, the cheapest product
is rarely the best. As a result, it’s important to
rate performance above price. This is a key
consideration in the supplier-selection
process. It’s crucial for companies and their
maintenance departments to find a supplier
that understands the lowest total cost solution versus simply focusing on the overall
upfront costs.
“Regardless of the brand, you want to
maximize production and good suppliers
should be able to help in this area,” says
Petro-Canada’s Bhatt. “You also want to
avoid trying to make substitutions, which
result in supply consolidation unless the
selected products fall within OEM specifications.”
Lack of attention to detail. Simply putting
a widespread plan in place isn’t enough.
Organizations need to pay attention to the
various “hot” points and prepare ahead for
potential catastrophic equipment failures.
Dave Pierman, lubrication product manager
for Canton, OH-based The Timken
Company, says that 50 percent of bearing
failures are directly tied to lubrication. As a
result, this should be motivation enough for
maintainers to grasp the concept that lubrication isn’t something to be overlooked.
“This includes under or over lubricating,
not following maintenance schedules or
using the wrong products,” he says.
“Unfortunately, people often realize this
when problems arise. Part of this is because
bearings aren’t typically a ‘front-of-mind’
item.” p
• Improve the quality of cutting fluids
Peter Fretty is a U.S.-based freelance writer. You can
reach him by email: peterfretty@verizon.net.
Online sources
Visit these Web sites for more useful
information:
• Anderol Inc.
www.anderol.com
• Dow Corning (MolyKote)
www.dowcorning.com
• Petro-Canada
Westfalia Separator
Canada, Inc.
www.petro-canada.ca
To learn how Westfalia Separator can
Leading Technologies. Individual Solutions
improve your operation, visit our web site
835 Harrington Court • Burlington • ON L7N 3P3
Tel: 905-319-3900 • Fax: 905-319-3903
www.gea-westfalia.ca E-mail: info@gea-westfalia.ca
or contact us at (905) 319-3900.
www.skf.ca
• The Timken Company
www.timken.com
A company of mg technologies group
To contact this advertiser turn to page 65
46
• SKF
PEM PLANT ENGINEERING AND MAINTENANCE
w w w. p e m - m a g . c o m
PEM-Sept06-PG26-50-2.qxd
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Page 47
CONFINED BY A SO-SO HYDRAULICS SUPPLIER
BUT THINK SWITCHING’S TOO DIFFICULT ?
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©2006 The Goodyear Tire & Rubber Company. All rights reserved.
To contact this advertiser turn to page 65
Goodyear_ISB_2006.indd 1
7/25/06 9:56:48 AM
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Safety First
More about explosions and fires in dust collectors
BY GARY BERWICK, P.ENG.
In this issue,
we continue with part two of the series
on explosions and fires in dust collectors. To be prepared for explosions
and fires in dust collectors, you also need to know the following to ensure
operating and safety performance:
REQUIREMENTS
48
PEM PLANT ENGINEERING AND MAINTENANCE
▲
When a dust can sustain an explosion, the dust concentration must be
within the explosive limits. These are often defined as:
L.E.L. (Lower Explosive Limit): Below this level of concentration, an
explosion will not occur and propagate itself. There’s not enough concentration of fuel to allow the flame front to grow. A typical range of values
would be 20-30 grains/cubic foot.; and
U.E.L. (Upper Explosive Limit): Above this limit, the concentration of
dust is so high that there’s insufficient oxygen to oxidize the fuel and the
unburned fuel stops the spread of the flame front.
As we discussed in part one of this series, some combustible dusts may
not have an LEL in any concentration of dust in a process gas stream. Fires
can occur, however, in ducts and in a dust collector. Fires in ducts are usually a result of poor duct design with dust dropping out in ducts.
Fires can occur in exhaust ducts, as well as inside dust collectors.
Requirements of fires or any combustion process are:
• Fuel in gas, liquid or solid form;
• Oxygen (atmosphere consists of 20 percent oxygen); and
• Fuel must be raised to the ignition temperature to start burning.
Sources of ignition. This includes overheating of coils, motors, friction,
spontaneous combustion, static discharge and burning debris drawn into
the vent system.
Spontaneous combustion. This occurs when dust slowly oxidizes in a
collector or in any accumulated pile. The fuel oxidizes very slowly, but is
insulated by the dust. A “hot spot” develops. When the collector flow is
resumed or the dust pile is agitated, it often acts like a spark to ignite the
dust (fuel).
Static discharge. Generally speaking, static built up in a collector is
reduced or eliminated by the jet-cleaning system. The jet-cleaning action
dissipates most charge build up on the surface of the bags or cartridges.
It should be noted that burning debris drawn into the exhaust system
can be a source of ignition.
Transport of sparks through ducts. Referring to Figure 1, there’s a glowing ember surrounded by hot air, which gives the spark buoyancy. This
spark and hot gas associated with it can travel hundreds of feet in a duct.
The ductwork is designed to give laminar (smooth) flow.
Spark suppressors are placed in the duct to change the flow to turbulent
(coarse) flow, as shown on the right. This agitation or turbulence strips the
air from around the ember and removes the fuel (oxygen), which extinguishes and cools the spark below ignition temperature.
Prevention. This important process depends on eliminating the causes
of ignition. Spark traps can change laminar to turbulent flow and extinguish any sparks in a duct (Figure 2). Design duct systems for proper dusttransport velocities. Install a pneumatic-actuated duct booster to flush
dust into the dust collector. Use air jets to remove electrostatic charges on
the duct surfaces.
FIGURE 1: Laminar flow
Ember: approx. 1400 °F
Envelop: approx. 800 °F
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To contact this advertiser turn to page 65
ReedEx_PEM_June_06.indd 1
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FIGURE 2: Swirling, highly turbulent flow
Envelop detached from
spark. Spark temperature
now just slightly above
process air temperature
and cooling rapidly.
Spontaneous combustion in pulse-jet collectors can be prevented by pulsing the collector
when the system is idle. This cools off the hot
spots (i.e. brass-furnace fires can be prevented
by pulsing the collector every hour when the
fan isn’t running).
You can put out fires by cooling below the
ignition temperature and cutting off the fuel
and oxygen supply.
WAT E R H O S E A N D N O Z Z L E S
This is an attempt to cool the solid fuels below the
ignition temperature and to cut off the flow of
oxygen to the fuel. It also takes away heat by turning water into steam. To boil one pound of water
consumes over a 1,000 BTU.Raising temperature
of water by 200 degrees Fahrenheit takes away less
than 250 calories per pound. The steam generated can cause serious injury or death.
That steam also displaces oxygen in the air
making it lethal, but will often act as an inert gas
to prevent oxygen from reaching the combustibles. Many dust collectors are equipped with
spray nozzles.The hoppers should have automatic drains to prevent the water from doing structural damage. A 10-foot by 10-foot dust collector
with 10-foot long filter bags can accumulate 40
tons of water, if the sprays aren’t shut down or
drained after the fire is extinguished.
INERT GAS SYSTEMS
Inert gas systems, such as carbon dioxide or
nitrogen gas, are sometimes provided. Usually
fire dampers will be provided to contain the
inert gases. This will cut off the supply of oxygen to the fuel (dust and media).
FA N O P E R AT I O N D U R I N G A F I R E
Whether to shut down a fan on a dust collector
because of fire can be a difficult decision, especially if the collector is vented outside. Often,
collectors are ignited at night and the smoke
isn’t detected. The next morning, the dust collector is virtually intact except the bags and dust
have been consumed. For example, a 10,000
SCFM collector removes heat at the following
rate with inlet temperature of 100 degrees
Fahrenheit and various outlet temperatures:
OUTLET (°F)
150
250
300
400
500
550
BTU/hr
500,000
1,000,000
2,000,000
3,000,000
4,000,000
4,500,000
With 1,000 square feet of cloth, the cloth
would weigh about 100 pounds and the dust
about 50 pounds. Assuming a heat of combustion of 5,200 BTU per pound, the BTU generated in a fire for this collector would be 780,000
BTU. Assuming an outlet temperature of 450
degrees Fahrenheit, it would take 30 minutes to
burn itself out and the collector would probably not have damage to the tube sheet or cages.
If the fan was turned off, the temperatures
immediately would easily reach 1,250 degrees
Fahrenheit and smolder for hours. The tube
sheet and cages would be also destroyed. If the
gas stream was re-circulated, the decision is to
shut down the fan unless you have an abort
damper to exhaust air to the atmosphere.
OTHER FIRE EXTINGUISHING SYSTEMS
Manual fire extinguishers are usually either
inert gas, such as carbon dioxide or inert powders. The gas extinguishers usually cool and put
a layer of inert gas between the fuel and the
flame. Manual gas extinguishers shouldn’t be
operated through doors of the dust collectors,
as the displaced gases can be vented out
through these access doors. Other manual
extinguishers spray powder into the flames.
They’re not suitable to spray through access
doors. p
Gary Berwick, P.Eng., is president of Waterloo, ONbased Quality Air Management Corp. You can reach
him by email: qam@rogers.com.
To contact this advertiser turn to page 65
50
PEM PLANT ENGINEERING AND MAINTENANCE
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Plant Facilities Review
EQUIPMENT AND SUPPLIES FOR BETTER PERFORMANCE
Generating plant switches oil
to improve performance
PHOTO: CHEVRONTEXACO
Located on 2,000 acres in Palatka, FL, Seminole
Cooperative’s Generating Station began commercial operation in 1984
as the state’s first cooperative-owned generating plant. The station consists of two 650-megawatt coal-fuelled generating units that burn 10,000
tons of coal and petroleum coke daily in a 24-hour, seven-day maximum
capacity operation.
Both of these units incorporate environmental protection systems
that originally cost more than US$233 million. Other environmental
safety measures in place at the plant include groundwater-monitoring
wells, continuous-emission monitors for flue gas and off-site ambient air
monitoring controls.
From approximately 1996 to 1998, the Seminole Generating Station
had previously used a hydraulic fluid in its hydraulic applications where
spills or leakage could result in damage to the environment. Seminole’s
maintenance staff, however, noticed that
Incorporated in 1948, Tampa,
the oil’s performance fell far short of
FL-based Seminole Electric
expectations, especially in the hydraulic
Cooperative, Inc. generates
systems that pull and position freight
and transmits bulk supplies of
cars through the coal unloading rotary
electricity through its member
dumper. Spoilage caused problems that
cooperatives. It represents
necessitated frequent maintenance servthe third largest segment of
ice. This included pump failures, filter
electrical consumers in Florida,
plugging, valve sticking and strong
serving more than 1.5 million
odour.
residential and business users
According to Brian Thorp, Seminole’s
throughout 45 counties.
predictive maintenance technician, each
incidence of hydraulic-fluid decay
required the entire system to be shut down for drainage, flushing and refilling of fluid. “Every four to six months, we had to conduct extensive
maintenance and clean up of all our hydraulic systems and oil reservoirs,” says Thorp. “In terms of labour, maintenance expenses, replacement oil and loss of efficiency—this cost us an inestimable amount.”
ChevronTexaco recommended that Seminole experiment with
Chevron Clarity Hydraulic Oil AW, with its ashless additive system that
offers oxidation stability, water separability, foam suppression and protection against wear, rust and corrosion. It’s inherently biodegradable,
Change in oil greatly helps Seminole Electric Cooperative in the U.S.
minimizing long-term environmental concerns and also meets the
Florida Administrative Code specification, says ChevronTexaco.
Seminole agreed to test the Chevron oil in the hydraulic systems of its
generating station’s coal unloading rotary dumper. Since using the
Chevron Clarity Hydraulic Oil, Seminole hasn’t experienced a single
costly hydraulic-system failure, says its maintenance team. Seminole
then began using the oil in additional applications. It has since eliminated copper leaching from ZDDP in oil coolers and motors. Seminole has
also been able to extend oil-change intervals.
“Since we started using the oil six years ago, we haven’t had a single
problem. We’ve been able to extend oil-drain intervals from the one year,
which was initially recommended by our vendor to as long as five years,”
says Thorpe. “And with some of our blowers, which use approximately
300 gallons per reservoir, this adds up to huge savings.” p
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Tel: (925) 842-1000 • www.chevrontexaco.com
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To contact this advertiser turn to page 65
w w w. p e m - m a g . c o m
SEPTEMBER 2006
51
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Asset Management
BY JOHN M. GROSS, P.ENG., CPE, CQE
Take a close look at
point-of-use spares
When deciding what stays in your managed parts
I co-led a recent total productive mainteninventory, keep it simple and don’t obsess about the
ance (TPM) kaizen event at my plant. During this time,
exact dividing line. One basic rule is: will I lose sleep
I came across a cabinet that sent shivers up my spine.
if I can’t find the part or would I just replace the part?
The cabinet contained all the spare parts for equipment
For example, I once had a specialty-packaging
in its area of the factory. The state of the cabinet was a
machine, which required a unique indexing gearbox
mess, however, and we lacked plans for a systematic
with a three-week lead time to replace. This gearbox
replenishment or maintaining stocking levels.
wasn’t a candidate for POU-spares storage.
To make matters worse, inside the cabinet were
Other decision rules include: regulatory requireparts worth several thousand dollars sitting next to
ments, frequency of replacement, normal wear item
expendable parts worth pennies—all of which looked
(i.e. batteries) and expendable items (i.e. nuts and
like they were suffering from neglect. Needless to say,
bolts). Also ask yourself if you can live with aggregate
I started to ask important questions. I discovered that
usage numbers for the parts being considered for
someone made a decision to use point-of-use (POU)
POU spares. If the answer is no, then keep the parts
spares. I also learned that a long-gone maintenance
in the managed inventory.
manager didn’t like the purchasing department
The next step is to create a visual-management
ordering his parts.
process for controlling replenishment. You’re essenThe purchasing team was
Establish rules for what’s
tially setting the red, yellow and green levels for recontent with the maintenance
ordering. Also figure out how you will actually order
department using POU spares
stocked in the managed
replacement POU spares without creating a new
and ordering parts for the plant.
bureaucracy. Consider standard re-order sheets, twoThis was a good idea, however,
inventory and at point of use.
bin systems or vendor-managed inventories as potentaken to extreme. While POU
tial options.
spares (or more precisely putThe visual-management process is an excellent
ting the parts you need to mainopportunity to draw the “lean” folks into your
tain your plant at the point-ofworld—this step should be child’s play for them. In
use for ready access) can greatly speed up response
terms of visual management, don’t forget the followtime, simplify inventory management and shrink the
ing physical-related logistics factors:
required space for the managed inventory—the con What type of storage will you use?;
cept still needs to be deployed with forethought.
Can you move some of the racks you currently use
While it makes sense to have common everyday
in your managed inventory?; and
material on the shop floor in different stocking loca How will you label these storage areas?
tions, it doesn’t make sense to have costly and rarely
Try to standardize the
used items or repair parts (i.e.
design of the storage locaprocess controller and beartions with the goal of making
ings) that you deem critical in
them open, clean and visual.
POU spares. The exception
T H E C O L U M N I S T:
This will help to avoid confuare big, bulky items that are
sion and unnecessary comJohn M. Gross works as a Six
hard to move and easy to visuplications. Consider removally manage (i.e. specialty
Sigma master Blackbelt and lean
ing the doors to help with the
gearboxes or large motors).
manufacturing manager for a
housekeeping and visual
Use the following steps to betmanagement, if you’re using
ter deploy POU spares:
Tier 1 automotive supplier. He’s
cabinets. Document all deci Establish rules for what’s
Try
to
standardize
the
design
of
the
storage
the author of Fundamentals of
stocked in the managed
locations with the goal of making them open, sions to outline how you got
Preventive Maintenance and costarted. It will also make stayinventory and at point of use;
clean and visual.
ing the course easier, while
Create a visual management
author of Kanban Made Simple. In
providing needed structure for
plan for replenishing the POU items;
addition to being a professional
those that follow you.
Just do it—deploy the parts. Don’t confuse planengineer, he’s also a certified
Lastly, use training to address expectations, housening as an excuse to avoid taking action;
keeping and re-ordering, as well as audit all storage
Train the technicians on how to manage POU
plant and quality engineer. You
areas. Make sure you don’t breeze through these final
spares; and
can reach him by email:
steps to POU-spares success. p
Audit the new POU storage areas.
john@drivingchange.com.
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Materials Handling
BY BILL VINCENT
Are your systems
at a breaking point?
Today, operations and systems in warehousing and distribution are strained to the breaking
point. Economic pressures and related capital expenditures cause operations and maintenance managers to
demand more from people, while cutting back on
staffing levels and related operations. And, despite economic limitations, technology advancements continue
to outstrip our ability to stay current.
Additionally, recent investments in enterprise resource
planning (ERP) and warehouse management systems
(WMS) technology haven’t provided promised functionality on the information technology (IT) side, as equipment automation wasn’t approved for upgrades. Many
world-class IT systems are handicapped by obsolete
material-handling systems. This leaves executive management and shareholders frustrated.
As a result, more pressure is placed on
It’s just like ignoring chest distribution centre managers to maximize the performance of their existing
pains because there’s no
operations and systems. Over time, these
pressures will have predictable results
time to visit the doctor.
because the system starts to crack. You
will see the following:
• Low or declining productivity (frequently coupled
with high or rising turnover);
• Unacceptable levels of product shrinkage;
• Inaccurate inventory records;
• Ineffective wave management (often constrained by
system limitations);
• Failure to fulfill orders on time;
• Communication misses and failures between departments or applications;
• High product re-circulation rates;
• Low sortation accuracy rates;
• Data loss;
• System downtime;
• Accidents; and
• Poor equipment performance and/or reliability.
Although every system experiences some of these
symptoms from time to time, they’re too frequently
accepted as a cost of doing business. This is an underT H E C O L U M N I S T:
standable response from management teams struggling
to deal with the pressures causing the problems, but it’s
This column is an edited version
a dangerous response. It’s just like ignoring chest pains
of a Tompkins white paper. Bill
because there’s no time to visit the doctor.
Vincent is a principal with
To optimize performance without requiring a major
Raleigh, NC-based Tompkins
investment, the first step is to locate the system “pain
Associates, a provider of total
points.” Answering simple questions about your syssupply chain solutions, includtem’s performance can be used to identify where system
ing manufacturing and stores
flaws are having the most damaging effect on operations
operations. For more informaand profitability. For example:
tion call (905) 456-3871 or
1. Which most accurately describes your system’s abilivisit www.tompkinsinc.com.
54
PEM PLANT ENGINEERING AND MAINTENANCE
w w w. p e m - m a g . c o m
ty to support operations in receiving?
a. Technology and information systems support errorfree, efficient receiving operations that never interfere
with the ability of downstream operations to accomplish their objectives.
b. Errors, inefficiencies and downtime or other interference with downstream operation occasionally occur.
c. Errors, inefficiencies and downtime or other interference with downstream operation regularly occur.
d. We don’t currently measure the performance of our
system’s ability to support effective receiving operations.
2.Which most accurately describes your system’s ability
to support operations in putaway?
a. Technology and information systems support errorfree, efficient put-away operations that never interfere
with the ability of downstream operations to accomplish their objectives.
b. Errors, inefficiencies and downtime or other interference with downstream operations occasionally occur.
c. Errors, inefficiencies and downtime or other interference with downstream operations regularly occur.
d. We don’t currently measure the performance of our
system’s ability to support effective put-away operations.
The pattern of questions can be carried out through
your entire operation, from receiving to shipping, with
more detailed questions asked inside the most complex
or critical operations. For example, because sorters are
typically the critical throughput constraint for a system
and often impact order accuracy directly, the following
questions are worth asking:
1.What’s your sorter scanner read rate?
a. Greater than 99 percent?
b. 95 to 99 percent?
c. 90 to 95 percent?
d. Less than 90 percent?
e. I don’t know?
2.What’s your sorter unknown bar-code rate?
a. Less than one percent?
b. One to five percent?
c. Greater than five percent?
d. I don’t know?
3.What’s your re-circulation rate?
a. Less than one percent?
b. One to five percent?
c. Greater than five percent?
d. I don’t know?
The objective of designing and selecting the questions
is to perform a high-level evaluation of your system’s
ability to support operations. Objective analysis conducted at system pain points often expose opportunities, which will lead to system modifications or
improvements. p
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S
D
L
O
H
O
N
E
N
I
L
R
I
D
A
E
R
R
BA
BENDS FREELY TO FIT YOUR NEEDS
Duratec Airline® is an innovative new compressed air and inert gas piping system
that uniquely combines all of the benefits of plastic and metal in one pipe.
Constructed of an inner and outer layer of HDPE sandwiched over an aluminum
core, Duratec bends freely by hand and maintains its shape for maximum
installation flexibility.
BEST OF ALUMINUM
+
BEST OF HDPE
• Rigidity
• Flexibility
• No memory –
"stays where it lays"
• Ease of installation
• Corrosion proof
• High temperature
capability
• No pitting or scaling
• High pressure capability
• Improved air/
gas quality
• Low expansion rate
LOWER
OPERATING COSTS
• Reduced Pressure Loss
• Smooth Interior
• Lightweight
• High mechanical strength
LOW COST OF
INSTALLATION
• Ease of Handling
• Quick Connections
• Fewer Fittings
• Flexible Yet Rigid
• Modifiable Connections
EXTENDED LIFE
• Corrosion Resistant
• Clean
• Safe
• CRN Listed &
• Chemical Resistance
ASME approved
Fast and Easy Installation
HDPE
Aluminum
HDPE
25 Sec.
5 Sec.
Total Time: 55 Sec.
www.duratec.ipexinc.com
AirLine System
U.S. Toll Free: 1-800-463-9572 • Canada Toll Free: 1-866-473-9462
To contact this advertiser turn to page 65
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Marketplace
Improve Safety.
Be Productive.
INDUSTRIAL PRODUCTS AND SERVICES
integration into almost any automation environment, says
Go Wireless.
the company. The inverters also feature selectable modes
for sensorless vector control that provides a high-starting
torque and precise control, says the company. The SK 520E
inverter contains added control modes for closed-loop,
flux-vector control, an optional position control and additional I/O.
Contact: Nord Gear Corp.,
41 West Dr., Brampton, ON L6T 4A1
Tel: (905) 796-3606
www.nord.com
Compact job-site table saw
DeWalt introduced its new 10-inch compact job-site table
saw (DW745) that’s suited for a wide range of end users,
including interior and exterior trim carpenters, deck
builders, and installers of hardwood floors, stairs, cabinets,
doors, and windows, etc. The saw has the ability to quickly and easily cut hardwood materials used in the construction of stairs and interior flooring, TREX decking materials, window and door casings, shelving, pressure-treated
In-line helical reducers
lumber, as well as standard sheathing and 2x construction
RotoPrecision Inc. announced the introduction of a com-
materials, says the company. The DW745 is equipped with
plete stocking and assembly program in Canada for
a 15-amp motor and is capable of handling heavy building
Motovario’s cast-iron, in-line helical reducers. The in-line
materials or dense man-made building products without
reducers feature a one-piece, cast-iron PowerCase gear
stalling the motor or slowing productivity, says the compa-
housing, which improves strength, transmission torque
ny. Additionally, the table saw is designed with a telescop-
and provides excellent protection against leakage, says
ing fence that provides 16 inches of rip to the right and 12
RotoPrecision. Single-stage reducers offer efficiencies up to
inches to the left of the blade.
98 percent; double- and triple-stage reducers up to 95 per-
Contact: DeWalt Industrial Tool Co.,
cent, says RotoPrecison. The reducers are adaptable for a
125 Mural St., Richmond Hill, ON L4B 1M4
wide range of NEMA and IEC applications in various foot,
Toll free (800) 4-DEWALT
flange, shaft and foot/flange configurations.
www.dewalt.com
Contact: RotoPrecision Inc.
304 Watline Ave., Mississauga, ON L4Z 1P4
Tel: (905) 712-3400
www.rotoprecision.com
Condition-based maintenance
Benchmark Maintenance Services Inc. announced the
North American arrival of a new measurement instrument
that’s designed for condition-based maintenance. The XViber with X-Trend software system can
measure vibration, enveloping and
bearing condition with selected frequency ranges and measurement units.
The software allows users to create a
route and trend all measurements, as
well as provide frequency analysis
Cattron-Theimeg Canada Limited
905-873-9440
salescdn@cattron.com
www.cattron-theimeg.com
New compact frequency inverters
capabilities plus speed and tempera-
Built for tough applications, Nord Gear Corp. says its
ture, says the company. Benchmark and
NORDAC SK 500E and 520E inverters feature high torque,
its agents distribute the X-Viber instru-
rapid response and wide speed range for extended power
ment in Canada and the U.S.
outputs that range from 0.25kW to 7.5 kW. Available in
Contact: Benchmark Maintenance Services Inc.
sizes between 7.32 x 2.99 x 5.94 inches and 11.26 x 3.86 x
599 Nomad Rd., Pickering, ON L1W 3T5
7.01 inches, both models offer a performance package that
Toll free (800) 598-1117
contains all standard drive functions, allowing for smooth
www.withinspec.com
To contact this advertiser turn to page 65
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Gorman-Rupp has the right pump for the job. Whether you’re pumping clear liquids,
highly viscous liquids at high pressures, chemical process or mild slurry, Gorman-Rupp
pumps are designed to handle tough abrasive and corrosive chemicals where other
pumps fail. Whether it’s a standard centrifugal, a self-primer, gear, submersible or
diaphragm pump, Gorman-Rupp meets your needs. Look to Gorman-Rupp for pumps
that solve all types of chemical handling problems.
Ask your local Gorman-Rupp distributor which pump is best for your job.
Gorman-Rupp of Canada, Ltd 70 Burwell Road
St. Thomas, Ontario N5P 3R7
PHONE: 519-631-2870
FAX: 519-631-4624
grcanada@grcanada.com
www.grcanada.com
C - 410
© Copyright, The Gorman-Rupp Company, 2005
Gorman-Rupp – Mansfield Division is an ISO 9001 Registered Company
PEM-Sept06-PG51-OBC.qxd
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EXPERT PRESENTATIONS • HANDS-ON WORKSHOPS • NETWORKING & SOCIAL EVENTS • EXHIBITS FROM LEADING VENDORS
Novotel Toronto Center
Main Conference: Nov. 28-29, 2006
Pre-and post event workshops & MMP: Nov. 27, 30, 2006
Experts will share the secrets of maintenance success!
This invaluable information can save your company
time and money — and boost your career!
Visit MainTrain.ca for event and
registration information.
Platinum Sponsors:
Gold Sponsor:
MainTrain 2006 is produced by the Plant
Engineering and Maintenance Association
of Canada (PEMAC). www.pemac.org
(905) 823-7255
To Do List:
✔ Book the dates on your
✔
calendar!
Add to your annual
training budget!
Media Sponsor:
CLB Media Inc.
Publishers of:
Plant Engineering
and Maintenance
To contact this advertiser turn to page 65
To contact this advertiser turn to page 65
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Marketplace
INDUSTRIAL PRODUCTS AND SERVICES
block, clay brick and other masonry materials. For precise
tion tools, thermal imagers and thermometers.
cutting and straighter tracking, the Contractor Pro seg-
Contact: Fluke Electronics Canada
mented blades feature a .125-inch thickness with a
400 Britannia Rd., E., Unit 1, Mississauga, ON L4Z 1X9
stronger core, so they can also be used on low horsepower
Tel: (905) 890-7600
walk-behind saws, says the company. For added quality
www.flukecanada.ca.
and durability when cutting concrete or asphalt, the segments are laser welded for a stronger bond, says the com-
Variable-speed AC industrial drives
pany.
Schneider Electric Canada introduced the Telemecanique
Certified oil-free compressor
Contact: Hilti (Canada) Corp.
Altivar 71 and Altivar 61 variable-speed AC industrial
Atlas Copco’s Oil-free Air division announced that the com-
Toll free (800) 363-4458
drives for 3-Phase asynchronous
pany’s Z series of oil-free rotary screw air compressors is the
www.ca.hilti.com
motors from 0.5 up to 900 HP. The
Altivar 71, which is dedicated to all
first in the world to be TUV-certified ISO 8573-1 Class 0.
industrial applications, is comple-
during food and beverage processing, pharmaceuticals
Test-tools
catalogue available
manufacturing and packaging, electronics manufacturing,
Fluke Electronics Canada intro-
specialist for pumps and fans.
automotive-paint spraying and powder coating, as well as
duced a new edition of its Test
Altivar 71 can deliver up to 220 per-
textile manufacturing, says the company. Certification was
Tools Catalogue. Available imme-
cent over torque and 130 percent for Altivar 61, says the
carried out using the most stringent test methods available,
diately at no charge, the 2006 product catalogue provides
company. Both drives offer flux-vector control (FVC) with
simulating realistic industrial installation environments. At
detailed information on features and specifications for the
or without sensor, online auto-tuning, speed or torque
all test conditions, no trace of oil could be determined and
full line of Fluke products, as well as selection guides and
control, output frequency up to 1000 Hz and an energy-
the compressed air was certified to be in the Category Class
ordering information. The catalogue has been updated with
saving function for pump and fan applications. The Altivar
0 in terms of oil content, says the company.
new products, including the Fluke Ti20 Thermal Imager, the
can multi-task—one drive can independently control up
Contact: Atlas Copco Compressors Canada
Fluke 971Temperature Humidity Meter and the Fluke 561
to three motors, ensuring their individual thermal protec-
30 Montrose, Dollard-des-Ormeaux, PQ H9B 3J9
HVACPro Thermometer. It also features new products for
tion, says the company.
Toll free (800) 513-3782
earth/ground testing, as well as the latest information on
Contact: Schneider Electric Canada
www.atlascopco.com
Fluke tools, including bench instruments, cable testers, cali-
19 Waterman Ave., Toronto, ON M4B 1Y2
bration instruments, data-acquisition equipment, electrical-
Toll free (800) 661-6699
test tools, HVAC/R, indoor air-quality tools, process-calibra-
www.schneider-electric.ca
Risk of any contamination by oil is effectively eliminated
Dodge take-up bearings
mented by the Altivar 61—the drive
The new Dodge Ultra Kleen wide-slot, take-up frame is
designed to withstand harsh washdown environments
found in many food-processing applications. Constructed
of 304-series stainless steel, Dodge Reliance says that its
mounted-bearing innovation is suited for conveyor systems
used in poultry, meat, vegetable, fruit
and other food plants. The
new take-up frame complements Dodge EZ Kleen
wide-slot, ball-bearing prod-
5
Day
Shipments
FREE STANDING
WORK STATION CRANES
ucts. These bearings offer a rugged,
solid-base injected moulded, fiberglass-reinforced polymer housing with no cavities or fillings
where contaminants can be trapped, says the company.
Contact: Dodge Reliance
6040 Ponders Court, Greenville, SC 29615
Tel: (864) 281-2171
www.dodge-pt.com
Gas-saw blades for tough work
With a faster cutting speed and up to
50 percent longer life than the current heavy-duty blades, Hilti
Inc. says its new Contractor Pro
High-Speed Diamond Blades
extend its line-up for high-speed
gas saws. Available in three versions:
general-purpose segmented; general-purpose turbo; and
asphalt segmented—the Contractor Pro blades are suited
for cutting applications in reinforced concrete, concrete
L If it’s late, we pay the freight*
L Aluminum bridges for
effortless movement
L 3X easier to move than
I-beam cranes
L 5-year warranty
L Increases productivity up
to 28%
L Capacities from 250 lbs.
to 4000 lbs.
*See a Gorbel Dealer for details.
800-821-0086
•
info@gorbel.com
Fax: 800-828-1808 • Internet: www.gorbel.com
To contact this advertiser turn to page 65
w w w. p e m - m a g . c o m
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Marketplace
INDUSTRIAL PRODUCTS AND SERVICES
G40 gloves are general-purpose industrial gloves that provide enhanced dexterity and grip, as well as hand protection,
using a latex coating over a comfortable poly-cotton liner,
says the company. The Kleenguard G60 gloves are designed
for industrial workers who need protection against hand
lacerations. Made with Dyneema, the gloves provide a high
level of cut resistance, while enhancing dexterity and comfort, says the company. The gloves are ambidextrous,
breathable and feature a flexible nitrile-dotted palm for
improved grip, says the company.
Contact: Kimberly-Clark Corp.
Toll free (800) 255-6401
Variable-speed compressors
www.kcprofessional.com
Sullair Corp. enhanced its 3700 series of 40-, 50-, and 60-HP
compressors with the Sullair variable-speed drive (VSD)the Sullair 3000V, 3700V, and 4500V. The VSD allows compressors to easily, efficiently, and cost-effectively adjust to
fluctuating compressed air demand—either seasonal
changes in demand, or from shift-to-shift, says the company. Like the Sullair 3700, these VSD compressors feature a
simplified WS microprocessor, low sound levels (as low as
68 dba) and a smaller footprint than similar compressors,
says the company.
Contact: Sullair Corp.
3700 East Michigan Blvd., Michigan City, IN 46360
Tel: (219) 879-5451
www.sullair.com
Casters and wheels catalogue
Gas-powered welder/generators
Revvo Caster Co. announced publication of its new master
With 23-HP Kohler and 22-HP Robin engine options now
catalogue that describes its full line
available, Miller Electric Mfg. Co. says its Bobcat and
of light-, medium, heavy- and
Trailblazer gas-powered welder/generators now feature the
extra-heavy-duty
and
most horsepower in their class. The additional horsepower
wheels. Offering load capacities
provides stronger welding output for running larger diame-
from 31 to 26,400 pounds and
ter wires and stronger generator power for sudden, heavier
wheel diameters from 1-5/8-inch
loads, such as motor starting, says the company. Other new
to 16 inches, the casters are
enhancements include: Miller’s exclusive Auto-Crater fea-
designed for industrial handling,
ture on the Trailblazers to help eliminate crater-related DC
business machines and other low-profile applications (i.e.
TIG weld defects and a low-fuel shutdown on all diesel mod-
appliances, furniture, retail displays and staging). The new
els that shuts down the engine before the fuel runs. This elim-
catalogue provides photographs, specifications with
inates the need to re-prime the engine, says the company.
schematics, top-plate drawings and complete part numbers.
Contact: Miller Electric Mfg. Co.
Options and accessories, including total-stop brakes, direc-
P.O. Box 100, Lithonia, GA 30058
tional locks, foot brakes, expanding plugs and threadguards
Toll free (800) 4-A-MILLER
are also shown and described.
www.millerwelds.com
casters
Contact: Revvo Caster Co.,
P.O. Box 236, Fort Erie, ON L2A 5M9
Plastic-framed HEGA filters
Toll free (888) 883-3596
Camfil Farr introduced a new line of HEGA (High-
www.revvocaster.com
Efficiency Gas Absorber) filters that help with the removal
of hazardous gaseous contaminants from air-handling con-
New gloves protect the hands
taminant systems. The HEGA filter frames are manufac-
Kimberly-Clark
tured of high-impact plastic that offers a less costly alterna-
the
maker
of
Kleenguard protective apparel, gloves,
tive to metal-framed devices, says the company. A V-bed
masks and accessories, introduced
design channels air through multiple beds of absorbent,
Kleenguard G40 latex-coated
reducing resistance to airflow. Typically installed in systems
gloves and Kleenguard G60
that include pre-filtration and HEPA filtration, the HEGA
purple nitrile cut-resistant
filters can be changed using a bag-in/bag-out procedure to
gloves. The Kleenguard
protect service personnel during change out. The HEGA fil-
To contact this advertiser turn to page 65
60
Professional,
PEM PLANT ENGINEERING AND MAINTENANCE
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ters are available with high-efficiency sorbent media in oneinch or two-inch bed depths to meet any gaseous filtration
demand, says the company.
Contact: Camfil Farr
2785 Frances Hughes Ave., Laval, PQ H7L 3J6
Toll free (866) 4CAMFIL
www.camfilfarr.info
Troubleshooting kit
Extech Instruments introduced the TK430-IR industrial troubleshooting kit, which is designed to help with the testing, installation and repair of electrical systems, HVAC equipment and
large appliances. The kit comes complete with an EX430 True
RMS auto-ranging digital multi-meter, an MA200 400A AC
To contact this advertiser turn to page 65
clamp meter, a 42510 mini InfraRed (IR) thermometer, a 40130
non-contact voltage detector, a set of CAT III-1000V test leads, a
Type K thermocouple bead probe, a Type K banana input
adapter, a multi-meter hanging strap and batteries. The EX430
True RMS multi-meter offers 11 functions, including: AC/DC
voltage and current; resistance; capacitance; frequency; temperature; duty cycle; diode; and continuity, says the company.
Contact: Extech Instruments
285 Bear Hill Rd., Waltham, MA 02451
Tel: (781) 890-7440 www.extech.com
There is no
upside to
down time
Line of maintenance greases
A complete line of EP Greases is now available from Jet Lube.
The grease is specifically formulated to extend the service life
and maintenance intervals associated with the most demanding industrial, processing, manufacturing and constructionequipment applications, says the company. For extreme tem-
Wide variety of metals in rod, bar, sheet, plate, structural,
tube & pipe • Stores coast-to-coast
• No minimums • Same day delivery or pickup
One stop shopping for any metal,
cut and ready, fast!
perature, high loads and salt-water resistance, users can
choose from more than 25 grease formulas. Depending on
the application, the greases meet a wide range of NSF, MIL,
USDA and DOT specifications, says the company.
Contact: Jet Lube
4849 Homestead Rd., Suite 200, Houston, TX 77028
Toll free (800) 538-5823
1-866-867-9344 or visit www.metalsupermarkets.com
p
To contact this advertiser turn to page 65
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MRO ress
Exp
Your guide to all the latest innovations
in plant engineering and maintenance
products and ser vices.
Roof-edge railing systems
FA C I L I T I E S
UVC kit for PTAC systems
Steril-Aire Inc. introduced a new terminal air-conditioning (PTAC) UVC kit.
Each kit contains one UVC Emitter and power supply, plus all necessary
hardware components to retrofit a PTAC coil or other room unit with UVC.
Designed for fast and easy snap-in installation, the space-saving kit uses
a 24-inch Emitter tube that fits all types of PTAC coils, says the company.
Installed opposite the coil, the high-output UVC energy provides continuous, non-chemical coil cleaning, which improves air flow, temperature and
humidity control to save energy, says the company. It also stops mould
and bacteria at the source, as well as viruses and other airborne microorganisms, enhancing indoor air quality and preventing the spread of
infectious diseases, says the company.
www.steril-aire.com
Kee Industrial Products introduced a
new open fitting (model #135-8) to
make the installation of its
KeeGuard roof-edge, fall-protection
railing systems faster and easier.
The new fitting allows the guardrail to
be placed into the saddle of the fitting instead of being fed through the
upright. This saves time and labour costs, while also providing design flexibility and heightened aesthetics for circular-roof configurations, says the
company. KeeGuard is a freestanding, counterbalanced modular guardrail
system for flat and low-sloped roofs that installs without welding, drilling
or penetrating the roof membrane, says the company.
www.keeguard.com
Concrete-set accelerator
Safety gate for access areas
Hydraset-Free, a non-chloride concrete-set
accelerator from W.R. Meadows, is a ready-touse, liquid admixture. It accelerates initial setting time one to three times faster than normal
for mortar and concrete, while making the mix
easier to place and speeding construction by
shortening the initial set and curing time, says
the company. Hydra-Set Free is recommended for
use during cool and cold weather to
accelerate the set time and reduce the
risk of frozen mortar and concrete
mixes, says the company.
Also available from W.R. Meadows is
the Whitewalk impact-absorbing walkway. The installation
of Whitewalk provides a designated “safe” area on which
to walk, says the company.
Whitewalk is designed as a
walkway for most types of
roofing systems. Whitewalk
is compatible with fibreglass mesh,
asphaltic coatings, asphalt-saturated
felts, butyl rubber, neoprene, EPDM and most polyvinylchloride and
plastic sheetings, says the company.
www.wrmeadows.com
Rite-Hite Aftermarket Corp. introduced the EX3 safety-gate system, which
can be used in plants or at warehouse loading docks. The EX3 system is
available for openings five feet up to 10 feet wide. The standard gate system includes two 43-inch high, five-inch diameter steel posts, two twoinch PVC rails with safety striping and anchoring hardware. The white
seven-inch by three-inch PVC rails provide a high visibility barrier, while
absorbing 200 pounds of force from any direction from materials handling
equipment, says the company. Safety yellow powder-coated, five-inch
diameter, 11-gauge steel posts provide support for the rails and make a
rugged barrier.
www.ritehite.com
62
PEM PLANT ENGINEERING AND MAINTENANCE
Display board for shop floor
Creform Corp. introduced a new display, training and
presentation board and frame structure for in-plant
information sharing. The frame is constructed using
Creform plastic-coated, steel-pipe sections and assembled with fastener-tightened metal joints or adhesivebonded plastic joints, plus other hardware accessories.
Options for different board materials, depending upon
presentation methods, are also available. Users may
supply their own display materials, says the company. Choices include cork,
white dry-erase materials, chalk boards, wood or plastic, magnetic surfaces
and combinations of materials.
www.creform.com
w w w. p e m - m a g . c o m
PEM-Sept06-PG51-OBC.qxd
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PREVENT
this Occupational Hazard
Standard plugs & receptacles can be dangerous
Sa
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DecontactorTM Series Switch Rated
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• CSA Switch rated up to 60 hp or 200A
• Short circuit close & withstand rated
up to 100kA
www.meltric.com • 800.433.7642
To contact this advertiser turn to page 65
Murphy means
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We have sold more than 14,000
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You need the high-productivity,
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The efficient way to clean your industrial floors is
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your machine. That's why you need the uptime and
productivity of rugged Advance sweepers, scrubbers
and combination floor-cleaning machines.
Features like QuickChange™ tools-free scrub decks
and simple-to-operate controls make cleaning more
productive. With easy-access designs and readily
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complicated, expensive floor-cleaning. All this, plus
on-site training, parts and service from your local
Advance dealer.
Advance your floor cleaning with our FREE bulletin,
How to select floor-cleaning equipment for increased
productivity. In Canada, call 1-888-382-0004 or email
info@nilfisk-advance.ca.
Driving down the cost to clean.SM
Nilfisk-Advance Canada Company
396 Watline Ave. Mississauga, Ontario L4Z 1X2
A U T O M AT I C S C R U B B E R S • S W E E P E R S
S W E E P E R - S C R U B B E R S • P R E S S U R E WA S H E R S
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(519) 621-6210
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Fax: (519) 621-2841
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E-mail: 4nodust@nrmurphyltd.com Web Site: www.nrmurphy.com
To contact this advertiser turn to page 65
To contact this advertiser turn to page 65
w w w. p e m - m a g . c o m
RMurphy_PEM_Sept_06.indd 1
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SEPTEMBER 2006
63
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Page 64
CUT COSTS!!!
PRODUCE YOUR OWN NITROGEN OR OXYGEN
• Gas generating systems available for
purchase or rent
• Nitrogen purities to 99.999%
• Oxygen purities to 99%
• Turnkey systems available for plant and lab use
Would you like more information?
Call: 905-305-0094 or e-mail:
sales@adgastech.com
230 Don Park Road, Unit 15,
Markham, ON
L3R 2P7
Rough.
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To contact this advertiser turn to page 65
SPRAYON® SAFETY-SYN LUBE
PROVIDES ENHANCED LUBRICITY IN A
NON-FLAMMABLE AEROSOL
Powerful.
Krylonn Productss Group introduces Sprayon®
Safety-Syn Lube, the first synthetic-based
lubricant modified with P.T.F.E in a non-flammable aerosol. Safety-Syn Lube is colourless
and low-odour, with a low HMIS rating that
allows for incidental food contact. Safety-Syn
Lube is approved to perform under extreme
pressure in applications including hinges,
cables, chains, conveyers, and food processing equipment. It is available in 250g net
weight cans.
The SC7750 removes dirt, grease and grime,
asseparate
well as loose
debris,
eliminating
the need
a
sweeper.
It leaves
your facility
withfora
The dry
SC7750
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clean,
floor surface.
This
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clean, dry floor surface. This high performance
For a copy of our FREE
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work of your
“Building
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email
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info@nilfisk-advance.ca or in Canada, call
1-888-382-0004.
For a copy of our FREE product brochure,
American-Lincoln
/ 396 Watline
Ave. / Mississauga, Ontario L4Z
1X2
“Building Quality
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email
For additional information contact:
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P: 1-866-736-1486,
F: 1-800-243-3075, or visit
www.KPG-Industrial.com.
info@nilfisk-advance.ca or in Canada, call
1-888-382-0004.
American-Lincoln / 396 Watline Ave. / Mississauga, Ontario L4Z 1X2
To contact this advertiser turn to page 65
To contact this advertiser turn to page 65
ITS
Warnock Hersey
ER
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Stanford Electric
Rebuilders Ltd.
90
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Plant Engineering and Maintenance (PEM) has one of the
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• AC/DC
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(416) 798-4530 Fax: (416) 798-4460
Web: www.stanfordelectric.ca E-mail: info@stanfordelectric.ca
To contact this advertiser turn to page 65
To contact this advertiser turn to page 65
64
PEM PLANT ENGINEERING AND MAINTENANCE
www.pem-mag.com
w w w. p e m - m a g . c o m
PEM-Sept06-PG51-OBC.qxd
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9:27 AM
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SEPTEMBER 2006
Plant Engineering
and Maintenance
Do you want to know more about any product advertised in this issue
of PEM Plant Engineering and Maintenance? Here, you’ll find all the
information you need to make the right connections! Every advertiser
is listed, along with several ways that you can get in touch. Whether
FOR YOUR INFORMATION
HOW TO CONNECT WITH ADVERTISERS IN THIS ISSUE
ADVERTISER
PG #
Advance Canada
63
Advanced Gas Technologies Inc.
11, 64
American-Lincoln Canada
64
BNA/Bonfiglioli Canada Inc.
41
Bosch Rexroth Canada Corporation
25
Canadian Bearings
43
Canadian Timken Limited
31
Canada Law Book
14
Cattron-Theimeg Canada Ltd.
56
Chevron Texaco
21
Columbus McKinnon Corporation
16
Enbridge Gas Distribution Inc.
67
Eurovac Inc.
11
Exair
7
Flir Systems
68
Fluke Electronics Canada
40
Forster Instruments Inc.
36
Gates Canada Inc.
45
Goodyear Hose
47
Gorbel
59
Gorman Rupp
57
Grundfos Cda Inc
60
Henkel Corporation
17
Hertz
3
High Reach Inc.
37
INA Canada/FAG Bearings
33
IPEX Inc.
55
J.W.Winco
36
Jancy Engineering
66
Johnston Equipment
15
Kinecor Corporation
53
Krylon Corp.
64
MainTrain
58
Masterlock
61
Metal Supermarkets Ltd.
61
Meltric Corporation
63
N.R. Murphy
63
Nilfisk-Advance Canada
44
Omron Canada
IFC
Petro-Canada
8&9
R&M Materials Handling, Inc.
22
REED Exhibitions
49
Renold Canada
12 & 13
Schneider
16
SKF Canada
35
Shat-R-Shield
50
SMRP
10
Stanford Electric Rebuilders
64
Thinkage Ltd.
66
T-G Compressed Air Systems
32
University of Toronto
37
WEG - V.J. Pamensky Canada Inc.
51
Vickers-Warnick
19
Weber Marking Systems
23
Westfalia Separator Canada Inc.
46
you phone or fax, visit a Web site or send an e-mail, getting the information you need has never been easier.
PHONE #
FAX #
E-MAIL ADDRESS
888-382-0004
905-305-0094
888-382-0004
905-738-4466
905-335-5511
905-670-6715
905-826-9520
905-841-6480
905-873-9440
905-670-6470
905-372-0153
1-866-844-9994
800-265-3878
800-903-9247
905-637-5696
905-890-7600
905-795-0555 or 800-561-2994
519-759-4141 #2218
--800-821-0086
--905-829-9533
1-800-263-5047
888-777-2700
(905) 844-4164
905-829-2750
1 (866) 473-9462
1-800-877-8351
563-391-1300
800-668-5586
-800-777-2966
--800-227-9599
800-807-8755
800-433-7642
519-621-6210
888-382-0004
416-491-7565
1-800-268-5850
800-955-996
888-322-7333
519-756-6118
905-678-5848
866-832-6753
800-223-0853
703-610-9000
416-798-4530
800-563-0894
905-335-1440 or 800-715-9466
888-233-8638
416-781-4617 or 877-Pamensky
800-263-6835 or 905-662-7737
905-564-6884 or 800-265-9974
905-319-3900
905-712-3255
905-305-0092
905-712-3255
905-738-8933
905-335-4184
905-670-0795
905-826-0482
905-841-5085
905-873-9449
905-670-6932
905-372-3078
--905-738-4603
866-329-3924
905-639-5488
905-890-6866
905-795-0570
519-759-0944
--800-828-1808
--905-829-9512
905-814-6511
--(905) 844-2135
905-829-2563
(905) 670-5295
1-800-472-0670
563-391-2323
905-712-6002
--800-243-3075
--905-829-8952
905-459-3690
414-817-6161
519-621-2841
905-712-3255
416-286-6159
--7937-325-5319
--519-756-1767
905-678-9814
888-753-6584
704-633-3420
703-610-9005
416-798-4460
519-895-1864
905-335-4033
-416-781-4352
905-560-6705
905-564-6886
905-319-3903
info@nilfisk-advance.ca
sales@adgastech.com
info@nilfisk-advance.ca
jmagee@bonfigliolicanada.com
karen.park@BoschRexroth.ca
jeff.lunn@canadianbearings.com
boeree@timken.com
jgordon@canadalawbook.ca
salescdn@cattron.com
canadalubricants@chevrontexaco.com
colin.basinger@cmworks.com
energyservices@enbridge.com
info@eurovac.com
techelp@exair.com
greg.bork@flir.com
canada@fluke.com
www.advance-us.com
www.adgastech.com
www.americanlincoln.com
www.bonfigliolicanada.com
www.BoschRexroth.ca
www.canadianbearings.com
www.timken.com
www.canadalawbookca
www.cattron-thiemeg.com
www.texaco.com
www.cmworks.com
www.enbridge.com/gas
www.eurovac.com
www.exair.com/39.440.htm
www.flir.com
www.flukecanada.ca
staylor@gates.com
stacyc@malonead.com
info@gorbel.com
www.gates.com
www.goodyear.com
www.gorbel/com
mmamone@grundfos.com
----questions@highreachinc.com
paul.mckenzie@ca.fag.com
----marketing@jancy.com
--msavaiano@kinecor.com
info@KPG-Industrial.com
mail@pemac@org
canadamarketing@mlock.ca
headoffice@metalsupermarkets.com
mail@meltric.com
4nodust@nrmurphyltd.com
info@nilfisk-advance.ca
askomron@omron.com
lubecsr@petro-canada.ca
---
www.grundfos.com
www.loctite.com
www.hertzequip.com
www.highreachinc.com
w w w. p e m - m a g . c o m
rperry@renoldcanada.com
skye.ball@ca.schneider.com
marketing@skf.ca
info@shatrshield.com
chapter@smrp.org
info@stanfordelectric.ca
info@mainboss.com
info@tg-aircompressor.com
pdc@efc.utoronto.ca
anthonyz@pamensky.com
stoney@vickers-warnick.com
info@webermarking.ca
forkes.gary@gea-westfalia.ca
WEB ADDRESS
www.ipexinc.com
www.jwwinco.com
www.jancy.com
www.johnstonequipment.com
www.kinecor.com
www.KPG-Industrial.com
www.maintrain.ca
www.masterlock.com
www.metalsupermarkets.com
www.meltric.com
www.nrmurphyltd.com
www.pa.nilfisk-advance.com
www.omron.ca
www.petro-canada.com
www.rmhoist.com
www.renoldcanada.com
www.schneider-electric.ca
www.skf.ca
www.shat-r-shield.com
www.smrp.org
www.standfordelectric.ca
www.mainboss.com
www.tg-aircompressor.com
www.pdc.utoronto.ca
www.pamensky.com
www.webermarking.ca
SEPTEMBER 2006
65
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11:46 AM
Page 66
People and Productivity
BY WILFRED LIST
In another, more peaceful time, Joe’s outburst in a dispute that concerned a return to work
after a lengthy disability leave might have been
shrugged off by his employer as a mere verbal
venting of anger and frustration. In light of
global-terrorism threats, however, Joe’s
comment to a union representative that
he would put a box of dynamite in his
truck and drive it into the plant was
taken seriously. In turn, the union
reported Joe to the company.
The employer then notified the
local police, who contacted Joe and
asked him whether he had any dynamite, and if he was returning to
the plant that night. “I don’t have
any dynamite and I’m not going anywhere,” Joe said. “It’s a labour problem—not a police problem.”
With that the police left. Although
no criminal charges were laid, Joe had
to sign a restrictive peace bond and
agree to undergo a psychiatric examination. He was also suspended. Along with the dynamite incident, Joe
made frequent visits to the union office. On one occasion and in tears,
Offering a complete line of metalworking tools.
Joe said that he was going to lose his house.
Foremost in Joe’s mind was his need to look after his family.
In one union meeting, Joe sifted through some papers and
said that he would be better off dead than alive in providing for his family.
“What does it take to get these people’s attention? Do I have to drive a truck load of dynamite
through the front door of the plant?” Joe asked.
“I should just come back tomorrow with dynamite in my truck. I won’t be responsible
for my actions.”
After some soul searching, the union representative also reported this conversation
to management. Ultimately, the company
fired Joe. At an arbitration hearing contesting his dismissal, Joe said that he had been
joking in his reference to driving a truck
with dynamite into the plant.
The arbitrator, however, concluded that
there was no reliable evidence that Joe wouldn’t repeat his threatening behaviour if reinstated. He dismissed Joe’s appeal for reinstatement.
Joe, who was fired after his comments about driving a dynamite-laden truck into the plant, subsequently lost his house
and remained jobless. p
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To view demo videos of our products vist Jancy.com
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To contact this advertiser turn to page 65
66
PEM PLANT ENGINEERING AND MAINTENANCE
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To contact this advertiser turn to page 65
w w w. p e m - m a g . c o m
ILLUSTRATION BY KATHY BOAKE W.
Better hide the dynamite
PEM-Sept06-PG51-OBC.qxd
9/19/06
4:01 PM
Page 67
Imagine a company that will send you an
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Enbridge Gas Distribution can help you develop a
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We will review the natural gas use of your facility
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To contact this advertiser turn to page 65
Enbridge_PEM_Sept_06.indd 1
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PEM-Sept06-PG51-OBC.qxd
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Page 68
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