3 Key Equipment Inspection Tips For Maximal Performance

Posted on January 13, 2012 by AJP Engineering

If you’re like many businesses, you have a lot of money invested in equipment that’s crucial for your day-to-day success. And if one of those pieces of equipment goes off line for any reason, your bottom line can be affected.

By scheduling and performing regular inspections as recommended by a professional engineer, you can avoid significant problems. Here are three ways to keep your heavy equipment operating at maximal capacity throughout the year.

(1) Keep equipment certifications current. An Occupational Health and Safety (OHS) Act in every province requires that any lifting device that can lift more than 2,000 kg must be certified at least every 12 months. And other lifting equipment such as cranes, hoists, and other lifting devices require different inspection intervals depending on the type of service and load capacity. By contracting with certified inspection organisations, you’ll be sure your equipment always meets OHS standards.

(2) Adapt for winter conditions. The winter months in Winnipeg can be harsh, with plenty of snow, ice, and rain. Excess moisture and extremely low temperatures can cause performance drop-offs for large equipment, especially those operating outside. Prepare for these difficult conditions by giving each piece of equipment a thorough check prior to the season and winterizing as needed.

(3) Properly certify out-of-Province equipment. When using equipment from another province, OHS regulations require an inspection under the direction of a professional engineer licensed to practise in Winnipeg, before the equipment is placed in service. Don’t risk potential fines or lost revenue from extended downtime on the job. Pre-book certification inspections to avoid delays.

Performing required inspections on all your equipment before certificates expire keeps your employees safe and ensures that work functions will run as smoothly as possible. A professional engineer knows the requirements for different pieces of heavy equipment and can help create an annual inspection schedule that saves you time and money.

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4 Steps to Get Your P.Eng Licence

Posted on January 11, 2012 by AJP Engineering

Getting your P.Eng or Professional Engineer’s licence elevates you from newly minted engineering graduate to true professional status. And it’s a must for anyone in the profession who wants to advance.

Are you an engineer in Canada or a recent university graduate? As you start your professional engineering career, you’re probably looking for ways to climb the ladder quickly. Achieving a P.Eng takes just four steps, and as a graduate, you’ve probably already completed the first. Here’s what you need to do.

(1) Get your degree from an accredited engineering program. Over 200 programs at 35 Canadian universities meet the standards of the Canadian Engineering Accreditation Board. If you’re going to school in another country, just be sure the program is the equivalent of an accredited Canadian engineering program.

(2) Register as an Engineer-In-Training with your local engineering licensing body. Once you have that degree in hand, you’re ready to take the first step on the P.Eng journey. Each provincial or territorial licensing organisation has an internship program. Becoming an EIT moves you up another rung on the ladder.

(3) Get on the job practical experience in the form of an internship, and become a true professional. Here’s where it gets good. As an EIT under the supervision of a P.Eng, you’ll apply the engineering theory and skills you learned in school in real-world projects. The work you do will improve your communication skills and help you gain a greater understanding of how engineers impact society.

(4) Complete a professional examination as determined by your local licensing body. Once you have the experience, it’s time to show it on paper. Get the details of examination schedules from your local licensing body. Some use the National Professional Practice Exam while others have their own exam. You’ll prove your understanding of the laws and code of ethics that all professional engineers follow.

Checked all the boxes? You’ll receive your P.Eng licence and an official seal to stamp your engineering designs and drawings. And you’ll join the elite community of over 160,000 Canadian professional engineers. You’ve earned it.

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Interested in a career in engineering with AJP Engineering Services

Posted on January 5, 2012 by AJP Engineering

Interested in a career in engineering? At AJP Engineering, we are committed to exceptional customer service and pursuit of excellence. We foster a dynamic work environment where you can build your career.

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What Class is Your Crane?

Posted on January 4, 2012 by AJP Engineering

Understanding CSA B167 Inspection Standards

Does your company own, operate, or maintain overhead cranes, monorails, hoists, trolleys, jib cranes, or gantries? Do you know how often these devices must be inspected? You might want to take a look at the guidelines from the Canadian Standards Association (CSA B167) discussing the required inspection intervals for different classes of cranes.

In 2008, CSA B167 saw significant changes, with the goal of bringing the Canadian standard more in line with international standards as defined by the ISO. In particular, the update clarified the time between inspections for different types of cranes based on application and intended service.

As laid out in Table 3 of CSA B167, cranes fall into five distinct categories (A1 through A8, special class, and out of service) with corresponding inspection frequencies. Here’s a quick recap.

Annual inspections (A1, A2, A3). Maintenance cranes and those used for regular light use – generally lifting less than 25% of rated capacity. Includes workshop cranes receiving regular light or moderate use.

Semi-annual inspections (A4, A5, A6). Cranes lifting moderate to heavy loads – up to 50% of capacity – with hook duty and magnet duty. Examples include container handling or other material handling cranes.

Quarterly inspections (A7, A8). Scrap-yard and steelwork cranes fall into this category, as do cranes performing intensive lifts with heavy loads – from 50-100% of capacity.

Special use cranes and those currently out-of-service require a specialized assessment by a Professional Engineer prior to classification. Examples of special use cranes include those designed for the combination of very heavy lifts at high cycles – a design life greater than two million load cycles.

For new cranes, the classification process ensures that the crane designer specifies a device meeting the desired operating life for the estimated service conditions as determined by the purchaser.

In determining the correct inspection frequency for an existing crane, a thorough engineering assessment is critical, especially when load capacity falls between categories. Engineers use original construction drawings, manufacturer operation and maintenance manuals, historical records of production rates over the life of the crane, and any service/maintenance reports, paying close attention to reports of fatigue cracking in critical areas. The assessment is also an opportunity to estimate the remaining reliable service life of the crane.

Whether you’re placing a new crane in service, estimating future capital budget costs for replacement of current equipment, or changing the service conditions for an existing crane, you’ll want to be familiar with the inspection standards for each class.

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Repair, Alteration and Re-Certification of Pressure Vessels

Posted on July 26, 2011 by AJP Engineering

Pressure vessels generally fail in a catastrophic fashion and can cause devastating consequences for workers, for other critical components and for the surrounding environment. So what do you need to know when preparing to repair, alter and re-certify a pressure vessel?

The re-certification process means that a pressure vessel will be evaluated for continued service based on safety and reliability. This evaluation determines whether a vessel can be returned to service within known and acceptable margins of safety.

There’s a strong incentive for re-certification rather than replacement of a pressure vessel, as the re-certification process typically runs less than 15% of replacement costs and doesn’t require a lot of downtime.

Here are the major steps that must be completed when you plan to repair, alter and re-certify a pressure vessel for continued service:

  • Locating original design documentation and service records.
  • Performing stress, fatigue and fracture testing.
  • Non-destructive testing and examination of the pressure vessel.
  • Evaluating the effects of corrosion.
  • Determining the most limiting factor mechanism.
  • Repairing or completing further analysis to demonstrate the acceptability of existing defects.
  • Setting the next inspection interval based on the most limiting factor mechanism.
  • Estimating the remaining life of the pressure vessel.
  • Documenting accurately the conditions for which the vessel can operate following re-certification.

Developing a specific plan of action based on these steps, when attempting to return a pressure vessel to service, will ensure an adequate factor of safety.

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Careers with AJP Engineering

Posted on July 22, 2011 by AJP Engineering

At AJP, we are passionate about making a difference, committed to exceptional customer service and pursuit of excellence. We foster a dynamic work environment where you can build your career. Interested in a career with AJP Engineering? Visit our careers page.

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How to Effectively Manage a Quality Assurance Program

Posted on July 21, 2011 by AJP Engineering

Effectively managing a quality assurance program requires an understanding of the differences between quality assurance (QA) and quality control (QC), and the ability to combine the two to produce an optimal end product.

Quality assurance is a set of activities providing a degree of certainty that products and services meet specific quality requirements. The objective of quality assurance is developing an environment driving continual improvement in the overall process. A well managed QA program should enhance quality, productivity, and customer satisfaction without neglecting any of these areas.

Quality control focuses more on determining whether an end product, service, or process meets minimum levels of quality, and can be delivered to the customer. QC stresses the quality of the end result while QA focuses on the process.

In laying the foundation for a quality assurance program, the following baseline conditions should exist:

1. Integration and communication between different departments.
2. Defined leadership roles and responsibilities for management.
3. An environment of constant improvement.
4. An ongoing program of education and self-improvement for individuals and groups.

Then, effective management of the QA/QC program must include these success principles.

Maintain a customer-oriented focus. Understand both the current and future needs of customers and the level of quality required to satisfy them.

Establish leadership at all levels. Effective leadership in an organization provides unity of purpose and direction for everyone in the company.

Develop a process approach. Help workers to achieve the desired result by developing systems to get them there.

Require constant improvement. Challenge everyone in the organization to find ways of continually improving over time.

Implement a fact-based decision making approach. Base decisions on real data analysis.

Involve people at all levels. People drive the quality of any organization. Use all available skills and abilities to enhance quality assurance.

By integrating these principles into your QA/QC program, you’ll be sure to get the most out of your available resources.

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Is your below the hook lifting device safe for use?

Posted on July 19, 2011 by AJP Engineering

Whether you have just a few below the hook lifting devices or maintain hundreds of them, you may wonder if you’re doing enough to ensure the safe operation of each one.

Used to provide a connection between the crane and the load being lifted, below the hook lifting devices run the gamut from structural mechanical lifting devices and vacuum lifters to magnets and grapples. Each device is manufactured to slightly different specifications but must meet the applicable safety standard once in service.

Assuring safe operation of below the hook lifting devices requires attention in each of the following areas:

1. Correctly matching nameplate ratings and service class with usage.
2. Assembling and installing equipment in accordance with manufacturer’s guidelines.
3. Providing regular training to lift operators based on the most current operating practices.
4. Visually inspecting lifting equipment on a daily or weekly schedule and prior to every lift.
5. Setting up and following a regular preventative maintenance and repair program. Replacement parts must meet or exceed the original manufacturer’s specifications.
6. Scheduling regular safety audits and inspections to ensure current standards are met. Typically an audit includes inspection of lifting devices for damage, review of lifting methods, equipment safety reviews, and review of structural calculations.

Just a few minutes spent each day evaluating your below the hook lifting devices will pay large dividends in safety.

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How much life is left in your existing piping system?

Posted on July 14, 2011 by AJP Engineering

Industrial piping systems over time can undergo many types of deterioration such as:

1. Corrosion under insulation (CUI)
2. Injection point corrosion
3. Service-specific and localized corrosion
4. Environmental cracking
5. Freeze damage
6. Fatigue cracking
7. Brittle fracture
8. Deadlegs
9. Erosion and corrosion
10. Creep cracking

And it can be difficult to determine the condition of an existing piping system. One of the most effective strategies is performing a fitness-for-service (FFS) evaluation.

Assessing the FFS of a piping system involves a quantitative engineering evaluation of the structural integrity of an in-service system. This evaluation helps engineers to make run-repair-replace decisions and ensure that a system will continue to operate safely.

When assessing the lifespan of a piping system, the process includes four primary parts.

Specific inspection and testing practices. Inspection types include internal and external visual, thickness measurements, vibrating piping, and supplemental strategies such as radiography and thermography.

Inspection frequency. Inspection intervals are based on the corrosion rate and remaining life calculations, the piping service classification, applicable requirements for the local jurisdiction, and the inspector’s judgement based on operating conditions, inspection history, and the current inspection results.

Evaluation and analysis of inspection data. Once the data is collected, the remaining life, corrosion rate, and the maximum permitted internal pressure for continuous operation at design temperature (MAWP) can be determined.

Repairs, alterations and re-rating. Once all the data has been evaluated, authorization and approval for repairs must be obtained. And if a change in design pressure or temperature is desired, the system must be re-rated.

While determining the lifespan of your existing piping system isn’t easy, the strategies outlined above will provide guidance in maintaining optimum performance and safe operation of this critical component.

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Guidelines For Welding Certification

Posted on July 11, 2011 by AJP Engineering

After the passage of Federal Bill C-45 under the criminal code of Canada, managers of industrial facilities must now ensure due diligence when related to safety issues. One of those areas of safety involves welding operations.

Industrial plant workers must independently authorize a variety of welding operations (structural, pressure, maintenance and others) every day. The average worker may not be able to distinguish between a situation when certified welding operations are absolutely required and another scenario where a certified welder is a wise choice but not mandated by law.

The following information, based on Legislation, Codes and Standards currently in effect in Manitoba, provides specific guidance in determining when certified welders must be called in. But there are two caveats.

1. Some welding operations are outside the scope of governing legislation and standards, and must be evaluated independently.
2. An individual risk assessment must be performed before beginning every job. Any risk assessment should be preceded by discussions with insurers.

Welding operations which must be performed by a welder holding a Manitoba Department of Labour High Pressure Welders License are as follows:

All pressure vessel and pressure piping systems. Including boilers, piping in steam heating and process systems, piping in hot water heating and process systems, compressed air systems over 15 psi, refrigeration systems, chemical handling systems, natural gas, propane and fuel oil delivery systems.

Any structural system designed to CSA S16.1 or S136. This includes building structures, crane runways, and any structural steel item designed by a Structural Engineering Consultant.

Oil storage tanks. Including any other American Petroleum Institute (API) regulated vessels.

Welded repairs to mobile cranes to be certified to CSA Z150. All repairs require welding certification to CSA W47.1 and must be conducted under the supervision of a Professional Engineer.

Any codes and standards related to welding and referring to ASME Section IX. These do not explicitly set welding certification requirements but recommend the welder hold a High Pressure Welders License.

The following operations refer to American Welding Society (AWS) Standards and it is recommended that work falling under this code be completed by CSA W47.1 certified welders:

Welded repairs to overhead cranes. As designed to Crane Manufacturers of America (CMAA) standards, these repairs must also be supervised by a PE.

Welding of other overhead cranes and lifting devices. Designed to ASME B30 codes.

Finally, there are several applications that fall under the Manitoba Workplace Safety & Health Act. As weld failures here can potentially cause injury, the recommendation again is to meet the standard of CSA W47.1:

1. Fall protection guards.
2. Fall arrest anchorages.
3. Repair to mobile equipment used to hoist or lift loads (under the supervision of a PE).
4. Fabrication of temporary or permanent work platforms.
5. Welded fabrication of any lifting device component.

In all cases, when the failure of a weld could potentially result in an insurance claim, a discussion should be held with insurers to determine the required welding credentials of a company or an individual.

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